KSB Amarex KRT Installation instructions

Submersible Motor Pump

Amarex KRT

Pump Sizes DN 40 to DN 300

Motor Sizes:

2-pole: 5 2 to 55 2

4-pole: 4 4 to 65 4

6-pole: 4 6 to 50 6

8-pole: 10 8 to 35 8

Installation/Operating

Manual

Ident. number: 01 196 129

Legal information/Copyright

Installation/Operating Manual Amarex KRT

Original operating manual

KSB Aktiengesellschaft Pegnitz

or processed for any other purpose, nor otherwise transmitted, published or made available to a third

party without KSB´s express written consent.

Subject to technical modification without prior notice.

Contents

Glossary ................................................................................................ 5

1 General ................................................................................................ 6

1.1 Principles .......................................................................................................... 6

1.2 Installation of partly completed machinery .................................................. 6

1.3 Target group ................................................................................................... 6

1.4 Other applicable documents .......................................................................... 7

1.5 Symbols ............................................................................................................ 7

2 Safety ................................................................................................... 8

2.1 Key to safety symbols/markings ..................................................................... 8

2.2 General ............................................................................................................ 8

2.3 Intended use .................................................................................................... 8

2.4 Personnel qualification and training ........................................................... 10

2.5 Consequences and risks caused by non-compliance with these operating

instructions .................................................................................................... 10

2.6 Safety awareness ........................................................................................... 10

2.7 Safety information for the operator/user .................................................... 10

2.8 Safety information for maintenance, inspection and installation work ... 11

2.9 Unauthorised modes of operation ............................................................... 11

2.10 Explosion protection ..................................................................................... 11

3 Transport/Temporary Storage/Disposal ........................................... 13

3.1 Transport ....................................................................................................... 13

3.2 Storage/Preservation ..................................................................................... 14

3.3 Return to supplier ......................................................................................... 14

3.4 Disposal .......................................................................................................... 15

4 Description of the Pump (Set) .......................................................... 16

4.1 General description ....................................................................................... 16

4.2 Designation ................................................................................................... 16

4.3 Name plate .................................................................................................... 16

4.4 Design details ................................................................................................ 16

4.5 Types of installation ...................................................................................... 17

4.6 Configuration and function ......................................................................... 18

4.7 Scope of supply ............................................................................................. 18

4.8 Dimensions and weights ............................................................................... 19

5 Installation at Site ............................................................................. 20

5.1 Safety regulations ......................................................................................... 20

5.2 Checks to be carried out prior to installation ............................................. 20

5.3 Installing the pump set ................................................................................. 22

5.4 Electrical connection ..................................................................................... 28

Contents

Amarex KRT 3 of 78

6 Commissioning/Start-up/Shutdown ................................................. 34

6.1 Commissioning/start-up ................................................................................ 34

6.2 Operating limits ............................................................................................ 34

6.3 Shutdown/storage/preservation ................................................................... 37

6.4 Returning to service ...................................................................................... 37

7 Servicing/Maintenance ...................................................................... 39

7.1 Safety regulations ......................................................................................... 39

7.2 Servicing/inspection ...................................................................................... 40

7.3 Drainage/disposal .......................................................................................... 45

7.4 Dismantling the pump set ............................................................................ 45

7.5 Reassembling the pump set .......................................................................... 49

7.6 Tightening torques ....................................................................................... 54

7.7 Spare parts stock ........................................................................................... 55

8 Trouble-shooting ............................................................................... 56

9 Related Documents ........................................................................... 57

9.1 General assembly drawings .......................................................................... 57

9.2 Wiring diagrams ............................................................................................ 70

9.3 Flamepaths of explosion-proof motors ....................................................... 71

9.4 Sectional drawings of the mechanical seal .................................................. 72

10 EC Declaration of Conformity .......................................................... 74

11 Certificate of Decontamination ....................................................... 75

Index .................................................................................................. 76

Contents

4 of 78 Amarex KRT

Glossary

Back pull-out unit

Pump without pump casing; partly completed

machinery

Certificate of decontamination

A certificate of decontamination certifies that

the pump (set) has been properly drained to

eliminate any environmental and health

hazards arising from components in contact

with the fluid handled.

Close-coupled design

Motor directly fitted to the pump via a flange

or a drive lantern

Hydraulic system

The part of the pump in which the kinetic

energy is converted into pressure energy

Glossary

Amarex KRT 5 of 78

1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicated

on the front cover (for details, please refer to the table below).

Table 1: Variants covered by this manual

Sizes Impeller types Material variant

Grey cast iron Industrial materials

G G1 G2 GH H C1 C2

40-250 F, K, S F, K, S F,K F F, K F, K F, K F, K

80-250 E, F E, F F F F F F F

80-251 F, K F, K K - K K K K

80-315 D D D - - - - -

80-316 F F F F F F - -

100-240 F F F F F F F F

100-250 E, F, K E, F, K F, K F F, K F, K F, K F, K

100-251 D D D - - - - -

100-315 D, E, F, K D, E, F, K D, F, K F F, K F, K F, K F, K

100-316 D D D - - - - -

100-400 K K - - - - - -

100-401 E, F, K E, F, K F, K F F, K F, K F, K F, K

150-251 D D D - - - - -

150-315 D, E, F, K D, E, F, K D, F, K F F, K F, K F, K F, K

150-400 D, K D, K D - - - - -

150-401 D, E, F, K D, E, F, K D, F, K F F,K F, K F, K F, K

151-401 K K K - K K K K

200-315 D, K D,K D, K - K K K K

200-316 K K K - K K K K

200-330 K K K - K K K K

200-400 D, K D, K D - - - - -

200-401 E, K E, K K - K K K K

250-400 D, K D,K D, K - K K K K

250-401 K K K - K K K K

300-400 D, K D, K D, K - K K K K

300-401 K K K - K K K K

The manual describes the proper and safe use of this equipment in all phases of

operation.

The name plate indicates the type series and size, the main operating data, the order

number and the order item number. The order number and order item number

clearly 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 Installation of partly 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 qualified specialist technical

personnel. (⇨ Section 2.4 Page 10)

1 General

6 of 78 Amarex KRT

1.4 Other applicable documents

Table 2: Overview of other applicable documents

Document Contents

Data sheet Description of the technical data of the pump

set

General arrangement drawing/

outline drawing

Description of mating and installation

dimensions for the pump set

Hydraulic characteristic curve Characteristic curves showing head, flow rate,

efficiency and power input

General assembly drawing1) Sectional drawing of the pump set

Sub-supplier product literature1) Operating manuals and other product

literature describing accessories and

integrated machinery components

Spare parts lists1) Description of spare parts

Supplementary operating manuals1) For example for special accessories

1.5 Symbols

Table 3: Symbols used in this manual

Symbol Description

✓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

1) If agreed to be included in the scope of supply

1 General

Amarex KRT 7 of 78

2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 4: Definition of safety symbols/markings

Symbol Description

!DANGER

DANGER

This signal word indicates a high-risk hazard which, if not avoided,

will result in death or serious injury.

!WARNING

WARNING

This signal word indicates a medium-risk hazard which, if not

avoided, could result in death or serious injury.

CAUTION

This signal word indicates a hazard which, if not avoided, could

result in damage to the machine and its functions.

Explosion protection

This symbol identifies information about avoiding explosions in

potentially explosive atmospheres in accordance with EC Directive

94/9/EC (ATEX).

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 identifies information

about protection against electrical voltage.

Machine damage

In conjunction with the signal word CAUTION 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 pump operation and prevent personal injury

and damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the responsible specialist

personnel/operators prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the site

at all times.

Information attached directly to the pump must always be complied with and be

kept in a perfectly legible condition at all times. This applies to, for example:

▪Arrow indicating the direction of rotation

▪Markings for connections

▪Name plate

The operator is responsible for ensuring compliance with all local regulations which

are not taken into account in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits described in the

other applicable documents.

▪Only operate pump sets which are in perfect technical condition.

▪Do not operate partially assembled pump sets.

!DANGER

2 Safety

8 of 78 Amarex KRT

▪Only use the pump set to handle the fluids described in the data sheet or product

literature of the pump model.

▪Never operate the pump set without the fluid to be handled.

▪Observe the limits for continuous operation specified in the data sheet or

product literature (Qmin2) and Qmax3) ) (to prevent damage such as shaft fracture,

bearing failure, mechanical seal damage, etc).

▪When untreated waste water is handled the duty points in continuous operation

lie within 0.7 to 1.2 x Qopt4) to minimise the risk of clogging/hardening.

▪Avoid duty points for continuous operation at very low speeds and small flow

rates (<0.7 x Qopt4) ).

▪Observe the maximum flow rates indicated in the data sheet or product

literature (to prevent overheating, mechanical seal damage, cavitation damage,

bearing damage, etc).

▪Do not throttle the flow rate on the suction side of the pump set (to prevent

cavitation damage).

▪Consult the manufacturer about any use or mode of operation not described in

the data sheet or product literature.

▪Only use the respective impeller types in combination with the fluids described

below.

Impeller with cutter

(impeller type S)

Suitable for the following fluids:

Faeces, domestic sewage and waste water

containing long fibres

Free-flow impeller

(impeller type F)

Suitable for the following fluids:

Fluids containing solids and stringy

material as well as fluids with entrapped

air or gas

Closed single-vane

impeller

(impeller type E)

Suitable for the following fluids:

Fluids containing solids and stringy

material

Closed multi-vane

impeller

(impeller type K)

Suitable for the following fluids:

Contaminated, solids-laden, non-gaseous

fluids without stringy material

2) Minimum permissible flow rate

3) Maximum permissible flow rate

4) Best efficiency point

2 Safety

Amarex KRT 9 of 78

Open, diagonal single-

vane impeller

(impeller type D)

Suitable for the following fluids:

Waste water with solid substances and

long fibres

Prevention of foreseeable misuse

▪Observe the minimum flow velocities required to fully open the swing check

valves to prevent the reduction of pressure and risk of clogging.

(Contact the manufacturer for the required minimum flow velocities/loss

coefficients.)

▪Never exceed the permissible operating limits specified in the data sheet and in

the product literature regarding pressure, temperature, etc.

▪Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain and

inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved in

installation, operation, maintenance and inspection must be clearly defined by the

operator.

Deficits in knowledge must be rectified by sufficiently trained specialist personnel

training and instructing the personnel who will carry out the respective tasks. If

required, the operator can commission the manufacturer/supplier to train the

personnel.

Training on the pump (set) must always be supervised by technical specialist

personnel.

2.5 Consequences and risks caused by non-compliance with these operating

instructions

▪Non-compliance with these operating instructions will lead to forfeiture of

warranty cover and of any and all rights to claims for damages.

▪Non-compliance can, for example, have the following consequences:

–Hazards to persons due to electrical, thermal, mechanical and chemical

effects and explosions

– Failure of important product functions

–Failure of prescribed 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 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

▪Applicable standards and laws

2.7 Safety information for the operator/user

▪The operator shall fit contact guards for hot, cold and moving parts, and check

that the guards function properly.

▪Never remove a contact guard while the pump is running.

2 Safety

10 of 78 Amarex KRT

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