KSB UPA Installation & Operating Manual
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KSB UPA Installation & Operating Manual

Submersible borehole pumps
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Submersible Borehole Pumps
UPA, UPZ, BSX
with motors of 1000 V operating voltage and above
50 Hz, 60 Hz
Installation/Operating
Manual
Mat.No.:
01463374

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Summary of Contents for KSB UPA

  • Page 1 Submersible Borehole Pumps UPA, UPZ, BSX with motors of 1000 V operating voltage and above 50 Hz, 60 Hz Installation/Operating Manual Mat.No.: 01463374...
  • Page 2 Legal information/Copyright Installation/Operating Manual UPA, UPZ, BSX Original operating manual KSB Aktiengesellschaft All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without KSB's express written consent.

  • Page 3: Table Of Contents

    Installing the pump set in vertical position ..........27 Installing the pump set in a horizontal position ..........30 Installing the pump set in an angled position ..........32 Notes on electrical connection ..............32 Electrical connection ..................34 UPA, UPZ, BSX 3 of 64...

  • Page 4: Related Documents

    General assembly drawing with list of components ........54 Mating dimensions for motors V, X, Z, E ............58 Mating dimensions for motor T ..............59 EC Declaration of Conformity ............60 Certificate of Decontamination ............61 Index ....................62 4 of 64 UPA, UPZ, BSX...

  • Page 5: Glossary

    Pump set Complete pump set consisting of pump, drive, additional components and accessories UPA, UPZ, BSX 5 of 64...

  • Page 6: General

    The order number and order item number uniquely identify the pump (set) and serve as identification for all further business processes. In the event of damage, immediately contact your nearest KSB service centre to maintain the right to claim under warranty. 1.2 Target group This manual is aimed at the target group of trained and qualified specialist technical personnel.(⇨...

  • Page 7: Symbols

    Conditions which need to be fulfilled before proceeding with the step-by-step instructions ⊳ Safety instructions ⇨ Result of an action ⇨ Cross-references Step-by-step instructions Note Recommendations and important information on how to handle the product UPA, UPZ, BSX 7 of 64...

  • Page 8: Safety

    ▪ 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. 8 of 64 UPA, UPZ, BSX...

  • Page 9: Personnel Qualification And Training

    In addition to the safety information contained in this manual and the intended use, the following safety regulations shall be complied with: ▪ Accident prevention, health and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances UPA, UPZ, BSX 9 of 64...

  • Page 10: Safety Information For The Operator/User

    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 of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use. 10 of 64 UPA, UPZ, BSX...

  • Page 11: Transport/Temporary Storage/Disposal

    On transfer of goods, check each packaging unit for damage. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) and the insurer about the damage in writing immediately.
  • Page 12 Use the lifting equipment to lift the pump set out and position it on a solid and level surface. Use appropriate means to secure the pump set against rolling off. 12 of 64 UPA, UPZ, BSX...

  • Page 13: Storage And Preservation

    3.3 Storage and preservation If commissioning is to take place some time after delivery, we recommend that the following measures be taken: See cable manufacturer's documentation or DIN VDE 0298-3. UPA, UPZ, BSX 13 of 64...

  • Page 14: Return To Supplier

    ▷ Never subject the pump set to ambient temperatures which are lower than those permitted for the drinking water/antifreeze mixture provided (see section on drinking water/antifreeze mixture / order documentation). Clean the pump set properly from the outside. See cable manufacturer's documentation or DIN VDE 0298-3. 14 of 64 UPA, UPZ, BSX...

  • Page 15: Disposal

    Always complete and enclose a certificate of decontamination when returning the pump (set). Always indicate any safety and decontamination measures taken. NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids handled posing a health hazard Hazard to persons and the environment! ▷...

  • Page 16: Description Of The Pump (Set)

    Verify the fluid composition against the data sheet. Not approved for handling explosive fluids or for forming part of an explosion-proof system! 4.2 Designation Submersible borehole pump Example: UPA 250C - 150 / 5b Table 4: Key to the designation Code Description Pump type...

  • Page 17: Name Plate

    ▪ Rubber expansion diaphragm for pressure equalisation ▪ Thrust bearing with tilting pads to absorb the pump's hydraulic thrust ▪ Single mechanical seal For motor sizes V, X, Z and E UPA, UPZ, BSX 17 of 64...

  • Page 18: Configuration And Function

    4 Description of the Pump (Set) 4.5 Configuration and function Fig. 3: Sectional drawing, example of a UPA Design Pump and motor are connected by a rigid coupling. The stage casings are supported by straps or stud bolts. A suction strainer at the suction casing protects the pump from coarse particles in the fluid.

  • Page 19: Dimensions And Weights

    – Automatic control units 4.7 Dimensions and weights For dimensions and weights please refer to the data sheet of the pump (set). To be attached outside the place of installation, e.g. control panel, pipeline or mounting bracket. UPA, UPZ, BSX 19 of 64...

  • Page 20: Installation At Site

    Improper handling of the power cable when placing the pump set in vertical position or transporting it Personal injury and damage to property! ▷ Secure power cables against falling down. See cable manufacturer's documentation or DIN VDE 0298-3. 20 of 64 UPA, UPZ, BSX...

  • Page 21: Preparing The Installation

    Do not expose power cables to direct sunlight. NOTE A separate name plate is included in KSB's scope of supply. This name plate must be attached in a clearly visible position outside the place of installation, e.g. at the control panel, pipeline or mounting bracket.
  • Page 22 Never install the pump set with the pump at the lowest point. Fig. 4: Checking the installation position A1, A2 Permissible installation position Permissible installation position, if approved in the order documentation Impermissible installation position 22 of 64 UPA, UPZ, BSX...
  • Page 23 Table 7: Type of motor fill Sticker colour Supplied condition Motor fill Green Filled Drinking water / antifreeze mixture (1,2 propylene glycol) Unfilled Drinking water or drinking water / antifreeze mixture (1,2 propylene glycol) UPA, UPZ, BSX 23 of 64...
  • Page 24 Monitor the screw plugs for escaping fluid. If required, fit new sealing elements. 5.2.4 Installing water storage tanks If the pump set is intended for horizontal installation, the motor has to be fitted with water storage tanks. 24 of 64 UPA, UPZ, BSX...
  • Page 25 2" 3" 4" 5" 6" 8" 10" Weigh t [kg] See product literature of the riser used. Applies to pumps with non-return valve if no other measures to drain the riser have been taken UPA, UPZ, BSX 25 of 64...
  • Page 26 To meet this condition the cable connector also has to be completely submerged. Extension cables connected by KSB If agreed with KSB, the extension cable can be supplied connected to the motor lead with a watertight cable connector. ▪ Unless otherwise specified in the order documentation, KSB's extension cables are designed for: –...

  • Page 27: Installing The Pump Set In Vertical Position

    Observe all safety instructions contained in this manual for the following installation instructions. (⇨ Section 5.1 Page 20) The measured value must be steady; a longer measurement period might be needed for larger cable cross-sections. UPA, UPZ, BSX 27 of 64...
  • Page 28 Allow time for the sealing agent to cure. The connection is now sufficiently secured against loosening. Applies to flanged risers only 28 of 64 UPA, UPZ, BSX...
  • Page 29 Attach a cable tie every 3 metres. Implement this arrangement over the entire length of the riser. Sizes 2, 3, 3a, 3b, 4 1 = turnbuckle (reusable) 2 = cable guard 3 = power cable 4 = metal strap 5 = riser UPA, UPZ, BSX 29 of 64...

  • Page 30: Installing The Pump Set In A Horizontal Position

    (See data sheet.) The required accessories depend on the weight and the overall length of the pump set. If agreed with KSB, the pump set is supplied with the accessories for the required installation type already fitted.
  • Page 31 In such cases, always refer to the additional documentation supplied with the delivery. See the operating instructions of the accessory "Suction, pressure or cooling shroud". Fig. 7: Example: pressure shroud Motor Pump Pressure shroud UPA, UPZ, BSX 31 of 64...

  • Page 32: Installing The Pump Set In An Angled Position

    The pump set must not be installed in this position. 5.6 Notes on electrical connection KSB's submersible borehole pumps > 1000 V are wired for DOL starting. During start- up and run-up the voltage must not fall below the value specified in the order documentation.
  • Page 33 (see data sheet, order documentation). In accordance with DIN EN 61800-4 the drive system supplier is responsible for clarifying the details of and reaching an agreement on the interface between motor and frequency inverter. UPA, UPZ, BSX 33 of 64...

  • Page 34: Electrical Connection

    Check the available mains voltage against the data on the name plate. Terminate the cable ends properly with suitable cable terminations. If cable terminations are included in KSB's scope of supply, observe the separate installation instructions. Check the starting method in the data sheet and select the corresponding circuit diagram.
  • Page 35 The 6 current-carrying conductors of the two parallel power cables are designated U1-1, V1-1, W1-1 and U1-2, V1-2, W1-2; the earth conductor is marked PE. (See circuit diagram.) The motors are wired in star (Y), and are fitted with two parallel cables. Electromagnetic compatibility UPA, UPZ, BSX 35 of 64...
  • Page 36 Dry running automatic dry running ▪ Wells with temporary low yields protection equipment (e.g. integrated in KSB's control unit UPA Control) ▪ Lightning protection Lightning/overvoltage Although a lightning protection device cannot offer protection against direct lightning strikes, it will with earthing terminal...
  • Page 37 Connection to the analysing device The sensor can be connected by 2-, 3- or 4-wire system. A1 A2 A3 A4 Pt 100 2-wire system Pt 100 3-wire system For 4-core cables do not connect core A2. UPA, UPZ, BSX 37 of 64...
  • Page 38 If the cut-out temperature t is reached, the motor must be tripped. It must Cut-out not be re-started until the malfunction has been remedied. Setting: Submersible motors with J2 winding (PE): t = 75 °C Cut-out 38 of 64 UPA, UPZ, BSX...

  • Page 39: Commissioning/Start-Up/Shutdown

    NOTE It is not necessary to delay the start-up of a shut-off element with electric actuator, as the running-up time of the pump is shorter than the dead time of the shut-off element. UPA, UPZ, BSX 39 of 64...
  • Page 40 If the direction of rotation is incorrect, switch the motor off at the control cabinet. Have the phase sequence (U, V, W) corrected on the motor connection side in the control cabinet by a trained electrician. 40 of 64 UPA, UPZ, BSX...

  • Page 41: Operating Limits

    Fig. 11: Minimum submergence depending on the flow rate The values in the above mentioned diagram apply to submersible borehole pumps up to size UPA 350. For larger pump sets refer to the value X in the order documentation or the data sheet.
  • Page 42 (dynamic) water level Fig. 13: Minimum submergence for horizontal installation Minimum submergence 6.2.3.2 Sand content Make sure the maximum sand content of 50 g/m³ is not exceeded. 42 of 64 UPA, UPZ, BSX...
  • Page 43 The pump set is freely suspended in the water and the water inlet is below the motor. ▪ Installation in suction, pressure or cooling shroud Installing the suction, pressure or cooling shroud leads to the required flow along the motor. UPA, UPZ, BSX 43 of 64...

  • Page 44: Shutdown

    Switch off the motor immediately after closing the shut-off element. NOTE To make sure that the pump set is always ready for instant start-up, start up the pump set approximately every 2 weeks for approximately 5 minutes during prolonged shutdown periods. 44 of 64 UPA, UPZ, BSX...

  • Page 45: Servicing/Maintenance

    Pump set tipping over Risk of squashing hands and feet! ▷ Suspend or support the pump set. ✓ Suitable lifting equipment for the total weight has been selected and is on hand. (⇨ Section 5.2.6 Page 25) UPA, UPZ, BSX 45 of 64...

  • Page 46: Separating Pump And Motor

    Secure the key in the shaft stub, e.g. with adhesive tape. Place the motor on a clean and level surface. Secure it against tipping over and rolling off. See cable manufacturer's documentation or DIN VDE 0298-3. If any 46 of 64 UPA, UPZ, BSX...

  • Page 47: Motor Fill

    Mixing ratio / purpose ▪ The motors must only be filled with an antifreeze agent on a 1,2 propylene glycol basis which has been approved by KSB. ▪ The drinking water / antifreeze mixture supplied by the factory is intended for operation as well as storage/transport/preservation.
  • Page 48 ▷ Always secure horizontally positioned pump sets against rolling off. ✓ The information sticker has been checked. Drinking water/antifreeze mixture filled in at the factory Operation only if explicitly approved in the order confirmation. 48 of 64 UPA, UPZ, BSX...

  • Page 49: Storage And Preservation

    To store for a prolonged period pump sets / motors which have not been used yet ensure the following conditions are met: Pump set / motor removed from packaging Vertical (with the motor below) See cable manufacturer's documentation or DIN VDE 0298-3. UPA, UPZ, BSX 49 of 64...

  • Page 50: Reassembling The Pump Set

    Pump sets / motors which have been operated must generally be overhauled by qualified specialist personnel, for example a service workshop authorised by KSB. After the pump set / motor has been overhauled, fill the motor with drinking water / antifreeze mixture providing protection up to -15 °C, and store it.
  • Page 51 CuAl10Ni CuNi1,5S class Rp 0.2 [N/mm²] Metric thread Coarse- Fine-pitch Tightening torque M [Nm] pitch thread thread 1.45 2.15 2.15 2.85 4.25 4.25 10.4 10.4 9.75 8.75 11.8 25.2 25.2 17.7 23.7 17.7 21.3 UPA, UPZ, BSX 51 of 64...
  • Page 52 908.0 1940 1940 636.0 1820 1360 817.0 1630 M33x2 1000 2130 2130 700.0 2000 1500 900.0 1800 1160 2480 2480 812.0 2325 1740 1040 2090 M36x3 1230 2630 2630 863.0 2465 1850 1110 2220 52 of 64 UPA, UPZ, BSX...

  • Page 53: Trouble-Shooting

    Check and replace, if necessary. ✘ Motor winding not suitable for Replace the pump set. operating voltage available Contact KSB. Pump set pressure must be released before attempting to remedy faults on parts which are subjected to pressure. UPA, UPZ, BSX 53 of 64...

  • Page 54: General Assembly Drawing With List Of Components

    58--1 920.11 81--39 901.01 545.02 550.01 940.03 412.01 502.02 940.01 940.04 940.02 525.01 529.02 529.01 902.01 545.01 920.01 502.01 940.05 900.01 904.03 901.02 920.02 Fig. 14: General assembly drawing: UPA 250C submersible borehole pump 54 of 64 UPA, UPZ, BSX...
  • Page 55 900.01 Screw Sleeve 901.01/.02/.11 Hexagon head bolt 525.01 Spacer sleeve 902.01/.02/.11 Stud 529.01/.02 Bearing sleeve 904.03 Grub screw Bush 914.11 Hexagon socket head cap screw 545.01/.02 Bearing bush 920.01/.11 550.01/.11 Disc Lockwasher 940.01/.02/.03/. 04/.05 UPA, UPZ, BSX 55 of 64...
  • Page 56 412.51 160.53 903.51 920.52 411.51 902.51 116.51 920.51 900.51 160.52 550.51 59-12 901.51 160.51 932.51 232 108 Fig. 15: General assembly drawing: submersible motor V, X 81-11* earthing offset by 90°, 932.52, 550.54, 901.53 56 of 64 UPA, UPZ, BSX...
  • Page 57 901.51/.52/.53/.54 Hexagon head bolt 433.51 Mechanical seal 902.51/.52/.53 Stud 59-6 Ball 903.51 Screw plug 59-12 Membrane 914.51/.52 Hexagon socket head cap screw Bearing sleeve 920.51/.52/.53 Bearing bush 932.51/.52 Circlip 550.51/.52/.54/.55 Disc 940.51/.53 Spacer disc UPA, UPZ, BSX 57 of 64...

  • Page 58: Mating Dimensions For Motors V, X, Z, E

    114 ± 0.1 ZBD ... 1.2 to 1.5 114 ± 0.1 ZMD ... 1.2 to 1.5 114 ± 0.1 EMD ... 1.2 to 1.5 114 ± 0.1 EBD ... 1.2 to 1.5 114 ± 0.1 58 of 64 UPA, UPZ, BSX...

  • Page 59: Mating Dimensions For Motor T

    9.3 Mating dimensions for motor T Fig. 17: Mating dimensions for motor T Observe the following dimensions: Table 26: Mating dimensions Motor type series Axial clearance Adjusting dimension A [mm] B [mm] 1.2 to 1.5 4.5 ± 0.1 UPA, UPZ, BSX 59 of 64...

  • Page 60: Ec Declaration Of Conformity

    10 EC Declaration of Conformity 10 EC Declaration of Conformity Manufacturer: KSB Service GmbH (Frankenthal) Neue Industriestraße 8 66424 Homburg (Germany) The manufacturer herewith declares that the product: UPA+TCD, VBD..EMD UPZ, BSX... BSF+TCD, VBD..EMD ▪ is in conformity with the provisions of the following Directives as amended from time to time: –...

  • Page 61: Certificate Of Decontamination

    We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the relevant legal provisions....................................Place, date and signature Address Company stamp Required fields UPA, UPZ, BSX 61 of 64...

  • Page 62: Index

    Order number 6 Other applicable documents 6 Description of the fluid handled 16 Designation 16 Disposal 15 Return to supplier 15 Intended use 8 Safety 8 Safety awareness 9 Scope of supply 18 Misuse 9 62 of 64 UPA, UPZ, BSX...
  • Page 64 KSB Aktiengesellschaft 67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com...

This manual is also suitable for:

BsxUpzUpa seriesUpa 300Upa 350Upa 250c

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