Astralpool Kivu Centrifugal Pump Manual

This manual contains fundamental information regarding safety measures for installation and commissioning. It is essential that both the installer and the user read the instructions before proceeding with assembly and startup.

1. General Safety Prescriptions

The following symbols indicate potential dangers due to non-compliance with corresponding prescriptions:

• ⚠️ DANGER. Risk of electric shock. Failure to observe this prescription carries a risk of electric shock.
• ⚠️ DANGER. Failure to observe this prescription carries a risk of harm to persons or property.
• ⚠️ ATTENTION. Failure to observe this prescription carries a risk of damage to the pump or installation.

2. General Safety Rules

Generalities

• The machines mentioned in this Manual are specifically designed for pre-filtration and recirculation of swimming pool water.
• They are designed to work with clean water at temperatures not exceeding 35°C (Figure 4, Max. Temp.).
• Perform installation according to the specific indications for each setup.
• Respect current accident prevention regulations.
• Any modification to the pump requires prior authorization from the manufacturer. Original spare parts and manufacturer-authorized accessories ensure greater safety. The pump manufacturer is exempt from all liability for damages caused by unauthorized spare parts or accessories.
• When working on the machine or its connected equipment, disconnect the equipment from the power supply and starting devices, as the pump's electrical parts are live during operation.
• Assembly and maintenance work must be carried out by qualified and authorized personnel who have thoroughly read the installation and service instructions.
• Comply with the installation and service instructions to ensure safe machine operation.
• In case of malfunction or breakdown, contact your supplier or their nearest representative.

Warnings during Installation and Assembly

• Once the pump is unpacked, handle it by gripping the suction port and motor housing; it cannot be lifted by a single point.
• When connecting electrical cables to the machine's motor, carefully manage the wiring inside the terminal box, ensuring no cable ends remain after closing, and that the earth conductor is correctly connected. Connect the motor following the electrical diagram provided with the machine.
• Ensure electrical cable connections to the machine's terminal box are well-seated and tightened.
• The equipment must be connected to a power outlet (refer to pump nameplate data) with an earth connection, protected by a Residual Current Device (RCD) with a rated residual operating current not exceeding 30 mA.
• Use the motor's terminal box gasket correctly to prevent water entry. Similarly, fit and tighten the cable gland inside the terminal box cable entry.
• Take particular care to prevent water from entering the motor and live electrical parts in any way.
• If the intended use differs from that described, apply supplementary technical adaptations and regulations.

Warnings during Startup

• Verify the calibration of the motor's electrical protection devices and ensure electrical and mechanical contact protections are correctly positioned and fixed before startup.
• NOTE: Do not use bathroom facilities while the pumping equipment is operating. Do not use the pump if people are in contact with water.

Warnings during Assembly and Maintenance

• Consider national installation regulations for pump assembly and installation.
• Take particular care to prevent water from entering the motor and live electrical parts in any way.
• Avoid contact, even accidental, with the machine's moving parts during operation or before it has completely stopped.
• Wait for the machine to stop completely before performing any manipulation.
• Disconnect the machine from the power supply and lock the startup devices before proceeding with any electrical or mechanical maintenance.
• Follow these steps before performing any intervention on the machine:
  1. Remove voltage from the machine.
  2. Lock the startup devices.
  3. Verify that no voltage is present in the circuits, including auxiliary and supplementary services.
  4. Wait until the impeller has completely stopped.
• The above list is indicative and not binding for safety purposes, as specific safety regulations may exist in particular norms.
• The installation, use, and maintenance instructions in this manual, due to the complexity of the cases covered, do not intend to cover all possible and imaginable service and maintenance scenarios. If supplementary instructions are needed or particular problems arise, do not hesitate to contact the nearest Technical Assistance Service.
• Electrical installation must be performed by qualified electrical installation personnel. This equipment is not intended for use by persons with reduced physical, sensory, or mental capabilities, or without experience, unless they have received supervision or instructions regarding its use from a responsible person.
• Do not allow children or adults to lean or sit on the apparatus. Children must be supervised to ensure they do not play with the equipment.

3. Pump Handling

Weight: Refer to the label on the packaging.

Notice: Motors are supplied with lifting eyes that must not be used for lifting the complete pump assembly. See Figure 1.

Pumps can only be lifted using nylon straps or a hook as shown in Figure 3.

Figure 1: Incorrect pump lifting. Shows lifting by motor lifting eyes, which is prohibited.

Figure 3: Correct pump lifting. Shows lifting using straps around the pump body.

4. Identification Label Information

Each pump has two identification labels providing information about it. The labels are located on the Motor (one on the terminal box cover and the other on the fan cover).

Label located on the Terminal Box Cover

Provides information on the pump's hydraulic characteristics (Figure 4).

Figure 4: Diagram showing the location of the terminal box label and its fields.

Manufactured by: Metalast, S.A.U.

Label located on the Fan Cover

Provides information about the motor (Figure 5).

Figure 5: Diagram showing the location of the motor label and its fields.

5. Location

• Notice: Do not install the pump in closed or poorly ventilated areas where unfavorable conditions for personnel may arise. Ensure sufficient lighting for the installer.
• Mount the pump below the swimming pool or pond water level to improve pump performance.
• If a self-priming pump must be installed above the water level, the suction pressure differential must not exceed 0.02 MPa (2 mH2O). Ensure the suction pipe is as short as possible, as a longer pipe increases suction time and installation head losses.
• The Kivu self-priming pumps are the 3cv, 4cv, 5.5cv models with pre-filter.
• Ensure the pump is protected from possible flooding and receives dry ventilation.

6. Installation and Assembly

• The installation of our pumps is only permitted in pools or ponds that comply with standard HD 384.7.702. In doubtful cases, consult your specialist.
• Pumps may be supplied with a pre-filter containing a basket to collect coarse particles, as these can damage the pump's internal hydraulics.
• All pumps are equipped with a foot with through-holes for securing them to the ground via anchoring.

Installation

• Pumps must be installed horizontally.
• Pumps require a clear space of 0.5 m behind the motor and at least 1 m above the motor for the use of lifting equipment (Figure 6).

Figure 6: Required clear space. Shows a diagram indicating 1m clearance above and 0.5m behind the motor.

Piping Installation (Recommendations)

• When installing piping, check that the pump body is not stressed by the pipes.
• Suction and discharge piping must be adequately sized, considering the pump's inlet pressure.
• Install piping to avoid air pockets, especially at the pump's suction end.

Figure 7: Piping diagrams illustrating correct and incorrect pipe installations, emphasizing avoiding sharp bends and air traps.

• Install shut-off valves on both sides of the pump to prevent the system from emptying if the pump needs cleaning or repair.
• Check that the piping is correctly supported as close as possible to the pump, both on the suction and discharge sides. The counter-flanges must be aligned with the pump flanges, without tension that could cause damage.
• The pump cannot operate against a closed valve, as this will cause an increase in temperature and vapor formation within the pump, potentially causing damage.

Figure 8: Pump Installation Diagram

This diagram illustrates a typical pump installation with various components labeled A through N. The corresponding descriptions are provided in the table below.

Noise and Vibration Elimination

For optimal operation and to minimize noise and vibrations, it is advisable to use anti-vibration dampers.

Noise and vibrations are generated by the motor's rotation and the flow in pipes and connections. The effect on the environment is subjective and depends on correct installation and the condition of other system components.

The best way to eliminate noise and vibrations is to use a concrete foundation, vibration dampers, and expansion joints.

7. Operating Conditions

Electrical Installation

• It is essential to use a multiple disconnection device with a minimum contact separation of 3 mm to disconnect the equipment from the electrical supply.
• Use a rigid cable for the mains connection. If using a flexible cable, it must have terminals for connection to the pump motor terminals.
• The equipment must be connected to a power outlet (refer to pump nameplate data) with an earth connection, protected by an RCD with a rated residual operating current not exceeding 30 mA.
• Adjust the thermal relay value appropriately according to the pump's current.
• Check the required fuse type before connecting the motor.
• Verify the correct arrangement and connection of the earth cable in the equipment installation.
• Respect the electrical installation and connection conditions; otherwise, the pump manufacturer disclaims all responsibility and considers the warranty void.
• Special installation regulations may apply.
• ⚠️ Risk of electric shock in case of an improper mains connection.

For Three-Phase Motor Pumps:

• Use a motor guard with magneto-thermal protection.
• Protect the pump against overload with a safety switch for the motor.
• Adjust the thermal protector value appropriately, according to the thermal protector table. For connection A (3 x 230 V supply), use the protector with the highest indicated value. For connection Y (3 x 400 V supply), use the protector with the lowest value.
• Connect the lowest voltage in A and the highest voltage in Y for voltage ranges other than 230/400V; 400/690V.
• For alternating current, use a connection hose type HO7 RN-F3 where the cable section is suitable for the motor's power and cable length.
• The mains cable connection can only be made by qualified and authorized personnel.

Frequency Variator

• These pumps are suitable for use with a frequency variator.
• It is recommended to operate within the frequency limits of 20Hz to 50Hz.
• For more information, contact the frequency variator supplier.

8. Commissioning Instructions

Pre-Startup Checks

Before starting the pump, perform the following operations:

1. Remove the pre-filter cover by unscrewing the retaining nut.
2. Fill the pump with water through the pre-filter until it appears at the suction pipe.
3. Replace the basket inside the pre-filter if it was removed during these operations, to prevent coarse particles from entering the pump and potentially blocking it.
4. Replace the pre-filter cover and close it by screwing, ensuring the gasket is in its housing.
5. Check that the supply voltage and frequency correspond to those specified on the pump's nameplate.

Pumps must never operate without the pre-filter being filled with water beforehand, as this can damage the mechanical seal, causing water leaks.

Check that the motor's rotation direction is correct (clockwise) by observing through the sight glass in the fan cover.

Startup

• Open all valves and connect the motor.
• Allow the piping to self-prime and wait for it to complete within a reasonable time.
• ⚠️ THE PUMP MUST NEVER RUN DRY. The pump must not be started dry, as this would damage its mechanical seal, causing water leaks.
• The pump cannot operate against a closed valve, as this will cause an increase in temperature and vapor formation within the pump, potentially causing damage.

Minimum Pressure - NPSHr / Cavitation

• The minimum suction pressure depends on the Kivu pump's flow rate and power. Refer to the NPSHr graphs.
• If the pump does not have the required minimum pressure, it may cavitate. Vaporization would cause vibration, damaging moving parts (impeller, mechanical seal, bearings) and fixed parts (flange, diffuser, volute).
• To prevent cavitation, ensure the minimum pressure at the pump inlet meets the requirement shown in the NPSHr graph.

Maximum Flow Rate

The maximum flow rate is determined by the pump's minimum pressure differential. The minimum pressure must never be lower than indicated on the pump label (Figure 4).

Minimum Flow Rate

• The pump must not operate against a closed discharge valve, as this would cause an increase in temperature, potentially damaging pump parts and shortening its operating life.
• The minimum continuous flow rate must be at least 10% of the nominal flow rate indicated on the pump label (Figure 4).

9. Maintenance

Perform periodic checks:

• Correct fastening of mechanical parts and condition of machine support screws.
• Clean the pre-filter basket regularly to prevent pressure drops. Do not hit it during cleaning to avoid possible breakage.
• The pump should be inspected every 100 operating hours or less, depending on water cleanliness.
• Monitor the machine and electric motor temperature. In case of anomaly, stop the machine immediately and contact the nearest Technical Assistance Service.
• Monitor machine vibrations. In case of anomaly, stop the machine immediately and contact the nearest Technical Assistance Service.

If the pump stops, check if the motor's operating amperage is equal to or lower than that marked on the manufacturer's nameplate, or contact the nearest Technical Assistance Service.

Empty the pump if it will remain out of service for an extended period, especially in cold countries where freezing may occur.

To empty the pump, remove the drain plug.

Each time the pre-filter is opened, clean the gasket seat and the gasket itself to ensure a watertight seal when closing the cover.

Pump components subject to normal wear and tear must be replaced periodically to maintain the pump's good performance. The following table lists the consumable components and their estimated lifespan.

The estimated lifespan of the above parts has been established under normal conditions of use and installation.

Follow the installation manual instructions to maintain the pump's lifespan.

10. Disassembly

• The motor assembly can be detached from the pump body without disconnecting the suction and discharge piping.
• To detach the motor assembly from the pump body, remove the screws that join them.

11. Fault Table