Contents Contents Glossary .............................. 5 General.............................. 6 Principles ................................ 6 Installation of partly completed machinery.................... 6 Target group.............................. 6 Other applicable documents.......................... 6 Symbols ................................ 7 Key to safety symbols/markings........................ 7 Safety .............................. 8 General................................ 8 Intended use .............................. 8 Personnel qualification and training....................... 9 Consequences and risks caused by non-compliance with this manual ............ 9 Safety awareness .............................. 9 Safety information for the operator/user ....................... 9 Safety information for maintenance, inspection and installation .............. 10...
Page 4
Contents Operating limits.............................. 38 6.2.1 Frequency of starts.......................... 38 6.2.2 Operation on the power supply mains..................... 38 6.2.3 Operating on a frequency inverter.................... 39 6.2.4 Fluid handled ............................. 39 Shutdown/storage/preservation ........................ 40 6.3.1 Measures to be taken for shutdown .................... 40 Returning to service ............................ 41 Servicing/Maintenance ........................ 42 Safety regulations............................ 42 Maintenance/inspection.......................... 44 7.2.1...
Glossary Glossary Certificate of decontamination A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled.
In the event of damage, immediately contact your nearest KSB service facility 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 General 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 1.6 Key to safety symbols/markings Table 4: Definition of safety symbols/markings...
2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER In addition to the present general safety information the action-related safety information given in the other sections must be observed. 2.1 General ▪ This operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property.
2 Safety Impeller with cutter Suitable for the following fluids: (impeller type S) faeces, domestic sewage and waste water containing long fibres Free-flow impeller Suitable for the following fluids: (impeller type F) fluids containing solids and stringy material as well as fluids with entrapped air or entrapped gas Open, diagonal single-vane Suitable for the following fluids:...
2 Safety ▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g. explosive, toxic, hot) so as to avoid any danger to persons and the environment. Adhere to all relevant laws. ▪ Eliminate all electrical hazards. (In this respect refer to the applicable national safety regulations and/or regulations issued by the local energy supply companies.) ▪...
2 Safety 2.9.1 Repair Special regulations apply to repair work on explosion-proof pumps. Modifications or alterations of the pump set can affect explosion protection and are only permitted after consultation with the manufacturer. Repair work at the flameproof joints must only be performed in accordance with the manufacturer's instructions.
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 and the insurer about the damage in writing immediately.
Indicate any safety measures and decontamination measures taken. (ð Section 11, Page 78) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids, consumables and supplies posing a health hazard Hazard to persons and the environment! ▷...
Page 14
3 Transport/Temporary Storage/Disposal Electrical or electronic equipment marked with the adjacent symbol must not be disposed of in household waste at the end of its service life. Contact your local waste disposal partner for returns. If the used electrical or electronic equipment contains personal data, the operator is responsible for deleting it before the equipment is returned.
AVERTISSEMENT - NE PAS OUVRIR SOUS TENSION AVERTISSEMENT - NE PAS OUVRIR SOUS TENSION Fig. 1: Name plate (example) a) Standard pump set b) Explosion-proof pump set Designation KSB order number Flow rate Maximum fluid and ambient temperature Enclosure Motor type...
4 Description of the Pump (Set) Power factor at design point Mode of operation Rated frequency Starting current ratio ATEX marking for the submersible motor ATEX marking for the pump set Motor number 4.5 Design details Design ▪ Fully floodable submersible motor pump ▪...
4 Description of the Pump (Set) 4.6 Installation types Table 7: Installation type S – stationary wet installation Installation type Description Comment Guide hoop arrangement Only for the following sizes: P1: pump 50-170 P2: installation parts for guide hoop arrangement, installation depth = 1.5 m / 50-172 1.8 m / 2.1 m 50-220...
▪ 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.
5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set! ▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information given in the data sheet and on the name plate of the pump set.
5 Installation at Site 5.2 Checks to be carried out prior to installation 5.2.1 Preparing the place of installation Place of installation for stationary models WARNING Installation on mounting surfaces which are unsecured and cannot support the load Personal injury and damage to property! ▷...
5 Installation at Site M = 40 mm M = 40 mm 2563:109 2563:108 Fig. 2: Checking the lubricant level a) Version YL & WL; b) Version YL & WL for sizes 50-170, 50-172 and 65-220 2. Unscrew and remove screw plug 903 with joint ring 411. ð...
5 Installation at Site Fig. 3: Checking the direction of rotation 3. If the impeller is running in the wrong direction of rotation, check the electrical connection of the pump and the control system, if necessary. 4. Disconnect the pump set from the power supply and make sure it cannot be switched on unintentionally.
Page 24
5 Installation at Site Table 9: Chemical anchor dimensions Size [mm] [mm] [mm] [mm] [mm] [Nm] × l M10 × 130 M16 × 190 Table 10: Curing times of mortar cartridge Floor temperature Curing time [°C] [min] -5 to 0 0 to +10 +10 to +20 > +20 5.3.1.2 Connecting the piping DANGER Impermissible loads acting on the flange of the duckfoot bend...
Page 26
5 Installation at Site Fitting the mounting bracket 90-3.37 920.36 59-18 920.36 59-24.01 920.37 Fig. 7: Fitting the mounting bracket 1. Fasten mounting bracket 894 to the edge of the sump opening with anchor bolts 90-3.37 and tighten the anchor bolts to a tightening torque of 10 Nm. 2.
Page 27
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 28
5 Installation at Site Fitting the guide rails (twin guide rail arrangement) CAUTION Improper installation of the guide rails Damage to the guide rail arrangement! ▷ Always adjust the guide rails so that they are in a perfectly vertical position. 1.
5 Installation at Site 5.3.1.6 Preparing the pump set Fastening the claw for guide wire, single guide rail and guide hoop arrangement 1. Fasten claw 732 with screw 914.05 and disc 550.35 to the discharge flange (see drawing). Tighten the screw to a torque of 17 Nm. 17 Nm 914.05 550.35...
Page 30
5 Installation at Site Table 14: Types of attachment Drawing Type of fastening 59-18 Shackle with chain at the pump casing 59-17 Shackle 59-18 Hook 59-17 Lifting chain/lifting rope UG1274869 59-18 Shackle with chain at the lifting bail 59-17 Shackle 59-18 Hook 59-17 Lifting bail...
5 Installation at Site Attaching the lifting chain/rope 1. Attach the lifting chain or rope to the shackle on the discharge nozzle side (see drawing and table "Types of attachment"). Connecting the piping The DIN connection can be connected to rigid or flexible pipes. UG1274785 Fig. 15: Attaching the lifting chain/rope...
Page 32
5 Installation at Site Automatic operation of the pump set in a tank requires the use of level control equipment. Observe the minimum level of fluid handled. (ð Section 6.2.4.2, Page 39) 5.4.1.3 Operation on a frequency inverter The pump set is driven by an induction machine to IEC 60034-12 designed for fixed speed operation.
Page 33
5 Installation at Site modifications are required on the power/control cable of the submersible motor pump. Suitable analysing devices must be selected. To monitor the leakage sensor inside the motor using a special relay available from KSB is recommended. 5.4.1.4 Sensors DANGER...
Page 34
5 Installation at Site WARNING Incorrect electrical connection Electric shock! ▷ Adequately insulate conductor 22. Conductor 22 has no function on standard pump sets. However, it can be live and must, therefore, be insulated or connected to a dummy terminal. Explosion-proof pump sets (version YL) Explosion-proof pump sets are equipped with double monitoring of the winding temperature.
5 Installation at Site 5.4.2 Electrical connection DANGER Electrical connection work by unqualified personnel Risk of fatal injury due to 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. WARNING Incorrect connection to the mains Damage to the mains network, short circuit!
Page 36
5 Installation at Site DANGER Connection of damaged power cables Danger of death from electric shock! ▷ Check the power cables for damage before connecting them. ▷ Never connect damaged power cables. ▷ Replace damaged power cables. CAUTION Flow-induced motion Damage to the power cable! ▷...
6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/Start-up 6.1.1 Prerequisites for commissioning/start-up DANGER Fluid level too low Explosion hazard! Damage to the pump set! ▷ Completely prime the pump set with the fluid to be handled to reliably prevent the formation of a potentially explosive atmosphere. ▷...
6 Commissioning/Start-up/Shutdown CAUTION 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. 1. Fully open the discharge line shut-off element, if any. 2. Start up the pump set. 6.2 Operating limits DANGER Non-compliance with operating limits...
6 Commissioning/Start-up/Shutdown 6.2.3 Operating on a frequency inverter DANGER Operation outside the permitted frequency range Explosion hazard! ▷ Never operate an explosion-proof pump set outside the specified range. Frequency inverter operation of the pump set is permitted in the following frequency ranges: ▪...
6 Commissioning/Start-up/Shutdown Fig. 17: 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). Operation with a dropping fluid level up to dimension R1 (see outline drawing) is permissible.
6 Commissioning/Start-up/Shutdown WARNING Fluids handled, consumables and supplies which are hot and/or pose a health hazard Risk of injury! ▷ Observe all relevant laws. ▷ When draining the fluid take appropriate measures to protect persons and the environment. ▷ Decontaminate pumps which handle fluids posing a health hazard. CAUTION Danger of frost/freezing Damage to the pump set!
7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations The operator ensures that maintenance, inspection and installation are performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual. DANGER Sparks produced during servicing work Explosion hazard! ▷ Observe the safety regulations in force at the place of installation! ▷...
Page 43
NOTE All maintenance work, service work and installation work can be carried out by KSB Service or authorised workshops. For contact details please refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet.
7 Servicing/Maintenance 7.2 Maintenance/inspection KSB recommends the following regular servicing schedule: Table 16: Overview of maintenance work Maintenance interval Maintenance work For details see ... Every 4000 operating hours; at Insulation resistance measurement (ð Section 7.2.1.3, Page 44) least once a year Checking the power cables (ð Section 7.2.1.2, Page 44)
7 Servicing/Maintenance ð The insulation resistance of the core ends to chassis ground must not be lower than 1 MΩ. If the resistance measured is lower, power cable and motor resistance must be measured separately. Disconnect the power cable from the motor for this purpose.
Page 46
7 Servicing/Maintenance 7.2.2.1.2 Lubricant quality DANGER Wrong quality of lubricating liquid Explosion hazard! ▷ Always use a lubricating liquid whose ignition temperature is higher than 185 °C for explosion-proof pump sets. The lubricant reservoir is filled at the factory with environmentally friendly, non-toxic lubricant of medicinal quality (unless otherwise specified by the customer).
Page 47
7 Servicing/Maintenance Draining the lubricant 1. Position the pump set as shown. 2563:106 2563:107 Fig. 18: Draining the lubricant a) Versions YL & WL for sizes 50-170, 50-172 and 65-220; b) Versions YL & WL 2. Place a suitable container under the screw plug. WARNING Excess pressure in the lubricant reservoir Liquid spurting out when the lubricant reservoir is opened at operating...
Page 48
7 Servicing/Maintenance Size [mm] 80-220 100-220 (versions YL & WL) 50-170 50-172 65-220 (versions YL & WL) Changing the lubricating liquid on version UL Draining the lubricant 2563:112 Fig. 20: Draining the lubricant ü The suction cover and the impeller have been removed. (ð Section 7.4.3, Page 52) 1.
Page 49
7 Servicing/Maintenance 7.2.2.1.4.1 Changing the lubricant — versions YL and WL WARNING Lubricants posing a health hazard and/or hot lubricants Hazard to persons and the environment! ▷ When draining the lubricant take appropriate measures to protect persons and the environment. ▷...
Page 50
7 Servicing/Maintenance M = 40 mm M = 40 mm 2563:109 2563:108 Fig. 23: Filling in the lubricant level a) Versions YL & WL; b) Versions YL & WL for size 50-170, 50-172 and 65-220 2. Fill lubricant through the lubricant filler opening until the lubricant in the lubricant reservoir reaches the required level M (see the following table).
7 Servicing/Maintenance Filling in the lubricant 2563:124 Fig. 25: Filling in the lubricant 1. Fill 0.25 litres of oil through the opening between the stationary assembly of mechanical seal 433.02 and rotor 818. 2. Thoroughly clean rotor 818 and the contact face of the stationary assembly of mechanical seal 433.02.
Observe the safety instructions and information. For dismantling and reassembly observe the general assembly drawing. In the event of damage you can always contact KSB Service. DANGER Insufficient preparation of work on the pump (set) Risk of injury! ▷...
Fig. 26: 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 part (versions YL and WL) NOTE Special regulations apply to repair work on explosion-proof pump sets.
7 Servicing/Maintenance 7.4.4.2 Removing the mechanical seal and motor part (version UL) ü The oil has been drained. (ð Section 7.2.2.1.4.2, Page 50) 1. Undo and remove screws 914.02 at bearing bracket 330. 2. Remove rotor unit 818 from bearing bracket 330. 3. Press mating ring 433.02 out of bearing bracket 330. 4.
7 Servicing/Maintenance 7.5.2 Reassembling the pump section 7.5.2.1 Installing the mechanical seal Observe the following to ensure trouble-free operation of the mechanical seal: ▪ The shaft surface must be absolutely clean and undamaged. ▪ Immediately before installing the mechanical seal, wet the seal faces with a drop of oil.
Page 56
7 Servicing/Maintenance CAUTION Incorrect assembly Clearance gap inaccurate! ▷ Pull the rotor assembly right up to the suction cover until it will not go any further. Maintain this position until dimensions x and y have been measured. Fig. 28: Pulling the rotor assembly right up to the suction cover 6.
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.
7 Servicing/Maintenance 7.5.4 Leak testing (versions YL and WL) After reassembly, the mechanical seal area/lubricant reservoir must be checked for leakage. The leak test is performed at the lubricant filler opening. Observe the following values for leak testing: ▪ Test medium: compressed air ▪...
7 Servicing/Maintenance Also specify the following data: ▪ Part number and description (ð Section 9.1, Page 62) ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight) 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 25: Quantity of spare parts for recommended spare parts stock Part No.
Check the cable connections. ✘ - Motor is not running because of lack of voltage. Check the electrical installation. Contact the energy supplier. - Motor winding or connection cable are Replace by new original KSB parts or contact the ✘ ✘ defective. manufacturer.
Page 61
8 Trouble-shooting A B C D E Possible cause Remedy ✘ - The temperature limiter (explosion protection) Have cause determined and eliminated by has tripped the pump as a result of excessive qualified and trained personnel. winding temperatures. ✘ - Motor has been tripped by leakage monitor. Have cause determined and eliminated by qualified and trained personnel.
9 Related Documents 9 Related Documents 9.1 General assembly drawings with list of components 9.1.1 General assembly drawing of Amarex N – version UL 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...
9 Related Documents 9.1.3 Exploded views with list of components 9.1.3.1 Exploded view of Amarex N ‑ S 50, versions YL and WL 412.01 932.04 412.04 914.01 321.01 932.02 914.01 321.02 932.01 932.04 412.04 412.02 433.01 433.01 932.03 412.03 914.02 433.02 914.04 81--59 23--7...
Page 65
9 Related Documents 9.1.3.2 Exploded view of Amarex N ‑ S 50, version UL 321.01 932.02 412.04 321.02 914.01 932.01 412.02 914.01 433.01 433.01 412.04 932.03 412.03 914.02 433.02 914.04 81--59 23--7 81--59 914.04 81--2 23--7 914.06 81--2 914.04 914.03 321.01 914.06 Fig. 33: Amarex N - S 50 serie, design UL Amarex N...
Page 66
9 Related Documents 9.1.3.3 Exploded view of Amarex N ‑ F 50-100, versions YL and WL 834 412.04 914.01 412.01 932.04 914.01 321.01 412.04 932.02 321.02 932.01 932.04 412.02 433.01 433.01 932.03 412.03 914.02 433.02 81--59 81--59 81--2 914.04 81--2 412.05 914.03 321.01 Fig. 34: Amarex N - F 50-100 version YL &...
Page 67
9 Related Documents 9.1.3.4 Exploded view of Amarex N ‑ F 50-100, version UL 834 412.04 914.01 321.01 914.01 932.02 321.02 932.01 412.04 412.02 476 476 433.01 433.01 932.03 412.03 914.02 433.02 81--59 81--59 81--2 914.04 81--2 412.05 914.03 321.01 Fig. 35: Amarex N - F 50-100, design UL Amarex N 67 of 84...
Page 68
9 Related Documents 9.1.3.5 Exploded view of Amarex N ‑ D 80-100, versions YL and WL 412.01 914.01 932.04 412.04 914.01 321.01 932.02 321.02 (32.01 932.04 412.02 433.01 433.01 412.04 932.03 412.03 914.02 433.02 914.04 81-- 59 81-- 59 81-- 2 (914.04) 81-- 2 914.03...
Page 69
9 Related Documents 9.1.3.6 Exploded view of Amarex N ‑ D 80-100, version UL 321.01 914.01 932.02 412.04 321.02 932.01 914.01 412.02 433.01 932.03 433.01 412.03 412.04 914.02 433.02 914.04 81-- 59 81-- 59 81-- 2 (914.04) 81-- 2 914.03 321.01 (904) Fig. 37: Amarex N ‑...
Page 70
9 Related Documents 9.1.3.7 List of components in the exploded views Table 30: List of components Part No. Description Part No. Description Casing Ring Intermediate casing Disc Suction cover Grooved pin Feet 69-6 Temperature sensor Shaft 69-16 Moisture sensor 23-7 Impeller body 81-2 Plug Impeller...
9 Related Documents 9.5 Installation drawings of the mechanical seal Table 34: 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 76 of 84...
128, rue Carnot, 59320 Sequedin (France) The EU Declaration of Conformity was issued in/on: Frankenthal, 1 January 2020 Thomas Heng Head of Product Development Series Pumps KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal Where applicable Amarex N 77 of 84...
Need help?
Do you have a question about the Amarex N Series and is the answer not in the manual?
Questions and answers