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Submersible Motor Pump

Amarex KRT

for use in the Amajet systemPump sizes:F 100-250, 150-315, 150-401D 100-251, 150-251, 150-315, 100-316Motor sizes:4-pole: 5 4 - 65 4, 6-pole.: 9 6 - 12 6

Installation/OperatingManual

Ident. number: 01232461

Legal information/Copyright Installation/Operating Manual Amarex KRTOriginal operating manual KSB Aktiengesellschaft Halle All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, editedor processed for any other purpose, nor otherwise transmitted, published or made available to a thirdparty without KSB´s express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 18.05.2010

Contents

Glossary ................................................................................................ 5

1 General ................................................................................................ 6

1.1 Principles .......................................................................................................... 6

1.2 Installation of partly completed machinery .................................................. 6

1.3 Target group ................................................................................................... 6

1.4 Other applicable documents .......................................................................... 6

1.5 Symbols ............................................................................................................ 7

2 Safety ................................................................................................... 8

2.1 Key to safety symbols/markings ..................................................................... 8

2.2 General ............................................................................................................ 8

2.3 Intended use .................................................................................................... 8

2.4 Personnel qualification and training ............................................................. 9

2.5 Consequences and risks caused by non-compliance with these operatinginstructions ...................................................................................................... 9

2.6 Safety awareness ........................................................................................... 10

2.7 Safety instructions for the operator/user .................................................... 10

2.8 Safety information for maintenance, inspection and installation work ... 10

2.9 Unauthorised modes of operation ............................................................... 10

2.10 Explosion protection ..................................................................................... 10

3 Transport/Temporary Storage/Disposal ........................................... 12

3.1 Transport ....................................................................................................... 12

3.2 Storage and preservation ............................................................................. 12

3.3 Return to supplier ......................................................................................... 13

3.4 Disposal .......................................................................................................... 13

4 Description of the Pump (Set) .......................................................... 14

4.1 General description ....................................................................................... 14

4.2 Designation ................................................................................................... 14

4.3 Name plate .................................................................................................... 14

4.4 Design details ................................................................................................ 15

4.5 Installation types ........................................................................................... 15

4.6 Design and function ...................................................................................... 15

4.7 Noise characteristics ...................................................................................... 16

4.8 Scope of supply ............................................................................................. 16

4.9 Dimensions and weights ............................................................................... 16

5 Installation at Site ............................................................................. 17

5.1 Safety regulations ......................................................................................... 17

5.2 Checking the site before installation ........................................................... 17

5.3 Installing the pump set ................................................................................. 18

Contents

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5.4 Electrical connection ..................................................................................... 18

6 Commissioning/Start-up/Shutdown ................................................. 23

6.1 Commissioning/start-up ................................................................................ 23

6.2 Operating limits ............................................................................................ 23

6.3 Shutdown/storage/preservation ................................................................... 25

6.4 Returning to service ...................................................................................... 25

7 Servicing/Maintenance ...................................................................... 27

7.1 Safety regulations ......................................................................................... 27

7.2 Maintenance/inspection ............................................................................... 27

7.3 Drainage/disposal .......................................................................................... 31

7.4 Dismantling the pump set ............................................................................ 31

7.5 Reassembling the pump set .......................................................................... 34

7.6 Tightening torques ....................................................................................... 37

7.7 Spare parts stock ........................................................................................... 37

8 Trouble-shooting ............................................................................... 39

9 Related Documents ........................................................................... 40

9.1 General assembly drawings .......................................................................... 40

9.2 Wiring diagrams ............................................................................................ 46

9.3 Flamepaths of explosion-proof motors ....................................................... 47

9.4 Sectional drawings of the mechanical seal .................................................. 48

10 EC Declaration of Conformity .......................................................... 50

11 Certificate of Decontamination ....................................................... 51

Index .................................................................................................. 52

Contents

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Glossary

Back pull-out unitPump without pump casing; partly completedmachinery

Certificate of decontaminationA certificate of decontamination certifies thatthe pump (set) has been properly drained toeliminate any environmental and healthhazards arising from components in contactwith the fluid handled.

Close-coupled designMotor directly fitted to the pump via a flangeor a drive lantern

Hydraulic systemThe part of the pump in which the kineticenergy is converted into pressure energy

Glossary

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1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicatedon the front cover (for details, please refer to the table below).

Table 1: Variants covered by this manual

Sizes Impeller types Material variantGrey cast iron Industrial materials

G G1 G2 GH H C1 C2100-250 F F F F F F F F100-251 D D D - - - - -100-316 D D D - - - - -150-251 D D D - - - - -150-315 D, F D, F D, F F F F F F150-401 F F F F F F F F

This manual describes the proper and safe use of this equipment in all phases ofoperation.

The name plate indicates the type series and size, the main operating data, the ordernumber and the order item number. The order number and order item numberclearly identify the pump set and serve as identification for all further businessprocesses.

In case of damage, immediately contact your nearest KSB service centre to maintainthe right to claim under warranty.

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, refer to the sub-sectionsunder Servicing/Maintenance.

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist technicalpersonnel. ( Section 2.4 Page 9)

1.4 Other applicable documents

Table 2: Overview of other applicable documents

Document ContentsTechnical data sheet Description of the technical data of the pump

setGeneral arrangement drawing/outline drawing

Description of mating and installationdimensions for the pump set

Hydraulic characteristic curve Characteristic curves showing head, flow rate,efficiency and power input

General assembly drawing1) Sectional drawing of the pump set

Sub-supplier documentation1) Operating manuals and other documentationof accessories and integrated machinerycomponents

Spare parts lists1) Description of spare partsSupplementary operatinginstructions1)

For example for special accessories

1) If agreed to be included in the scope of supply

1 General

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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-references1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

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2 SafetyAll the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 4: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.Explosion protectionThis symbol identifies information about avoiding explosions inpotentially explosive atmospheres in accordance with EC Directive94/9/EC (ATEX).General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies informationabout protection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent injury anddamage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the responsible specialistpersonnel/operators prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pump must always be complied with and bekept in a perfectly legible condition at all times. This applies to, for example:

Arrow indicating the direction of rotation

Markings for connections

Name plate

The operator is responsible for ensuring compliance with all local regulations whichare not taken into account in this manual.

2.3 Intended use

Only operate the pump (set) within the operating limits which are described in theother applicable documents.

Only operate pump sets which are in perfect technical condition.

Do not operate partially assembled pump sets.

! DANGER

2 Safety

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Only use the pump set to handle the fluids described in the data sheet or productliterature of the pump variant.

Never operate the pump set without the fluid to be handled.

Consult the manufacturer about any use or mode of operation not described inthe data sheet or product literature.

Only use impeller types designed for the fluid handled, as described below.

Free-flow impeller (impeller type F)

Suitable for the following fluids:Fluids containing solids and stringymaterial as well as fluids with entrappedair or gas

Open, diagonal single-vane impeller (impeller type D)

Suitable for the following fluids:Waste water with solid substances andlong fibres

Prevention of foreseeable misuse

Never exceed the permissible operating limits specified in the data sheet orproduct literature regarding pressure, temperature, etc.

Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain andinspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved ininstallation, operation, maintenance and inspection must be clearly defined by theoperator.

Deficits in knowledge must be rectified by sufficiently trained specialist personneltraining and instructing the personnel who will carry out the respective tasks. Ifrequired, the operator can commission the manufacturer/supplier to train thepersonnel.

Training on the pump (set) must always be supervised by technical specialistpersonnel.

2.5 Consequences and risks caused by non-compliance with these operatinginstructions

Non-compliance with these operating instructions will lead to forfeiture ofwarranty 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 chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2 Safety

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2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,the following safety regulations shall be complied with:

Accident prevention, health and safety regulations

Explosion protection regulations

Safety regulations for handling hazardous substances

Applicable standards and laws

2.7 Safety instructions for the operator/user

The operator shall fit contact guards for hot, cold and moving parts, and checkthat the guards function properly.

Never remove the contact guard when the pump is in operation.

Provide the personnel with protective equipment and make sure it is used.

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 nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

2.8 Safety information for maintenance, inspection and installation work

Modifications or alterations of the pump are only permitted with themanufacturer's prior consent.

Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughlyfamiliar with the manual.

Carry out work on the pump (set) during standstill only.

The pump casing must have cooled down to ambient temperature.

Pump pressure must have been released and the pump must have been drained.

When taking the pump set out of service always adhere to the proceduredescribed in the manual.

Decontaminate pumps which handle fluids posing a health hazard.

As soon as the work is completed, re-install and/or re-activate any safety-relevantand protective devices. Before returning the product to service, observe allinstructions on commissioning. ( Section 6.1 Page 23)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in thismanual.

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.

2.10 Explosion protection

Always observe the information on explosion protection given in this section whenoperating an explosion-proof pump set.

! DANGER

2 Safety

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Sections of the manual marked by the Ex symbol apply to explosion-proof pump setsalso when temporarily operated outside potentially explosive atmospheres.Only pumps/pump sets marked as explosion-proof and identified as such in the datasheet must be used in potentially explosive atmospheres.

Special conditions apply to the operation of explosion-proof pump sets in accordancewith EC Directive 94/9/EC (ATEX). When operating explosion-proof pump sets, especially adhere to the additionalrequirements marked by the Ex symbol. The explosion-proof status of the pump set is only assured if the pump set is used inaccordance with its intended use. Never operate the pump (set) outside the limits stated in the data sheet and on thename plate.Prevent impermissible modes of operation at all times.

2.10.1 Repair

Special regulations apply to repair work on explosion-proof pumps. Modifications oralteration of the pump set may affect explosion protection and are only permittedafter consultation with the manufacturer.

Repair work at the flameproof joints must only be performed in accordance with themanufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 isnot permitted.

2 Safety

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3 Transport/Temporary Storage/Disposal

3.1 Transport

DANGERImproper transportDanger to life from falling parts!Damage to the pump set!

▷ Use the attachment point provided (eyebolt, lifting lug or bail) for attachinglifting tackle.

▷ Never suspend the pump set by its power cable.

▷ Never use the chains or lifting ropes included in KSB's scope of supply for liftingloads other than the KSB product supplied.

▷ Securely attach the lifting ropes or chains to the pump and crane.

Transport the pump set as illustrated.

Fig. 1: Transporting the pump set

3.2 Storage and preservation

If commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for pump storage:

CAUTIONImproper storageDamage to the power cables!

▷ Support the power cables at the cable entry to prevent permanent deformation.

▷ Only remove the protective caps from the power cables at the time ofinstallation.

CAUTIONDamage during storage by humidity, dirt, or verminCorrosion/contamination of the pump (set)!

▷ For outdoor storage cover the pump (set) or the packaged pump (set) andaccessories with waterproof material.

CAUTIONWet, contaminated or damaged openings and connectionsLeakage or damage to the pump set!

▷ Only remove caps/covers from the openings of the pump set at the time ofinstallation.


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Table 5: Ambient conditions for storage

Ambient conditions ValueRelative humidity 5 % to 85 %

(non-condensing)Ambient temperature - 10 °C to + 70 °C

Store the pump set under dry and vibration-free conditions, if possible in itsoriginal packaging.

1. Spray-coat the inside wall of the pump casing, and in particular the impellerclearance areas, with a preservative.

2. 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).

NOTEObserve the manufacturer's instructions for application/removal of the preservative.

3.3 Return to supplier

1. Drain the pump as per operating instructions.

2. Always flush and clean the pump, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.

3. If the fluids handled by the pump leave residues which might lead to corrosiondamage when coming into contact with atmospheric humidity, or which mightignite when coming into contact with oxygen, the pump set must also beneutralised, and anhydrous inert gas must be blown through the pump fordrying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set). ( Section 11 Page 51)It is imperative to indicate any safety and decontamination measures taken.

NOTEIf required, a blank certificate of decontamination can be downloaded from the KSB website at: www.ksb.com/certificate_of_decontamination

3.4 Disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pump (set).Collect greases and other lubricants during dismantling.

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 controlledmanner.


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http://www.ksb.com/GRAS-Cert

4 Description of the Pump (Set)

4.1 General description

Pump for handling untreated waste water containing long fibres and solidsubstances, fluids containing gas and air as well as raw, activated and digestedsludge.

4.2 Designation

Example: KRTF 100-250/164XG-S

Table 6: Key to the designation

Code DescriptionKRT Type seriesF Impeller type, e.g. F = free flow impeller100 Nominal discharge nozzle diameter (DN) [mm]250 Maximum nominal impeller diameter [mm]16 Motor size4 Number of polesX Motor version e.g. X = explosion-proof to ATEX II 2GT3G Material variant e.g., G = complete pump in cast ironS Installation type, e.g. S = stationary wet installation

without cooling system

4.3 Name plate

TYPE

No.Q

P2

KSB Aktiengesellschaft67227 Frankenthal

Mat. No: 01080556 ZN 3826 - M 12

TEMP. MAX.

WARNUNG - NICHT UNTER SPANNUNG ÖFFNENWANING - DO NOT OPEN WHEN ENERGIZEDAVERTISSEMENT - NE PAS OUVRIR SOUS TENSION

a) b)

°C kg

H

Motor IP 68 SUBM. MAX. 30 m CLASS F3~ M.-No.

kW V Hz cos φmin-1

A IA/IN S1

TYPE

No.Q

P2

KSB Aktiengesellschaft67227 Frankenthal

Mat. No: 01080566 ZN 3826 - M 16

TEMP. MAX.

WARNUNG - NICHT UNTER SPANNUNG ÖFFNENWANING - DO NOT OPEN WHEN ENERGIZEDAVERTISSEMENT - NE PAS OUVRIR SOUS TENSION

II2G Ex d IIB T

°C kg

H

Motor IP 68 SUBM. MAX. 30 m CLASS F3~ M.-No.

kW V Hz cos φmin-1

A IA/IN S1

0035 II2G Ex d IIB

1234

111213

65

789

10

151617

14

181920 21

21 Amarex KRT F 100 - 250 / 16 4 UG-S 9971511000/000310 300 m³/h 14 m

40 150

2010

DKN 160.4-12 16 1475 33/19 4,9

0,81 400/690 50 123456

Amarex KRT F 100 - 250 / 16 4 UG-S 9971511000/000310 300 m³/h 14 m

40 150

2010

DKN 160.4-12 16 1475 33/19 4,9

0,81 400/690 50 123456

Fig. 2: Name plate a) Standard pump set b) Explosion-proof pump set

1 Designation 2 KSB order number3 Flow rate 4 Maximum fluid and ambient temperature5 Enclosure 6 Motor type7 Rated power 8 Rated speed9 Rated voltage 10 Rated current11 Head 12 Year of construction13 Total weight 14 Maximum immersion depth15 Thermal class of winding insulation 16 Motor number17 Power factor at design point 18 Rated frequency19 Mode of operation 20 Starting current ratio21 Marking for explosion-proof pump sets


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4.4 Design details

Design

Fully floodable submersible motor pump

Not self-priming

Close-coupled design

Impel ler type

Various, application-based impeller types

Shaft seal

Two bi-directional mechanical seals in tandem arrangement, with liquid reservoir

Reinforced bearings with leakage chamber

Standard bear ing assembly

Grease-packed bearings sealed for life

Maintenance-free

Drive

Three-phase asynchronous squirrel-cage motor

Motors integrated in explosion-proof pump sets are supplied in type of protection Exd IIB.

4.5 Installation types

See Amajet installation/operating manual!

4.6 Design and function

1

34

6

7

8

9

10

5

2

Fig. 3: Sectional drawing

1 Casing wear ring 2 Discharge nozzle3 Discharge cover 4 Shaft5 Bearing bracket 6 Suction nozzle7 Impeller 8 Shaft seal9 Bearing, pump end 10 Bearing, motor end


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The pump is designed with an axial fluid inlet and a radial outlet. The hydraulicsystem sits on the extended motor shaft. The shaft runs in common bearings.

The fluid enters the pump axially via a suction nozzle (6) and is accelerated outwardin a cylindrical flow by the rotating impeller (7). The flow profile of the pump casingconverts the kinetic energy of the fluid into pressure energy. The fluid is pumped tothe discharge nozzle (2), where it leaves the pump. The casing wear ring (1) preventsany fluid from flowing back from the casing into the inlet. At the rear side of theimpeller, the shaft (4) enters the casing via the discharge cover (3). The shaft passagethrough the discharge cover is sealed towards the atmosphere with a shaft seal (8).The shaft runs in rolling element bearings (9 and 10), which are supported by abearing bracket (5) linked with the pump casing and/or discharge cover.

The pump is sealed by two bi-rotational mechanical seals in tandem arrangement.A lubricant reservoir in-between the seal elements ensures cooling and lubrication ofthe mechanical seals.

4.7 Noise characteristics

Table 7: Surface sound pressure level LpA2)

Rated power input PN

[kW]

Pump set1450 rpm

[dB]4 62

5.5 63.57.5 6511 6715 68

18.5 68.522 6930 70.537 7145 7155 71.565 72

4.8 Scope of supply


4.9 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outlinedrawing or data sheet of the pump set.

Design

Function

Sealing

2) Measured at a distance of 1 m from the pump outline (as per DIN 45635 Part 1 and 24)


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5 Installation at Site

5.1 Safety regulations

DANGERImproper installation in potentially explosive atmospheresExplosion 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 thepump set.

DANGERPersons in the tank during pump operationElectric shock!

▷ Never start up the pump set when there are persons in the tank.

5.2 Checking the site before installation

5.2.1 Checking the operating data

Before installing the pump set, verify that the name plate data matches the datagiven in the purchase order and the site system data.

5.2.2 Preparing the place of installation


5.2.3 Checking the lubricant level

The lubricant reservoirs are filled with an environmentally-friendly, non-toxiclubricant at the factory.

1. Install the pump set as illustrated.

903.03411.03903.03

411.03

Fig. 4: Checking the lubricant level

2. Unscrew screwed plug 903.03 with joint ring 411.03.

The lubricant must be level with the filler opening.

3. If the lubricant level is lower, fill the lubricant reservoir via the filler openinguntil the reservoir overflows. ( Section 7.2.2.1.4 Page 30)

4. Close screwed plug 903.03 with joint ring 411.03 again.


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5.2.4 Checking the direction of rotation

DANGERPump set running dryExplosion hazard!

▷ The direction of rotation of explosion-proof pump sets must be checked outsidethe potentially explosive atmosphere.

WARNINGHands or objects inside the pump casingRisk 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.

CAUTIONPump set running dryIncreased vibrations!Damage to mechanical seals and bearings!

▷ Never operate the pump set for more than 60 seconds outside the fluid to behandled.

The pump set has been connected to the power supply.

1. Start up the pump set and switch it off again immediately to check the directionof rotation of the motor.

2. Check the direction of rotation. When looking at the pump mouth, the impeller must turn in anti-clockwisedirection (on some pump casings, the direction of rotation is marked by anarrow).

Fig. 5: Checking the direction of rotation.

3. If the impeller runs in the wrong direction of rotation, check the connection ofthe pump and the switchgear, if any.

4. Disconnect the pump set from the power supply again and make sure it cannotbe switched on accidentally.

5.3 Installing the pump set


5.4 Electrical connection

5.4.1 Information for planning the control system

For the electrical connection of the pump set observe the wiring diagrams containedin the Annex. The pump set is supplied with power cables; it is designed for direct starting. Star-delta starting is also possible.


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NOTEWhen laying a cable between the control system and the pump set's connection point,make sure that the number of conductors is sufficient for the sensors. A minimum cross-section of 1.5 mm² is required.

The motors may be connected to electrical low-voltage grids with nominal voltagesand voltage tolerances to IEC 38 or other grids or power supply facilities withmaximum nominal voltage tolerances of ± 10 %.

5.4.1.1 Overload protection

1. Protect the pump set against overloading by a thermal time-lag overloadprotection device in accordance with IEC 947 and local regulations.

2. Adjust the overload protection device to the rated current specified on the nameplate.

5.4.1.2 Level control


▷ Never allow an explosion-proof pump set to run dry!

5.4.1.3 Sensors

DANGEROperating an incompletely connected pump setExplosion hazard!Damage to the pump set!

▷ Never start up a pump set with incompletely connected power cables or non-operational monitoring devices.

CAUTIONIncorrect connection to power supplyDamage to the sensors!

▷ Observe the limits stated in the following sections of this manual whenconnecting the sensors.

The pump set is equipped with sensors designed to prevent hazards and damage tothe pump set.

Measuring transducers are required for analysing the sensor signals supplied. Suitabledevices for 230V~ can be supplied by KSB.

NOTEReliable and safe operation of the pump within the scope of our warranty is only possibleif the sensor signals are properly analysed as stipulated in these operating instructions.

All sensors are located inside the pump set and are connected to the power cable. For information on wiring and core marking please refer to the wiring diagrams. The individual sensors and the limit values to be set are described in the followingsections.


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5.4.1.3.1 Motor temperature

DANGERInsufficient coolingExplosion hazard!Winding damage!

▷ Never operate a pump set without operational temperature monitoring.

▷ For explosion-proof pump sets use a thermistor tripping unit with manual resetwhich is ATEX-approved for monitoring the temperature of explosion-proofmotors in "flameproof enclosure" Ex d type of protection.

The pump set is equipped with double monitoring of the winding temperature. Twobimetal switches (terminals 21 and 22, max. 250V~/2A) serve as temperature controldevices which open when the winding temperature is too high.

Opening of the switch contacts must result in the pump set cutting out. Automaticre-start is permissible. For explosion-proof pump sets, the three additional, series-connected (PTC)thermistors with terminals 10 and 11 must be used. They must be connected to athermistor tripping unit with manual reset and ATEX approval for monitoring thetemperature of explosion-proof motors in "flameproof enclosure Ex d" type ofprotection.

5.4.1.3.2 Leakage inside the motor

PE

K 1

9

B2

Connecting the electrode relay

B2

Position of the electrode in the motor housing

An electrode fitted inside the motor monitors the winding and connection space forleakage. This electrode must be connected to an electrode relay (conductor marked9). Tripping of the electrode relay must result in the pump set cutting out.

The electrode relay (K1) must meet the following requirements:

Sensor circuit 10 to 30V ~

Tripping current 0.5 to 3 mA(equivalent to a tripping resistance of 3 to 60 kΩ)

5.4.1.3.3 Bearing temperature

As an option, the pump set can be supplied with temperature monitoring in the areaof the lower bearing.Check on the data sheet if whether the pump set is equipped with bearingtemperature monitoring.

The bearing temperature sensor is a PT100 resistance thermometer. It has to beconnected to a temperature control device with a PT100 input and 2 separateoutputs for two different switching points (sensor circuit maximum 6V/2mA).


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Set the following limits:

Alarm at 110 °C

Cut-out of the pump set at 130°C

5.4.2 Electrical connection

DANGERWork on the pump set by unqualified personnelDanger of death from electric shock!

▷ Always have the electrical connections installed by a trained electrician.

▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pumpsets, IEC 60079 (DIN VDE 0165).

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

CAUTIONImproper wiringDamage to the power cables!

▷ Never move the power cables at temperatures below -25 °C.

▷ Never bend or crush the power cables.

▷ Never use the power cables to lift up the pump set.

CAUTIONMotor overloadDamage to the motor!

▷ Protect the motor against overloading by a thermal time-lag overloadprotection device in accordance with IEC 947 and local regulations.

For the connection to power supply observe the wiring diagrams in the Annex andthe information on planning the control system. ( Section 5.4.1 Page 18)

The pump set is supplied complete with power cables. Always use all cables providedand connect all marked cores of the control cable.

DANGERCables laid incorrectlyExplosion hazard!

▷ The core ends must be connected outside of the potentially explosiveatmosphere or inside electrical equipment approved to equipment categoryII2G.

DANGEROperating an incompletely connected pump setExplosion hazard!Damage to the pump set!

▷ Never start up a pump set with incompletely connected power cables or non-operational monitoring devices.

1. Only remove the protective caps from the power cables immediately beforeconnecting the cables.

2. If necessary, adjust the length of the power cables to the site requirements.


Amarex KRT 21 of 54

3. After shortening the cables, correctly re-affix the markings on the individualconductors at the cable ends.

The pump set does not have an external PE connection (risk of corrosion).

DANGERIncorrect wiringExplosion hazard!

▷ Explosion-proof pump sets installed in a tank must never be retrofitted with anexternal potential equalisation connection!

DANGERTouching the pump set during operationElectric shock!

▷ Make sure that the pump set cannot be touched during operation.

Also see• Information for planning the control system [ 18]

Potential equalisation


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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, ensure that the following conditionsare met:

The pump set has been properly connected to the electric power supply and isequipped with all protection devices.

The pump has been primed with the fluid to be pumped.

The direction of rotation has been checked.

The lubricant has been checked.

If the pump (set) has been shut down for a prolonged period of time, themeasures described in ( Section 6.4 Page 25) have been carried out.

6.1.2 Start-up

1. Start up the pump set.

6.2 Operating limits

DANGERNon-compliance with operating limitsDamage to the pump set!

▷ Comply with the operating data indicated in the data sheet.

▷ Avoid operation against a closed shut-off element.

▷ Never operate an explosion-proof pump set at ambient and fluid temperaturesexceeding those specified in the data sheet or on the name plate.

▷ Never operate the pump set outside the limits specified below.

6.2.1 Temperature of the fluid handled

The pump set is designed for transporting liquids. The pump set is not operationalunder freezing conditions.

CAUTIONDanger of frost/freezingDamage 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 plateand in the data sheet.

6.2.2 Frequency of starts

CAUTIONExcessive frequency of startsDamage to the motor!

▷ Never exceed the specified frequency of starts.

To prevent high temperature increases in the motor and excessive loads on themotor, seal elements and bearings, the frequency of starts shall not exceed thenumber of starts per hour given below and a total number of 5,000 starts per year.


Amarex KRT 23 of 54

Table 8: Frequency of starts

Motor rating [kW] Maximum No. of starts [Starts/hour]

≤ 7.5 30> 7.5 10

These values apply to mains start-up (direct or with star-delta contactor,autotransformer, soft starter). The limit does not apply to frequency inverteroperation.

CAUTIONRe-starting while motor is still running downDamage to the pump set!

▷ Do not re-start the pump set before it has come to a standstill.

▷ Never start up the pump set while the pump is running in reverse.

6.2.3 Minimum level of fluid handled


▷ Never allow an explosion-proof pump set to run dry!

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 willtrip the pump set and automatically re-start it after the motor has cooled down.

For pumps with F impeller, slurp mode (partly involving air intake) is permissible for aperiod of up to 60 seconds.For pumps with D impeller, slurp mode is impermissible! Make sure that the pump setswitches off in time.

6.2.4 Density of the fluid handled

The power input of the pump increases in proportion to the density of the fluidhandled.

CAUTIONImpermissibly high density of the fluid handledMotor overload!

▷ Observe the information on fluid density indicated in the data sheet.

▷ Make sure the power reserve of the motor is sufficient.

6.2.5 Supply voltage

DANGERNon-compliance with permissible supply voltage tolerancesExplosion hazard!

▷ Never operate an explosion-proof pump (set) outside the specified range.

The maximum permissible supply voltage deviation is ±10%, for explosion-proofpump sets ±5% of the rated voltage. The voltage difference between the individualphases must not exceed 1%.

Slurp mode


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6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump set remains instal led

WARNINGPump set started up inadvertentlyRisk of injury by moving parts!

▷ Make sure that the pump set cannot be started up accidentally.

▷ Always make sure the electrical connections are disconnected before carryingout work on the pump set.

WARNINGFluids posing a health hazard or hot fluidsRisk of personal injury!

▷ Observe all relevant laws.

▷ When draining the fluid take appropriate measures to protect persons and theenvironment.

▷ Decontaminate pumps handling fluids posing a health hazard.

CAUTIONDanger of frost/freezingDamage to the pump set!

▷ If there is any danger of frost/freezing, remove the pump set from the fluidhandled and clean, preserve and store it.

Make sure sufficient fluid is available for the operation check run of the pumpset.

1. For prolonged shutdown periods, start up the pump set regularly between oncea month and once every three months for approximately one minute. This will prevent the formation of deposits within the pump and the pumpintake area.

The pump (set) i s removed from the pipe and stored

All safety regulations are observed. ( Section 7.1 Page 27)

1. Clean the pump set.

2. Preserve the pump set.

3. Observe the instructions given in ( Section 3.2 Page 12) .

6.4 Returning to service

For returning the pump set to service observe the sections on commissioning/start-up( Section 6 Page 23) and the operating limits ( Section 6.2 Page 23).

For returning the pump set to service after storage also follow the instructions formaintenance/inspection.

WARNINGFailure to re-install or re-activate protective devicesRisk 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.


Amarex KRT 25 of 54

NOTEOn pumps/pump sets older than 5 years we recommend replacing all elastomer seals.


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7 Servicing/Maintenance

7.1 Safety regulations

The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughly familiarwith the manual.

DANGERSparks produced during maintenance workExplosion hazard!

▷ Always perform maintenance work on explosion-proof pump sets outsidepotentially explosive atmospheres.

WARNINGPump set started up inadvertentlyRisk of injury by moving parts!

▷ Always make sure the electrical connections are disconnected before carryingout work on the pump set.

▷ Make sure that the pump set cannot be started up accidentally.

WARNINGFluids posing a health hazard or hot fluidsRisk of personal injury!

▷ Observe all relevant laws.

▷ When draining the fluid take appropriate measures to protect persons and theenvironment.

▷ Decontaminate pumps handling fluids posing a health hazard.

NOTESpecial regulations apply to repair work on explosion-proof pump sets. Modification oralteration of the pump set may affect explosion protection and are only permitted afterconsultation with the manufacturer.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the pump (set) with a minimum of maintenanceexpenditure and work.

NOTEAll maintenance, service and installation work can be carried out by KSB Service. Findyour contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/contact".

Never use force when dismantling and reassembling a pump set.

7.2 Maintenance/inspection

KSB recommends the following schedule for pump set maintenance:

Table 9: Overview of maintenance work

Maintenance interval Maintenance work For details see ...After 4,000 operating hours3) Insulation resistance test ( Section 7.2.1.3 Page 28)

Check the power cables ( Section 7.2.1.2 Page 28)Visually inspect the lifting chain/rope ( Section 7.2.1.1 Page 28)

3) At least once a year


Amarex KRT 27 of 54

https://shop.ksb.com/esales/contactfinder/contact.jsp?language=en&country=_C

https://shop.ksb.com/esales/contactfinder/contact.jsp?language=en&country=_C

Maintenance interval Maintenance work For details see ...After 10,000 operating hours4) Check the sensors

Change the lubricant ( Section 7.2.2.1.4 Page 30)Every five years General overhaul

7.2.1 Inspection work

7.2.1.1 Checking the lifting chain/rope

The pump set has been pulled out of the pump sump and cleaned.

1. Inspect the lifting chain or rope as well as the attachment for any visible damage.

2. Replace any damaged components by original spare parts.

7.2.1.2 Checking the power supply cables


1. Inspect the power supply cables for any visual damage.



1. Measure the resistance between earth conductor and earth.The resistance measured must be less than 1 Ω.


DANGERDefective earth conductorElectric shock!

▷ Never switch on a pump set with a defective earth conductor.

7.2.1.3 Measuring the insulation resistance

Measure the insulation resistance of the motor winding during annual maintenancework.

The pump set has been disconnected in the control cabinet.

Use an insulation resistance measuring device.

The maximum measuring voltage equals 1000 V.

1. Measure winding against earth.To do so, connect all winding ends together.

2. Measure winding temperature sensor against earth.To do so, connect all conductor ends of the winding temperature sensorstogether and connect all winding ends to earth.

The insulation resistance of the conductor ends against earth must not be lowerthan 1 MΩ.If the resistance measured is lower, cable and motor resistance must be measuredseparately. Disconnect the power cable from the motor for this purpose.

NOTEIf the insulation resistance for one of the power cables is below 1 MΩ, the cable isdefective and must be replaced.

Visual inspection

Checking the earthconductor

4) At least every three years


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NOTEIf the insulation resistance values measured on the motor are too low, the windinginsulation is defective. The pump set must not be returned to service in this case.

7.2.1.4 Checking the sensors

CAUTIONExcessive test voltageDamage to the sensors!

▷ Never test the sensors with voltages exceeding 30 V.

The tests described below measure the resistance at the conductor ends of thecontrol cable. The actual sensor function is not tested.

Table 10: Resistance measurement

Measurement between terminals ... Resistance21 and 22 < 1 Ω10 and 11 200 Ω - 750 Ω

If the specified tolerances are exceeded, disconnect the power cable at the pump setand conduct another test inside the motor.If the tolerances are exceeded again, the motor must be opened and overhauled. Thetemperature sensors are fitted in the stator winding and cannot be replaced.

Table 11: Measuring resistance of leakage sensor in the motor

Measurement between terminals ... Resistance9 and earth conductor (PE) > 60 kΩ

Lower resistance values suggest water ingress into the motor. In this case the motormust be opened and overhauled.

Table 12: Resistance measurement of the bearing temperature sensor

Measurement between terminals ... Resistance15 and 16 100 Ω - 120 Ω

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.

7.2.2.1.2 Lubricant quality

The lubricant reservoir is filled at the factory with an environmentally friendly, non-toxic lubricant of medical quality (unless otherwise required by the customer).The following lubricants can be used for lubricating the mechanical seals:

Thin-bodied paraffin oil; made by Merck, No.: 7174

Merkur white oil Pharma 40; made by DEA

Equivalent brand of medical quality, non-toxic

Water-glycol mixture

All non-doped and doped motor oils of classes SAE 10W to SAE 20W

Temperature sensors inthe motor winding

Leckage sensor in themotor

Bearing temperaturesensor

Recommended quality oflubricant

Alternative:


Amarex KRT 29 of 54

WARNINGContamination by lubricant of fluid handledHazardous 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 13: Lubricant quantity

Motor sizes 5 4, 7 4, 11 4, 16 4, 23 4, 29 4 35 4, 50 4, 65 4Pump size100-250/251 2.1 l - -150-251100-316 4.6 l 7 l -150-315150-401 - 4.5 l 6.5 l

7.2.2.1.4 Changing the lubricant

WARNINGLubricants posing a health hazardHazard to persons and the environment!

▷ When draining the lubricant take appropriate measures to protect persons andthe environment.

▷ Observe all legal regulations on the disposal of liquids posing a health hazard.

WARNINGExcess pressure in the lubricant reservoirLiquid spurting out when the lubricant reservoir is opened at operating temperature!

▷ Open the screwed plug of the lubricant reservoir very carefully.

1. Position the pump set as illustrated.

903411.03

Fig. 6: Draining the lubricant

2. Place a suitable container under the screwed plug.

3. Unscrew screwed plug 903 or 903.03 with joint ring 411.03 and, if applicable,screwed plug 903.04 with joint ring 411.05. Drain the lubricant.

1. Position the pump set as illustrated.

903.03411.03903.03

411.03

Fig. 7: Filling in the lubricant

Draining the lubricant

Filling in the lubricant


30 of 54 Amarex KRT

2. Pour lubricant into the lubricant filler opening until the lubricant reservoiroverflows.

3. Close screwed plug 903.03 again with a new joint ring 411.03.

7.2.2.2 Lubricating the rolling element bearings

The rolling element bearings of the pump come are packed with maintenance-freegrease, with the exception of the greases described below.

7.2.2.2.1 Grease quality

The following greases can be used to lubricate the rolling element bearings:

Lithium soap grease suitable for high temperatures

ESSO UNIREX N3

FAG ARCANOL L40

TEXACO HYTEX EP3/DEA Pragon

7.2.2.2.2 Grease quantity

Use 60g grease to lubricate the rolling element bearings.

7.3 Drainage/disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Always flush the pump if it has been used for handling noxious, explosive, hot orother hazardous fluids.

2. Always flush and clean the pump before sending it to the workshop.Make sure to add a certificate of decontamination. ( Section 11 Page 51)

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

WARNINGUnqualified personnel performing work on the pump (set)Risk of personal injury!

▷ Always have repair and maintenance work performed by specially trained,qualified personnel.

WARNINGHot surfaceRisk of personal injury!

▷ Allow the pump set to cool down to ambient temperature.

Observe the general safety instructions and information.

For dismantling and reassembly observe the general assembly drawing.

In case of damage you can always contact our service staff.

Grease quality

Recommendedcommercially available

brands


Amarex KRT 31 of 54

DANGERInsufficient preparation of work on the pump (set)Risk of personal injury!

▷ Properly shut down the pump set.

▷ Close the shut-off elements in the 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.

7.4.2 Preparing the pump set

The notes and steps stated in ( Section 7.4.1 Page 31) have been observed/carried out.

1. Completely disconnect the pump set from the power supply.

2. Drain the lubricant.

3. Drain the leakage chamber and leave it open during dismantling.

7.4.3 Dismantling the pump section

Dismantle the pump section in accordance with the relevant general assemblydrawing.

7.4.3.1 Removing the back pull-out unit

1. Unscrew screwed connection 902.01 and 920.01 and pull the complete back pull-out unit out of pump casing 101.

2. Place the back pull-out unit in a safe and dry installation area and secure itagainst tipping over or rolling off.

7.4.3.2 Removing the impeller

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.

NOTEThe forcing screw is not included in the scope of supply. It can be ordered separatelyfrom KSB.

Table 14: Forcing screws for pulling off the impeller

Size Impeller type Forcing screwThread Code

100-250 F M16 ADS 1M20 ADS 2150-315 F

100-251 D M16 ADS 3150-251100-316 D M20 ADS 4150-315

914.10550.23

230

Fig. 8: Removing theimpeller


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Size Impeller type Forcing screwThread Code

150-400 D M24 ADS 5150-401200-400250-400300-400

7.4.3.3 Dismantling the mechanical seal

Dismantle the mechanical seal in accordance with the general arrangementdrawings.

7.4.3.3.1 Dismantling the pump-end mechanical seal

The back pull-out unit and the impeller have been removed as described above.

1. Pull the rotating assembly of mechanical seal 433.02 off shaft 210.

2. Remove discharge cover 163 from bearing bracket 330.

3. Push the stationary seat of mechanical seal 433.02 out of discharge cover 163.

7.4.3.3.2 Dismantling the motor-end mechanical seal

The back pull-out unit and the impeller have been removed as described above.

1. Remove taper lock ring 515 or circlip 932.03.

2. Pull the rotating assembly of mechanical seal 433.01 off shaft 210.

7.4.3.4 Removing the wear plate

The back pull-out unit has been separated from the pump casing.

The inside of the casing has been cleaned.

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.

7.4.4 Dismantling the motor section

NOTESpecial regulations apply to repair work on explosion-proof pump sets. Modifications oralteration of the pump set may affect explosion protection and are only permitted afterconsultation with the manufacturer.

NOTEThe motors of explosion-proof pump sets are supplied in "flameproof enclosure" type ofprotection. Any work on the motor section which may affect explosion protection, such asre-winding and machining repairs, must be inspected and approved by an approvedexpert or performed by the motor manufacturers. No modifications must be made to theinternal configuration of the motor space. Repair work at the flameproof joints must onlybe performed in accordance with the manufacturer's instructions. Repair to the values intables 1 and 2 of EN 60079-1 is not permitted.

When dismantling the motor section and the power cables make sure that the cores/terminals are clearly marked for future reassembly.

914.12

135101

Fig. 9: Removing the wearplate


Amarex KRT 33 of 54

7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

CAUTIONImproper reassemblyDamage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of soundengineering practice.

▷ Use original spare parts only.

NOTEBefore reassembling the motor section, check that all joints relevant to explosionprotection (flamepaths) are undamaged. Replace any components with damagedflamepaths. Refer to the "Flamepaths" annex for the position of the flamepaths.

Always reassemble the pump set in accordance with the corresponding generalassembly drawing.

O-rings

– Check O-rings for any damage and replace them by new O-rings, if required.

– Never use O-rings that have been glued together from material sold by themetre.

Assembly adhesives

– Avoid the use of assembly adhesives, if possible.

During reassembly tighten all screws and bolts as specified in this manual. ( Section7.6 Page 37) All bolted/screwed connections closing off the flameproof enclosure must be securedwith a thread-locking agent (Loctite Type 243).

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 mechanicalseal:

Only remove the protective wrapping of the contact faces immediately beforeassembly takes place.

Make sure the surface of the shaft is absolutely clean and undamaged.

Before the actual installation of the mechanical seal, wet the contact faces with adrop of oil.

For easier installation of bellows-type mechanical seals, wet the inside diameterof the bellows with soapy water (no oil).

To prevent any damage to the rubber bellows, place a thin foil (thicknessapproximately 0.1 to 0.3 mm) around the free shaft stub. Slip the rotating assembly over the foil into its installation position. Then remove the foil.

The shaft and rolling element bearings have been properly fitted in the motor.

1. Push drive-end mechanical seal 433.01 onto shaft 210 and secure it with taperlock ring 515 or circlip 932.03.

2. Insert O-rings 412.04 or 412.35 and 412.15 or 412.11 into discharge cover 163,and press them into bearing bracket 330 as far as they will go.

3. Push pump-end mechanical seal 433.02 onto shaft 210.

Sequence

Seal elements

Tightening torques


34 of 54 Amarex KRT

For special mechanical seals with covered springs, tighten the socket head cap screwat the rotating assembly before fitting the impeller. Observe installation dimension"A".

Table 15: Installation dimension "A"

Pump size Installation dimension "A"[mm]

40-250, 80-250, 100-250 2980-251, 100-251, 150-251, 80-315/-316,150-315, 200-315/-316, 100-316

38.5

100-401, 150-401, 151-401, 200-330,200-400, 250-400/-401, 300-400/-401

48.3

7.5.2.2 Fitting the impeller

NOTEFor bearing brackets with tapered fit make sure that the tapered fit of impeller and shaftis undamaged and installed free from grease.

The shaft and rolling element bearings have been properly installed.

The mechanical seals have been properly installed.

1. Slip impeller 230 onto the shaft end.

2. Screw in impeller screw 914.10 and disc 550.23. Tighten them with a torquewrench.

Table 16: Tightening torque for the impeller screw

Pump size Thread Tightening torque[Nm]

40-250, 80-250, 100-250,150-251, D 100-251

M 10 35

80-251, F, E, K 100-251,80-315/-316, 150-315,200-315/-316, 100-316

M 16 150

100-401, 150-401, 151-401,200-330, 200-400,250-400/-401, 300-400/-401

M 20 290

7.5.2.3 Installing the back pull-out unit

7.5.2.3.1 Design with wear plate

The shaft, rolling element bearings, mechanical seal and impeller have beenassembled properly.

A

Fig. 10: Installationdimension "A"

914.10550.23

230

Fig. 11: Fitting theimpeller


Amarex KRT 35 of 54

0.4 +0.2m

m

914.12

412.34

914.24

135 412.33 230

101

Fig. 12: Fitting the wear plate

1. Equip wear plate 135 with two new O-rings 412.33 and 412.34.

2. Insert wear plate 135 into pump casing 101.

3. Fasten wear plate 135 to pump casing 101 with socket head cap screws 914.12.

4. Adjust the clearance between impeller 230 and wear plate 135 by loosening andtightening screws 914.12 and 914.24.

Screw 914.24 pushes the wear plate in the direction of the impeller.

The clearance equals 0.4 +0.2 mm (measured on the suction side from theouter surface of the impeller vane to the wear plate).

5. Insert the complete back pull-out unit into the pump casing.

6. Evenly tighten screwed connection 920.01 between pump casing and bearingbracket.

7.5.3 Reassambling the motor section

NOTEBefore reassembling the motor section, check that all joints relevant to explosionprotection (flamepaths) are undamaged. Any components with damaged flamepathsmust be replaced. Only use original spare parts made by KSB for explosion-proofpumps. Observe the flamepath positions specified in the Annex. Secure all screwedconnections closing off a flameproof enclosure with a thread-locking agent (Loctite type243).

DANGERIncorrect screwsExplosion hazard!

▷ Always use the original screws for assembling an explosion-proof pump set.

▷ Never use screws of different dimensions or of a lower property class.

7.5.4 Performing a leak test

After reassembly the mechanical seal area/lubricant reservoir must be tested forleakage. The lubricant filler opening is used for leak testing.

Observe the following values for leak testing:

Test medium: compressed air


36 of 54 Amarex KRT

Test pressure: 0.8 bar (max.)

Test period: 2 minutes

P0.5 bar

Fig. 13: Screwing in the testing device

1. Unscrew and remove the screwed plug and joint ring of the lubricant reservoir.

2. Tightly screw the testing device into the filler opening for the lubricant.

3. Perform the leak test to the above conditions.The pressure must not drop during the test period.If the pressure does drop, check the seals and screwed connections.Then perform another leak test.

4. Once the leak test has been successful, fill in the lubricant. ( Section 7.2.2.1 Page29)

7.5.5 Checking the connection of motor/power supply

Once the reassembly has been completed, carry out the steps described in ( Section7.2.1 Page 28).

7.6 Tightening torques

Table 17: Tightening torques

Thread Tightening torque [Nm]M 5 4M 6 7M 8 17M 10 35M 12 60M 16 150M 20 290M 24 278M 27 409M 30 554

7.7 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.


Amarex KRT 37 of 54

Also supply the following data:

Part description

Part No.

Quantity of spare parts

Shipping address

Mode of dispatch (freight, mail, express freight, air freight)

Refer to the general assembly drawing for part numbers and descriptions.

7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296

Table 18: Quantity of spare parts for recommended spare parts stock5)

Part No. Description Number of pump sets (including stand-by pump sets)2 3 4 5 6 and 7 8 and 9 10 and

more80-1 Motor unit - - - 1 1 2 30 %834 Cable gland 1 1 2 2 2 3 40 %818 Rotor - - - 1 1 2 30 %230 Impeller 1 1 1 2 2 3 30 %502 Casing wear ring 2 2 2 3 3 4 50 %433.01 Mechanical seal, motor

end2 3 4 5 6 7 90 %

433.02 Mechanical seal, pumpend

2 3 4 5 6 7 90 %

321.01 / 322 Rolling element bearing,motor end

1 1 2 2 3 4 50 %

320 / 321.02 Rolling element bearing,pump end

1 1 2 2 3 4 50 %

99-9 Set of seal elements forthe motor

4 6 8 8 9 10 100 %

99-9 Set of seal elements forthe hydraulic system

4 6 8 8 9 10 100 %

5) For two years of continuous operation or 17,800 operating hours


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8 Trouble-shootingPump is running but does not deliver

Pump delivers insufficient flow rate

Excessive current/power consumption

Insufficient discharge head

Vibrations and noise during pump operation

Table 19: Trouble-shooting

A B C D E Possible cause Remedy X Pump delivers against an excessively high

discharge pressure.Re-adjust to duty point.

X Gate valve in the discharge line is not fullyopen.

Fully open the gate valve.

X X Pump is running in the off-design range (lowflow / overload).

Check the pump's operating data.

X Pump or piping are not completely vented. Vent by lifting the pump off the duckfoot bendand lowering it again.

X Pump intake clogged by deposits. Clean the intake, pump components and non-return valve.

X X X Suction line or impeller clogged. Remove deposits in the pump and/or piping. X X Dirt/fibres in the clearance between the

casing wall and impeller of a sluggish rotor.Check whether the impeller can be easilyrotated.Clean the impeller, if required.

X X X X Wear of internal pump parts Replace worn parts by new onesX X X Defective riser (pipe and seal elements). Replace defective riser pipes,

replace seal elements X X X Impermissible air or gas content in the fluid

handledContact KSB.

X System-induced vibrations Contact KSB. X X X X Wrong direction of rotation Check the connection of the motor and

switchgear, if any. X Wrong supply voltage Check the mains power supply.

Check the connection of the power cables.X Motor is not running because of lack of

voltage.Check the electrical installations.Contact the energy supplier.

X X Motor winding or power cable are defective. Replace by new original KSB parts or contactKSB.

X Defective rolling element bearing Contact KSB. X X In case of star-delta configuration: motor

running in star configuration only.Check star-delta contactor.

X Water level lowered too much duringoperation.

Check the level control.

X The temperature switch monitoring thewinding has tripped because of excessivetemperature rise in the winding.

The motor will restart automatically once thewinding has cooled down.

X Thermistor tripping unit with manual resetfor temperature limiter (explosion protection)has tripped the pump as a result of thepermissible winding temperature beingexceeded.

Assign qualified and trained personnel todetermine and remedy the cause of failure.

X The leakage monitoring system of the motor has tripped.


X The mechanical seal monitoring system hastripped.


X The bearing temperature monitoring systemhas tripped


A

B

C

D

E

8 Trouble-shooting

Amarex KRT 39 of 54

9 Related Documents

9.1 General assembly drawings

NOTEFor a detailed view of the general assembly drawing (e.g. upper bearing) see thefollowing table.

* If applicable

*1) Sectional drawings of the mechanical seal

*2) For material variant C1/C2Hydraulic system sizes40-25080-250/25180-315/316100-240/250100-251100-315/316150-251150-315200-315/316

Motor sizes5 2, 6 2, 8 2, 12 2, 17 2,23 25 4, 7 4, 11 4, 16 4, 23 4,29 44 6, 6 6, 9 6, 12 6

General assembly drawing with motor type DKN 132/160/161/181 and tapered fit(impeller type F)

9 Related Documents

40 of 54 Amarex KRT

Table 20: Detailed views of general assembly drawing with motor type DKN 132/160/161/181 and tapered fit

Section Detailed viewCable gland

Upper bearing

Motor sizes5 2, 6 2, 8 2,5 4, 7 4,4 6, 6 6

Upper bearing

Motor sizes12 2, 17 2, 23 2,11 4, 16 4, 23 4,29 4,9 6, 12 6

Impeller type D

550.23

914.10

135

412.34

914.12

163

230

101

412.33

914.24

Part No. Description Part No. Description23-7 Impeller body 421.01 Lip seal69-14 Leakage sensor 433.01/.02 Mechanical seal80-1 Motor unit 441 Shaft seal housing81-17 Butt joint 500.02 Ring81-44.28 Clamping piece 502 Casing wear ring81-51 Shim 503 Impeller wear ring81-59 Stator 529 Bearing sleeve99-17 Dessicant 550.11/.23/.24 Disc101 Pump casing 561.01 Grooved pin113 Intermediate casing 811 Motor housing131 Inlet ring 818 Rotor135 Wear plate 834 Cable gland162 Suction cover 900.28 Bolt/screw163 Discharge cover 901.14/.15/.20 Hexagon head bolt230 Impeller 903 Screwed plug

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Amarex KRT 41 of 54

Part No. Description Part No. Description320 Rolling element

bearing904.01 Grub screw

321.01/.02 Radial ball bearing 914.02/.04/.10/.15/.12/.24/.26 Socket head cap screw322 Radial roller bearing 920.01/.26 Nut330 Bearing bracket 930.28 Safety device360 Bearing cover 931 Lockwasher411.03 Joint ring 932.01/.02/.03 Circlip412./.02/.03/.04/.07/.15/.16/.33/.34 O-ring

* If applicable


*2) For material variant C1/C2Hydraulic system sizes100-401150/151-401200-330200-400250-400/401300-400/401

Motor sizes23 4, 29 420 6, 26 610 8, 17 8, 21 8

General assembly drawing pump set with motor type DKN 161/181 and cylindricalinterference fit (impeller type K/E)

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Table 21: Detailed views of general assembly drawing pump set with motor type DKN 161/181 and cylindricalinterference fit

Section Detailed viewImpeller type F

Cable gland

Part No. Description Part No. Description13-6 Casing insert 433.01/.02 Mechanical seal69-14 Leakage sensor 441 Shaft seal housing81-17 Butt joint 502 Casing wear ring81-44.28 Clamping piece 529 Bearing sleeve81-51 Shim 811 Motor housing81-59 Stator 818 Rotor99-17 Dessicant 834 Cable gland101 Pump casing 900.28 Bolt/screw163 Discharge cover 901.20 Hexagon head bolt260 Impeller hub cap 902.01 Stud230 Impeller 903.03/.05 Screwed plug321.02 Radial ball bearing 914.02/.10/.04/.26 Socket head cap screw322 Radial roller bearing 920.01/.26 Nut330 Bearing bracket 930.28 Safety device411.03/.05 Joint ring 932.01/.02/.22 Circlip412.02/.03/.04/.07/.15 O-ring 940 Key421.01 Lip seal 970.03/.04 Plate

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Amarex KRT 43 of 54

* If applicable


*2) For material variant C1/C2Hydraulic system sizes100-401150/151-401200-330200-400250-400/401300-400/401

Motor sizes35 4, 50 4, 65 432 6, 40 6, 50 626 8, 35 8

General assembly drawing pump set with motor type DKN 226 (impeller type K/E)

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Table 22: Detailed views of general assembly drawing of pump set with motor type DKN 226

Section Detailed viewCable glands

Impeller type F

Part No. Description Part No. Description13-6 Casing insert 433.01/.02 Mechanical seal59-17 Shackle 441 Shaft seal housing69-14 Leakage sensor 502 Casing wear ring81-29 Terminal 550.01/.03/.44 Disc81-51 Shim 811 Motor housing81-59 Stator 818 Rotor101 Pump casing 834/.03 Cable gland163 Discharge cover 900.04/.20 Bolt/screw230 Impeller 902.01 Stud260 Impeller hub cap 903.03/.05 Screwed plug322 Radial roller bearing 914.01/.02/.04/.05/.10 Socket head cap screw330.01/.02 Bearing bracket 920.01 Nut321.02 Radial ball bearing 932.01/.02/.03/.20/.22 Circlip411.03/.05 Joint ring 940 Key412.01/.02/.03/.04/.07/.08/.15

O-ring 970.03/.04 Plate

421.01 Lip seal

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Amarex KRT 45 of 54

9.2 Wiring diagrams

Motors: 5 2, 6 2, 8 2, 12 2, 17 2, 23 25 4, 7 4, 11 4, 16 4, 23 4, 29 4, 4 6, 6 6, 9 6, 26 6, 10 8, 17 8, 21 8

Motors:37 2, 55 2, 35 4, 50 4, 65 4, 32 6, 40 6, 50 6, 26 8, 35 8

U1 V1 W1

W2V2U2

21 22 10 11 9

F4 R1

R2

R3

B2

F5

3 ~

12 x ... mm2

7 x ... +5 x 1,5 mm2

U1 U2V1 V2W2W1 21 22

12

11 9 PE

(1)

(1)

(1)

(2)

(2)

(2)

(3)

(3)

(3)

(6)

(6)

(4)

(4)

(4)

(5)

(5)

(5)

(7)

(8)

(9)

(10)

(11)

U1

U1

V1

V1

W1

W1

U2

U2

V2

V2

W2

W2

PE

21 22 10 11 9

Y

U1

V1

W1

U2

V2

W2

Y-

L1

L1

L2

L2

L3

L3

0W380161-00

11

B2

11V1

PE U1

W1

21 22 PE

(2)

(3)

(4)

(5)

(1)

(6)

(7)

(8)

(11)

(10)

(9)

4910

124

PEU2

V2

W2

F4

21 22

F5

910

R3

R1

R2

W2U2

U1 W1

V2

3~

V1

U1

U2

V1

V2

W1

W2

PE PE (21)

(22)

(10)

(11)

(3)

(4)

(9)

U1

U1

U2

U2

V1

V1

V2

V2

W1

W1

W2

W2

PEPE PE

PE (21)

(22)

(10)

(11)

(3)

(4)

(9)

(21)

(22)

(10)

(11)

(3)

(4)

(9)

Y

Y

-

L1 L2 L3 PE

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9.3 Flamepaths of explosion-proof motors

Table 23: Overview of flamepaths

Motor sizes Pump set5 2, 6 2, 8 2, 12 2,17 2, 23 25 4, 7 4, 11 4,16 4, 23 4, 29 44 6, 6 6, 9 6, 12 6,20 6, 26 6

1

23

1,2, 3 Flamepaths37 2, 55 235 4, 50 4, 65 432 6, 40 6, 50 626 8, 35 8

5

1

4

32

1,2, 3, 4, 5 Flamepaths

9 Related Documents

Amarex KRT 47 of 54

9.4 Sectional drawings of the mechanical seal

Table 24: Sectional drawings of the mechanical seal

Section Sectional drawingSizes of hydraulic system40-25080-250100-240100-250

Motor sizes5 2, 6 2, 8 2, 12 2, 17 25 4, 7 4, 11 4, 16 4

433.01 Mechanical seal (bellows-type mechanical seal) 433.01

515

433.02

OW 309130-00

515 Taper lock ring433.02 Mechanical seal (bellows-

type mechanical seal)

433.01 Mechanical seal (bellows-type mechanical seal)

A

433.01

433.02

OW 309130-05

515

515 Taper lock ring433.02 Mechanical seal (mechanical

seal with covered springs -HJ)

Sizes of hydraulic system80-25180-315100-315150-315200-315/316D 80-315D 100-251D 100-315/316D 150-251D 150-315D 200-315

Motor sizes5 2, 6 2, 8 2, 12 2, 17 2,23 25 4, 7 4, 11 4, 16 4, 23 4,29 44 6, 6 6, 9 6, 12 6

433.01 Mechanical seal (bellows-type mechanical seal)

433.01

515

433.02

OW 309131-00

932.03

515 Taper lock ring433.02 Mechanical seal (bellows-

type mechanical seal)932.03 Circlip

433.02 Mechanical seal (mechanicalseal with covered springs -HJ)

433.02

OW 309131-05

A

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Section Sectional drawingSizes of hydraulic system100-401150/151-401200-330200-400250-400/401300-400-401D 80-315D 100-315

Motor sizes37 2, 55 223 4, 29 4, 35 4, 50 4, 65 420 6, 26 6, 32 6, 40 6,50 610 8, 17 8, 21 8, 26 8, 35 8

433.01 Mechanical seal (bellows-type mechanical seal) 433.01

932.03

433.02

550.44

550.03

550.03 Disc932.03 Circlip433.02 Mechanical seal (bellows-

type mechanical seal)Disc

550.44

412.17 O-ring

433.02 Mechanical seal (mechanicalseal with covered springs -HJ)

433.02

A

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Amarex KRT 49 of 54

10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

Amarex KRT

KSB order number: ...................................................................................................

is in conformity with the provisions of the following directives as amended from time to time:

– EC Machinery Directive 2006/42/EC

The manufacturer also declares that

the following harmonised international standards were applied:

– ISO 12100-1/A1, ISO 12100-2/A1,

– ISO 14121-1,

– EN 809/A1,

– EN 60034-1, EN 60034-5/A1

Halle, 29 December 2009

...........................................................

Name

Function

Responsible for compiling the technical documentationKSB Aktiengesellschaft

Turmstraße 92

06110 Halle (Germany)

10 EC Declaration of Conformity

50 of 54 Amarex KRT

11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number6) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled6) : ................................................................................................................................

Please tick where applicable6) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return6) : ................................................................................................................................ Comments: ................................................................................................................................ ................................................................................................................................ The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placingat your disposal.

On seal-less pumps, the rotor has been removed from the pump for cleaning.

⃞ No special safety precautions are required for further handling.⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

............................................................................................................................................................... ............................................................................................................................................................... We confirm that the above data and information are correct and complete and that dispatch is effected in accordance withthe relevant legal provisions.

.................................................................... ....................................................... .......................................................Place, date and signature Address Company stamp

6) Required fields

11 Certificate of Decontamination

Amarex KRT 51 of 54

Index

AApplications 8

BBearing temperature monitoring 20

CCertificate of decontamination 51Clearance gaps 35Commissioning/start-up 23Connection to power supply 21

DDesignation 14Direction of rotation 18Dismantling 31Disposal 13

EExplosion protection 11, 17, 18, 19, 20, 21, 22, 23, 24,27, 36

FFlamepaths 47Function 15

GGeneral assembly drawing 40Grease lubrication

Grease quality 31Grease quantity 31

IInsulation resistance measurement 27Intended use 8

LLeakage monitoring 20Lubricant

Intervals 28Quality 29Quantity 30

MMaintenance work 27Mechanical seal 48Misuse 9

OOrder number 6Other applicable documents 6Overload protection device 19

PPartly completed machinery 6Preservation 12Product description 14

RReassembly 31Return to supplier 13Returning to service 25

SSafety 8Safety awareness 10Sensors 19Shutdown 25Spare parts stock 38Storage 12, 25Supply voltage 24

TTemperature monitoring 20Tightening torques 37Trouble-shooting 39

WWiring diagrams 46

Index

52 of 54 Amarex KRT

KSB AktiengesellschaftP.O. Box 200743 • 06008 Halle (Saale) • Turmstraße 92 • 06110 Halle (Germany)Tel. +49 345 4826-0 • Fax +49 345 4826-4699www.ksb.com

2553

.88-

10