Amarex KRT series User manual

Submersible Motor Pump
Amarex KRT
Sizes DN 200 to DN 700; 60 Hz
6 poles: 530 6_N to 850 6_N
8 poles: 460 8_N to 760 8_N
10 poles: 390 10_N to 660 10_N
12 poles: 340 12_N to 560 12_N
Installation/Operating Manual
Mat. No.: 01463269

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.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 9/7/2018

Contents
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Amarex KRT
Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Target group.....................................................................................................................................................6
1.3 Other applicable documents............................................................................................................................6
1.4 Symbols .............................................................................................................................................................7
1.5 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.2.1 Prevention of foreseeable misuse.......................................................................................................9
2.3 Personnel qualification and personnel training.............................................................................................9
2.4 Consequences and risks caused by non-compliance with these operating instructions ..............................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the operator/user.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ..............................................................10
2.8 Unauthorized modes of operation................................................................................................................10
2.9 Information for use in Class I, Division 2, Hazardous (Classified) Locations ...............................................10
3 Transport/Temporary Storage/Disposal............................................................................................. 12
3.1 Checking the condition upon delivery..........................................................................................................12
3.2 Transport.........................................................................................................................................................12
3.2.1 Placing the pump set down...............................................................................................................13
3.2.2 Placing the pump set in a vertical position ......................................................................................14
3.3 Storage/preservation......................................................................................................................................14
3.4 Return to supplier...........................................................................................................................................15
3.5 Disposal ...........................................................................................................................................................16
4 Description of the Pump (Set)............................................................................................................. 17
4.1 General description ........................................................................................................................................17
4.2 Designation.....................................................................................................................................................17
4.3 Name plate......................................................................................................................................................18
4.4 Design details..................................................................................................................................................18
4.5 Types of installation .......................................................................................................................................19
4.6 Configuration and function...........................................................................................................................19
4.7 Noise characteristics (for dry installation only - installation type D)...........................................................20
4.8 Scope of supply...............................................................................................................................................20
4.9 Dimensions and weights ................................................................................................................................20
5 Installation at Site................................................................................................................................ 21
5.1 Safety regulations...........................................................................................................................................21
5.2 Checks to be carried out prior to installation...............................................................................................21
5.2.1 Checking the operating data ............................................................................................................21
5.2.2 Preparing the place of installation ...................................................................................................22
5.2.3 Removing the transport lock.............................................................................................................22
5.2.4 Checking the lubricant level (installation type S) ............................................................................22
5.2.5 Checking the coolant level (installation types K and D)..................................................................24
5.2.6 Checking the direction of rotation ...................................................................................................24
5.3 Installing the pump set ..................................................................................................................................25
5.3.1 Stationary wet installation................................................................................................................26
5.3.2 Stationary dry installation.................................................................................................................34
5.4 Electrical system..............................................................................................................................................39
5.4.1 Information for planning the control system ..................................................................................39
5.4.2 Electrical connection..........................................................................................................................44

Contents
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6 Commissioning/Start-up/Shutdown................................................................................................... 47
6.1 Commissioning/start-up .................................................................................................................................47
6.1.1 Prerequisites for commissioning/start-up .........................................................................................47
6.1.2 Priming and venting the pump set (dry installation only - installation type D) ............................47
6.1.3 Start-up...............................................................................................................................................48
6.1.4 Shutdown (dry installation only - installation type D) ....................................................................49
6.2 Operating limits..............................................................................................................................................50
6.2.1 Frequency of starts.............................................................................................................................50
6.2.2 Operation on the power supply network ........................................................................................50
6.2.3 Operation on a frequency inverter...................................................................................................50
6.2.4 Fluid handled .....................................................................................................................................51
6.3 Shutdown/storage/preservation ....................................................................................................................52
6.3.1 Measures to be taken for shutdown ................................................................................................52
6.4 Returning to service .......................................................................................................................................53
7 Servicing/Maintenance........................................................................................................................ 54
7.1 Safety regulations...........................................................................................................................................54
7.2 Maintenance/inspection.................................................................................................................................56
7.2.1 Inspection work..................................................................................................................................56
7.2.2 Coolant (pump sets with cooling system only - installation types D and K) ..................................61
7.2.3 Lubrication and lubricant change.....................................................................................................65
7.3 Drainage/cleaning ..........................................................................................................................................72
7.4 Dismantling the pump set..............................................................................................................................72
7.4.1 General information/Safety regulations...........................................................................................72
7.4.2 Preparing the pump set.....................................................................................................................73
7.4.3 Dismantling the pump section ..........................................................................................................73
7.4.4 Dismantling the motor section .........................................................................................................78
7.5 Reassembling the pump set...........................................................................................................................79
7.5.1 General information/Safety regulations...........................................................................................79
7.5.2 Reassembling the pump section .......................................................................................................80
7.5.3 Reassembling the motor section.......................................................................................................83
7.5.4 Leak testing........................................................................................................................................86
7.5.5 Checking the connection of motor/power supply ...........................................................................88
7.6 Tightening torques.........................................................................................................................................88
7.7 Spare parts stock.............................................................................................................................................88
7.7.1 Ordering spare parts..........................................................................................................................88
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 ..........................................89
8 Trouble-shooting.................................................................................................................................. 90
9 Related Documents.............................................................................................................................. 92
9.1 General assembly drawings with list of components...................................................................................92
9.1.1 Pump sets with cooling system (installation types K and D) ...........................................................92
9.1.2 Pump sets without cooling system (installation type S) ..................................................................94
9.2 Detailed views.................................................................................................................................................96
9.2.1 Side views ...........................................................................................................................................96
9.2.2 Top views............................................................................................................................................98
9.2.3 Attachment points...........................................................................................................................100
9.2.4 Sensors and terminals......................................................................................................................102
9.2.5 Drive-end bearing assembly............................................................................................................106
9.2.6 Further details..................................................................................................................................106
9.3 Wiring diagrams ...........................................................................................................................................108
9.3.1 Wiring diagram for the power cables ............................................................................................108
9.3.2 Wiring diagram for the sensors ......................................................................................................109
9.4 Sectional drawings of the mechanical seal.................................................................................................116
10 Certificate of Decontamination......................................................................................................... 118
Index ................................................................................................................................................... 119

Glossary
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Amarex KRT
Glossary
Back pull-out unit
Pump without pump casing; partly completed
machinery
Certificate of decontamination
If a product is to be returned to the manufacturer,
the customer declares in a certificate of
decontamination that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Close-coupled design
Motor directly fitted to the pump via a flange or a
drive lantern
Discharge line
The pipeline which is connected to the discharge
nozzle
Hydraulic system
The part of the pump in which the kinetic energy
is converted into pressure energy
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Suction lift line/suction head line
The pipeline which is connected to the suction
nozzle

1 General
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1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variant
indicated on the front cover (for details, please refer to the table below).
Table1: Variants covered by this manual
Size Impeller type Material variant
Gray cast iron Industrial materials
G G1 G2 GH H C1 C2
200-631 K K K - - - - -
250-630 K K K - - - - -
250-632 K K K - - - - -
250-900 K K K - - - - -
350-632 K K K - - - - -
350-633 K K K - - - - -
350-636 K K K - - - - -
350-710 K K K - - - - -
350-713 K K K - - - - -
400-900 K K K - - - - -
401-710 K K K - - - - -
401-713 K K K - - - - -
500-632 K K K - - - - -
500-634 K K K - - - - -
500-640 K K K - - - - -
501-710 K K K - - - - -
501-900 K K K - - - - -
600-710 K K K - - - - -
700-901 K K K - - - - -
700-902 K K K - - - - -
The manual describes the proper and safe use of this equipment in all phases of
operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the pump set and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB Service center to
maintain the right to claim under warranty.
1.2 Target group
This supplementary operating manual is aimed at the target group of trained and
qualified specialist technical personnel.
1.3 Other applicable documents
Table2: Overview of other applicable documents
Document Contents
Data sheet Technical data of the pump set
General arrangement drawing/
outline drawing
Mating dimensions, installation dimensions
and weights of the pump set
Hydraulic characteristic curve Characteristic curves showing head, flow rate,
efficiency and power input

1 General
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Amarex KRT
Document Contents
General assembly drawing1) Sectional drawing of the pump set with part
numbers
Sub-supplier product literature1) Operating manuals and other product
literature describing accessories and
integrated machinery components
Spare parts lists1) Description of spare parts
Supplementary operating manual1) E.g. for special accessories
For accessories and/or integrated machinery components observe the product
literature of the corresponding manufacturer.
1.4 Symbols
Table3: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1.5 Key to safety symbols/markings
Table4: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
1) If agreed to be included in the scope of supply

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
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 which
are not taken into account.
2.2 Intended use
▪The pump set must only be operated within the operating limits described in the
other applicable documents.
▪Only operate pump sets which are in perfect technical condition.
▪Do not operate partially assembled pump sets.
▪Only use the pump set to handle the fluids described in the data sheet or product
literature of the pump variant.
▪Never operate the pump set without the fluid to be handled.
▪Observe the limits for continuous duty specified in the data sheet or product
literature (Qmin and Qmax) (to prevent damage such as shaft fracture, bearing
failure, mechanical seal damage, etc).
▪When untreated waste water is handled, the duty points in continuous operation
lie within 0.7 to 1.2×Qoptto minimize the risk of clogging/hardening.
▪Avoid duty points for continuous operation at very low speeds and small flow
rates (<0.7xQopt).
▪Observe the minimum flow rates and maximum flow rates indicated in the data
sheet or product literature (to prevent overheating, mechanical seal damage,
cavitation damage, bearing damage, etc).
▪Do not throttle the flow rate on the suction side of the pump set (to prevent
cavitation damage).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
▪Only use this pump for the fluids described below.
Closed multi-channel impeller
(impeller type K/K-max)

2 Safety
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Amarex KRT
2.2.1 Prevention of foreseeable misuse
▪Observe the minimum flow velocities required to fully open the swing check
valves to prevent the reduction of pressure and risk of clogging.
(Contact the manufacturer for the required minimum flow velocities/loss
coefficients.)
▪Never exceed the permissible operating limits and use limits specified in the data
sheet or product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
2.3 Personnel qualification and personnel training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by sufficiently trained specialist personnel
training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.4 Consequences and risks caused by non-compliance with these operating
instructions
▪Non-compliance with these operating instructions 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
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.5 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 regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety information for the operator/user
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.

2 Safety
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▪Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪If shutting down the pump does not increase potential risk, fit an emergency
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts/components authorized by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation is performed
by authorized, qualified specialist personnel who are thoroughly familiar with
the manual.
▪Only carry out work on the pump (set) during standstill of the pump.
▪Only perform work on the pump set when it has been disconnected from the
power supply (de-energized).
▪The pump (set) 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 procedure
described in the manual. (ðSection6.3,Page52)
▪Decontaminate pumps which handle fluids posing a health hazard.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page47)
2.8 Unauthorized modes of operation
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 pump (set)
supplied is only valid if the equipment is used in accordance with its intended use.
2.9 Information for use in Class I, Division 2, Hazardous (Classified)
Locations
Only certified pump sets with FM-approved nonincendive submersible motors, with
name plates marked accordingly, may be used in Class I, Division 2, Hazardous
(Classified) Locations.
Special conditions apply to the operation of nonincendive pump sets:
▪The explosion–proof status of the pump set is only assured if the pump set is used
in accordance with its designated use.
▪The limits stated in the data sheet and on the name plate must not be exceeded
under any circumstances.
▪Correct monitoring of the motor temperature is imperative to ensure explosion
protection.
▪Observe the wiring diagrams.
▪Never operate a nonincendive pump set without temperature monitoring.
▪Repairs or modifications of the pump set can affect explosion protection and
may, therefore, only be made by the manufacturer or a repair shop certified by
FM Approvals.