KSB Amarex KRT Montageanleitung

Submersible Motor Pump

Amarex KRT

Sizes DN 50 to DN 80

Motor Sizes

2-pole: 012 to 032

4-pole: 014 to 034

Material Variants H, C1, C2

Installation/Operating

Manual

Mat. No.: 01047331

Legal information/Copyright

Installation/Operating Manual Amarex KRT

Original operating manual

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.

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 .............................................................................................................6

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 ..... 10

2.9 Unauthorised modes of operation ................................................................11

2.10 Explosion protection ...................................................................................... 11

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

3.1 Checking the condition upon delivery .......................................................... 12

3.2 Transport ......................................................................................................... 12

3.3 Storage/Preservation ...................................................................................... 13

3.4 Return to supplier ........................................................................................... 14

3.5 Disposal ...........................................................................................................14

4 Description of the Pump (Set) ............................................................15

4.1 General description ........................................................................................ 15

4.2 Designation ..................................................................................................... 15

4.3 Name plate ...................................................................................................... 15

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

4.5 Types of installation .......................................................................................16

4.6 Configuration and function ........................................................................... 17

4.7 Scope of supply ............................................................................................... 17

4.8 Dimensions and weights ................................................................................18

5 Installation at Site ...............................................................................19

5.1 Safety regulations ........................................................................................... 19

5.2 Checks to be carried out prior to installation ............................................... 19

5.3 Installing the pump set .................................................................................. 21

5.4 Electrical system .............................................................................................. 26

Contents

Amarex KRT 3 of 60

6 Commissioning/Start-up/Shutdown ...................................................32

6.1 Commissioning/start-up ................................................................................. 32

6.2 Operating limits .............................................................................................. 33

6.3 Shutdown/storage/preservation .................................................................... 35

6.4 Returning to service .......................................................................................36

7 Servicing/Maintenance .......................................................................37

7.1 Safety regulations ........................................................................................... 37

7.2 Servicing/inspection ........................................................................................ 38

7.3 Drainage/cleaning ..........................................................................................41

7.4 Dismantling the pump set .............................................................................. 41

7.5 Reassembling the pump set ........................................................................... 43

7.6 Tightening torques ......................................................................................... 47

7.7 Spare parts stock ............................................................................................. 47

8 Trouble-shooting ................................................................................49

9 Related Documents ............................................................................50

9.1 General assembly drawings ........................................................................... 50

9.2 Wiring diagram ............................................................................................... 53

9.3 Flamepaths on explosion-proof motors ........................................................ 54

9.4 Sectional drawings of the mechanical seal ...................................................55

10 EC Declaration of Conformity ............................................................56

11 Certificate of Decontamination .........................................................57

Index ....................................................................................................58

Contents

4 of 60 Amarex KRT

Glossary

Certificate of decontamination

A certificate of decontamination is enclosed by

the customer when returning the product to

the manufacturer to certify 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

Flamepath

The surface of motor housing components

which form flameproof joints when an

explosion-proof motor is installed.

Hydraulic system

The part of the pump in which the kinetic

energy is converted into pressure energy

Glossary

Amarex KRT 5 of 60

1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicated

on the front cover. It 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

uniquely identify the pump (set) and serve as identification for all further business

processes.

In the event of damage, contact your nearest KSB service centre immediately 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.

1.4 Other applicable documents

Table 1: 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, weights

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) E.g. for special accessories

For accessories and/or integrated machinery components observe the relevant

manufacturer's product literature.

1.5 Symbols

Table 2: 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) If agreed to be included in the scope of supply

1 General

6 of 60 Amarex KRT

Symbol Description

Step-by-step instructions

Note

Recommendations and important information on how to handle

the product

1 General

Amarex KRT 7 of 60

2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: 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

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 specialist personnel/

operators responsible 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 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.

▪Only use the pump set to handle the fluids described in the data sheet or product

literature of the pump model.

!DANGER

2 Safety

8 of 60 Amarex KRT

▪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 indicated in

the table below.

Table 4: Applications of impeller types

Impeller type Suitable for the following fluids

Free-flow impeller

(impeller type F)

Fluids containing solids and stringy material

as well as fluids with entrapped air or gas

Closed multi-vane

impeller

(impeller type K)

Contaminated, solids-laden, non-gaseous

fluids without stringy material

Impeller with cutter

(impeller type S)

Faeces, domestic sewage and waste water

containing 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) Minimum permissible flow rate

3) Maximum permissible flow rate

4) Best efficiency point

2 Safety

Amarex KRT 9 of 60

2.4 Personnel qualification and 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 means of training and instruction

provided by sufficiently trained specialist personnel. 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.

▪Do not remove any contact guards during 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 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.

2.8 Safety information for maintenance, inspection and installation work

▪Modifications or alterations of the pump are only permitted with the

manufacturer's prior consent.

▪Use only original spare parts or parts authorised by the manufacturer. The use of

other parts can invalidate any liability of the manufacturer for resulting damage.

2 Safety

10 of 60 Amarex KRT

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