Amarex KRT series Manuale utente

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

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.

Contents

3 of 124

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

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

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

9 of 124

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

10 of 124 Amarex KRT

▪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.

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