KSB Amarex KRT Installation instructions

Submersible Motor Pump
Amarex KRT
Pump Sizes DN 40 to DN 300
Motor Sizes:
2-pole: 5 2 to 55 2
4-pole: 4 4 to 65 4
6-pole: 4 6 to 50 6
8-pole: 10 8 to 35 8
Installation/Operating
Manual
Ident. number: 01 196 129

Legal information/Copyright
Installation/Operating Manual Amarex KRT
Original operating manual
KSB Aktiengesellschaft Pegnitz
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited
or processed for any other purpose, nor otherwise transmitted, published or made available to a third
party without KSB´s express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 01.09.2010

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 .......................................................................... 7
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 ........................................................... 10
2.5 Consequences and risks caused by non-compliance with these operating
instructions .................................................................................................... 10
2.6 Safety awareness ........................................................................................... 10
2.7 Safety information for the operator/user .................................................... 10
2.8 Safety information for maintenance, inspection and installation work ... 11
2.9 Unauthorised modes of operation ............................................................... 11
2.10 Explosion protection ..................................................................................... 11
3 Transport/Temporary Storage/Disposal ........................................... 13
3.1 Transport ....................................................................................................... 13
3.2 Storage/Preservation ..................................................................................... 14
3.3 Return to supplier ......................................................................................... 14
3.4 Disposal .......................................................................................................... 15
4 Description of the Pump (Set) .......................................................... 16
4.1 General description ....................................................................................... 16
4.2 Designation ................................................................................................... 16
4.3 Name plate .................................................................................................... 16
4.4 Design details ................................................................................................ 16
4.5 Types of installation ...................................................................................... 17
4.6 Configuration and function ......................................................................... 18
4.7 Scope of supply ............................................................................................. 18
4.8 Dimensions and weights ............................................................................... 19
5 Installation at Site ............................................................................. 20
5.1 Safety regulations ......................................................................................... 20
5.2 Checks to be carried out prior to installation ............................................. 20
5.3 Installing the pump set ................................................................................. 22
5.4 Electrical connection ..................................................................................... 28
Contents
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6 Commissioning/Start-up/Shutdown ................................................. 34
6.1 Commissioning/start-up ................................................................................ 34
6.2 Operating limits ............................................................................................ 34
6.3 Shutdown/storage/preservation ................................................................... 37
6.4 Returning to service ...................................................................................... 37
7 Servicing/Maintenance ...................................................................... 39
7.1 Safety regulations ......................................................................................... 39
7.2 Servicing/inspection ...................................................................................... 40
7.3 Drainage/disposal .......................................................................................... 45
7.4 Dismantling the pump set ............................................................................ 45
7.5 Reassembling the pump set .......................................................................... 49
7.6 Tightening torques ....................................................................................... 54
7.7 Spare parts stock ........................................................................................... 55
8 Trouble-shooting ............................................................................... 56
9 Related Documents ........................................................................... 57
9.1 General assembly drawings .......................................................................... 57
9.2 Wiring diagrams ............................................................................................ 70
9.3 Flamepaths of explosion-proof motors ....................................................... 71
9.4 Sectional drawings of the mechanical seal .................................................. 72
10 EC Declaration of Conformity .......................................................... 74
11 Certificate of Decontamination ....................................................... 75
Index .................................................................................................. 76
Contents
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Glossary
Back pull-out unit
Pump without pump casing; partly completed
machinery
Certificate of decontamination
A certificate of decontamination certifies that
the pump (set) 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
Hydraulic system
The part of the pump in which the kinetic
energy 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 indicated
on the front cover (for details, please refer to the table below).
Table 1: Variants covered by this manual
Sizes Impeller types Material variant
Grey cast iron Industrial materials
G G1 G2 GH H C1 C2
40-250 F, K, S F, K, S F,K F F, K F, K F, K F, K
80-250 E, F E, F F F F F F F
80-251 F, K F, K K - K K K K
80-315 D D D - - - - -
80-316 F F F F F F - -
100-240 F F F F F F F F
100-250 E, F, K E, F, K F, K F F, K F, K F, K F, K
100-251 D D D - - - - -
100-315 D, E, F, K D, E, F, K D, F, K F F, K F, K F, K F, K
100-316 D D D - - - - -
100-400 K K - - - - - -
100-401 E, F, K E, F, K F, K F F, K F, K F, K F, K
150-251 D D D - - - - -
150-315 D, E, F, K D, E, F, K D, F, K F F, K F, K F, K F, K
150-400 D, K D, K D - - - - -
150-401 D, E, F, K D, E, F, K D, F, K F F,K F, K F, K F, K
151-401 K K K - K K K K
200-315 D, K D,K D, K - K K K K
200-316 K K K - K K K K
200-330 K K K - K K K K
200-400 D, K D, K D - - - - -
200-401 E, K E, K K - K K K K
250-400 D, K D,K D, K - K K K K
250-401 K K K - K K K K
300-400 D, K D, K D, K - K K K K
300-401 K K K - K 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 centre to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB, refer to the sub-sections
under Servicing/Maintenance.
1.3 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel. (⇨ Section 2.4 Page 10)
1 General
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1.4 Other applicable documents
Table 2: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump
set
General arrangement drawing/
outline drawing
Description of mating and installation
dimensions 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 product literature1) Operating manuals and other product
literature describing accessories and
integrated machinery components
Spare parts lists1) Description of spare parts
Supplementary operating manuals1) For example for special accessories
1.5 Symbols
Table 3: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1) If agreed to be included in the scope of supply
1 General
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2 Safety
All 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
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.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EC Directive
94/9/EC (ATEX).
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.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage 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 specialist
personnel/operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
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 in this manual.
2.3 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.
!DANGER
2 Safety
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▪Only use the pump set to handle the fluids described in the data sheet or product
literature of the pump model.
▪Never operate the pump set without the fluid to be handled.
▪Observe the limits for continuous operation specified in the data sheet or
product literature (Qmin2) and Qmax3) ) (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 x Qopt4) to minimise the risk of clogging/hardening.
▪Avoid duty points for continuous operation at very low speeds and small flow
rates (<0.7 x Qopt4) ).
▪Observe the 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 the respective impeller types in combination with the fluids described
below.
Impeller with cutter
(impeller type S)
Suitable for the following fluids:
Faeces, domestic sewage and waste water
containing long fibres
Free-flow impeller
(impeller type F)
Suitable for the following fluids:
Fluids containing solids and stringy
material as well as fluids with entrapped
air or gas
Closed single-vane
impeller
(impeller type E)
Suitable for the following fluids:
Fluids containing solids and stringy
material
Closed multi-vane
impeller
(impeller type K)
Suitable for the following fluids:
Contaminated, solids-laden, non-gaseous
fluids without stringy material
2) Minimum permissible flow rate
3) Maximum permissible flow rate
4) Best efficiency point
2 Safety
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Open, diagonal single-
vane impeller
(impeller type D)
Suitable for the following fluids:
Waste water with solid substances and
long fibres
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 specified in the data sheet and in
the product 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 and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
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.
2.5 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
2.6 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 information for the operator/user
▪The operator shall fit contact guards for hot, cold and moving parts, and check
that the guards function properly.
▪Never remove a contact guard while the pump is running.
2 Safety
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