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

Submersible motor pump, 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
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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

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Summary of Contents for KSB Amarex KRT

  • Page 1 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.
  • Page 2 All rights reserved. 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 KSB´s express written consent. Subject to technical modification without prior notice.

  • Page 3: Table Of Contents

    Scope of supply ..................... 18 Dimensions and weights ................19 Installation at Site ................20 Safety regulations ..................20 Checks to be carried out prior to installation ..........20 Installing the pump set ................. 22 Electrical connection ..................28 Amarex KRT 3 of 78...
  • Page 4 General assembly drawings ................57 Wiring diagrams .................... 70 Flamepaths of explosion-proof motors ............71 Sectional drawings of the mechanical seal ..........72 EC Declaration of Conformity ............74 Certificate of Decontamination ............75 Index ....................76 Amarex KRT 4 of 78...

  • Page 5: Glossary

    The part of the pump in which the kinetic the pump (set) has been properly drained to energy is converted into pressure energy eliminate any environmental and health hazards arising from components in contact with the fluid handled. Amarex KRT 5 of 78...

  • Page 6: General

    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.

  • Page 7: Other Applicable Documents

    ⊳ Safety instructions ⇨ Result of an action ⇨ Cross-references Step-by-step instructions Note Recommendations and important information on how to handle the product If agreed to be included in the scope of supply Amarex KRT 7 of 78...

  • 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 KRT 8 of 78...
  • Page 9 Fluids containing solids and stringy (impeller type E) material Closed multi-vane Suitable for the following fluids: impeller Contaminated, solids-laden, non-gaseous (impeller type K) fluids without stringy material Minimum permissible flow rate Maximum permissible flow rate Best efficiency point Amarex KRT 9 of 78...

  • Page 10: Personnel Qualification And Training

    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. Amarex KRT 10 of 78...

  • Page 11: Safety Information For Maintenance, Inspection And Installation Work

    Prevent impermissible modes of operation at all times. 2.10.1 Repair Special regulations apply to repair work on explosion-proof pumps. Modifications or alteration of the pump set may affect explosion protection and are only permitted after consultation with the manufacturer. Amarex KRT 11 of 78...
  • Page 12 2 Safety 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 12 of 78...

  • Page 13: Transport/Temporary Storage/Disposal

    ▷ Never suspend the pump set by its power cable. ▷ Never use chains or lifting ropes included in KSB's scope of supply for lifting loads other than the KSB product supplied. ▷ Safely attach transport ropes or chains to the pump and crane.

  • Page 14: Storage/Preservation

    3. If the fluids handled by the pump leave residues which might lead to corrosion damage when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the pump set must also be Amarex KRT 14 of 78...

  • Page 15: Disposal

    4. Always complete and enclose a certificate of decontamination when returning the pump (set). (⇨ Section 11 Page 75) It is imperative to indicate any safety and decontamination measures taken. NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.4 Disposal...

  • Page 16: Description Of The Pump (Set)

    ZN 3826 – M 34 Mat. No. 01231886 ZN 3826 – M 29 Fig. 2: Name plate a) Standard pump set b) Explosion-proof pump set Designation (⇨ Section 4.2 Page 16) KSB order number Flow rate Maximum fluid and ambient temperature Total weight Enclosure...

  • Page 17: Types Of Installation

    The pump set is designed for continuous operation in submerged condition. The motor is cooled by the pumped fluid on the motor surface. Operation with the motor outside the fluid handled is possible for short periods. Amarex KRT 17 of 78...

  • Page 18: Configuration And Function

    S t a t i o n a r y w e t i n s t a l l a t i o n ( i n s t a l l a t i o n t y p e s S ) ▪ Pump set complete with power cables ▪ Claw with sealing material and mounting elements ▪ Lifting rope or chain ▪ Mounting bracket with mounting elements Amarex KRT 18 of 78...

  • Page 19: Dimensions And Weights

    ▪ Lifting rope or 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 20: 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 KRT 20 of 78...
  • Page 21 4. Close screw plug 903.03 with joint ring 411.03 again. 5.2.4 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 KRT 21 of 78...

  • Page 22: 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 and/or foundation rails. Amarex KRT 22 of 78...
  • Page 23 ▷ 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. Mounting accessories of respective manufacturer required. Amarex KRT 23 of 78...
  • Page 24 3. 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 24 of 78...
  • Page 25 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 26 Observe the tightening torques. (⇨ Section 7.6 Page 54) 2. Fit profile joint 410 or round cord seal 99-6 into the groove of the claw. This will seal the duckfoot bend / pump connection. 550.35 920.35 Fig. 14: Fitting the claw Amarex KRT 26 of 78...
  • Page 27 59-17 Shackle 920.26 59-17 59-24.02 Rope Chain 914.26 Hexagon socket head cap screw 920.26 Chain attached to the eyebolt with a shackle 59-17 Shackle Chain Lifting rope attached to the bail 59-24.02 59-24.02 Rope Hoop Amarex KRT 27 of 78...

  • Page 28: Electrical Connection

    When laying a cable between the control system and the pump set's connection point, make sure that the number of cores is sufficient for the sensors. A minimum cross- section of 1.5 mm² is required. Amarex KRT 28 of 78...
  • Page 29 If the pump sets are operated via frequency inverter, RFI emissions will occur, the compatibility level of which varies depending on the inverter used (inverter type, interference suppression features, manufacturer). To ensure compliance of the drive system Amarex KRT 29 of 78...
  • 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 PT100 input and 2 separate outputs for two different switching points (sensor circuit maximum 6V/2mA). Set the following limits: ▪ Alarm at 110 °C ▪ Cut-out of the pump set at 130°C Amarex KRT 31 of 78...
  • Page 32 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 KRT 32 of 78...
  • Page 33 ▷ 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 33 of 78...

  • Page 34: Commissioning/Start-Up/Shutdown

    ▷ Never operate an explosion-proof pump set at ambient and fluid temperatures exceeding those specified in the data sheet or on the name plate. ▷ Never operate the pump set outside the limits specified below. Amarex KRT 34 of 78...
  • Page 35 The pump is ready for operation as soon as the motor is fully submerged (dimension A). Exact dimensions see general arrangement drawing/outline drawing. The pump can be operated at a lower fluid level for short periods. If the motor is not sufficiently cooled, an internal temperature monitoring device will Amarex KRT 35 of 78...
  • Page 36 Operation outside the permitted frequency range Explosion hazard! ▷ Never operate explosion-proof pump sets outside the specified range. Frequency inverter operation of the pump set is permissible in the frequency range from 25 to 50 Hz. Amarex KRT 36 of 78...

  • Page 37: Shutdown/Storage/Preservation

    For returning the pump set to service observe the sections on commissioning/start-up (⇨ Section 6 Page 34) and operating limits (⇨ Section 6.2 Page 34) . For returning the pump set to service after storage also follow the instructions for servicing/inspection. (⇨ Section 7.2 Page 40) Amarex KRT 37 of 78...
  • Page 38 Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is completed, 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 KRT 38 of 78...

  • Page 39: Servicing/Maintenance

    (set) with a minimum of maintenance expenditure and work. NOTE All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/ contact".

  • Page 40: Servicing/Inspection

    7 Servicing/Maintenance 7.2 Servicing/inspection KSB recommends the following schedule for pump set maintenance: Table 15: Overview of maintenance work Maintenance interval Maintenance work For details see ... Insulation resistance test (⇨ Section 7.2.1.3 Page 40) After 4,000 operating hours Check the power cables (⇨...
  • Page 41 If the readings suggest an open switch, check for mechanical seal leakage. Section 4.4 Page 16) Bearing temperature Table 19: Resistance measurement of the bearing temperature sensor sensor Measure between terminals ... Resistance 100 Ω - 120 Ω 15 and 16 Amarex KRT 41 of 78...
  • Page 42 ▪ All non-doped and doped motor oils of classes SAE 10W to SAE 20W WARNING Contamination by lubricant of fluid handled Hazardous to persons and the environment! ▷ Using machine oil is only permitted if the oil is disposed of properly. Amarex KRT 42 of 78...
  • Page 43 3. Unscrew screw plug 903 or 903.03 with joint ring 411.03 and, if applicable, screw plug 903.04 with joint ring 411.05. Drain the lubricant. Filling in the lubricant 1. Position the pump set as illustrated. Amarex KRT 43 of 78...
  • Page 44 Hands or objects inside the pump casing Risk of injuries, damage to the pump! ▷ Never insert your hands or any other objects into the pump. ▷ Check that the inside of the pump is free from any foreign objects. Amarex KRT 44 of 78...

  • Page 45: Drainage/Disposal

    ▷ Always have repair and maintenance work performed by specially trained, qualified personnel. WARNING Hot surface Risk of personal injury! ▷ Allow the pump set to cool down to ambient temperature. Observe the general safety instructions and information. Amarex KRT 45 of 78...
  • Page 46 1. Unscrew socket head cap screw 914.10 with disc 550.23. 2. Completely screw the grub screw into the shaft thread. 3. Use a forcing screw to pull off impeller 230. 914.10 550.23 Fig. 22: Removing the impeller Amarex KRT 46 of 78...
  • Page 47 1. Unscrew socket head cap screw 914.10 and impeller hub cap 260. 940.01 914.10 2. Remove the impeller using a special impeller mounting and removal device. (⇨ Section 7.4.3.2.2.1 Page 48) 3. Remove key 940.01. Fig. 23: Cylindrical interference fit Amarex KRT 47 of 78...
  • Page 48 ✓ Result of visual inspection: The wear plate needs to be replaced. 1. On transportable models, separate the pump casing from the piping. 2. Undo hexagon socket head cap screws 914.12. 3. Remove wear plate 135.01 and O-rings 412.34. Fig. 25: Removing the wear plate Amarex KRT 48 of 78...

  • Page 49: Reassembling The Pump Set

    7.5.2 Reassembling the pump section 7.5.2.1 Installing the mechanical seal Observe the following points to ensure trouble-free operation of the mechanical seal: ▪ Only remove the protective wrapping of the contact faces immediately before assembly takes place. Amarex KRT 49 of 78...
  • Page 50 Fig. 27: Fitting the [Nm] impeller 40-250, 80-250, 100-240, M 10 100-250, 150-251, D 100-251 80-251, F, E, K 100-251, M 16 80-315/-316, 150-315, 200-315/-316, 100-315/316 100-400/401, 150-400, M 20 151-401, 200-330, 200-400/401, 250-400/-401, 300-400/-401 Amarex KRT 50 of 78...
  • Page 51 Insert grooved pin 561.01 into the impeller and place impeller body 23-7 onto the centring hub. Screw in impeller screw 914.10 and use a torque wrench to tighten the screw to a torque of 50 Nm. Amarex KRT 51 of 78...
  • Page 52 ▷ Always adjust and check the axial clearance with the pump set in vertical position. 4. Use a rubber mallet to push casing wear ring 502 in until it is close to impeller 230. 5. Suspend the pump set vertically, as illustrated. Fig. 31: Suspending the pump set Amarex KRT 52 of 78...
  • Page 53 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. Secure all screwed connections closing off a flameproof enclosure with a thread-locking agent (Loctite type 243).

  • Page 54: Tightening Torques

    Once the reassembly has been completed, carry out the steps described in (⇨ Section 7.2.1 Page 40). 7.6 Tightening torques Table 25: Tightening torques Thread Tightening torque [Nm] M 10 M 12 M 16 M 20 M 24 Amarex KRT 54 of 78...

  • Page 55: Spare Parts Stock

    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 16) Also supply the following data: ▪...

  • Page 56: Trouble-Shooting

    Motor is not running because of lack of Check the electrical installations. 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. In case of star-delta configuration: motor Check star-delta contactor.

  • Page 57: Related Documents

    4 4, 5 4, 7 4, 11 4, 16 4, 19 4, 21 4, 23 4, 29 4, 4 6, 6 6, 9 6, 12 6, 15 6, 19 6 General assembly drawing with motor type DKN 132/160/161/181 and tapered fit (impeller type F) Amarex KRT 57 of 78...
  • Page 58 15 6, 19 6 Upper bearing Motor sizes 12 2, 17 2, 23 2, 11 4, 16 4, 23 4, 29 4, 9 6, 12 6 Impeller type D 550.23 914.10 412.33 412.34 914.12 914.24 Amarex KRT 58 of 78...
  • Page 59 Shaft seal housing 81-17 End connector 500.02 Ring 81-44.28 Clamping piece Casing wear ring 81-51 Shim Impeller wear ring 81-59 Stator Bearing sleeve 99-17 Dessicant 550.11/.23/.24 Disc Pump casing 561.01 Grooved pin Intermediate casing Motor housing Amarex KRT 59 of 78...
  • Page 60 Rolling element 904.01 Grub screw bearing 321.01/.02 Radial ball bearing 914.02/.04/.10/.15/.12/.24/.26 Hexagon socket head cap screw Radial roller bearing 920.01/.26 Bearing bracket 930.28 Safety device Bearing cover Lockwasher 411.03 Joint ring 932.01/.02/.03/.13 Circlip 412./.02/.03/.04/.07/.15/.16/.33/.34 O-ring Amarex KRT 60 of 78...
  • Page 61 9 Related Documents Sectional drawings of the mechanical seal Hydraulics sizes D 80-315 D 100-315 Motor sizes 37 2 55 2 General assembly drawing with motor type DKN 226, 2-pole (impeller type D) Amarex KRT 61 of 78...
  • Page 62 Pump casing Grease quantity control Wear plate Rotor Discharge cover 834.01/.03 Cable gland Impeller 900.20 Screw Rolling element Hexagon head bolt bearing 330.01 Bearing bracket 903.03/.04/.05/.46 Screw plug Bearing cover 914.01/.02/.03/.04/.05/.10/.12/ Hexagon socket head cap screw Amarex KRT 62 of 78...
  • Page 63 300-400/401 Motor sizes 23 4, 29 4 20 6, 26 6 10 8, 17 8, 21 8 General assembly drawing of pump set with motor type DKN 161/181 and cylindrical interference fit (impeller types K/E) Amarex KRT 63 of 78...
  • Page 64 Impeller 903.03/.05 Screw plug 321.02 Radial ball bearing 914.02/.10/.04/.26 Hexagon socket head cap screw Radial roller bearing 920.01/.26 Bearing bracket 930.28 Safety device 411.03/.05 Joint ring 932.01/.02/.22 Circlip 412.02/.03/.04/.07/.15 O-ring 421.01 Lip seal 970.03/.04 Plate Amarex KRT 64 of 78...
  • Page 65 200-400/401 250-400/401 300-400/401 Motor sizes 35 4, 50 4, 65 4 32 6, 40 6, 50 6 26 8, 35 8 General assembly drawing of pump set with motor type DKN 226 (impeller types K/E) Amarex KRT 65 of 78...
  • Page 66 Impeller hub cap 903.03/.05 Screw plug Radial roller bearing 914.01/.02/.04/.05/.10 Hexagon socket head cap screw 330.01/.02 Bearing bracket 920.01 321.02 Radial ball bearing 932.01/.02/.03/.20/.22 Circlip 411.03/.05 Joint ring 412.01/.02/ O-ring 970.03/.04 Plate .03/.04/.07/ .08/.15 421.01 Lip seal Amarex KRT 66 of 78...
  • Page 67 D 300-400 Motor sizes 35 4, 50 4, 65 4 32 6, 40 6, 50 6 26 8, 35 8 General assembly drawing of pump set with motor type DKN 226, 4/6/8-pole (impeller type D) Amarex KRT 67 of 78...
  • Page 68 9 Related Documents Table 32: Detailed views of general assembly drawing of pump set with motor type DKN 226, 4/6/8-pole Section Detailed view Cable gland Bearing temperature sensor Lubricant reservoir/leakage chamber Amarex KRT 68 of 78...
  • Page 69 Rolling element bearing 902.01 Stud Radial roller bearing 903.03/.04/.05/.46 Screw plug 330.01/.02 Bearing bracket 914.01/.02/.03/.04/.05/.10/.12/.24 Hexagon socket head cap screw Bearing cover 920.01 411.03/.04/.05/.26/.46 Joint ring 932.01/.02/.03/.20 Circlip 412.01/.02/.03/.04/.07/ O-ring 970.02 Plate .08/.15/.24/.33/.34 421.01/.02/.03 Lip seal Amarex KRT 69 of 78...

  • Page 70: Wiring Diagrams

    12 x ... mm 7 x ... +5 x 1,5 mm 21 22 11 9 21 22 3 U1 V1 W1 21 22 10 11 0W366474-00 0W380161-00 * Only for reinforced bearings (⇨ Section 4.4 Page 16) Amarex KRT 70 of 78...

  • Page 71: Flamepaths Of Explosion-Proof Motors

    15 6, 19 6, 20 6, 26 6, 1,2, 3 Flamepaths 37 2, 55 2 35 4, 50 4, 65 4 32 6, 40 6, 50 6 26 8, 35 8 1,2, 3, 4, 5 Flamepaths Amarex KRT 71 of 78...

  • Page 72: Sectional Drawings Of The Mechanical Seal

    4 4, 5 4, 7 4, 11 4, 16 4, OW 309131-00 19 4, 21 4, 23 4, 29 4 433.02 Mechanical seal (mechanical 4 6, 6 6, 9 6, 12 6, 15 6, seal with covered springs - 19 6 433.02 OW 309131-05 Amarex KRT 72 of 78...
  • Page 73 23 4, 29 4, 35 4, 50 4, 65 4 20 6, 26 6, 32 6, 40 6, 50 6 10 8, 17 8, 21 8, 26 8, 35 8 433.02 550.44 433.02 Mechanical seal (mechanical seal with covered springs - 433.02 Amarex KRT 73 of 78...

  • Page 74: Ec Declaration Of Conformity

    D-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/Pump set: Machinery Directive 2006/42/EC The manufacturer also declares that ▪...

  • Page 75: 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 75 of 78...

  • Page 76: Index

    Supply voltage 36 Transportable installation 28 Intended use 8 Interference immunity 30 Temperature monitoring 30 Tightening torques 54 Trouble-shooting 56 Leakage monitoring 31 Level control 29 Lubricant Intervals 40 Wiring diagrams 70 Quality 42 Quantity 43 Amarex KRT 76 of 78...
  • Page 78 KSB Aktiengesellschaft P.O. Box 200743 • 06008 Halle (Saale) • Turmstraße 92 • 06110 Halle (Germany) Tel. +49 345 4826-0 • Fax +49 345 4826-4699 www.ksb.com...

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