KSB Amarex N Operating Manual
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KSB Amarex N Operating Manual

Submersible motor pump
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Submersible Motor Pump
Amarex N
Pump Sizes DN 50 to DN 100
Motors:
2 Poles: 002 to 042
4 Poles: 004 to 044
Non-ATEX
Installation/Operating Manual

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Summary of Contents for KSB Amarex N

  • Page 1 Submersible Motor Pump Amarex N Pump Sizes DN 50 to DN 100 Motors: 2 Poles: 002 to 042 4 Poles: 004 to 044 Non-ATEX Installation/Operating Manual...
  • Page 2 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. Subject to technical modification without prior notice. © KSB SE & Co. KGaA, Frankenthal 12/03/2018...

  • Page 3: Table Of Contents

    Transportable wet installation...................... 27 Electrical system.............................. 28 5.4.1 Information for planning the control system .................. 28 5.4.2 Electrical connection.......................... 31 Commissioning/Start-up/Shutdown.................... 34 Commissioning/start-up .......................... 34 6.1.1 Preconditions for commissioning/startup.................. 34 6.1.2 Start-up............................... 34 Operating limits.............................. 35 6.2.1 Frequency of starts.......................... 35 6.2.2 Supply voltage............................ 35 Amarex N 3 of 72...
  • Page 4 7.7.3 Sets of spare parts.......................... 53 Trouble-shooting.......................... 54 Related Documents .......................... 55 General assembly drawing with list of components .................. 55 9.1.1 Amarex N — version ULG ........................ 55 9.1.2 Amarex N — version YLG/WLG ...................... 56 9.1.3 Exploded views........................... 57 Wiring diagrams ............................. 61 9.2.1 Version WLG/YLG .......................... 61...

  • Page 5: Glossary

    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 Amarex N 5 of 72...

  • Page 6: General

    The order number and order item number clearly identify the pump (set) and serve as identification for all further business processes. In case 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.

  • 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 Amarex N 7 of 72...

  • Page 8: Safety

    ▪ 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. Amarex N 8 of 72...

  • Page 9: Personnel Qualification And Training

    Deficits in knowledge must be rectified by means of training and instruction provided by sufficiently trained specialist personnel. 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. Amarex N 9 of 72...

  • Page 10: Consequences And Risks Caused By Non-Compliance With This Manual

    ▪ Decontaminate pumps which handle fluids posing a health hazard. ▪ As soon as the work has been completed, re-install and/or re-activate any safety- relevant and protective devices. Before returning the product to service, observe all instructions on commissioning. (ð Section 6.1, Page 34) Amarex N 10 of 72...

  • 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 N 11 of 72...

  • Page 12: Transport/Temporary Storage/Disposal

    1. On transfer of goods, check each packaging unit for damage. 2. 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: Return To Supplier

    2. Separate and sort the pump 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. Amarex N 13 of 72...

  • Page 14: 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 N F 50 - 170 / 012 YLG 120 Table 6: Designation key Code...

  • Page 15: Design Details

    ▪ Maintenance-free Reinforced bearings (optional, only for S impeller) ▪ Amarex N S 50-172, motor version YL / motor size and number of poles 002, 012, ▪ Amarex N S 50-222, motor version YL / motor size and number of poles 032, 042 Pump-end bearings: ▪...

  • Page 16: Installation Types

    P4: installation parts P4: installation parts for guide hoop for guide wire for single guide rail arrangement arrangement, arrangement, (Amarex N 50 and 65 installation depth P5: claw only), 4.5 m P7: chain and shackle, installation depth P5: claw length = 5 m 1.5 m / 1.8 m / 2.1 m...

  • Page 17: Configuration And Function

    ▪ Claw with sealing elements and fasteners ▪ Lifting rope/lifting chain ▪ Mounting bracket with fasteners ▪ Duckfoot bend with mounting elements ▪ Guiding accessories (guide rails are not included in KSB's scope of supply) Optional Amarex N 17 of 72...

  • Page 18: Dimensions And Weights

    ▪ Lifting rope/lifting chain 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 19: Installation At Site

    1. 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 N 19 of 72...

  • Page 20: Checking The Lubricant Level

    4. Screw in screw plug 903 with joint ring 411. Observe the tightening torques. (ð Section 7.6, Page 52) 5.2.3 Checking the direction of rotation DANGER Pump set running dry Explosion hazard! ▷ Check the direction of rotation of explosion-proof pump sets outside the potentially explosive atmosphere. Amarex N 20 of 72...

  • Page 21: Installing The Pump Set

    5.3 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 fastened with chemical anchors. Amarex N 21 of 72...
  • Page 22 ▷ Take appropriate measures to compensate thermal expansion of the piping. NOTE When the pump set is used for draining low-level building areas, install a swing check valve in the discharge line to avoid backflow from the sewer system. Amarex N 22 of 72...
  • Page 23 3. Fasten fully threaded stud 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. 7: Fitting the mounting bracket Amarex N 23 of 72...
  • Page 24 NOTE The guide rails are not included in KSB's scope of supply. Select guide rail materials which are suitable for the fluid handled or as specified by the operator.
  • Page 25 1. Insert the ends of guide hoop 571 into the grooves of duckfoot bend 72.1. 2. Fasten the duckfoot bend to the tank/sump floor with 2 anchor bolts 90-3.38. (ð Section 5.3.1.1, Page 21) 72.1 90-3.38 UG1274642 Fig. 12: Fitting the guide hoop arrangement Amarex N 25 of 72...

  • Page 26: Transportable Wet Installation

    Attach the lifting chain with shackle or the lifting rope to the recess in the pump handle on the discharge nozzle side of the pump set. This attachment point achieves an upright position of the pump set. UG1274785 Attaching the lifting chain/rope - transportable wet installation Amarex N 26 of 72...
  • Page 27 3. Tighten screws 914.03 again to the indicated tightening torque. (ð Section 7.6, Page 52) Fitting the foot plate 1. Fit the foot plate to the three pump feet with screws, discs and nuts. Observe the tightening torques. (ð Section 7.6, Page 52) Amarex N 27 of 72...

  • Page 28: Electrical System

    ▷ Never allow an explosion-proof pump set to run dry! CAUTION Fluid level below the specified minimum Damage to the pump set by cavitation! ▷ Never allow the fluid level to drop below the specified minimum. Amarex N 28 of 72...

  • Page 29: Frequency Inverter Operation

    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. Amarex N 29 of 72...
  • Page 30 The pump set is equipped with sensors designed to prevent hazards and damage to the pump set. 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 31 Work on the pump set by unqualified personnel Danger of death from electric shock! ▷ Always have the electrical connections installed by a trained and qualified electrician. ▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079. Amarex N 31 of 72...

  • Page 32: Information For Planning The Control System

    DANGER Connection of damaged power cables Danger of death from electric shock! ▷ Check the power cables for damage before connecting them to the power supply. ▷ Never connect damaged power cables. Amarex N 32 of 72...
  • Page 33 ▷ If the pump set is used in chemically corrosive fluids, never use the external terminal for potential equalisation. ▷ Connect the potential equalisation conductor to a non-wetted flange of the discharge line and establish an electric connection between the newly fitted potential equalisation and the pump set. Amarex N 33 of 72...

  • Page 34: Commissioning/Start-Up/Shutdown

    Increased vibrations! Damage to mechanical seals and bearings! ▷ Never operate the pump set against a closed shut-off element. 1. Fully open the discharge line shut-off element, if any. 2. Start up the pump set. Amarex N 34 of 72...

  • Page 35: Operating Limits

    Explosion hazard! ▷ Never operate explosion-proof pump sets outside the specified range. Frequency inverter operation of the pump set is permitted in the following frequency ranges: ▪ 50 Hz: 30 to 50 Hz ▪ 60 Hz: 30 to 60 Hz Amarex N 35 of 72...

  • Page 36: Fluid Handled

    (see outline drawing). Fig. 18: Minimum fluid level NOTE For pump sets with cutters we recommend continuing pump operation for about 10 seconds after the minimum suction level has been reached (see dimension RS in the outline drawing). Amarex N 36 of 72...

  • Page 37: Shutdown/Storage/Preservation

    ▷ Decontaminate pumps which handle fluids posing a health hazard. CAUTION Danger of frost/freezing Damage to the pump set! ▷ If there is any danger of frost/freezing, remove the pump set from the fluid handled and clean, preserve and store it. Amarex N 37 of 72...

  • Page 38: 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. Amarex N 38 of 72...

  • Page 39: Servicing/Maintenance

    ▷ Use suitable transport devices, lifting equipment and lifting tackle to move heavy assemblies or components. WARNING Insufficient stability Risk of crushing hands and feet! ▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent tipping or falling over. Amarex N 39 of 72...

  • Page 40: Maintenance/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 41 Table 17: Resistance measurement of the leakage sensor in the motor motor Measurement between terminals ... Resistance 9 and earth conductor (PE) > 1 Ω Lower resistance values suggest water ingress into the motor. In this case the motor must be opened and overhauled. Amarex N 41 of 72...

  • Page 42: Lubrication And Lubricant Change

    Hazard to persons and the environment! ▷ Using machine oil is only permitted if the oil is disposed of properly. 7.2.2.1.3 Lubricant quantity Table 19: Lubricant quantity Motor version Lubricant quantity YL and WL 0.74 0.25 Amarex N 42 of 72...
  • Page 43 However, if the coolant is severely contaminated by the fluid handled, this suggests a defect at the mechanical seals. Filling in the lubricant 1. Position the pump set as shown. Amarex N 43 of 72...
  • Page 44 4. Fit impeller 230 and suction cover 162. Observe the tightening torques. (ð Section 7.6, Page 52) 7.2.2.2 Lubricating the rolling element bearings 2563:124 The rolling element bearings of the pump sets are grease-packed and maintenance- free. Fig. 22: Filling in the lubricant Amarex N 44 of 72...

  • Page 45: Drainage/Cleaning

    ▷ Close the shut-off elements in suction and discharge line. ▷ Drain the pump and release the pump pressure. ▷ Close any auxiliary connections. ▷ Allow the pump set to cool down to ambient temperature. Amarex N 45 of 72...

  • Page 46: Preparing The Pump Set

    Fig. 23: Forcing screw NOTE The forcing screw is not included in the scope of supply. It can be ordered separately from KSB. 7.4.4 Removing the mechanical seal and motor section 7.4.4.1 Removing the mechanical seal and motor section (versions YLG and WLG) NOTE Special regulations apply to repair work on explosion-proof pump sets.
  • Page 47 7. Remove primary ring 433.01. 8. Pull off mating ring holder 476. 9. Take mating ring 433.01 out of mating ring holder 476. 10. Remove circlip 932.01. 11. Extract rolling element bearing 321.02. 12. Extract rolling element bearing 321.01. Amarex N 47 of 72...

  • Page 48: Reassembling The Pump Set

    515 or circlip 932.03. 2. 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. 3. Slide pump-end mechanical seal 433.02 onto shaft 210. Amarex N 48 of 72...
  • Page 49 Maintain this position until dimensions x and y have been measured. Fig. 25: Pulling the rotor assembly right up to the suction cover 6. Pull the rotor assembly right up to the suction cover until it will not go any further. Amarex N 49 of 72...
  • Page 50 1. Slide impeller 230 onto the shaft end and fasten it with impeller screw 914.04. 2. Then, remove the impeller screw again. 3. Screw in an M8 x 100 eyebolt (not included in KSB's scope of supply) instead of the impeller screw.

  • Page 51: Reassambling The Motor Section

    Before reassembling the motor section, check that all joints relevant to explosion protection (flamepaths) are undamaged. Any components with damaged flamepaths must be replaced. Only use original spare parts made by KSB for explosion-proof pumps. Observe the flamepath positions specified in the Annex.

  • Page 52: 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. Also supply the following data: ▪...

  • Page 53: Sets Of Spare Parts

    Part No. Rolling element bearing, motor end 321.01 Rolling element bearing, pump end 3210.02 Mechanical seal, motor end 433.01 Mechanical seal, pump end 433.02 Set of seal elements 99-9 Repair kit 99-20 1 set of circlips Amarex N 53 of 72...

  • Page 54: 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 55: Related Documents

    9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components 9.1.1 Amarex N — version ULG 561.02 Sizes of hydraulic system DN 50 ... 100 Motor sizes 321.01 002...042 004...044 914.01 81-59 321.02 932.01 412.04 81-96 932.02...

  • Page 56: Amarex N - Version Ylg/Wlg

    9 Related Documents 9.1.2 Amarex N — version YLG/WLG 561.02 Sizes of hydraulic system DN 50 ... 100 Motor sizes 321.01 002...042 004...044 914.01 81-59 321.02 932.01 412.04 81-96 932.02 932.04 412.02 412.01 433.01 932.03 412.03 914.02 433.02 914.04 914.03 412.05...

  • Page 57: Exploded Views

    9 Related Documents 9.1.3 Exploded views Amarex N - S 50 YLG - - WLG 321.01 412.01 932.02 321.02 932.04 932.01 412.04 914.01 412.02 321.01 932.02 914.01 321.02 433.01 932.01 433.01 932.03 932.04 412.03 412.04 412.02 433.01 433.01 932.03 412.03 914.02...
  • Page 58 932.02 321.02 433.01 932.01 433.01 932.03 932.04 412.03 412.04 412.02 433.01 433.01 932.03 412.03 914.02 914.02 433.02 81--59 81--59 81--2 914.04 81--2 412.05 914.03 321.01 Fig. 30: Exploded view Amarex N with F 50 - 100 Amarex N 58 of 72...
  • Page 59 (32.01 932.03 433.01 932.04 412.03 412.02 433.01 433.01 932.03 412.04 412.03 914.02 914.02 433.02 914.04 81-- 59 81-- 59 81-- 2 (914.04) 81-- 2 914.03 321.01 (904) Fig. 31: Exploded view Amarex N with D 80-100 Amarex N 59 of 72...
  • Page 60 Bearing bracket housing Cable gland Profile joint 99-9 Set of seal elements Joint ring Screw plug 412.01/.02/.03/.04/.05 O-ring Grub screw 433.01/.02 Mechanical seal 914.01/.02/.03/.04/.06 Socket head cap screw Mating ring holder 932.01/.02/.03/.04 Circlip 59-17 Shackle Amarex N 60 of 72...

  • Page 61: Wiring Diagrams

    9 Related Documents 9.2 Wiring diagrams 9.2.1 Version WLG/YLG Fig. 32: Wiring diagram for version WLG/YLG Amarex N 61 of 72...

  • Page 62: Version Ulg

    9 Related Documents 9.2.2 Version ULG Fig. 33: Wiring diagram for version ULG Amarex N 62 of 72...

  • Page 63: Wiring Diagrams Overload Protection

    KM: Motor contactor 3~ e.g. Télémécanique LC1 D0910 SM: Insulation monitor, de-energised 1 3 5 e.g. V12G1LOHM SM21 Merlin Guérin F: Remote control 2 4 6 H: Auxiliary supply 2 4 6 230/240 V U V W Amarex N 63 of 72...

  • Page 64: Flamepaths On Explosion-Proof Motors

    Tolerance in µm inside diameter to Maximum DIN ISO 286/2 Minimum Tolerance in µm outside diameter to Maximum DIN ISO 286/2 Minimum Tolerance in µm inside diameter Maximum Minimum Tolerance in µm outside diameter Maximum Minimum Amarex N 64 of 72...
  • Page 65 Tolerance in µm inside diameter to Maximum DIN ISO 286/2 Minimum Tolerance in µm outside diameter to Maximum DIN ISO 286/2 Minimum Tolerance in µm inside diameter Maximum Minimum Tolerance in µm outside diameter Maximum Minimum Amarex N 65 of 72...

  • Page 66: Installation Drawings Of The Mechanical Seal

    Table 31: Sectional drawings of the mechanical seal Part No. Description Sectional drawing 433.01 Mechanical seal (bellows-type mechanical seal) 433.01 932.01 Circlip 433.02 Mechanical seal (bellows-type mechanical seal) 932.01 433.02 Mechanical seal (mechanical seal with covered springs - HJ) Amarex N 66 of 72...

  • Page 67: Eu Declaration Of Conformity

    128, rue Carnot, 59320 Sequedin (France) The EU Declaration of Conformity was issued in/on: Frankenthal, 1 February 2018 Thomas Heng Head of Product Development Series Pumps KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal Amarex N 67 of 72...

  • Page 68: 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 N 68 of 72...

  • Page 69: Index

    General assembly drawing 55, 56 Storage 12, 38 Impeller type 15 Installation Tightening torques 52 Transportable installation 27 Trouble-shooting 54 Insulation resistance measurement 40 Intended use 8 Interference immunity 29 Leakage monitoring 31 Level control 29 Lubricant 42 Intervals 40 Quality 42 Maintenance work 40 Mechanical seal 66 Minimum fluid level 36 Misuse 9 Amarex N 69 of 72...
  • Page 72 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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