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

Submersible motor pump
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Submersible Motor Pump
Amarex KRT
for use in the Amajet system
50 Hz
Installation/Operating Manual
Mat. No.:
01232461

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Summary of Contents for KSB Amarex KRT

  • Page 1 Submersible Motor Pump Amarex KRT for use in the Amajet system 50 Hz Installation/Operating Manual Mat. No.: 01232461...
  • 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

    Configuration and function .........................16 Noise characteristics .............................17 Scope of supply .............................17 Dimensions and weights ..........................17 Installation at Site ........................18 Safety regulations ............................18 Checks to be carried out prior to installation .....................18 Installing the pump set ..........................20 Amarex KRT 3 of 66...
  • Page 4 Related Documents ........................48 General assembly drawings .........................48 Wiring diagrams ............................56 Flamepaths on explosion-proof motors ......................59 Sectional drawings of the mechanical seal ....................60 EU Declaration of Conformity ....................63 Certificate of Decontamination ....................64 Index ............................65 Amarex KRT 4 of 66...

  • Page 5: Glossary

    Pump set components in contact with the fluid handled. Complete pump set consisting of pump, drive, additional components and accessories Close-coupled design Motor directly fitted to the pump via a flange or a drive lantern Amarex KRT 5 of 66...

  • 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: 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 KRT 7 of 66...

  • Page 8: Safety

    ▪ Only operate pump sets which are in perfect technical condition. ▪ Do not operate partially assembled pump sets. ▪ Only use the pump to handle the fluids described in the data sheet or product literature of the pump model. Amarex KRT 8 of 66...

  • Page 9: Personnel Qualification And Training

    ▪ Non-compliance with this operating manual 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 Amarex KRT 9 of 66...

  • Page 10: Safety Awareness

    Never operate the pump (set) outside the limits stated in the data sheet and in this manual. The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use. Amarex KRT 10 of 66...

  • Page 11: Explosion Protection

    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 66...

  • 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-coat the inside wall of the pump casing, and in particular the impeller clearance areas, with a preservative. 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). Amarex KRT 13 of 66...

  • Page 14: Return To Supplier

    Always indicate any safety and decontamination measures taken. (⇨ Section 11 Page 64) 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 and/or pose a health hazard Hazard to persons and the environment! ▷...

  • Page 15: Description Of The Pump (Set)

    Mat. No. 01231886 ZN 3826 – M 29 Fig. 2: Name plate (example) a) Standard pump set b) Explosion-proof pump set Designation (⇨ Section 4.2 Page 15) KSB order number and KSB order item number Flow rate Maximum fluid and ambient temperature...

  • Page 16: Installation Types

    (7). In the flow passage of the pump casing the kinetic energy of the fluid is converted into pressure energy. The fluid is pumped to the discharge nozzle (2), where it leaves the pump. The casing wear ring (1) prevents Amarex KRT 16 of 66...

  • Page 17: Noise Characteristics

    For dimensions and weights refer to the general arrangement drawing/outline drawing or data sheet of the pump set. Measured at a distance of 1 m from the pump outline (as per DIN 45635 Part 1 and 24) Amarex KRT 17 of 66...

  • Page 18: Installation At Site

    Checking the operating data Before installing the pump set, verify that the name plate data matches the data given in the purchase order and the site system data. 5.2.2 Preparing the place of installation See Amajet installation/operating manual. Amarex KRT 18 of 66...
  • Page 19 Also see ● Changing the lubricant [⇨ 35] 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 potentially explosive atmospheres. Amarex KRT 19 of 66...

  • Page 20: Installing The Pump Set

    Information for planning the control system For the electrical connection of the pump set observe the "Wiring diagrams" section. The pump set is supplied with power cables; it is wired for DOL starting. Star-delta starting is also possible. Amarex KRT 20 of 66...
  • Page 21 Operation Observe the following limits during operation on a frequency inverter: ▪ Only utilise up to 95 % of the motor rating P indicated on the name plate. ▪ Frequency range 25 to 50 Hz Amarex KRT 21 of 66...
  • Page 22 Suitable analysing devices must be selected. To monitor the leakage sensor inside the motor using a special relay available from KSB is recommended. Also see ● Name plate [⇨ 15] 5.4.1.4...
  • Page 23 5.4.1.4.3 Bearing temperature As an option, the pump set can be supplied with temperature monitoring in the area of the pump-end bearing. Check in the data sheet whether the pump set is equipped with bearing temperature monitoring. Amarex KRT 23 of 66...
  • Page 24 The pump set is supplied complete with power cable. Always connect all marked cores. DANGER Incorrect wiring Explosion hazard! ▷ The connection point of the cable ends must be located outside of the potentially explosive atmosphere or inside electrical equipment approved to equipment category II2G. Amarex KRT 24 of 66...
  • Page 25 ▷ 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 25 of 66...

  • Page 26: Commissioning/Start-Up/Shutdown

    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. Amarex KRT 26 of 66...

  • Page 27: Operating Limits

    The voltage difference between the individual phases must not exceed 1 %. 6.2.3 Operation on a frequency inverter DANGER Operation outside the permitted frequency range Explosion hazard! ▷ Never operate an explosion-proof pump set outside the specified range. Amarex KRT 27 of 66...
  • Page 28 The pump input power changes in proportion to the density of the fluid handled. CAUTION Impermissibly high density of the fluid handled Motor overload! ▷ Observe the information on fluid density in the data sheet. ▷ Make sure the motor has sufficient power reserves. Amarex KRT 28 of 66...

  • Page 29: Shutdown/Storage/Preservation

    WARNING Failure to re-install or re-activate protective devices 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. Amarex KRT 29 of 66...
  • Page 30 6 Commissioning/Start-up/Shutdown NOTE On pumps/pump sets older than 5 years we recommend replacing all elastomer seals. Amarex KRT 30 of 66...

  • Page 31: Servicing/Maintenance

    ▷ When draining the fluid take appropriate measures to protect persons and the environment. ▷ Decontaminate pumps which handle fluids posing a health hazard. WARNING Hot surface Risk of injury! ▷ Allow the pump set to cool down to ambient temperature. Amarex KRT 31 of 66...

  • Page 32: Maintenance/Inspection

    NOTE All maintenance, service 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.
  • Page 33 The actual sensor function is not tested. Temperature sensors in Table 10: Resistance measurement the motor winding Measurement between terminals ... Resistance [Ω] 21 and 22 < 1 10 and 11 200 to 750 Amarex KRT 33 of 66...
  • Page 34 ▪ Equivalent brands of medical quality, non-toxic ▪ Water-glycol mixture WARNING Lubricant contaminating fluid handled Hazard to persons and the environment! ▷ Using machine oil is only permitted if the oil is disposed of properly. Amarex KRT 34 of 66...
  • Page 35 903.04 with joint ring 411.05. Drain the lubricant. Filling in the lubricant Position the pump set as illustrated. 903.03 903.03 411.03 411.03 Fig. 7: Filling in the lubricant Pour lubricant into the lubricant filler opening until the lubricant reservoir overflows. Amarex KRT 35 of 66...

  • Page 36: 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 KRT 36 of 66...
  • Page 37 550.23 Fig. 8: Removing the impeller NOTE The forcing screw is not included in the scope of supply. It can be ordered separately from KSB. Table 15: Forcing screws for pulling off the impeller Size Impeller type Forcing screw Thread...
  • Page 38 Use a forcing screw to pull off impeller 230. 914.10 550.23 Fig. 11: Removing the impeller NOTE The forcing screw is not included in the scope of supply. It can be ordered separately from KSB. Amarex KRT 38 of 66...
  • Page 39 Repair to the values in tables 1 and 2 of EN 60079-1 is not permitted. When dismantling the motor section and the power cable make sure that the cores/ terminals are clearly marked for future reassembly. Amarex KRT 39 of 66...

  • Page 40: Reassembling The Pump Set

    ▪ Only remove the protective wrapping of the contact faces immediately before assembly takes place. ▪ The shaft surface must be absolutely clean and undamaged. ▪ Immediately before installing the mechanical seal, wet the contact faces with a drop of oil. Amarex KRT 40 of 66...
  • Page 41 Installing the back pull-out unit 7.5.2.3.1 Design with axial clearance NOTE After casing wear rings with a radial clearance have been fitted in pump casing 101, they have the required inside diameter and do not need to be readjusted. Amarex KRT 41 of 66...
  • Page 42 Lift off the pump set and adjust the axial clearance to 0.3 ± 0.1 mm. 904.01 Fig. 16: Fitting the casing wear ring 7.5.2.3.2 Design with wear plate ✓ The shaft, rolling element bearings, mechanical seal and impeller have been assembled properly. Amarex KRT 42 of 66...
  • Page 43 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/bolted connections closing off the flameproof enclosure...

  • Page 44: Tightening Torques

    A4-50 A4-70 1.4462 Property class Rp 0.2 mm² 1000 1400 1300 2750 3900 1950 4200 6000 7.7 Spare parts stock 7.7.1 Ordering spare parts Always quote the following data when ordering replacement or spare parts: Amarex KRT 44 of 66...
  • Page 45 Rolling element bearing, pump end 50 % 99-9 Set of sealing elements for the motor 100 % 99-9 Set of sealing elements for the hydraulic system 100 % For two years of continuous operation or 17,800 operating hours Amarex KRT 45 of 66...

  • Page 46: Faults: Causes And Remedies

    Check the electrical installation. voltage. Contact the energy supplier. ✘ - ✘ - Motor winding or connection cable are Replace by new original KSB parts or contact defective. KSB. - ✘ - ✘ Defective rolling element bearing Contact the manufacturer.
  • Page 47 - Motor has been tripped by leakage monitor. Have cause determined and eliminated by qualified and trained personnel. ✘ - Bearing temperature monitor has tripped. Have cause determined and eliminated by qualified and trained personnel. Amarex KRT 47 of 66...

  • Page 48: Related Documents

    5 4, 7 4, 11 4, 16 4, 19 4, 21 4, 23 4, 29 4, 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 48 of 66...
  • Page 49 5 4, 7 4 Upper bearing Motors 5 4, 7 4 UK.../ XK... 19 4, 21 4, 15 6, 19 6 Upper bearing Motors 11 4, 16 4, 23 4, 29 4, 9 6, 12 6 Amarex KRT 49 of 66...
  • Page 50 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 Lock washer 411.03 Joint ring 932.01/.02/.03/.13 Circlip 412./.02/.03/.04/.07/.15/.16/.33/.34 O-ring Amarex KRT 50 of 66...
  • Page 51 For material variant C1/C2 Hydraulic system sizes 150-401 Motors 23 4, 29 4 20 6, 26 6 General assembly drawing of pump set with motor type DKN 161/181 and cylindrical interference fit (impeller types K/E) Amarex KRT 51 of 66...
  • Page 52 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 Label/plate Amarex KRT 52 of 66...
  • Page 53 For material variant C1/C2 Hydraulic system sizes 150-401 Motors 35 4, 50 4, 65 4 32 6, 40 6, 50 6 General assembly drawing of pump set with motor type DKN 226 (impeller types K/E) Amarex KRT 53 of 66...
  • Page 54 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/.03/. O-ring 970.03/.04 Label/plate 04/.07/.08/.15 421.01 Lip seal Amarex KRT 54 of 66...
  • Page 55 Bearing temperature sensor C - C 69-6.02* 520.02* 914.12 Part No. Description Part No. Description 412.07/.08 O-ring 834.01/.03 Cable gland 520.01 Sleeve 914.01/.04/.05/.12 Hexagon socket head cap screw 69-6.01 Temperature sensor 970.02 Label/plate 81-51 Clamping element Amarex KRT 55 of 66...

  • Page 56: Wiring Diagrams

    23 4, 29 4, 4 6, 6 6, 9 6, 15 6, 19 6, 26 6 Electric cables: 12G1.5 12G2.5 Ⓐ Motor temperature (PTC) Ⓔ Motor temperature Ⓕ Leakage inside the motor * Shielded cable optional Amarex KRT 56 of 66...
  • Page 57 23 4, 29 4, 4 6, 6 6, 9 6, 15 6, 19 6, 26 6 Electric cables: 7G4 + 5×1.5 7G6 + 5×1.5 7G10 + 5×1.5 Ⓐ Motor temperature (PTC) Ⓔ Motor temperature Ⓕ Leakage inside the motor Amarex KRT 57 of 66...
  • Page 58 Wiring diagram Motors: 35 4, 50 4, 65 4, 32 6, 40 6, 50 6 Ⓐ Motor temperature (PTC) Ⓒ Bearing temperature (lower bearing) Ⓔ Motor temperature Ⓕ Leakage inside the motor * Shielded cable optional Amarex KRT 58 of 66...

  • Page 59: Flamepaths On Explosion-Proof Motors

    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, 20 6, 26 6, 1,2, 3 Flamepaths Amarex KRT 59 of 66...

  • Page 60: Sectional Drawings Of The Mechanical Seal

    Hydraulic system sizes 433.01 Mechanical seal (bellows- 433.01 100-250 type mechanical seal) Locking ring Motors 433.02 Mechanical seal (bellows- 5 4, 7 4, 11 4, 16 4, 19 4, type mechanical seal) 21 4 433.02 OW 309130-00 Amarex KRT 60 of 66...
  • Page 61 5 4, 7 4, 11 4, 16 4, 19 4, 932.03 21 4, 23 4, 29 4 9 6, 12 6, 15 6, 19 6 433.02 OW 309131-00 433.02 Mechanical seal (mechanical seal with covered springs - 433.02 OW 309131-05 Amarex KRT 61 of 66...
  • Page 62 23 4, 29 4, 35 4, 50 4, 65 4 433.02 Mechanical seal (bellows- 20 6, 26 6, 32 6, 40 6, type mechanical seal) 50 6 550.44 Disc 550.03 932.03 433.02 550.44 433.02 Mechanical seal (mechanical seal with covered springs - 433.02 Amarex KRT 62 of 66...

  • Page 63: Eu 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 64: 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 64 of 66...

  • Page 65: Index

    General assembly drawing 48 Storage 13, 29 Supply voltage 27 Impeller type 16 Intended use 8 Temperature monitoring 23 Interference immunity 22 Transport 12 Leakage monitoring 23 Wiring diagrams 56 Lubricant 34 Intervals 32 Quality 34 Quantity 35 Amarex KRT 65 of 66...
  • Page 66 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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