Amarex KRT8041e

Amarex KRTOperating manual2553.8041-10

Submersible motor pumps

Amarex KRTSeries

DN 100...DN 300Size

23 4...65 4 (4pol.)20 6...50 6 (6pol.)10 8...21 8 (8pol.)Motor size

G, GH Material types

Works-No.: see nameplate

The operating manual contains important information andhazard/danger warnings. It is imperative to read the instructionsset out in the manual prior to installation, making electricalconnections and commissioning. Additional operating instructionsrelatingto the components of this plant will also have to be observed.

Ident-No. 01 053 562

In principle if any work has to be carried out to the plant all electricalsupplies (inclusive of the control cable) should be disconnected at themains supply switch. The plant has to be safeguarded against accidentalstarting.

KSB

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Amarex KRTKSB

These operating instructions contain important notes for the individualmaterial versions of the below sizes:

Type Size Material version

F, E, K =impeller type Cast iron

G G1 G2 GH

F,E,K 100 - 401 F, E, K F, K F F, K

F,E,K 150 - 401 F, E, K F F F

K 151 - 401 K K -- K

K 200 - 330 K K

E,K 200 - 401 E, K K

K 250 - 370 K K

K 250 - 401 K K

K 300 - 380 K K

K 300 - 381 K

Contents Page1. General 3

2. Safety 32.1 Identification of symbols used

within the operating manual 32.2 Personnel skills and training 32.3 Dangerous practices - non-observance of

safety instructions 32.4 Safe working methods 32.5 Safety instructions for operators 32.6 Safety instructions during maintenance,

inspection and installation 32.7 Unauthorized modifications to the pump 4

and fitting of spare parts2.8 Impermissible modes of operation 4

3. Transport and interim storage 43.1 Transport 43.2 Storage/conservation 4

4. Description of pump 44.1 General description 44.2 Identification data 44.3 Construction 44.4 Ancillary equipment 5

5. Assembly/Installation 55.1 Safety regulations 55.2 Checking procedure prior to commencement

of the installation 55.3 Installation 55.4 Connection of the pipeline 55.5 Electrical connection 65.6 Assembly kit installation 7

6. Start up/shut down 86.1 Initial start up of pump 86.2 Limitations of the operating range 86.3 Shutdown / storage / preservation 96.4 Re-starting pump after storage 9

7. Service and maintenance 97.1 General instructions 97.2 Service/Inspection 107.3 Drainage / Disposal 117.4 Dismantling 117.5 Re-assembly 127.6 Stockkeeping of spare parts 13

8 Trouble-shooting 14

9. Appendix 15

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1. General

This KSB pump has been developed in accordance with the latesttechnology, it was manufactured with great care and is subject toconstant quality control.The operating manual is designed to introduce the pump to you,and to make operation easier and to make full use of all itsapplications.The operating manual contains important information to ensuresafe, correct and economic operation. It is imperative to observethe contents of the operating manual to ensure reliability and longoperating life of the pump and to avoid dangerous practices.The operating manual does not take into account any localregulations which have to be complied with by the operator or byany hired installation staff.This pump must never be operated outside the limits laid down inthe technical documentation with regard to pumped media, rate offlow, speed, density, pressure and temperature, including motorrating or contrary to any other instructions stipulated in theoperating manual or contract documentation.The nameplate states series/size, the most important operatingdata and the Works No./Serial No., which must always be statedwhen making enquiries, subsequent orders and especially whenordering spare/replacement parts.Should any additional information or instructions be required, or ifthere is any damage to the equipment, then please contact yournearest KSB service.

2. Safety

This operating manual contains basic instructions, which must beobserved during installation, operation and servicing. Therefore it isimperative that this manual is read prior to assembly by the fitterand relevant skilled staff/and operators, and it must always be keptwithin the locality of the machine/plant.Do not only observe the general safety notes under this section,but as well any other notes regarding safety included in themanual.

2.1 Identification of symbols used within theoperating manual

The symbols contained within this manual calling attention tosituations where non-observance could endanger lives, areespecially identified such as:

Warning sign in accordance with DIN 4844 – W9

Calling attention to electric current with

Warning sign in accordance with DIN 4844 – W8Safety instructions relating to situations where non-observancecould damage the machine and its functions are identified with theword

Attention

Any instructions which are actually printed on the machine such as:- arrow indicating the direction of rotation- identification for fluid connections

must be observed without fail and be kept clean and legible.

2.2 Personnel skills and training

Operators, as well as service, inspection and assembly personnelmust have proof of having the appropriate skills to carry out suchwork. Area of responsibility, allocation and supervision of thepersonnel must be controlled by the operator. Should the personnelnot have the required knowledge, training must be arranged. Ifrequired, the operator can arrange such training to be carried outby the manufacturer/supplier. The operator must also ensure thatthe instruction manual is fully understood by the personnel.

2.3 Dangerous practices - non-observance of safety instructions

Non-compliance with the safety instructions can endanger people‘slives, the environment and the pumps.In detail, non-compliance could, for example, cause the following:

- Failure of pump/plant to operate

- Failure of servicing and maintenance methods

- Endangering people by contact with electrical, mechanical andchemical matters

- Contamination of the environment by leakage of dangeroussubstances.

2.4 Safe working methods

The operator must observe all safety instructions outlined in thisleaflet, the existing national safety precautions to preventaccidents, and also any inter-company working, operating andsafety regulations.

2.5 Safety instructions for operators

- If hot or cold machine parts are considered a danger, then theseparts must be protected where contact is possible.

- Safety equipment to prevent contact with hot or cold movableparts must not be removed while the machine is in operation.

- Leakages (for example at shaft seals) of dangerous media (e.g.explosive, poisonous, hot liquids) must be disposed of in such amanner as to avoid any danger to personnel and environment.

- Danger caused by electric supply must be eliminated (in thisrespect, see details of any regulations enforced by individualcountries of the VDE and/or local power supply stations).

2.6 Safety instructions during maintenance,inspection and installation

The operator bears the responsibility to ensure that all service,inspection and maintenance work is carried out by authorized andfully trained personnel, who have read and are familiar with theoperating instructions.Basically, all work to the plant should only be carried out when themachine is not operating. The operating instructions relating to themethod of switching off the equipment must be adhered to withoutfail.Pumps or plants pumping dangerous media must bedecontaminated.Once maintenance work is completed, all safety equipment mustbe reinstated again and checked to ensure they function correctly.Read and follow the point listed in the paragraph 6.1 prior toinstallation.

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2.7 Unauthorized modifications to the pump andfitting of spare parts

Modifications to the pump can only be carried out afterauthorization has been obtained from the manufacturer. Originalspare parts and ancillary equipment supplied by the manufacturerprovide safety. Installation of any other equipment cancels theguarantee for any pump failure which occurs as a result of installingnon-manufacturer‘s parts.

2.8 Impermissible modes of operation

Operating safety of the equipment is only guaranteed if alloperating instructions as outlined in paragraph 1 - General - areobserved. The limits given in the data sheet must under nocircumstances be exceeded.

3 Transport and interim storage

The chain or lifting wire which is supplied mustonly be used for lifting the appropriate pumpunit. General use for lifting heavy loads is notpermitted.

Do not lift the pump by the motor cable.

The pump must be handled carefully duringtransport. The chain or lifting wire must beattached securely at the pump and crane end.Personnel can be injured and the pump unitdamaged should the pump slip out of thechain/guide rope.

3.1 Transport

The motor housing/cover of the pump has been prepared forattaching the chain supplied with the unit. For lifting the unit duringunpacking only this prepared fixing should be used for attachingthe lifting chain.

3.2 Storage/conservation

The procedure has been outlined in paragraph 6.3 ”Shutdown”.

4. Description of pump

4.1 General description

KSB submersible pumps are close-coupled units which are non-self-priming. The impellers in these pumps can vary, depending onthe impeller type required by the customers to suit a particularapplication. Usually, the pumps are operated fully submerged. Forshort periods, they may run dry until the minimum filling level isreached.

4.2 Identification data

Identification can be found on the nameplate, which is fitted to themotor. Illustration nameplate for non-flameproof and flameproofdesign see appendix: ”General pump outline” Fig 1.

4.3 Construction

4.3.1 Driver

KSB submersible pump sets are supplied with three-haseasynchronous motors complete with connecting cable.Electrical data in compliance with nameplate. Starting methodstandard: direct or Y∆.

4.3.1.1 Motors in flameproof design

In accordance with EN 50014/ EN 50018; Protection type EEx d IIBT3.

4.3.2 Shaft seal

The shaft seal consists of a mechanical seal which is independentof the direction of rotation at pump and motor end. The oilchamber which is fitted between the two mechanical seals ensurescooling and lubrication.

4.3.3 Bearing assembly

All sizes are fitted with grease-lubricated, maintenance-ree deep-groove anti-riction bearings.

Series Impeller type (E,F,K)

Hydraulic size

Motor size

Impeller diameter

KRT F 100-401 / 50 4 X G - 390

Number of poles

Motor version (U, W, X)

E = single-vane impellerF = free-flow impellerK = non-clogging impeller

U = standard versionW = hot water design (max. 60 °C)X = explosionproof version T3

G = Pump complete in cast iron GraugußG1 = GG Pump with impeller in duplex steel (1.4517)G = GG Pump with impeller in chilled casting (0.9635)GH = Pump manufactured in chilled casting ( 0.9635)

4-pole6-pole8-pole

Material version / variants (G, G1, G2, GH)

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4.3.4 Impeller types

4.3.5 Installation methods

- stationary wet-well installationtransportable installation

For detailed installation description, see item 5.6.

4.3.6 DimensionsInformation regarding dimensions and weight can be found inAppendix "Dimension tables”.

4.4 Ancillary equipmentSuitable KSB switchgears are available to ensure trouble-freefunctioning of the monitoring equipment. Recommended equipment isdescribed in Appendix ”Electrical connection diagram”

Any information relating to other ancillary equipment will be given byour Sales Office.

5. Assembly/Installation

5.1 Safety regulations

It is not permitted for any person to enter the tankduring operation of the pump unless special safetyprecautions have been taken in accordance withcurrent safety regulations.

5.2 Checking procedure prior to commencement ofthe installation

Construction lay-out must be in accordance with measurements setout on the table of dimensions. The construction of the concretefoundations should be sufficiently strong (min. B 25 in accordancewith DIN 1045) to ensure a secure and functionally correct installationin compliance with DIN 1045 or equivalent standard. Concretefoundations must have set before installation of the unit. Its surfacemust be level and even.

5.3 InstallationExamine the unit carefully prior to commencement of installationregarding any damage incurred to the unit and cabling duringtransport. Before installation of the pump all items listed in paragraph6.1 have to be checked in sequence. A separate nameplate statingpump and motor data is supplied within the scope of supply. Thisnameplate must be fixed in a clearly visible position outside the tank(for example switch panel, pipework, mounting bracket).

5.3.1 Checking of operating data

A check must be carried out to ensure that the details stated on thenameplate correspond to the order and pump data (for exampleoperating voltage, frequency and pumped media temperature etc.).

5.3.2 Oil level controlThe oil chambers of our submersible pumps were filled withenvironmentally safe non-toxic paraffin oil at works.The oil level must be checked prior to initial operation of theunit.Procedure see item 6.1.1

5.3.3 Checking of the direction of rotationBefore starting with the installation, make sure that the direction ofrotation is the correct one, acc. to para. 5.5.6.

5.4 Connection of the pipeline(Appendix ”General outline-installation set” Fig 1).The discharge pipe must be connected to the pump without tension.

AttentionUnder no circumstances must the pump beused as an anchoring point for the pipeline.

Any expansion of the pipes caused by high temperatures must beadjusted by taking appropriate corrective measures, to ensure that thepump does not come under undue stress due to pipeline forces andtorques.

Excessive pipeline forces can cause leakages ofpumped media for example. Toxic and hot mediacan endanger life.

When emptying objects on a lower level, a non-return valve must befitted into the discharge pipe to avoid backflow from the channel,which could be led via the backflow level (road level) upwards and onlythen into the sewage channel.

AttentionScrewed pipeline joints where plastic partswere used, must not be damaged by carelesshandling of tools during the installation ofpump and pipeline.

Fitting of a non-return valve is also essential for longer rising pipes toavoid excessive backflow when the pump is turned off. Ensure thatventilation is taken into account when fitting a non-return valve.

Free-flow impeller (F-impeller) for pumpingliquids containing larger solid particles andfibres liable to twist and bunch and also gasand air inclusions.

Single-vane impeller (E-impeller) for pumpinglliquids containing larger solid particles andfibres liable to twist and bunch, and also forthe damage-free transport of solids.

Closed non-clogging impeller (K-impeller) forcontaminated, non-gaseous liquidscontaining solids, without fibres liable to twistand bunch.

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5.5 Electrical connection

General

The electrical connection must be carried outby a trained electrician and in compliance withlocal regulations. The voltage must complywith the voltage indicated on the nameplate.

Electrical installation must be in accordance with the appendix”Electrical connection diagrams” for the appropriate motor sizes.The pump is delivered with cable.

AttentionDo not remove the protective cover, which issituated at the cable gland until immediatelybefore installation.

The individual cores of the cable ends bear marking tapes (e.g. U(T1).V(T2), W(T3), 21, 22, or 10, 11, ...)If cables have to be shortened, take care of the core index or colourimprints. In such a case, remove the core marking and reaffix itafterwards.

AttentionWhen laying an earth cable between thepumping station and the electrical switchgear,an additional multi-core control cable (min. 1.5mm2) must be installed for motor monitoringequipment and float switch control. Adjustcores to suit requirement.

5.5.1 Monitoring equipment

The unit has been supplied with monitoring equipment to preventoverloading. Installation, description and functioning of the monitoringequipment can be taken from Appendix ”Electrical connectiondiagrams”.

5.5.2 Frequency inverter operation

In case of using frequenzy converters, the power output of the motorP2 is limited to- 85 % of nominal value, if a voltage source converter (VSC) is used,

- 95 % of nominal value, if a current source converter (CSC) is used.

5.5.3 Fitting of electric cabling

AttentionAfter installing the unit, it is advised toposition the motor cable straight upward inorder not to have it affected by the swirlcreated by the pumped liquid.

For correct installation of the electric cabling within the pump sump(Appendix ”General pump outline” Fig. 5) we recommend usingcable socks, which can be supplied as an additional extra (paragraph4.4). Slack installation of cables could cause damage to the electriccabling because of vibrations when the pump is operating.

AttentionFitting of cable protection sheath

If a protection sheath is included in the scope of supply for the electriccabling, it has to be fitted according to the instructions given in thesupplementary operating manual „Assembly of protection sheath“.

5.5.4 Overcurrent relay

The motor must be protected against overloading by a thermallyretarded overcurrent relay to comply with VDE 0660 / IEC 947 andregulations which are in accordance with local requirements. Thismust be adjusted to the nominal motor current indicated on thenameplate.

5.5.5 Level control switch

Pumping stations with automatic pump operation should be fitted witha level control switch. The cut-off point should be set as ‘R’ inaccordance with Appendix ”Dimension tables”.This prevents an interruption of the delivery by the pump which wouldcause dry running.

5.5.6 Checking of the direction of rotation

Once the electrical connections are complete, the following should bechecked:

AttentionThe pump cannot reach its duty point if thedirection of rotation is incorrect. Non-observance can lead to damaging the pumpset.

Prior to carrying out any tests check that thereare no foreign objects within the pump casing.Never put hands or any objects into the pump.

AttentionThe running time should be as short aspossible (max 3 minutes).

Correct direction of rotation:

If the phase sequence of the circuit is known, the correct direction ofrotation will occur automatically, providing the instructions in 5.5 havebeen carried out correctly (rotating of the motor to the left). Thedirection of rotation is checked by short starts and observations of theimpeller.When looking at the pump mouth, the impeller must move to the left(with some pumps, the direction of rotation is marked by an arrow).(see appendix ”General pump outline” Fig. 6).

If the direction of rotation is incorrect, interchange 2 of the3 phases in the switch cabinet.

5.5.7 Connection of a potential equaliser

For potential equalisation, follow the instructions to EN 60 204.The potential-equalising conductor is connected to the externalconnection terminal at the cable entry.(Appendix ”General pump outline”).

Special requirements for chemically corrosive media

Do not use the outside terminal if the unit is used for chemicallycorrosive media and with a flameproof pump.

Instead, the potential equaliser should be fitted to a flange at thedischarge pipe, which does not come into contact with the media.Please ensure that there is an electrical connection between the newlycreated potential equaliser and the pump.

(Appendix ”General pump outline” Fig. 5).

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5.6 Assembly kit installation

The following assembly kits are available for assembly/installation ofthe KRT pump unit.

- 5.6.1 Stationary wet-well installation- 5.6.2 Transportable installation

5.6.1 Stationary installation/guide cable

5.6.1.1 Description

(Appendix ”General outline-installation set“ Fig. 1)

Stationary installation provides the facility to insert and lift out thepump unit at any time regardless of liquid level within the sump bymeans of a double guide cable.

Guided securely by two parallel, previously tightened stainless steelcables the pump slides into the well or tank and attaches itself to theduckfoot bend which has been fitted to the bottom.The weight of the pump acts as seal between pump and duckfootbend. A profile joint between pump and duckfoot bend achieves apressure-proof elastic connection.Walking on the well is not permitted during inspection andmaintenance work.

5.6.1.2 Scope of supply for stationary wet-well installation

Please refer to the Appendix ”Wet-well installation with partslist”

5.6.1.3 Installation of pump with clawconnection

Use appendix ”Wet-well installation” with parts list for guidance.

1- Prior to lowering the pump fit claw 732 to the discharge flange ofthe pump housing.Screws have to be tightened in accordance with the instructions.This is described under item 7.5.1 in the table ”Bolt tighteningtorque”.

2. Fit profile seal 410.35 or 99-6 into the groove of the claw/pumpcasing flange. This profile seal will serve to seal the duckfootbend during installation.

5.6.1.3 Fitting of the mounting bracket/duckfoot bend/guide cable

Construction of the base/concrete foundations should be sufficientlystrong (min. B 25 in accordance with DIN 1045) to ensure afunctionally correct fixing of guide cable equipment and duckfootbend.

Refer to the drawing as illustrated in Appendix ”Wet-wellinstallation with parts list‘ for all installation tasks outlined below.

1. Secure mounting bracket 894 using anchor bolt 90-3.37 at thesump opening rim. Borehole diameter and depth for the anchorbolt to be taken from Appendix ” Dimension tables”. Bolttightening instructions are outlined in the table below.

Up to size 200-401, all means of fixation are part of the scope ofsupply. Fixations for larger sizes have to be carefully selected bythe owner of the plant and must be adapted to his conditions atsite.For the bolt of the mounting bracket refer to Appendix”Dimension tables”.

2. Fit threaded bolt 904 with clamping piece 571/ support piece 572to the mounting bracket. Do not unscrew hexagonal nut 920.36too much, just enough to allow sufficient play for tightening thecable subsequently. Ensure that the two clamping pieces 553 arefitted correctly to a support piece.

3. The duckfoot bend should be positioned and secured to the baseof the sump so that the tightened cable will run vertically later on.Should construction/pipework etc. require the cable to run off thevertical, then a maximum angle of 5o should be adhered to, thusensuring safe fitting function.Securing of the duckfoot bend iscarried out by using bolts or foundation bolts regardless of pumpsize or material variation.Units larger than approx. 2,000 kg in weight are suppliedcomplete with foundation slide rails. Refer to Appendix”Dimension tables” and Appendix ”Wet-well installationwith parts list” for details relating to appropriate fittinginstructions and hole dimensions.

4. Insertion of cable and fitting. Lift thrust plug and clamp and insertone end of the cable. Lead the cable around the duckfoot bend72–1 and back again towards the guide bracket and insert intoclamp of thrust plug. Manually tension the cable and secure byusing hex. nuts 920.37.

5. Tighten the cable by fastening the hexagonal nut 920.36 situatedon top of the mounting bracket(s). Tighten the hexagonal nut witha torque of MA as outlined in the table Appendix ”Guide cabletension” to achieve sufficient cable tension. Subseqently secureby using a second hexagonal nut.

6. The loose end of the cable at the clamp 572 can either be twistedinto a ring or the end can be cut off. After length adjustment, sealoff ends to avoid fraying.

7. Place shackle 59-18 into the mounting bracket 894 to enable thelifting chain to be attached at a later stage.

Table Bolt tightening torque ”Steel anchor bolt”

Size (ø, mm) Torque (Nm)10 1018 80

Table Bolt tightening torque ”Foundation bolt”

Size (ø, mm) Torque (Nm)12 2516 6520 12524 210

Table ”Guide cable - tension”Size MA

(Nm)P

(N)100-401 200-330 14 6 000150-401 200-401151-401250-370 300-381 30 10 000250-401300-380

MA = tightening torqueP = cable tension

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5.6.1.5 Fitting of chain / lifting rope stationary wet-well installation

Installation of this equipment should be carried out in accordance withthe ”General pump outline”, Fig. 2a by inserting the chain/liftingrope into the opposite the outlet branch. Further details can be foundin ”Wet-well installation with parts list”.

This type of fixing achieves a forward inclination of the pump towardsthe outlet branch and permits the fitting of the pump to the duckfootbend.

5.6.1.6 Installation of the pump

(Appendix ”General outline installation set” Fig. 1)

The pump is lowered into the sump by guiding it from above over theclamp 572. It is then attached to the guide cable and slowly loweredinto the sump. Once the pump is lowered, it will attach itself to theduckfoot bend 72-1 and is then securely fixed to the outlet pipe readyfor use. Finally, attach the chain or rope to the shackle 59-18 on themounting bracket

5.6.1.7 Connection of the pipeline

(Appendix ”General outline installation set ”, Fig. 1)

For procedure, see para. 5.4.

5.6.2 Transportable installation

5.6.2.1 Description

Pumps for transportable installation are supplied with a pump stand.The outlet flange with DIN connections can be used for fitting eitherrigid or flexible piping. Examples for typical installation possibilitiescan be taken from Appendix ”General outline installation set” Fig.2. Ancillary equipment can be requested and purchased from oursales offices.

5.6.2.2 Components/extent of supply fortransportable installationFor parts supplied and detailed illustration, see Appendix ”Wet-wellinstallation transportable with parts list”

5.6.2.3 Assembly kit installationPlease refer to drawing in Appendix ”Wet-well installationtransportable with parts list” for assembly.The base plate or the pump stand must be fitted prior to installing thepump. All screws must be tightened according to instructions. Referto table ”Bolt tightening torque” paragraph 7.5.1 for instructions.

5.6.2.4 Assembly chain/lifting rope/ transportable installation

Fitting of chain/lifting wire should be carried out as outlined inAppendix ”Wet-well installation transportable with parts list”.Always use the slot which is fitted on the discharge side, seeAppendix ”General pump outline” Fig. 2b.

5.6.2.5 Installation of pump

Transportable installation permits to operate the pumps in differentlocations.For example, they can be used for draining minesthe emergencydraining of canals pumping water out of rivers etc. For suchapplications the pump must be installed in a vertical position with themotor on the top and fitted to a firm base.

6. Start up/shut down

AttentionIt is important to fulfil the followingrequirements. Any damage incurred as aresult of non-compliance is not covered by theguarantee.

AttentionDo not pump any media which is unsuitablefor the material outlined in the technicaldocumentation.

6.1 Initial start up of pump

Prior to starting the pump it has to be ascertained that the followingpoints have been checked and executed:

- Operating data must be checked to comply with paragraph5.3.1,Oil level paragraph 6.1.1 and direction of rotation paragraph5.5.6.

- Check that the installation of the electrical supply was carried outcorrectly in accordance with Appendix: ”Electrical connectiondiagrams”.

AttentionTemperature monitoring in the windingprotects the motor in case of insufficientcooling conditions (e.g. if pump is partially notsubmerged). Reliable operation and explosionprotection can only be guaranteed if thecircuits for temperature monitoring functionproperly.

- Ensure that the pump has been installed correctly to comply with installation kit paragraph 5.6.

- Should the pump have been out of service for a long period, then the steps outlined in paragraph 6.4 must be carried out.

6.1.1 Oil level check

Procedure according to appendix „General pump outline“

Fig. 3. Remove screwed plug with joint ring 411.03. The oil level mustbe at the height of the oil inlet. If it is lower, fill the oil chamber via feedopening until overflow. Regarding oil quality and quantity, see point7.2.4 (Oil change).Tighten screwed plug with joint ring again.

6.2 Limitations of the operating range

6.2.1 Minimum liquid level

The pump is ready for operation when the liquid level has reachedmeasuring mark ”R”.This minimum liquid level also applies to pumping stations withautomatic pump operation.(Appendix ”General pump outline” Fig. 7)

”R” = Lowest switch-off point for automatic operation”M” = Minimum liquid level for constant operation

Built-in temperature controls within the winding will protect the motorfrom overheating. If the motor overheats (for example during longoperation with a completely exposed motor), the built-in temperaturecontrols will switch off the motor and turn it on again automaticallyafter cooling down.The control system must provide a protection against dry running bystopping the pump automatically (cut-off contact, see 5.5.5).

AttentionDry running leads to increased wear (and tear)and should be avoided.

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6.2.2 Temperature of pumped media and surroundings

KRT .... type X flameproof version 40 OC

KRT .... type U 1) 40 OC oras indicatedon data plate

KRT .... type W 1) 60 OC oras indicated

on data plate 1) Can be operated up to 80 oC for a limited period (3–5 min. or until

the thermal protection equipment is activated)

AttentionDo not operate the equipment at temperatureshigher than those indicated above, unless themanufacturer has given written consent.Damage caused due to non–observance ofthis warning will not be covered by theguarantee.

6.2.3 Switching frequency

In order to avoid intolerably high temperature rises within the motorand excessive overloading of motor, seals and bearings, the followingnumber of switching operations per hour (S) should not be exceeded:

Motor capacity(kW)

max. S(Switching operations/h)

up to 7,5 30from 7,5 10

6.2.4 Operating voltageThe maximum admissible deviation of the operating voltage amountsto ± 10%, with flameproof versions to ± 5% of the rated voltage. Themaximum admissible voltage difference between the single phasesamounts to 1%.

6.2.5 Density of pumped media

Power input of the pump increases directly with the density of thepumped medium. To avoid overloading of the motor this density mustcomply with the data stated in the order.

6.2.6 Abrasive media

When pumping media containing abrasive particles, increased wearof hydraulic and mechanical seals must be expected. Themaintenance intervals must be halved compared to those usuallyrecommended (as outlined in paragraph 7). In addition, it isrecommended to limit the flow velocity in relation to the rising main to> 1.5 m/sec < 5 m sec in order to achieve the maximum operatingperiods possible.

6.3 Shutdown/storage/preservation

If operation is not required until some time after delivery, werecommend the following steps for storage of the pump:

6.3.1 Storage of new pumps

- Spray the inside of the pump housing with oil by paying specialattention to the area around the impeller gap. Spray oil through inletand outlet flanges. It is then recommended to protect the flanges (withplastic caps or similar).

- Store the pump in an upright position in a dry place. Support allelectrical cables at cable entry points to avoid permanent distortion.

- Electric connecting cables are capped securely for protectionpurposes prior to delivery. This protection must not be removed.

6.3.2 Measures for prolonged shutdown periods

1. The pump remains installed ready for operation when required.

In order to secure pump availability as and when required and toavoid formation of deposits within the pump and the immediatepump surroundings, the plant should be switched on for briefperiods (approx. 1 minute) once every month.

2. The pump is dismantled and stored

Prior to storage the pump should be checked and maintained inaccordance with paragraph 7.1 and 7.2. Subsequently, thepreservation outlined in paragraph 6.3.1 must be carried out.

6.4 Re-starting pump after storage

Prior to re-starting the pump, all checks and maintenance stepsoutlined in paragraphs 7.1 and 7.2 have to be carried out.

Always disconnect all electricity supplies prior toworking at the pump. Safeguard the pump frombeing started accidentally. Otherwise, there will bedanger to life.

In addition, free-running of the impeller should bechecked. This can be done by putting one handinto the pump casing and manually turning theimpeller.

When restarting the pump the items outlined in paragraph 6.1 andparagraph 6.2 have to be observed.

Immediately after completion of the maintenancework, all safety and protection equipment has tobe installed expertly and must be set working.

7. Service and maintenance7.1 General instructions

The operator must ensure that all maintenance, inspection and repairwork is carried out by qualified, authorized staff who are familiar withthe equipment and who have read the operating instructions.

By compiling a maintenance plan it is possible to cut maintenanceexpenses and avoid extensive repair costs, thus achieving trouble-freeand reliable operating of the pump.

Always disconnect all electricity supplies prior toworking on the pump. Safeguard the pump frombeing started accidentally.Otherwise, there will be danger to life.

If the pumped media are harmful, the pump mustbe decontaminated. Special care should be takento prevent an endangering of personnel andenvironment when draining leakage liquid/oil. Allofficial regulations must be adhered to.

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7.2 Service/Inspection

The following points must be observed to ensure reliableoperation:

This work must only be carried out by experienced personnel!

Item Maintenance tasks Maintenance tobe carried out atfollowingintervals

7.2.1 Insulation resistance check

7.2.2 Visual inspection of electric cables every7.2.3 Check of monitoring equipment 4,000 hours7.2.4 Oil change but at least7.2.5 Bearings and lubrication once a year7.2.6 Visual check of lifting chain / rope

General overhaul every 5 years

7.2.1 Insulation resistance check

The insulation resistance of the motor winding has to bechecked every 4,000 hours but at least once a year duringgeneral maintenance.

Measurements should be taken at the cable ends (disconnected at thestarting panel). The measurement should be taken by using a megger.– Measuring voltage: max 1,000 V d.c. voltage

The insulation resistance of the motor winding with cable ends tiedtogether must not be less than 5 megohm. If measurements are less,then cable and motor must be checked separately. During themeasurement procedure the supply cable must be disconnected fromthe motor.

The measurements to be taken are:

a) Winding against earth- All winding ends connected with each other

b) Winding temperature sensor against earth- All cable ends of the winding temperature sensors should be

connected to one another and all winding ends be connected to earth

If the insulation resistance for the electric supply cable is less than 5megohm, this indicates damage and needs replacement.

Low reading of the insulation resistance values of the motor indicatesthat there is a fault in the winding. If this is the case, contact either themanufacturer or the nearest KSB Agent/Distributor.

7.2.2 Inspection of the electric cable

- Visual inspection of the electric cable.Whenever the pump is inspected, the electrical supply cables should also be checked with regard to damage such as cracks or bubbles, due to either mechanical or chemical causes. If such damage is detected, then all electric cables must be replaced.

- Checking the protection cable. Measurement of theresistance between the cores should be R < 1 Ohm.

7.2.3 Checking the monitoring equipment

The performance tests should form part of general periodicmaintenance work, carried out every 4,000 hours or at leastannually.

a) Temperature switch – Check resistance between the connection ends 21 and 22: R < 1 Ω

b) PTC–resistor sensor– resistance measuring –resistance between connection ends 10 and 11:100 Ω < R < 750 Ω

If the given tolerances are exceeded, disconnect the electricsupply/control cable at the unit and check again directly at theterminals of the unit. If tolerances are exceeded here, too, the windingmust be replaced.

c) Moisture protection electrode

The motor area is being monitored by a moisture monitoring electrodewhich is fitted into the motor area (Part No. 81-56). It is not alwaysfitted as standard. Core identification 9 will show whether or not it hasbeen fitted.Instructions relating to performance and technical data can be foundin Appendix ”Moisture monitoring”.

The moisture monitoring electrode is okay if the insulation resistancemeasured at the electrode is > 5 MΩ . Lower values indicate moistureor even intrusion of water into the motor. In such cases, the motorneeds to be opened and overhauled.

A new moisture sensor must be fitted in the event of damage.

d) Float switch - continuity check-

The motor interior will be monitored by a built-in float switch whichdoes not always form part of the standard scope of supply. Coreidentities 3 and 4 show whether it has been installed or not.Resistance between connection ends 3 and 4: R < 1 Ω .If resistances exceed these values, check for leakage. If there is noleakage in the motor interior, but the resistance amounts to > 1 Ω ,contact your nearest KSB Service.

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Amarex KRTKSB

7.2.4 Oil change

The oil chamber of our submersible pump has been filled withenvironmentally friendly, non-toxic paraffin oil of medical quality onthe pump end.However, the oil should be changed after 4,000 operatinghours, but at least annually.

Pumped liquid might enter the oil chamber when itis warm after operation, which can cause apressure rise within the chamber. It is, therefore,advisable to cover the filling plug 903 (with a cloth)during the opening process to avoid hot liquid(squirting out) escaping.

Procedure

(Appendix ”General pump outline”)

Erect the pump as shown in Fig. 3 and put a suitable containerunder the plug. Unscrew screwed plug 903.03 with joint ring 411.03„oil filler plug“ and 903.05/411.05 „oil drain“ and drain the oil.

The oil is light in colour and transparent in appearance. Slightdiscolouring, caused by running in of new mechanical seal or smallleakage of dirt via the pumped media will have no adverse effect.Severe contamination of the oil by the pump media, however,indicates damaged mechanical seals. In this case, replace themechanical seal.

Screw in screwed plug 903.05 with joint ring 411.05.

Refilling

Erect the pump as demonstrated in Fig. 3 and fill the oil chamberwith oil until overflow (see also paragraph 6.1.1). Replace the plug903.03 and fit a new gasket 411.03.

Oil quantity:

The quantity of oil required amounts to 6,5 l.

Recommended quality of oil:

Paraffinoil, free-flowing, Messrs. Merck No. 7174 orequivalent,non-toxic.This quality is harmless and as such complies with the regulationsapplicable to food.

Alternative:

All non-alloyed and alloyed motor oils of classes SAE 10 W up toSAE 20 W can be used for lubrication of the mechanical seals. Withregard to disposal all general Government regulations must beobserved.

Attention Regional regulations have to be observed tothe extent that the oil does not contaminatethe pumped media (for example drinkingwater) and that safe disposal is guaranteed.Otherwise, it is not permitted to fill the pumpwith oil, but paraffin oil must be used for thispurpose.

7.2.5 Bearing and lubrication

The pump/motor shaft is supplied with grease-lubricated ballbearings.

7.2.6 Visual check of lifting chain / lifting rope

Maintenance checks to the pump should also include the liftingchain/lifting rope inclusive of fitting to the pump with regard topossible damage - caused either mechanically or chemically.Damaged parts must be replaced by manufacturer‘s original spareparts.This also refers to the correct fixing of the lifting chain/lifting rope tothe pump.

7.3 Drainage/Disposal

Attention If the pump has been used to pumphazardous media, care must be taken that,when draining the leakage liquid/oil filling,personnel and environment are notendangered. All government regulationshave to be observed.

7.4 Dismantling

7.4.1 Basic guidelines and instructions

All repair and maintenance work to the pump must only be carriedout by especially trained straff, and original replacement partsmust be used.

The safety precautions as outlined in paragraph 7.1 and 7.4.4 haveto be observed.

Dismantling and re-assembly may only be carried out in linewith the appropriate sectional drawing. The sectional drawingand other instructions are detailed in the appendix . Thedismantling sequence should be carried out as outlined in thesectional drawing.If there are any problems, please contact our servicedepartment for advice.

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Amarex KRTKSB

7.4.2 Preparing for dismantling

Prior to dismantling the oil chamber is to be emptied.

7.4.3 Dismantling the pump section

Dismantling the pump section is carried out as illustrated in thedrawing (Appendix ”General arrangement drawing”). Special toolsare not required. The only exceptions relate to the impellerdismantling/assembly process for the following sizes.

7.4.3.1 Special points relating to thedismantling of the impeller

The impeller/shaft connection is achieved by a parallel seat withlocating key. The impellers have been prepared to accept a specialimpeller withdrawing device. This can be purchased as a special toolfrom KSB.

Further details relating to procedures and references relating tospecial tools are outlined in the assembly instructions Appendix”Impeller mounting/dismantling ”.

7.4.3.2 Dismantling of mechanical seal

Exact instructions relating to fitting positions of the mechanical seals,either motor side or pump side, are outlined in Appendix”Mechanical seal with parts list”.

7.4.4 Dismantling the motor component

Please ensure, when dismantling the motor part and the electricconnecting cabling, that core identifications are clearly marked forfuture reference during re-assembly.

- Special points for version ” X ” explosionproof

All other work affecting the flameproofness, suchas new windings and mechanical repairs at themotor section, require a subsequent acceptancetest by an approved engineer or have to be carriedout at the premises of the manufacturer.

7.5 Re-assembly

7.5.1 General instructions

Assembly of the pump must be carried out in accordance with thecurrent mechanical engineering regulations. All parts which weredismantled must be cleaned and tested with regard to wear. Damagedor worn parts must be replaced by using manufacturer‘s spareparts. Ensure that all sealing surfaces are clean and the O-rings orflat seals fit perfectly. We recommend the use of O-rings/seals at alltimes.O–rings made from continuous strips which were gluedtogether must not be used.

Assembly of the pump takes place in reverse order of dismantling.The drawing combined with the individual parts index should be usedas a guide. All screws must be tightened during assembly as outlinedin the instructions. General instructions in this respect are outlined inthe table below ”bolt tightening torque” and special points arestated in the installation instructions.

Table ”Bolt tightening torque”

Thread Torque (Nm)A4-70 / 1.4462

M 5 4M 6 7M 8 17M 10 35M 12 60M 16 150M 20 290M 24 278M 27 409M 30 554

7.5.2 Special points relating to components for re-assembly

7.5.2.1 Mechanical seal

In principle, we recommend to use new manufacturer‘s spare parts formechanical seals. In this respect it should be noted:

To achieve perfect performance, it is important to ensure that all partsare immaculately clean and that greatest care is taken during thefitting of the mechanical seal. Protectors of the moving surfaces mustnot be removed until immediately before fitting the part. The surface ofthe shaft must be perfectly clean and undamaged.

In principle to assist with the fitting of the bellows mechanical seal, theinside of the bellows to avoid any damage to the mechanical sealshould be wetted with soapy water (do not use oil).

Attention: Fitting of the bellows mechanical seal at the motor end.

To avoid damage to the rubber bellows by a keyway or shaft recess,the shaft stub should be covered with a thin sheet of foil (approx.0.1...0.3 mm thick). Push the rotating unit over foil cover and placeinto fitting position. Then remove the foil.

7.5.2.2 Impeller assembly

Instructions and procedures are outlined in Appendix ”Impellermounting/dismantling ” and in paragraph 7.4.3.

7.5.2.3 Checking seals

After assembly the mechanical seal part/oil chamber should be testedfor leaks.

Procedure:

(Appendix ”General pump outline” Fig. 8)

The oil inlet tapping should be used to test for leaks.Securely screw the testing device into the oil inlet opening.

Test media: Compressed airTest pressure: max. 0.5 barTest duration: 2 min.

Make sure that the pressure does not decrease during the test.Afterwards, fill the oil chamber (compare para. 7.2.4).

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Amarex KRTKSB

7.5.2.4 Motor / electrical connections

Ensure prior to re-assembly of explosionproof motors that all thespecial points outlined in paragraph 7.4.4 were observed.All motors must be tested electrically in line with paragraph 6.1, 6.2and 7.2.

7.6 Stockkeeping of spare parts

Always quote the following data when ordering spare parts:

Pump type: e.g. KRTF 100-401/504XG-390Works-No./ Identity-No.Motor-No.

fill in

This data can be taken from the nameplate (appendix ”Generalpump diagram” Fig. 1)

7.6.1 Recommended stock of spare parts for a two–year operation in accordance with VDMA 24296(applicable for continuous operation)

Part–No.

Part description Number of pumps(including stand-by pumps)2 3 4 5 6 8 10

andmore

80-1 Part motor - - - 1 1 2 3834 Cable entry 1 1 2 2 2 3 40%818 Rotor - - - 1 1 2 3230 Impeller 1 1 1 2 2 3 30%502 Wear ring 2 2 2 3 3 4 50%433.01 Mechanical seal

motor side2 3 4 5 6 7 90%

433.02 Mechanical sealpump side

2 3 4 5 6 7 90%

321.01/322

Grooved ballbearingmotor side

1 1 2 2 3 4 50%

320/321.02

Grooved ballbearingpump side

1 1 2 2 3 4 50%

Set of joint rings(gasket)motor

4 6 8 8 9 10 100%

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Amarex KRTKSB

8. Trouble-shooting

Cause Remedy:Prior to carrying out work to the pressure containingparts - release pressure from the pump!Disconnect power supply to the pump.

Pump delivers against excessively high dischargepressure

Open discharge valve further until duty point isreached

Valve in discharge pipe not fully open Open gate valve completelyPump not running within operating limits Check operating data of the pump

Pump and/or pipeline are not completely vented orprimed

Vent - by lifting the pump off the duckfoot bend andlowering it back again.

Pump inlet blocked by deposits Clean inlet, pump parts and non return valveInlet pipe or impeller blocked - rotor running sluggishly Remove deposits from within the pump and/or

pipelinesDirt/fibres in impeller chambers Check impeller ensuring that it rotates slightly - if

necessary clean hydraulicWear of internal pump parts Replace worn partsDamaged column pipe (pipe and seal) Replace defective column pipe

Renew sealsUnacceptable air or gas content within the pumpedmedia

Contact your nearest authorized KSB agent

Oscillations caused by plant Contact your nearest authorized KSB agentWrong direction of rotation Switch two phases of the circuit cablingInsufficient operating voltage Check electric supply

Check cable connectionsMotor not running due to no voltage supply Check electrical installation

Inform electrical companyMotor running on two phases only Replace defective fuses

Check electric cable connectionsMotor winding or electric cable defective Replace by new original KSB cabling or contact your

nearest authorized KSB agentRadial bearing in the motor defective Contact your nearest authorized KSB agentWith star delta connection - Motor only running in starposition

Check star delta connection

Water level dropping excessively during operation Check supply and capacity of system - (sump depth)check level control

Temperature monitor for winding control has ceased tooperate due to excessively high winding temperature

The motor will switch on automatically after coolingdown

Thermistor release unit without automatic restartfacility for temperature limit (flameproof) has beenreleased due to exceeding the permissible windingtemperature

Check the pump

Moisture protection relay has been released due tomoisture within the motor

Check the pump

Attention: If working inside the pump is necessary whilst the pump is under warranty, then contact yournearest authorized KSB agent prior to commencement of work. Non-observance will negate anywarranty claims.

Unit not pumping Pump delivers insufficiently

Current/power consumption too high Head too low Pump operation is uneven and noisy

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Amarex KRTKSB

9. Appendix Page

• General Pump Outline 16

• General arrangement drawing with parts list 19

• Installation plan mechanical seal with parts list 22

• Dimension tables 24

• General outline - installation set 26

• General arrangement drawing Wet-well installation - guide cable with parts list 27

• Wet-well installation - transportable with parts list 29

• Electrical connection diagrams 31

• Operational diagram moisture monitoring 32

• Assembly instructions Impeller mounting/dismantling device 33

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Amarex KRTKSB

General pump outline Amarex KRTDN 100...DN 300Motor23 4...65 4; 20 6...50 6;10 8...21 8

Diagram nameplate

explosionproof version

Works No. / Identity No.

Works No. / Identity No.

Important information for ordering spare parts

Motor No.

Motor No.

Identity No ofexplosionproof certificate

Pump type

Pump type

Fig. 1

17

Amarex KRTKSB

Fig. 2aFig. 2b

903.03411..03

Oil-priming plug

903..05411..05

Oil-drain plug

Fig.3

B

Fig. 4

B

A

A

81-29.02

81-29.02

Fig. 5

18

Amarex KRTKSB

Fig. 6

Fig. 7

Fig. 8

19

Amarex KRTKSB

General arrangement drawing 100-401Motoren: 23 4...65 4 150/151-401

20 6...50 6 200-33010 8...21 8 200-401

250-370250-401300-380300-381

OW 382 429-00

20

Amarex KRTKSB

Part No. Part description59-17 Shackle811 motor casing81-59 Stator101 Pump casing163 Discharge cover230 Impeller260 Impeller hub cap321 Radial ball bearing322 Radial roller bearing330 Bearing bracket411 Gasket412 O-ring421 Radial shaft seal ring433 Mechanical seal502 Casing wear ring550 Washer818 Rotor834 Cable duct900 Screw902 Stud903 Screwed plug914 Socket head cap screw920 Nut932 Circlip940 Key

21

Amarex KRTKSB Amarex KRTKSB

Installation plan - mechanical seal Amarex KRT

Motor: 23 4...65 4, 100/150/151-40120 6...50 6, 200-33010 8...21 8 200-401

250-370250-401300-380300-381

Part No Part description433 Mechanical seal550 Washer932 Circlip

433.02

433.01

550.03

932.03

433.02

550.44

Special mechanical seal

Standard-mechanical seal

22

Amarex KRTKSB

Dimension table Amarex KRT 100-401/150-401/151-401

Stationäre AufstellungStationary InstallationInstallation stationnaire

Transportable AufstellungTransportable InstallationInstallation transportable

1) tiefster Ausschaltpunkt bei AutomatikbetriebLowest shut-off point for automatic operationPoint d’ arret le plus bas en service automatique

2) Mindestüberdeckung bei DauerbetriebMinimum covering for continuous operationRecouvrement minimal pour service continu

Maße in mm 0W 382 433-00Dimensions in mmCotes en mm

23

Amarex KRTKSB

Dimension table Amarex KRT 200-330/200-401





Maße in mm 0W 382433-00Dimensions in mmCotes en mm

24

Amarex KRTKSBDimension table Amarex KRT 250-370

250-401300-380300-381





Maße in mmDimensions in mmCotes en mm

0W 382 434-00

25

Amarex KRTKSB

General outline-installation set

26

Amarex KRTKSB

Wet-well installation with guide cable Amarex KRT DN

Motor: 23 4, 29 4, 35 4, 50 4, 65 4 100 / 150 / 200 / 250 / 30020 6, 26 6, 32 6, 40 6, 50 610 8, 17 8, 21 8

99-6

902.35920.35

Motor:35 4...65 622 6...50 6 59-17

90-3.38

Epoxy resin tarcoating

Counter nut

Standard Standard variants

27

Amarex KRTKSB

0W 380772-00

Z V

900.38

72-1

59-24.01

0W 380772-00

K 250-370K 250-401K 300-380K 300-381

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Amarex KRTKSB

Part No. Part description59-17 Shackle59-18 Hook59-24.01/02 Rope72-1 Flanged bend90-3 Dowel99-6 Round cord550 Washer553 Thrust insert571 Clamp572 Clamp732 Holder885 Chain894 Bracket900 Screw901 Hexagon head bolt902 Stud904 Threaded pin914 Socket head cap screw920 Nut

29

Amarex KRTKSB

Wet-well installation transportable Amarex KRT DN

Motor: 23 4, 29 4, 35 4, 50 4, 65 4 100 / 150 / 200 / 250 / 30020 6, 26 6, 32 6, 40 6, 50 610 8, 17 8, 21 8

914.26

920.26

0W 309307-00

Motors35 4, 50 4, 65 432 6, 40 6, 50 6

59-17

914.26920.26

88559-24.0259-17

Z

Z

Epoxy resin tar coating

88559-24.02

88559-24.02

Motors23 4, 29 420 6, 26 610 8, 17 8, 21 8

902.04920.04182

59-17

30

Amarex KRTKSB

Part No. Part description182 Foot59-17 Shackle59-24 Rope885 Chain902 Stud914 Socket head cap screw920 Nut

31

Amarex KRTKSB

Description - Thermal cutout Amarex KRT,explosionproof

With explosionproof motors, the windings are protected by twoindependent temperature monitoring circuits.Two bimetal switches F4, F5 (identification tape 21,22) serve astemperature monitoring devices which, as soon as the max. windingtemperature is reached, switch off the pump and automatically onagain after the windings have cooled down.This requires that the conductors are directly connected to thecontrol circuit of the motor contactor.Three PTC thermistors R1, R2, R3 (identification tape 10, 11) arefitted as additional temperature controlslimiters which, in the event oftemperature switch failure, shut down the pump before thetemperature permissible for explosionproof applications is exceeded.Automatic reset is not allowed.A thermistor control unit „T“ with manual reset must be installed inthe control circuit of the motor contactors.This equipment is of a commercial brand, which can also bepurchased via KSB.

For operation with frequency converter, a release device bearing thetest mark „PTB 3.53-PTC/A“ must be used.

If the pump has been shut down by thermistors, it is necessary tooverhaul it.In urgent cases the reset may be used after the motor has cooleddown. The thermistor must not be shut off at any time.

Explosionproof requirements for the pumps are onlymet if the built-in temperature monitoring devices(bimetal switches and thermistors) includingconductors 21, 22, 10, and 11 are connected.

Temperature switchF4, F5 = Monitoring circuit = 2 bimetal switches in the motor

windingIdentification tape 21, 22max. operating voltage of switch: 250 Vmax. current: 2 A

R1,R2,R3 = Temperature control circuit = 3 PTC thermistors in the motor windingIdentification tape: 10, 11max.operating voltage on terminalsUmax = 30 V =resistance between terminals 10/11- at ambient temperature R 100-750 Ω- at shutdown temperature R > 4000 Ω

AttentionDo not test monitoring circuits by means of ahand megger. Use an ohmmeter.

Description - thermal cutout Amarex KRT, non-explosionproof

The winding is protected by one temperature monitoring circuit.

Bimetal switches F4, F5 (identifications tape 21,22) are used fortemperature monitoring. It switches off the pump as soon as themax. winding temperature is reached, and automatically switches iton again after the winding has cooled down.

The bimetal switch must be directly connected to the control circuitof the motor contactor.Conductors 10 and 11 (used for explosionproof version only) will beconnected to dummy terminals.

Electrical diagram

Motor: 23 4, 29 4, 20 6, 26 6, 10 8, 17 8, 21 8

Motor version X, Y

Motor version U, W

32

Amarex KRTKSB

Electrical diagram

Motor: 35 4, 50 4, 65 4, 32 6, 40 6, 50 6

Description - Thermal cutout Amarex KRT,explosionproof

With explosionproof motors, the windings are protected by twoindependent temperature monitoring circuits.Two bimetal switches F4, F5 (identification tape 21,22) serve astemperature monitoring devices which, as soon as the max. windingtemperature is reached, switch off the pump and automatically onagain after the windings have cooled down.This requires that the conductors are directly connected to thecontrol circuit of the motor contactor.Three PTC thermistors R1, R2, R3 (identification tape 10, 11) arefitted as additional temperature controls/limiters which, in the eventof temperature switch failure, shut down the pump before thetemperature permissible for explosionproof applications is exceeded.Automatic reset is not allowed.A thermistor control unit „T“ with manual reset must be installed inthe control circuit of the motor contactors.This equipment is of a commercial brand, which can also bepurchased via KSB.

For operation with frequency converter, a release device bearing thetest mark „PTB 3.53-PTC/A“ must be used.

If the pump has been shut down by thermistors, it is necessary tooverhaul it.In urgent cases the reset may be used after the motor has cooleddown. The thermistor must not be shut off at any time.

Explosionproof requirements for the pumps are onlymet if the built-in temperature monitoring devices(bimetal switches and thermistors) includingconductors 21, 22, 10, and 11 are connected.

Temperature switchF4, F5 = Monitoring circuit = 2 bimetal switches in the motor

windingIdentification tape 21, 22max. operating voltage of switch: 250 Vmax. current: 2 A

R1,R2,R3 = Temperature control circuit = 3 PTC thermistors in the motor windingIdentification tape: 10, 11max.operating voltage on terminalsUmax = 30 V =resistance between terminals 10/11- at ambient temperature R 100-750 Ω- at shutdown temperature R > 4000 Ω

AttentionDo not test monitoring circuits by means of ahand megger. Use an ohmmeter.

Description - thermal cutout Amarex KRT, non-explosionproof

The winding is protected by one temperature monitoring circuit.

Bimetal switches F4, F5 (identifications tape 21,22), are used fortemperature monitoring. It switches off the pump as soon as themax. winding temperature is reached, and automatically switches iton again after the winding has cooled down.

The bimetal switch must be directly connected to the control circuitof the motor contactor.Conductors 10 and 11 (used for explosionproof version only) will beconnected to dummy terminals.

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Amarex KRTKSB

Operational diagram - Moisture monitoring

Motor chamber / moisture detection(see also „Electrical diagram“)

If moisture penetrates into the motor chamber, first of all, a currentwill be flowing from terminal 9 to earth via the built-in moistureelectrode. This leads to the triggering of the Fl fault currentprotective switch fitted for monitoring the moisture electrode.The K4 auxiliary relay will drop and switch off the motor contactor.This switching does, however, not represent a fault currentmonitoring according to VDE 0100 / IEC 364.After tripping the moisture monitoring the pump will have to beoverhauled.

Check of the moisture electrode

An insulation resistance test acc. to 7.2.1 has to be carried out.If the insulation resistance is < 5 MΩ , the motor has to be opened,inspected and overhauled.After dismantling the pump restore or replace the moisture sensor.To restore the sensor dry it in an oven for about 1 hour at120 °C.Thereafter, soak it in transformer oil.

WE RECOMMEND FITTING A NEW MOISTURE SENSOR INTHE EVENT OF DAMAGE.

B2 = Moisture transmitter (electrode) inside the motor spaceIdentifications tape: 9Operating voltage 110...250 V-a. c.Nominal fault current 30-50 mA

F1 = Fault current protective switch

K4 = Auxiliary relay

Motor chamber / moisturedetection(see also „Electrical diagram“)

If water penetrates into the motor chamber, the built-in float switchwill open its contact. This will release an alarm or switch the motoroff.

B 3 = float switch (break contact)core identification 3, 4

nominal operating voltage 230 V ∼nominal operating current 1 Abreaking capacity 100 VA

M∼

B3B 2

34

Amarex KRTKSB

Mounting/dismantling of impeller

Tools required:

Dismantling device Identity-No. 19 138 913

Offset screwdriver Identity-No. 00 588 089DIN 911

Necessary tools are to be taken from table„Mounting/dismantling device“.The impeller is mounted/dismantled by using thespecial device illustraded in Fig. 2.

Dismantling

1. Loosen impeller fixation according to the appertainingappendix „General drawing“.

Fig. 1 Unscrew impeller screw 914.10 and removeimpeller hub cap 260.

Dismantling the impeller Fig. 2b

2. Impeller 230 is removed by means of themounting/dismantling device.For this purpose, screw hex. bolt, part 4, into shaftend to avoid damage to the shaft thread.

Fit special impeller mounting/dismantling device byscrewing in part 2.After that, screw down threaded bolt, part. 1, andremove impeller.

Assembly Fig. 2a

1. Screw part 1of the impeller mounting device into theshaft end of the pump unit in order to mount impeller230.

2. After that, fit part 2 by screwing it down onto thethreaded bolt part 1.

3. Mount impeller fixation according to fig.1/2.

Assembly instructions - Impeller mounting/dismantling device Amarex KRT100 / 150 / 151-401200-330200-401250-370/401300-380/381

Fig. 1

230914.10 260

35

Amarex KRTKSB

Amarex KRTKSB Amarex KRT

KSB AktiengesellschaftIndustry and Water Engineering PumpsP. O. Box 200743 D-06008 Halle (Saale) . Turmstraße 92 D-06110 Halle (Saale)Tel. (+49) 3 45 48 26-0 Fax (+49) 3 45 48 2646 99 . Telex 465211 ks d . http://www.ksb.de

KSB

2553

.804

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Amarex KRT8041e