krt-operatinginstructionscaev

Operating manual2553.804/6-14 KRT

Submersible motor pumps

KRTSeries

DN 40...DN 2002...8

Size

5 2...23 2 (2pol.)5 4...29 4 (4pol.)4 6...26 6 (6pol.)Motor size

G, GH, HC1, C2

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 instructions relatingto the components of this plant will also have to be observed.

Ident-No. 01 056 818

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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This operating manual contains important notes for the individualmaterial versions of the below sizes:

Type size Material version

S,F,E, K =Impeller type Cast iron

G G1 G2 GH

S, K 40 - 250 S, K K -- K

E 80 - 251 E -- -- --

K 80 - 315 K K -- K

F 100 - 250 F F F F

E, K 100 - 251 E K -- K

F, K 100 - 316 F, K F, K F F, K

F, E, K 150 - 315 F, E, K F, K F F, K

K 200 - 280 K K -- K

K 200 - 281 K --

Type Size Material versionF, K =

impeller type Industrial materialH C1 C2

K 40 - 250 K K K

K 80 - 315 K K K

F 100 - 250 F F F

K 100 - 251 K K K

F, K 100 - 316 F, K F, K F, K

F, K 150 - 315 F, K F, K F, K

F, K 200 - 280 K K 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 3

of safety instructions2.4 Safe working methods 32.5 Safety instructions for operators 32.6 Safety instructions during maintenance, 3

inspection and installation2.7 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 5

of the installation5.3 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 maintnance 97.1 General instructions 97.2 Service / Inspection 107.3 Drainage / Disposal 117.4 Dismantling 117.5 Re-assembly 127.6 Spare parts 13

8. Trouble-shooting 14

9. Appendix 15

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1. GeneralThis KSB pump has been developed with the latest technology, itwas manufactured with great care and is subject to constant qualitycontrol.The operating manual is designed to introduce the pump to you andto make operation easier and to make full use of all its applications.The operating manual contains important information to ensure safe,correct and economic operation. It is imperative to observe thecontents 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 by anyhired installation staff.This pump must never be operated outside the limits laid down in thetechnical documentation with regard to pumped media, rate of flow,speed, density, pressure and temperature, including motor rating orcontrary to any other instructions stipulated in the operating manualor contract documentation.The nameplate states series / size, the most important operatingdata and the Works No. / Serial No., which must always be statedwhen making inquiries, 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 KSB.

2. SafetyThis 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 fitter andrelevant 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, butas well any other notes regarding safety included in the manual.

2.1 Identification of symbols used within theoperating manual

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

Calling attention to electric current with

Safety instructions relating to situations where non-observance coulddamage the machine and its functions are identified with the word

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 trainingOperators, as well as service, inspection and assembly personnelmust have the appropriate skills to carry out such work. Area ofresponsibility, allocation and supervision of the personnel must becontrolled by the operator. Should the personnel not have therequired knowledge, training must be arranged. If required, theoperator can arrange such training to be carried out by KSB. Theoperator must also ensure that the instruction manual is fullyunderstood by the personnel.

2.3 Dangerous practices non-observance of safetyinstructions

Non-compliance with the safety instructions can endanger peopleslives, 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 prevent accidents,and also any inter-company working, operating and safetyregulations.

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 movable partsmust 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 pumping dangerous media must be decontaminated.Once maintenance work is completed, all safety equipment must bereinstated 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 after authorizationhas been obtained from the manufacturer. Original spare parts andancillary equipment supplied by the manufacturer provide safety.Installation of any other equipment cancels the guarantee for anypump failure which occurs as a result of installing non-manufacturersparts.

2.8 Impermissible modes of operationOperating safety of the equipment is only guaranteed if all operatinginstructions as outlined in paragraph 1 - General - are observed. Thelimits given in the data sheet must under no circumstances beexceeded.

3. Transport and interim storageThe chain or lifting wire which is suppliedmust only be used for lifting the appropriatepump unit. General use for lifting heavyloads is not permitted.

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 attaching thelifting chain.

3.2 Storage and ConservationThe procedure has been outlined in paragraph 6.3 Shutdown.

4. Description of pump4.1 General descriptionKSB submersible pumps are close-coupled units which are non-self-priming. The impellers in these pumps can vary, depending on theimpeller 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 dataIdentification can be found on the nameplate, which is fitted to themotor.

4.3 Construction

4.3.1 DriverKSB submersible pump sets are supplied with three-phaseasynchronous motors complete with connecting cable.Electrical data in compliance with the nameplate. Starting methodstandard: direct.

4.3.1.1 Motors in explosionproof designIn accordance with NEC 500:Class I, Division I, Group C & D.

4.3.2 Shaft sealThe shaft seal consists of a mechanical seal which is independent ofthe direction of rotation at pump and motor end. The oil chamberwhich is fitted between the two mechanical seals ensures cooling andlubrication.

4.3.3 Bearing assemblyAll sizes are fitted with grease-lubricated, maintenancefree deepgroove anti-friction bearings.

SeriesImpeller type (E,F,K,S)

Hydraulic sizeMotor size

Impeller diameter

KRT F 100-250 / 11 4 X G - 238

Number of poles

E = single-vane impellerF = free-flow impellerK = non-clogging impellerS = with cutter

Motor version (U, W, X, Z)U = standard versionW = warm water versionX = explosionproof standardZ = explosionproof warm water

G = Pump complete in castG1 = GG Pump with impeller in duplex steel A 743 CD 4 MCU (1.4517)G2 = GG Pump with impeller in chilled casting A 532 II C 15 %

CrMo-Hc (0.9635)GH = GG Pump with impeller and discharge cover

in chilled casting A 532 II C 15 % CrMo-Hc (0.9635)H = Pump manufactured in chilled casting A 532 II C 15 %

CrMo-Hc (0.9635)C1/C2 = Pump manufactured in duplex steel A 743 CD 4 MCU

2-pole4-pole6-pole

Material combination(G, G1, G2, GH/H, C1/C2)

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4.3.4 Impeller type

4.3.5 Installation methods- stationary wet-well installation- transportable 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 equipmentRecommended equipment is described in appendix Electricalconnection diagrams.Any information relating to other ancillary equipment will be given byour Sales Office.

5. Assembly/Installation5.1 Safety regulations

It is not permitted for any person to enter thetank during operation of the pump unlessspecial safety precautions have been taken inaccordance with current 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 concrete foundations should be sufficientlystrong (min. 3000 psi) to ensure a secure and functionally correctinstallation in compliance with DIN 1045 or equivalent standard.Concrete foundations must have set before installation of the unit. Itssurface must 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 inparagraph 6.1 have to be checked in sequence. A separatenameplate stating pump and motor data is supplied within the scopeof supply. This nameplate must be fixed in a clearly visible positionoutside the tank (for example switch panel, pipework, mountingbracket).

5.3.1 Checking of operating dataA 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 the factury.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.

Attention Under 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 thatthe pump does not come under undue stress due to pipeline forcesand torques.

Excessive pipeline forces can causeleakages of pumped media for example.Toxic and hot media can endanger life.

When emptying objects on a lower level, a non-return valve shouldbe fitted into the discharge pipe to avoid backflow from the 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.

Cutter (S) for faeces, domestic sewage andsewage containing long fibrous admixtures

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

Single-vane impeller (E-impeller) for pumpingliquids 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 fibers liable to twistand bunch.

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5.5 Electrical connection

The electrical connection must be carried outby a trained electrician and in compliancewith local regulations.The voltage must comply with the voltageindicated on the nameplate.

Electrical installation must be in accordance with the appendixElectrical 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 colorimprints. In such a case, remove the core marking and reaffix itafterwards.

Attention When laying a conduit between thepump station and the electrical switchgear,additional control cable (min. 1.5 mm2) mustbe installed for pump monitoring equipment.Adjust cores to suit requirement.

5.5.1 Monitoring equipmentThe 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 Fitting of electric cabling

Attention After 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. 4) we recommend usingcable socks, which can be supplied for additional cost (paragraph4.4). Slack installation of cables could cause damage to the electriccabling when the pump is operating.

Fitting of cable protection sheath:

If a protection sheath is included in the scope of supply for theelectric cabling, it has to be fitted according to the instructions givenin the supplementary operating manual Assembly of protectionsheath.

5.5.3 Overcurrent relayThe motor must be protected against overloading by a thermallyretarded overcurrent relay to comply with NEC and regulations whichare in accordance with local requirements. This must be adjusted tothe nominal motor current indicated on the nameplate.

5.5.4 Level control switchPumping 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.

5.5.5 Checking of the direction of rotation

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

Attention The 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 thatthere are no foreign objects within the pumpcasing.Never put hands or any objects into thepump.

Attention The running time should be as short aspossible (max. 3 minutes).Correct direction of rotation:

If the right phase sequence of the circuit is known, the correctdirection of rotation will occur automatically, providing the instructionsin 5.5 have been carried out correctly (rotating of the motor to theleft).The direction of rotation is checked by short starts and observationsof the impeller.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. 5).

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

5.5.6 Connection of a potential equalizerFor potential equalization use the external connection terminal at thecable entry.(Appendix General pump outline Fig. 3).

Special requirements for chemically corrosive media:Do not use the outside terminal if the unit is used for chemicallycorrosive media.

Instead, the potential equalizer 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 thenewly created potential equalizer and the pump.(Appendix General pump outline Fig. 4).

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5.6 Assembly kit installationThe following assembly kits are available for assembly / installationof the KRT pump unit.

5.6.1 Stationary wetwell installation 5.6.2 Transportable installation

5.6.1 Stationary installation with 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 thedischarge elbow which has been fitted to the bottom.The weight of the pump acts to seal the connection between pumpand discharge elbow. A profile gasket between the pump anddischarge elbow achieves a zero leakage, pressure-proof elasticconnection.Walking on the well is not permitted during inspection andmaintenance work.

5.6.1.2 Scope of supply for stationary wet-wellinstallation

Please refer to the appendix Wet-well installation.

5.6.1.3 Installation of pump with claw connectionUse appendix Wet-well installation 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 dischargeelbow during installation.

5.6.1.4 Fitting of the mounting bracket / dischargeelbow / guide cable

Construction of the base foundations should be sufficiently strong(min. 3000 psi) to ensure a functionally correct fixing of guide cableequipment and discharge elbow.

Refer to the drawing as illustrated in appendix Wet-wellinstallation 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 tables below.

All means of fixation are part of the scope of supply

For the bolt of the mounting bracket refer to appendixDimension 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.

3. The discharge elbow should be positioned and secured to thebase of the sump so that the tightened cable will run verticallylater on.Should construction / pipework etc. require the cable to run offthe vertical, then a maximum angle of 5o should be adhered to,thus ensuring safe fitting function.Securing of the dischargeelbow is carried out by using steel anchor bolts 90-3.38 orfoundation bolts 900.38 regardless of pump size or materialcombination. Refer to appendix Dimension tables andappendix Wet-well installation for details relating toappropriate fitting instructions and hole dimensions.

4. Insertion of cable 59-24.01 and fitting. Lift thrust plug and clampand insert one end of the cable. Lead the cable around thedischarge elbow 72-1 and back again towards the guide bracketand insert into clamp of thrust plug. Manually tension the cableand secure by using hexagonal 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 Guide cable tension toachieve sufficient cable tension. Subseqently secure by using asecond 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 hook 59-18 into the mounting bracket 894 toenable the lifting chain 885 or rope 59-24.02 to be attached at alater stage.

Table Bolt tightening torque: Steel anchor bolt

Size () (mm) Torque (Nm)10 1018 80

Table Bolt tightening torque: Foundation bolt

Size () ) (mm) Torque (Nm)12 2516 6520 125

Table Guide cable - tensionSize MA

(Nm)P

(N)40-250 100-316 14 6 00080-251 150-31580-315 200-280

100-250 200-281100-251

MA = tightening torqueP = cable tension

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5.6.1.5 Fitting of chain or lifting ropestationary wet-well installation

Installation of this equipment should be carried out in accordancewith the General pump outline, Fig. 1a by inserting the chain /lifting rope into the opposite the outlet branch. Further details can befound in Wet-well installation.

This type of fixing permits the fitting of the pump to the dischargeelbow.

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 thesupport piece 572. It is then attached to the guide cable and slowlylowered into the sump. Once the pump is lowered, it will attach itselfto the discharge elbow 72-1 and is then securely fixed to the outletpipe ready for use. Finally, attach the chain or rope to the hook 59-18on the mounting 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 DescriptionPumps for transportable installation are supplied with a pump stand.The outlet flange can be used for fitting either rigid or flexible piping.Examples for typical installation possibilities can be taken fromappendix General outline-installation set Fig. 2.Ancillary equipment can be requested and purchased from our salesoffices.

5.6.2.2 Components / extent of supply for transportable installation

For parts supplied and detailed illustration, see appendix Wet-wellinstallation - transportable.

5.6.2.3 Assembly kit installationPlease refer to drawing in appendix Wet-well installation -transportable 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 or lifting ropetransportable installation

Fitting of chain / lifting rope should be carried out as outlined inappendix Wet-well installation-transportable.Always use the slot which is fitted on the discharge side, seeappendix General pump outline Fig. 1b.

5.6.2.5 Installation of pumpTransportable installation permits to operate the pumps in differentlocations.For example, they can be used for:

draining minesthe emergency draining of canalspumping water out of rivers etc.

For such applications the pump must be installed in a verticalposition with the motor on the top and fitted to a firm base.

6 Start up / shut down

Attention It is important to follow these requirements.Any damage incurred as a result of noncompliance is not covered by the guarantee.

Attention Do 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 (see 5.3.1), oil level (see 6.1.1) and direction ofrotation (see 5.5.5).- Check that the installation of the electrical supply was carried outcorrectly in accordance with appendix Electrical connectiondiagrams.

Attention Temperature monitoring in the windingprotects the motor in case of insufficientcooling conditions. Reliable operation andexplosion protection can only be guaranteedif the circuits for temperature monitoringfunction properly.

- 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 checkProcedure according to appendix General pump outlineFig. 2. Remove screwed plug 903.03 with joint ring 411.03. Theminimum oil level must not fall short of measure M. If it is lower, fillthe oil chamber via feed opening until overflow. Regarding oil qualityand quantity, see point 7.2.4 (Oil change).Tighten screwed plug with joint ring again.

6.2 Limitations of the operating range

6.2.1 Minimum liquid levelThe 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. 6).

R = Lowest switch-off point for automatic operationM = 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 protectionagainst dry running by stopping the pump automatically (cut-offcontact, see 5.5.4).

Attention Dry running leads to increased wear (andtear) and should be avoided.6.2.2 Temperature of pumped media and

surroundingsThe maximum temperature is indicated on the nameplate. KRT .... version U 1), X: 104 F/ 40 C

KRT .... version W 1), Z: 140 F/ 60 C1) Can be operated up to 80C for a limited period (35 min. until the thermal protection equipment is activated).

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Attention Do not operate the equipment attemperatures higher than those indicatedabove, unless KSB has given writtenconsent. Damage caused due to nonobservance of this warning will not becovered by the guarantee.

6.2.3 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

6.2.4 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 7.2). 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.

6.2.5 Switching frequencyIn order to avoid overloading of winding, seals and bearings, thefollowing number of switching operations must not be exceeded:

Motor ratings up to 10 Hp: max. 30/hrMotor ratings up to 125 Hp: max. 20/hr5.000 switching operations per year as maximum.

6.2.6 Operating voltageThe maximum admissible deviation of the operating voltage amountsto 10% of the rated voltage. The maximum admissible voltagedifference between the single phases amounts to 1%.

6.2.7 Frequency converter operation

If frequency converters are used, the power output of the motor P2 islimited 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.The output frequency is limited at 60 Hz because of the risk ofoverloading the motor.For the possible speed range the following criteria have to beobserved:- Qmin and Qmax according to characteristic curve- minimum speed capable to carry solids- minimum flow velocity to fully open a non-return valve- inherent frequency ranges of tubes.

6.3 Shutdown / storage / preservationIf 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 special

attention to the area around the impeller wear ring. Spray oil throughinlet and outlet flanges. It is then recommended to protect the flanges(with plastic 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 periods1.The pump remains installed ready for operation whenrequired.

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

2. The pump is dismantled and storedPrior 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 storagePrior 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 and6.2 have to be observed.

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

7. Service and maintenance7.1 General instructionsThe 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-free and reliable operating of the pump.

Always disconnect all electricity supplies prior toworking on the pump. Safeguard the pump frombeing started accidentally. Otherwise, there will bedanger 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.All official regulations must be adhered to.

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7.2 Service/InspectionThe following points must be observed to ensure reliableoperation:

This work must only be carried out by experienced personnel!

Item Maintenancetasks

Maintenance tobe carried out atfollowing intervals

7.2.1 Insulation resistance check after every7.2.2 Visual inspection of electric cables 10,000 hours7.2.3 Check of monitoring equipment of use, or 3 years,7.2.4 Oil change whichever7.2.5 Visual check of lifting chain / rope comes first

General overhaul every 5 years

The pump/motor shaft is supplied with grease-lubricated for life ballbearings. They need no maintenance tasks.

7.2.1 Insulation resistance checkThe 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 atthe starting panel). The measurement should be taken by using amegger.- Measuring voltage: max 1,000 V d.c. voltage.

The measurements to be taken are:

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

b) Winding temperature sensor against ground- All winding ends be connected to ground (green-yellow core).

All cable ends of the winding temperature sensors must beconnected to one another. Otherwise the sensors will bedamaged.

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

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

Low reading of the insulation resistance values of the motorindicates that there is a fault in the winding. If this is the case, contactKSB.

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 protective earthing conductors. Measurement of theresistance between green-yellow cores and exposed metalsurface on pump. Resistance should be < 1 .

7.2.3 Checking the monitoring equipmentThe 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 .

b) PTCresistor sensor resistance measuring resistance between connection ends 10 and 11:100 < R < 750 .

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, thewinding must be replaced.

c) Moisture protection electrode

The motor area is being monitored by a moisture monitoringelectrode which is fitted into the motor area (Part No. 81-56). It is notalways fitted as standard. Core identification 9 will show whether ornot it has been 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 M. 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.

11

KRTKSB

7.2.4 Oil changeThe 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 operating hours,but at least annually.

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

Procedure

(Appendix General pump outline).

Erect the pump as shown in Fig. 7 and put a suitable container underthe plug. Unscrew screwed plug 903 with joint ring 411.03 and drainthe oil.

The oil is light in color 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.

RefillingErect the pump as demonstrated in Fig. 2 and fill the oil chamberwith oil until overflow (see also paragraph 6.1.1). Replace the plug903 and fit a new joint ring 411.03.

Oil quantity:

The quantity see table 7.2.4.1 Lubricating instructions

Recommended quality of oil:

Paraffinoil, free-flowing, Merkur Pharma 40, made by DEA,Duoprime 90 made by LYONDELL or equivalent,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.

7.2.4.1 Table Lubricating instructions

Size S, K 40-250 K 80-315E 80-251 F, K 100-316

F 100-250 F, E, K 150-315E, K 100-251 K 200-280

K 200-281Motor sizes

2-pole 5 2, 6 2, 8 2, 12 2,17 2 23 24-pole 5 4, 7 4,11 4, 16 4 23 4, 29 46-pole 4 6, 6 6, 9 6, 12 6 20 6, 26 6

Oil quantity: (l) 2,1 l 4,6 l 7,0 lFor recommended quality of oil, see paragraph 7.2.4

7.2.5 Visual check of lifting chain/lifting ropeMaintenance 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 manufacturers 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 regulations haveto be observed.

7.4 Dismantling

7.4.1 Basic guidelines and instructionsAll repair and maintenance work to the pump must only be carriedout by trained straff, and original replacement parts must beused.

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.

12

KRTKSB

7.4.2 Preparing for dismantlingPrior to dismantling the oil chamber is to be emptied.

7.4.3 Dismantling the pump sectionDismantling the pump section is carried out as illustrated in thedrawing (appendix General arrangement drawing with part list).Special tools are not required. The only exceptions relate to theimpeller dismantling/assembly process for the following sizes.

7.4.3.1 Special points relating to the dismantling of theimpeller

- Size: KRT S 40-250

see Appendix Impeller dismantling/assembly with cutter

40-250 100-250 100-25180-251 100-316 150-315

Sizes:KRT

80-315 200-280 200-281

The impeller/shaft connection is made by using a cone seat/taperedseat. Appendix Impeller dismantling/assembly with taperconnection.

7.4.3.2 Dismantling of mechanical sealExact instructions relating to fitting positions of the mechanical seals,either motor side or pump side, are outlined in appendixMechanical seal with parts list.

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

Special points for explosionproof.

All other work affecting the flameproofness,such as new windings and mechanical repairsat the motor section, require a subsequentacceptance test by an approved engineer orhave to be carried out at the premises of themanufacturer or factory certified repair center.

7.5 Re-assembly

7.5.1 General instructionsAssembly 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.Damaged or worn parts must be replaced by using manufacturersspare parts. Ensure that all sealing surfaces are clean and the O-rings or flat seals fit perfectly. We recommend the use of O-rings/seals at all times.O-rings made from continuous strips whichwere glued together 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)A 276 Type 316 Ti (A4-70) /

A 276 S 31803 (1.4462)M 5 4M 6 7M 8 17

M 10 35M 12 60M 16 150M 20 290

7.5.2 Special points relating to components for re-assembly

7.5.2.1 Mechanical sealIn principle, we recommend to use new manufacturers spare partsfor mechanical seals. In this respect it should be noted:

To achieve perfect performance, it is important to ensure that allparts are immaculately clean and that greatest care is taken duringthe fitting of the mechanical seal. Protectors of the moving surfacesmust not be removed until immediately before fitting the part. Thesurface of the shaft must be perfectly clean and undamaged.

In principle to assist with the fitting of the bellows mechanical seal,the inside of the bellows should be wetted with soapy water (do notuse oil).

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 assemblyInstructions and procedures are outlined in appendix Impellermounting/dismantling device and in paragraph 7.4.3.

7.5.2.3 Checking sealsAfter assembly the mechanical seal part oil chamber should betested for 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).

13

KRTKSB

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

7.6 Spare parts

Always quote the following data when ordering spare parts:

This data can be taken from the nameplate.

Pump type:e.g. KRTF100-250/114XG-238Works-No./Identity-No.Motor-No.

fill in

14

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 is reached

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 restart facilityfor temperature limit (flameproof) has been releaseddue to exceeding the permissible winding temperature

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 your nearest authorized KSB agent prior to commencement of work. Non-observance will negate any warranty claims.

Unit not pumping Pump delivers insufficiently Current/power consumption too high Head too low Pump operation is uneven and noisy

15

KRTKSB

9. Appendix Page

General pump outline 16

General arrangement drawing 18

Installation plan - mechanical seal 21

General outline - installation set 23

General arrangement drawing - Wet-well installation with guide cable 24

- Wet-well installation transportable 26

Dimension tables 28

Electrical connection diagrams 38

Operational diagram - Moisture monitoring 40

Assembly instructions - Impeller dismantling/fitting with tapered connection 41

- Cutter 44

16

KRTKSB

General pump outline DN 40...DN 300Motor5 2...23 2;5 4...29 4;4 6...26 6

Fig. 4

B

A B

Fig. 1a Fig. 1b

Motor:23 2,23 4, 29 420 6, 26 6

903411.03

Fig. 2

M=70

A81-29.03A

81-29.02

Fig. 3

Motor:5 2, 6 2, 8 2,12 2,17 25 4, 7 4,11 4, 16 44 6, 6 6, 9 6,12 6

A

903411.03

M=25

17

KRTKSB

Motor:23 223 4, 29 420 6, 26 6

Motor:5 2, 6 2, 8 2, 12 2, 17 25 4, 7 4, 11 4, 16 44 6, 6 6, 9 6, 12 6

Fig. 8

Fig. 7

Fig. 5

Fig. 6

P

7.25 psi (0.5 bar)

18

KRTKSB

General arrangement drawing 40-250 80-251

Motor: 5 2...23 2; 80-3155 4...29 4; 100-2504 6...26 6 100-251

100-316150-315200-280200-281

OW 382 461-00

G, GH, H Motor: 5 2, 6 2 5 4, 7 4 4 6, 6 6

* if present

19

KRTKSB

if present

20

KRTKSBs=

0.2

0.1

mm

Part-No. Part description23-7 Impeller body80-1 Submersible motor81-17 Butt joint81-44 Clamp81-56 Moisture protection of motor81-59 Stator99-17 Desiccant101 Pump casing113 Intermediate casing131 Inlet ring162 Suction cover163 Discharge cover230 Impeller321 Radial ball bearing322 Radial roller bearing330 Bearing bracket410 Profile joint411 Gasket412 O-ring

421 Radial shaft seal ring433 Mechanical seal441 Seal casing500 Ring502 Casing wear ring503 Impeller wear ring529 Bearing sleeve550 Washer561 Grooved pin811 Motor casing818 Rotor834 Cable duct900 Screw901 Hexagon head bolt903 Screwed plug914 Socket head cap screw920 Nut930 Safety device931 Lockwasher932 Circlip

S 40-250321 02

21

KRTKSB

Installation plan - mechanical seal 40-250, 100-250

Motor: 5 2...17 2,5 4...16 4

Part No. Part description433 Mechanical seal515 Clamping ring

29

H, C2 G, GH, C1

GLRD HJ

StandardStandard variants

G, GH, C1

433.02

433.02

515

433.01

515

433.01

0W309130-00

0W309130-00

22

KRTKSB

Installation plan - mechanical seal

Motor: 5 2...23 2, 80-251 / 80-315 / 100-251 / 100-316 / 150-315/5 4...29 4, 200-280, 200-2814 6...26 6

Part No. Part description433 Mechanical seal515 Clamping ring932 Circlip

Standard Standard variants

G, GH, C1

0W309131-05

932.03( =55)515 ( =33)

433.02

433.01

H, C2

433.02

0W309131-05

23

KRTKSB

General outline - installation set

24

KRTKSB

Wet-well installation with guide cable KRT DN

Motor: 5 2...23 2, 40 / 80 / 100 / 150 / 2005 4...29 4,4 6...26 6

99-6

902.35920.35

90-3.38900.38

Epoxy resin tarcoating

Counter nut

StandardStandard variants

0W 380 772-00 G, GH, H, C1 C2

25

KRTKSB

Part No. Part description59-17 Shackle59-18 Hook

59-24.01/02 Rope72-1 Flanged bend90-3 Dowel99-6 Round cord410 Profile joint550 Washer571 Clamp572 Clamp732 Holder885 Chain894 Bracket900 Screw902 Stud904 Threaded pin914 Socket head cap screw920 Nut970 Plate

26

KRTKSB

Wet-well installation transportable KRT DN

Motor: 5 2...23 2, 5 4...29 4, 4 6...12 6 40 / 80 / 100 / 150 / 200

StandardStandard variants0W 309308-00

Epoxy resin tar coating

27

KRTKSB

Part No. Part description182 Foot183 Support foot59-17 Shackle59-24 Rope595 Buffer885 Chain892 Foot plate901 Hexagon head bolt902 Stud914 Socket head cap screw920 Nut932 Circlip

40-250 (G...H)80-251 (G),80-315,100-250, 100-251

100-316, 150-315

80-315, 100-250, 100-251, 100-316, 150-315

1) Lowest shut-off point for automatic operation1) Point d arrt le plus bas en service automatique1) Nivel minimo de parada en operacin automtica1) Menor ponto de shut-off com operao automtica

AA

1)

C

B

B

1)DN2

DN3

A - A

5 7 (C2)

60

165 Cm

in.

450

N min

d

175

O min

1010

0

k1

153b1

e1

18

l1

150

85

260

110

300

DN1

300

240

22020

40300

150

200

Z

C 2

170

V 70

50

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

85

200

zf x lf

gfKfDf

DN2/DN3

KRT

28

Dimension tableSize: 40-250

Permanent installation Portable installationInstallation stationnaire Installation transportableInstalacin fija Instalacin porttilInstalao fixa Instalao mvel

Transportable -- DIN 2501, PN 16Flange/Bride/Brida [mm]

DN2 gf Kf Df zf lf40 88 110 150 4 18

Stationary -- ANSI B 16.1Class 125

Flange/Bride/Brida [mm]

DN3 gf Kf Df zf lf50 92 121 152 4 19

zf = number of holes

Dimensions/Cotes/Dimensiones/Dimenses [mm] WeightKRT .../... [kg]

DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*40-250/ 6 2 65 545 685 555 445 345 448 225 100 670 780 600 400 200 133 175/

8 2 (only (C1= (C1= 142 18412 2 K) 575 715 540) 270) 157 20417 2 168 2155 4 545 685 136 1787 4 150 192

11 4 575 715 160 202

0W 382 514--00 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

zf x lf

gfKfDf

DN2/DN3A - A

3/16 5/16 (C2)

2 3/8

6 1/2 Cm

in.

N min

173

4/

d

67

8/

O min

3/8

378/

k1

6 1/16b1

e1

11/16

l1

5 7/8

3 3/8 3 3/8

101

4/

43

8/7

78/

117

8/

DN1

117

8/

91

2/

8 11/1613/16

1 9/1611 7/8

57

8/

77

8/

Z

C 2

63

4/

V 2 3/4

2

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

KRT

29



Transportable -- DIN 2501, PN 16Flange/Bride/Brida [inch]

DN2 gf Kf Df zf lf1 1/2 3 1/2 4 5/16 5 7/8 4 11/16


Flange/Bride/Brida [inch]

DN3 gf Kf Df zf lf2 3 5/8 4 3/4 6 4 11/16


Dimensions in inches/Cotes e inches/Dimensiones e inches/Dimenses em polegadas WeightKRT .../... [lbs]

DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*40-250/ 6 2 2 5/8 21 1/2 27 21 7/8 17 1/2 13 5/8 17 5/8 8 7/8 3 7/8 26 3/8 30 3/4 23 5/8 15 3/4 7 7/8 295 385/

8 2 (C1= (C1= 315 40512 2 22 5/8 28 1/4 21 1/4) 10 5/8) 345 45017 2 370 4755 4 21 1/2 27 300 3957 4 330 425

11 4 22 5/8 28 1/4 360 445

0W 382 514--50 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

A - A

5 7 (C2)

60

165 Cm

in.5

00

N min

d

200

O min

1010

0

k1

153b1

e1

18

l1

140

85

300

110

380

DN1

325

225

22020

40300

150

200

Z

C 2

170

V 2 3/4

50

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

85

200

zf x lf

gfKfDf

DN2/DN3

KRT

30

Dimension tableSize: 80-251, 80-315



DN2 gf Kf Df zf lf80 138 160 200 8 18



DN3 gf Kf Df zf lf80 127 152 191 4 20

100 157 191 229 8 20



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*80-251/ 7 4 100 596 717 570 475 382 470 255 76 690 810 610 400 200 150 ----

11 4 626 747 165 ----16 4 (C1= (C1= 175 ----

80-315/ 8 2 80 610 715 565 470 355 465 250 87 685 805 600 540) 270) 151 227/12 2 640 745 166 24217 2 177 25323 2 780 885 600 505 400 720 840 720 254 300

0W 382 515--00 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

zf x lf

gfKfDf

DN2/DN3A - A

3/16 5/16 (C2)

2 3/8

6 1/2 Cm

in.

N min

193

4/

d

77

8/

O min

3/8

378/

k1

6 1/16b1

e1

11/16

l1

5 1/2

3 3/8 3 3/8

117

8/

43

8/7

78/

15

DN1

123

4/

87

8/

8 11/1613/16

1 9/1611 7/8

57

8/

77

8/

Z

C 2

63

4/

V 2 3/4

2

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

KRT

31




DN2 gf Kf Df zf lf3 5 7/16 6 5/16 7 7/8 8 11/16



DN3 gf Kf Df zf lf3 5 6 ---- 4 13/164 6 1/4 7 1/2 9 8 13/16



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*80-251/ 7 4 4 23 1/2 28 1/4 22 1/2 18 3/4 15 18 1/2 10 3 27 1/8 31 7/8 24 15 3/4 7 7/8 330 ----

11 4 24 5/8 29 3/8 365 ----16 4 (C1= (C1= 390 ----

80-315/ 8 2 3 1/8 24 28 1/4 21 1/4) 10 5/8) 335 500/12 2 25 1/4 29 3/8 370 53517 2 390 56023 2 30 3/4 34 7/8 23 5/8 19 7/8 15 3/4 28 3/8 33 1/8 28 3/4 560 660

0W 382 515--50 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

A - A

5 7 (C2)

60

165 Cm

in.5

00

N min

d

220

O min

1010

0

k1

165b1

e1

18

l1

140

85

345

110

430

DN1

345

255

22020

45310

150

200

Z

C 2

170

V 70

50

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

85

240

zf x lf

gfKfDf

DN2/DN3

KRT

32

Dimension tableSize: 100-250, 100-251, 100-316



DN2 gf Kf Df zf lf100 158 180 220 8 18



DN3 gf Kf Df zf lf100 157 191 229 8 20



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*100-250/ 5 4 100 600 725 580 475 388 485 255 112 705 830 610 400 200 141 205100-251/ 7 4 (C1= (C1= 155 219

11 4 630 755 540) 270) 170 23416 4 180 244

100-316/ 11 4 100 655 790 640 535 420 545 315 122 765 890 800 550 275 198 27516 4 208 28523 4 795 930 675 570 800 925 277 32029 4 765 900 295 338

0W 382 516--00 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

zf x lf

gfKfDf

DN2/DN3A - A

3/16 5/16 (C2)

2 3/8

6 1/2 Cm

in.

N min

193

4/

d 811

16/

O min

3/8

378/

k1

6 1/2b1

e1

11/16

l1

5 1/2

3 3/8 3 3/8

139

16/

43

8/9

12/

DN1

139

16/

101

16/

8 11/1613/16

1 3/412 3/16

57

8/

77

8/

Z

C 2

63

4/

V 2 3/4

2

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

1615

16/

KRT

33

Dimension tableSize: 100-250, 100-251, 100-316



DN2 gf Kf Df zf lf4 6 1/4 7 1/16 8 5/8 8 11/16



DN3 gf Kf Df zf lf4 6 1/4 7 1/2 9 8 13/16



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*100-250/ 5 4 4 23 5/8 28 8/16 22 13/16 18 11/16 15 1/4 19 1/8 10 1/16 4 7/16 27 3/4 32 11/16 24 15 3/4 7 7/8 310 455100-251/ 7 4 (C1= (C1= 345 485

11 4 24 13/16 29 3/4 21 1/4) 10 5/8) 375 52016 4 400 540

100-316/ 11 4 4 25 13/16 31 1/8 25 3/16 21 1/16 16 9/16 21 7/16 12 3/8 4 13/16 30 1/8 35 1/16 31 1/2 21 5/8 10 7/8 440 61016 4 460 63023 4 31 5/16 36 5/8 26 9/16 22 7/16 31 1/2 36 7/16 610 71029 4 30 1/8 35 7/16 650 745

0W 382 516--50 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

A - A

5 7 (C2)

60

230 Cm

in.5

00

N min

d

290

O min

1010

0

k1

200b1

e1

18

l1

325

85

525

110

630

DN1

455

310

43020

60550

215

285

Z

C 2

170

V 70

50

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

85

380

zf x lf

gfKfDf

DN2/DN3

KRT

34




DN2 gf Kf Df zf lf150 212 240 285 8 22



DN3 gf Kf Df zf lf150 216 241 279 8 23



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*150-315/ 4 6 150 710 855 775 640 535 650 370 214 920 1085 850 550 275 226 298

6 6 236 3089 6 740 885 246 318

12 6 256 32820 6 880 1025 317 37826 6 850 995 343 403

0W 382 517--00 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

zf x lf

gfKfDf

DN2/DN3A - A

3/16 5/16 (C2)

2 3/8

9C

min

.

N min

193

4/

d 11

12/

O min

3/8

378/

k1

7 7/8b1

e1

11/16

l1

12 3/4

3 3/8 3 3/8

203

4/

43

8/15

DN1

177

8/

121

4/

16 15/1613/16

2 3/821 5/8

87

16/

111

4/

Z

C 2

63

4/

V 2 3/4

2

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M16x200

247

8/

KRT

35




DN2 gf Kf Df zf lf6 8 3/8 9 7/16 11 1/4 8 7/8



DN3 gf Kf Df zf lf6 8 1/2 9 1/2 11 8 7/8



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*

150-315/ 4 6 6 28 33 5/8 30 1/2 25 1/4 21 1/8 25 5/8 14 5/8 8 1/2 36 1/4 42 3/4 33 5/8 21 5/8 10 7/8 500 660

6 6 520 680

9 6 29 1/8 34 7/8 545 700

12 6 565 725

20 6 34 5/8 40 3/8 700 835

26 6 33 1/2 39 1/4 755 890

0W 382 517--50 C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

A - A

5 7 (C2)

60

275 Cm

in.

800

N min

d

350

O min

1010

0

k1

235b1

e1

18

l1

340

85

550

110

660

DN1

550

400

45022

70580

300

380

Z

C 2

250

V 120

65

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M20x250

85

400

zf x lf

gfKfDf

DN2/DN3

200-280

KRT

36



Transportable -- DIN 2501, PN 16Flange/Bride/Brida [mm]DN2 gf Kf Df zf lf200 268 295 340 8 22


Flange/Bride/Brida [mm]DN3 gf Kf Df zf lf200 268 298 343 8 30



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*200-280/ 6 6 200 730 925 900 840 595 785 450 194 1075 1245 1100 900 390 320 395200-281/ 9 6 760 955 330 405/

12 6 340 41520 6 900 1095 401 46526 6 870 1065 427 490

0W 382 518--00 only 200-280: C*= H, C1, C2


AA

1)

C

B

B

1)DN2

DN3

zf x lf

gfKfDf

DN2/DN3A - A

3/16 5/16 (C2)

2 3/8

10 7/8 Cm

in.

N min

311

2/

d 13

78/

O min

3/8

378/

k1

9 1/4b1

e1

11/16

l1

13 3/8

3 3/8 3 3/8

213

4/

43

8/15

34/

26

DN1

213

4/

153

4/

17 3/47/8

2 3/422 7/8

117

8/

15

Z

C 2

97

8/

V 4 3/4

Z

V

b2e2

a 2 T

h 1a 1

DN1

5o

M20x250

200-280

25

8/

KRT

37




DN2 gf Kf Df zf lf8 10 9/16 11 5/8 13 3/8 8 7/8



DN3 gf Kf Df zf lf8 10 9/16 11 5/8 13 3/8 8 1



DN1 a1 a2 b1 b2 d e1 e2 h1 k1 l1 N/O T V G C*200-280/ 6 6 8 28 3/4 36 1/2 35 1/2 33 1/8 23 1/2 30 7/8 17 3/4 7 5/8 42 3/8 49 43 1/4 35 1/2 15 3/8 705 870200-281/ 9 6 29 7/8 37 5/8 730 895/

12 6 750 91520 6 35 1/2 43 1/8 885 102526 6 34 1/4 42 945 1080

0W 382 518--50 only 200-280: C*= H, C1, C2

38

KRTKSB

Description Thermal motor monitoring

The winding is protected by two independent temperaturemonitoring circuits:

F4, F5 = 2 bimetallic switches in the motor windingIdentification tape 21,22

max. operating voltage of switch: 250 Vmax. current: 2 A

R1, R2, R3 = 3 PTC thermistors in the motor winding Identification tape 10, 11

max. operating voltage on terminalsUmax = 30 V d.c.

resistance between terminals 10 / 11- at ambient temperature 100-750 - at shutdown temperature > 4000

It is necessary to use one of both circuits to protect the winding.

Using of bimetallic switches:

The conductors have to be directly connected to the control circuitof the motor contactor.It must switch of the pump when the maximum winding temperatureis reached and automatically on again after the motor have cooleddown.

Optional use of thermistors (PTC):

If frequency converter with motor-protection unit are installed, it isrecommanded to use thermistors (PTC).In this case no additional equipment is necessary.

Do not use the pump without correctfunction of temperature monitoring devices.

Electrical connection diagram

Motors: 5 2...23 2;5 4...29 4;4 6...26 6

7x..+5x1.5mm2

KRTKSB

39

Detail Dual-Voltage Winding 230 V / 460 V

460 V

0W 7010870W 701088

230 V

0W 7010870W 701088

40

KRTKSB

Moisture monitoring

K1

PE 9

Motor chamber / moisture detection(see also Electrical connection diagram)The moisture sensor inside of the motor chamber is like a piece ofinsulation of the winding. That needs an insulation control relay (e.g. Warrick Relay 16 MB) to detect moisture inside.The relay has to contactet on Terminal 9 and ground (PE).

After tripping the moisture monitoring the pump will have to beoverhauled.

Check of the moisture electrodeAn insulation resistance test acc. to 7.2.1 has to be carried out.

The moisture monitoring electrode is okay if the insulationresistance measured at the electrode is > 5 M. Lower valuesindicate moisture or even intrusion of water into the motor. In suchcases, the motor needs to be opened and overhauled.

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

B2 = Moisture transmitter (electrode) inside the motor space

core identification: 9Voltage max. 600 V

K1 = Insulation control relay

41

KRTKSB

Assembly instructions-Impeller dismantling/fitting with tapered connection 40-250, 80-251, 100-250/251,80-315, 100-316, 150-315,200-280/281

Size Pulling-off screw Identity-No.

SK 40-250F 100-250 M 16x60 11197135

E 80-251K 80-315E, K 100-251F, K 100-316F, E, K 150-315K 200-280K 200-281

M 20x95 11197784

all dimensions in mm

Pulling-off screw

Pulling-off screw

42

KRTKSB

Assembly instructions-Impeller dismantling/fitting with tapered connection40-250, 80-251,100-250/251,80-315, 150-315,200-280/281

M16

8

min

20

3225

118

R6

118

M20

8

min

30

50.5

45

Size Pulling-off screw Identity-No.

S, K 40-250F 100-250 M 16x60 11197135

E 80-251K 80-315E, K 100-251F, K 100-316F, E, K 150-315K 200-280K 200-281

M20x95 11197784

Pulling-off screw

K 40-250K 80-315

K 100-251K 100-316K 150-315

all dimensions in mm

43

KRTKSB

Removing impellers with taper fit

The following sequence of operations must be observed whenremoving the impeller:

1. Remove impeller screw 914.10.

2. Use pulling-off screw to pull off impeller. (Tight taper fit-impeller may be firmly locked on shaft).Screw pulling-off screw either directly into the impeller230 or into locking sleeve 531, see drawing detailsopposite and relevant sectional drawing.

Installation of S/F/E/K-Impeller (without locking sleeve)

1. Having installed the pump-side mechanical seal 433.02,push the impeller 230 (S/F/E/K-impeller) onto the shaftend.

2. Apply Loctite L

243 to the thread of impeller screw914.10.Observe Loctite handling instructions. Screw in impellerscrew 914.10 and tighten with a torque wrench.

S/K 40-250 (M10) 50 NmF 100-250 (M10) 50 NmE 80-251 (M16) 150 NmK 80-315 (M16) 150 Nm

E/K 100-251 (M16) 150 NmF/K 100-316 (M16) 150 Nm

F/K/E 150-315 (M16) 150 NmK 200-280/281 (M16) 150 Nm

3. Mount pump casing 101 with bolts 901.14, square nuts 920.01 with lockwasher 931 and O-rings 412.15.Use torque wrench to tighten hex. head bolts 901.14

S/K 40-250 (M12) 65 NmE 80-251 (M12) 65 NmF 100-250 (M12) 65 Nm

E/K 100-251 (M12) 65 NmK 80-315 (M16) 150 Nm

F/K 100-316 (M16) 150 NmF/K/E 150-315 (M16) 150 Nm

K 200-280/281 (M16) 150 Nm

Adjustment of axial clearance

If an axial casing wear ring is fitted at the pump casing, theclearance between the casing and the impeller should be adjustedto 0.5 mm (K 40-250 0.2 mm) by tightening the bolts 901.14.For the Amarex KRT 200-280/281 (radial clearance) an adjustmentis not necessary.

44

KRTKSB

Assembly instruction - Cutter

Dismantling of the S-impeller (Amarex KRT S 40-250)

1. After fitting the pump-side mechanical seal 433.02, push impeller 230 onto the shaft, fit grooved pin 561.01 into the impeller.The impeller body 23-7 is fitted onto the centering device. Then fit impeller screw 914.10 and tighten it by using a torque wrench.Tightening torque: M 10; 50 Nm

2. Fit pump casing with joint O-ring 412.16 using hex. screws 901.14 and tighten it by a torque wrench.Tightening torque: M 12; 60 Nm.

3. Insert joint O-ring 412.16 into suction cover 162 and mount ring 500.02 with cylindrical pin 914.07 in the suction cover.Insert suction cover into the pump casing until it borders on the impeller blades (cylindrical pin 914.15 must not protrude from the threads of the suction cover!) - but do not yet tighten!

4. Measure the distance between pump casing and suction cover and shift the suction cover with cylindrial pin 914.15 byS = 0,2 0,1 mm vis--vis the pump casing.Tightening torque: M 12; 30 Nm

5. Make sure that the impeller is running smoothly by turning itsbody (sliding between suction cover and impeller is not admissible)

Dismantling of the S-impeller (Amarex KRT S 40-250)

Dismantling takes place in reserve order. The impeller can bepulled off from the shaft by means of the same forcing screws usedfor the Amarex KRT K 40-250 (Attention: tight cone seat!)

Pay attention to assembly instruction Impeller dismantling /fitting with tapered connection.

45

KRTKSB

KRTKSB KRT

KSB AktiengesellschaftIndustry and Water Engineering PumpsP. O. Box 200743 D-06008 Halle (Saale) . Turmstrae 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

/6-1

409

/99

Subj

ect t

o ch

ange

with

out n

otic

e.

krt-operatinginstructionscaev

Documents

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operating manual2553

theoperating manual

description of pump

general instructions

assembly installation