KSB Amarex KRT Installation & Operating Manual
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KSB Amarex KRT Installation & Operating Manual

Submersible motor
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Submersible Motor Pump
Amarex KRT
Sizes DN 50 to DN 80
Motor Sizes
2-pole: 012 to 032
4-pole: 014 to 034
Material Variants H, C1, C2
Installation/Operating
Manual
Mat. No.:
01047331

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Summary of Contents for KSB Amarex KRT

  • Page 1 Submersible Motor Pump Amarex KRT Sizes DN 50 to DN 80 Motor Sizes 2-pole: 012 to 032 4-pole: 014 to 034 Material Variants H, C1, C2 Installation/Operating Manual Mat. No.: 01047331...
  • Page 2 Legal information/Copyright Installation/Operating Manual Amarex KRT Original operating manual 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 the manufacturer's express written consent.

  • Page 3: Table Of Contents

    Scope of supply ....................17 Dimensions and weights ................18 Installation at Site ................19 Safety regulations ................... 19 Checks to be carried out prior to installation ..........19 Installing the pump set .................. 21 Electrical system ....................26 Amarex KRT 3 of 60...
  • Page 4 Related Documents ................5 0 General assembly drawings ................50 Wiring diagram ....................53 Flamepaths on explosion-proof motors ............54 Sectional drawings of the mechanical seal ........... 55 EC Declaration of Conformity ............56 Certificate of Decontamination ............57 Index ....................58 4 of 60 Amarex KRT...

  • Page 5: Glossary

    The part of the pump in which the kinetic energy is converted into pressure energy Close-coupled design Motor directly fitted to the pump via a flange or a drive lantern Amarex KRT 5 of 60...

  • Page 6: General

    (set) and serve as identification for all further business processes. In the event of damage, contact your nearest KSB service centre immediately 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.
  • Page 7 1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product Amarex KRT 7 of 60...

  • Page 8: Safety

    ▪ Only operate pump sets which are in perfect technical condition. ▪ Do not operate partially assembled pump sets. ▪ Only use the pump set to handle the fluids described in the data sheet or product literature of the pump model. 8 of 60 Amarex KRT...
  • Page 9 ▪ 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. Minimum permissible flow rate Maximum permissible flow rate Best efficiency point Amarex KRT 9 of 60...

  • Page 10: Personnel Qualification And Training

    ▪ Modifications or alterations of the pump are only permitted with the manufacturer's prior consent. ▪ Use only original spare parts or parts authorised by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for resulting damage. 10 of 60 Amarex KRT...

  • Page 11: Unauthorised Modes Of Operation

    Repair work at the flameproof joints must only be performed in accordance with the manufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 is not permitted. Amarex KRT 11 of 60...

  • Page 12: 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 13: Storage/Preservation

    Spray the preservative through the suction and discharge nozzles. It is advisable to then close the pump nozzles (e.g. with plastic caps or similar). NOTE Observe the manufacturer's instructions for application/removal of the preservative. Amarex KRT 13 of 60...

  • Page 14: Return To Supplier

    Always indicate any safety and decontamination measures taken. (⇨ Section 11 Page 57) 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, consumables and supplies which are hot or pose a health hazard Hazard to persons and the environment! ▷...

  • Page 15: Description Of The Pump (Set)

    Pump for handling untreated waste water containing long fibres and solid substances, fluids containing air/gas as well as raw, activated and digested sludge. 4.2 Designation Example: Amarex KRT F 80 - 210 / 02 4 Y H - S Table 6: Key to the designation Code...

  • Page 16: Types Of Installation

    Pump sets of installation types P and S are designed for continuously submerged operation. The motor is cooled by the fluid handled on the motor surface. Operation with the motor outside the fluid handled is possible for short periods. 16 of 60 Amarex KRT...

  • Page 17: Configuration And Function

    Depending on the model, the following items are included in the scope of supply: Stationary wet installation (installation types S and K) ▪ Pump set complete with power cables ▪ Claw with sealing element (O-ring) and mounting elements ▪ Lifting rope, lifting chain or lifting bail (optional) Amarex KRT 17 of 60...

  • Page 18: Dimensions And Weights

    ▪ Foot plate or pump stool with mounting elements ▪ Lifting rope, lifting chain or lifting bail (optional) 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 19: Installation At Site

    Check the structural requirements. All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing/general arrangement drawing. Amarex KRT 19 of 60...
  • Page 20 ▷ Never insert your hands or any other objects into the pump. ▷ Check that the inside of the pump is free from any foreign objects. ▷ Take suitable precautions (e.g. wear safety goggles, etc). 20 of 60 Amarex KRT...

  • Page 21: Installing The Pump Set

    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 duckfoot bend is either fastened with chemical anchors and/or foundation rails. Amarex KRT 21 of 60...
  • Page 22 ▷ Install a swing check valve in longer riser pipes to prevent the pump from excessive running in reverse. When fitting a swing check valve, make sure that the unit can still be vented properly. 22 of 60 Amarex KRT...
  • Page 23 Fasten threaded bolt 904 with the pre-assembled clamping arrangement to the mounting bracket with nut 920.36. Do not tighten nut 920.36 too much in order to allow sufficient play for subsequently tensioning the guide wire. Fig. 9: Fitting the mounting bracket Amarex KRT 23 of 60...
  • Page 24 Fasten claw 732 to the discharge flange with studs 902.35, discs 550.35 and nuts 920.35. 902.35 Observe the tightening torques. Fit profile joint 410 in the groove of the claw. This will seal the duckfoot bend/pump connection. 550.35 920.35 Fig. 12: Fitting the claw 24 of 60 Amarex KRT...
  • Page 25 Fit the foot plate or pump stool before installing the pump. Tighten the bolts as specified, see table “Tightening torques”. Connecting the piping The DIN connection can be connected to rigid or flexible pipes. Fig. 14: Attaching the lifting chain/rope Amarex KRT 25 of 60...

  • Page 26: Electrical System

    Damage to the pump set by cavitation! ▷ Never allow the fluid level to drop below the specified minimum. Automatic operation of the pump set in a tank requires the use of level control equipment. Observe the minimum fluid level. 26 of 60 Amarex KRT...
  • Page 27 No modifications are required on the power/control cable of the pump set. Suitable analysing devices must be selected. To monitor the leakage sensor inside the motor, it is recommended to use a special relay available from KSB. 5.4.1.4 Sensors DANGER...
  • Page 28 5 Installation at Site Measuring transducers are required for analysing the sensor signals supplied. Suitable devices for 230V~ can be supplied by KSB. NOTE Reliable and safe operation of the pump within the scope of our warranty is only possible if the sensor signals are properly analysed as stipulated in these operating instructions.
  • Page 29 ▷ 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. Amarex KRT 29 of 60...
  • Page 30 After shortening the cables, correctly re-affix the markings on the individual cores at the cable ends. Fig. 16: Fastening the power cables Potential equalisation The pump set does not have an external PE connection (risk of corrosion). 30 of 60 Amarex KRT...
  • Page 31 ▷ Explosion-proof pump sets installed in a tank must never be retrofitted with an external potential equalisation connection! DANGER Touching the pump set during operation Electric shock! ▷ Make sure that the pump set cannot be touched during operation. Amarex KRT 31 of 60...

  • Page 32: Commissioning/Start-Up/Shutdown

    Pump start-up against a closed shut-off element Increased vibrations! Damage to mechanical seals and bearings! ▷ Never operate the pump set against a closed shut-off element. Fully open the discharge line shut-off element, if any. Start up the pump set. 32 of 60 Amarex KRT...

  • Page 33: Operating Limits

    Danger of frost/freezing Damage to the pump set! ▷ Drain the pump set or protect it against freezing. Refer to the maximum permissible fluid and ambient temperature on the name plate and in the data sheet. Amarex KRT 33 of 60...
  • Page 34 The fluid level must not drop below the specified minimum (dimension B). Exact dimensions see general arrangement drawing/outline drawing. Fig. 17: Minimum fluid level 34 of 60 Amarex KRT...

  • Page 35: Shutdown/Storage/Preservation

    This will prevent the formation of deposits within the pump and the pump intake area. The pump (set) is removed from the pipe and stored ✓ All safety regulations are observed. (⇨ Section 7.1 Page 37) Clean the pump set. Amarex KRT 35 of 60...

  • Page 36: Returning To Service

    Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is complete, 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. 36 of 60 Amarex KRT...

  • Page 37: Servicing/Maintenance

    NOTE Special regulations apply to repair work on explosion-proof pump sets. Modification or alteration of the pump set may affect explosion protection and are only permitted after consultation with the manufacturer. Amarex KRT 37 of 60...

  • Page 38: Servicing/Inspection

    (set) with a minimum of maintenance expenditure and work. NOTE All maintenance, service and installation work can be carried out by KSB Service or authorised workshops. Find your contact in the attached "Addresses" booklet or on the Internet at "www.ksb.com/contact".
  • Page 39 7.2.2 Lubrication and lubricant change 7.2.2.1 Lubricating the mechanical seal The mechanical seal is supplied with lubricant from the lubricant reservoir. 7.2.2.1.1 Intervals Replace the lubricant after every 10,000 operating hours but at least every 3 years. Amarex KRT 39 of 60...
  • Page 40 ▷ Open the screw plug of the lubricant reservoir very carefully. Draining the lubricant Position the pump set as shown. 90 3 Fig. 18: Draining the lubricant Place a suitable container under the screw plug. 40 of 60 Amarex KRT...

  • Page 41: Drainage/Cleaning

    Unqualified personnel performing work on the pump (set) Risk of injury! ▷ Always have repair and maintenance work performed by specially trained, qualified personnel. WARNING Hot surface Risk of injury! ▷ Allow the pump set to cool down to ambient temperature. Amarex KRT 41 of 60...
  • Page 42 The impeller/shaft connection is a tapered fit. For removing the impeller, an M10 jacking thread is provided at the impeller hub. Screw in the jack as shown in the drawing below and remove the impeller. 42 of 60 Amarex KRT...

  • Page 43: Reassembling The Pump Set

    7 Servicing/Maintenance Fig. 20: Forcing screw NOTE The forcing screw is not included in the scope of supply. It can be ordered separately from KSB. 7.4.5 Dismantling the motor section NOTE Special regulations apply to repair work on explosion-proof pump sets.
  • Page 44 515 or circlip 932.03. Insert O-rings 412.04/412.35 and 412.15/412.11 into discharge cover 163, and press them into bearing bracket 330 as far as they will go. Push pump-end mechanical seal 433.02 onto shaft 210. 44 of 60 Amarex KRT...
  • Page 45 Use a torque wrench to tighten the bolts to a tightening torque of 60 Nm. Insert O-ring 412.16 in suction cover 162. Fasten ring 500.02 with socket head cap screw 914.07 in the suction cover. Amarex KRT 45 of 60...
  • Page 46 ▪ Test medium: compressed air ▪ Test pressure: 0.5 bar max. ▪ Test duration: 2 minutes 2563:115 Fig. 24: Screwing in the testing device Unscrew and remove the screw plug and joint ring of the lubricant reservoir. 46 of 60 Amarex KRT...

  • Page 47: Tightening Torques

    7.7.1 Ordering spare parts Always quote the following data when ordering replacement or spare parts: ▪ Pump type ▪ KSB order number ▪ Motor number Refer to the name plate for all data. (⇨ Section 4.3 Page 15) Also supply the following data: ▪...
  • Page 48 8 and 9 10 and more 433.02 Mechanical seal, pump- 90 % 321.01 / 322 Rolling element bearing, 50 % motor-end 320 / 321.02 Rolling element bearing, 50 % pump-end 99-9 Set of sealing elements 100 % 48 of 60 Amarex KRT...

  • Page 49: Trouble-Shooting

    Motor is not running because of lack of Check the electrical installation. voltage. Contact the energy supplier. Motor winding or power cable are defective. Replace by new original KSB parts or contact KSB. X Defective rolling element bearing Contact KSB. Water level lowered too much during Check level control equipment.

  • Page 50: Related Documents

    9.1 General assembly drawings 561.02 321.01 81-59 59-17 1-79 321.02 914.01 81-51 412.04 914.05 932.05 932.01 932.02 412.01 412.02 412.03 914.02 433.02 932.04 914.04 433.01 932.03 914.03 0W 382 369-00 Fig. 25: General assembly drawing 50 of 60 Amarex KRT...
  • Page 51 81-18 914.28 81-56 Impeller type F Impeller type K 914.02 914.04 Impeller type S 914.03 914.07 23-7 914.04 561 914.06 Part No. Description Part No. Description 1-79 Coating Casing wear ring Pump casing Disc Amarex KRT 51 of 60...
  • Page 52 Motor housing Profile seal Rotor Joint ring Rotor core pack 412.01/.02/.03/.04 O-ring Cable gland 433.01/.02 Mechanical seal Screw plug Mating ring carrier 914.01/.02/.03/.04/.05/.06/.07/. Hexagon socket head cap screw 59-17 Shackle 932.01/.02/.03./.04/.05 Circlip Ring Name plate 52 of 60 Amarex KRT...

  • Page 53: Wiring Diagram

    9 Related Documents 9.2 Wiring diagram Fig. 26: Wiring diagram Amarex KRT 53 of 60...

  • Page 54: Flamepaths On Explosion-Proof Motors

    9 Related Documents 9.3 Flamepaths on explosion-proof motors Table 20: Overview of flamepaths Pump set 1,2, 3 Flamepaths 54 of 60 Amarex KRT...

  • Page 55: Sectional Drawings Of The Mechanical Seal

    Table 21: Sectional drawings of the mechanical seal Sectional drawing Standard, 433.01 Mechanical seal (bellows- material: C1 type mechanical seal) 433.01 433.02 Mechanical seal (bellows- type mechanical seal) 433.02 Standard H, C2 433. Mechanical seal Standard variant C1 43 3 Amarex KRT 55 of 60...

  • Page 56: Ec Declaration Of Conformity

    67227 Frankenthal (Germany) The manufacturer herewith declares that the product: Amarex KRT KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: – Pump set: Machinery Directive 2006/42/EC The manufacturer also declares that ▪...

  • Page 57: 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 Amarex KRT 57 of 60...

  • Page 58: Index

    Spare parts stock 47 Intended use 8 Start-up 32 Interference immunity 27 Storage 13, 35 Supply voltage 33 Leakage monitoring 29 Level control 26 Tightening torques 47 Lubricant 39 Trouble-shooting 49 Intervals 38 Quality 40 Maintenance work 38 58 of 60 Amarex KRT...
  • Page 60 KSB Aktiengesellschaft 67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com...

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