KRT2553.8041/2-14Operating manual

Submersible motor pumps

Material types

Series

Size

Motor size

KRT

DN 100...DN 300

23 4...65 4 (4--poles)20 6...50 6 (6--poles)10 8...35 8 (8--poles)

G, GH, H, C1, C2

4”... 12”

Works No.: see nameplate:

The operating manual contains important information and hazard / dangerwarnings. It is imperative to read the instructions set out in the manual priorto installation, making electrical connections and commissioning. Additionaloperating instructions relating to the components of this plant will also have tobe observed.

In principle if any work has to be carried out to the plant all electrical supplies(inclusive of the control cable) should be disconnected at the mains supply switch.The plant has to be safeguarded against accidental starting.

Ident. No.: 01 055 756

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

Type size Material combination

G G1 G2 GH

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

D 150 -- 400 D D ---- ----

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

K 151 -- 401 K K ---- K

K 200 -- 330 K K ---- K

D 200 -- 400 D D ---- ----

E,K 200 -- 401 E,K K ---- K

K,D 250 -- 400 K,D K,D ---- K

K 250 -- 401 K K ---- K

K,D 300 -- 400 K,D K,D ---- K

K 300 -- 401 K K ---- K

Type size Material combination

F, K Industrial material

H C1 C2

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

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

K 151 -- 401 K K K

K 200 -- 330 K K K

K 200 -- 401 K K K

K 250 -- 400 K K K

K 250 -- 401 K K K

K 300 -- 400 K K K

K 300 -- 401 K K K

Contents Page

1 General 3

2 Safety 32.1 Identification of symbols used within the

operating manual3

2.2 Personnel skills and training 3

2.3 Dangerous practices non-observance of safetyinstructions

3

2.4 Safe working methods 3

2.5 Safety instructions for the operators 3

2.6 Safety instructions during maintenance,inspection and installation

4

2.7 Unauthorized modifications to the pump andfitting of spare parts

4

2.8 Impermissible modes of operation 4

3 Transport and interim storage 43.1 Transport 4

3.2 Storage and Conservation 4

4 Description of pump 54.1 General description 5

4.2 Identification data 5

4.3 Construction 5

4.4 Ancillary equipment 5

5 Assembly / Installation 65.1 Safety regulations 6

5.2 Checking procedure prior to commencement ofthe installation

6

5.3 Installation 6

5.4 Connection of the pipeline 6

5.5 Electrical connection 7

5.6 Assembly kit installation 8

6 Start up / shut down 96.1 Initial start up of pump 9

6.2 Limations of the operating range 10

6.3 Shut down / storage / preservation 10

6.4 Re-starting pump after storage 11

7 Service and maintenance 117.1 General instructions 11

7.2 Service / Inspection 11

7.3 Drainage / Disposal 13

7.4 Dismantling 13

7.5 Reassembly 14

7.6 Spare parts 14

8 Trouble-shooting 15

9 Appendix 16

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1 GeneralThis KSB pump has been developed with the latest technology,it was manufactured with great care and is subject to constantquality control.The operating manual is designed to introduce the pump to youand 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, rateof flow, speed, density, pressure and temperature, includingmotor rating 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 inquiries, subsequent orders and especially whenordering spare / replacement parts.Should any additional information or instructions be required, orif there 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. Thereforeit is imperative that this manual is read prior to assembly by thefitter and relevant skilled staff / and operators, and it must alwaysbe kept within 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:

Calling attention to electric current with

Safety instructions relating to situations where non--observancecould damage the machine and its functions are identified with theword

Caution

Any instructions which are actually printed on the machine suchas:-- arrow indicating the direction of rotation,-- identification for fluid connectionsmust be observed without fail and be kept clean and legible.

2.2 Personnel skills and trainingOperators, as well as service, inspection and assemblypersonnel must have the appropriate skills to carry out such work.Area of responsibility, allocation and supervision of the personnelmust be controlled by the operator. Should the personnel not havethe required knowledge, training must be arranged. If required,the operator can arrange such training to be carried out by KSB.The operator must also ensure that the instruction manual is fullyunderstood by the personnel.

2.3 Dangerous practices non--observance ofsafety instructions

Non--compliance with the safety instructions can endangerpeople’s lives, the environment and the pumps.In detail, non--compliance could, for example, cause thefollowing-- Failure of pump / plant to operate.-- Failure of servicing and maintenance methods.-- Endangering people by contact with electrical, mechanical

and chemical matters.-- Contamination of the environment by leakage of dangerous

substances.

2.4 Safe working methodsThe 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

these parts must be protected where contact is possible.-- Safety equipment to prevent contact with hot or cold movable

parts 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 insuch a manner as to avoid any danger to personnel andenvironment.

-- 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).

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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 tothe method of switching off the equipment must be adhered towithout fail.Pumps pumping dangerous media must be decontaminated.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.

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 ofinstalling non--manufacturer’s parts.

2.8 Impermissible modes of operationOperating 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 storageThe chain or lifting wire which is supplied must onlybe used for lifting the appropriate pump unit. General

use for lifting heavy loads is not permitted.Do not lift the pump by the motor cable.

The pump must be handled carefully during transport.The chain or lifting wire must be attached securely at

the pump and crane end. Personnel can be injured and thepump unit damaged should the pump slip out of the chain /guide rope.

3.1 TransportThe 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 and ConservationThe procedure has been outlined in paragraph 6.3 ”Shut down”.

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4 Description of pump

4.1 General descriptionKSB submersible pumps are close--coupled units which arenon--self--priming. The impellers in these pumps can vary,depending on the impeller type required by the customers to suita particular application. Usually, the pumps are operated fullysubmerged. For short periods, they may run dry until the minimumfilling level is reached.

4.2 Identification dataIdentification can be found on the nameplate, which is fitted to themotor.

Impeller typeD = diagonal single--vane impellerE = single--vane impellerF = free--flow impellerK = non--clogging impeller

Motor version (U, W, X, Z)U = standard versionW = hot water versionX = explosion proof standardZ = explosion proof hot water

Material combination(G, G1, G2,GH)G = Pump complete in cast ironG1 = G Pump with impeller in duplex steel

A 743 CD 4 MCUG2 = G Pump with impeller in chilled casting

A 532 II C 15 %GH = G Pump with impeller and discharge cover

In chilled casting a %§” ii c !%5

H Pump manufactured in chilled castingA 532 II C 15%

C1/C2 = Pump manufactured in duplex steelA 743 CD 4 MCU

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

Installation type

S = stationary wet--well installationP = transportable wet--well installation

Number of poles4--pole6--pole8--pole

Motor size

Size of hydraulics

Series

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 method standard: direct.

4.3.1.1 Motors in explosion proof 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 independentof the direction of rotation at pump and motor end. The oilchamber which is fitted between the two mechanical sealsensures cooling and lubrication.

4.3.3 Bearing assemblyThe shafts are supported by grease--packed rolling elementbearings. The bearings of some pump sizes can be re--lubricated.

4.3.4 Impeller types

Free-flow impeller (F impeller) for pump-ing liquids containing larger solid par-ticles and fibres liable to twist and bunchand also gas and air inclusions.

Single-vane impeller (E impeller) forpumping lliquids containing larger solidparticles and fibres liable to twist andbunch, and also for the damage-freetransport of solids.

Open, diagonal single vane impeller (Dimpeller) for sewage with solid and longfibrous admixtures and with coarser so-lids.

Closed non-clogging impeller (K impel-ler) for contaminated, non-gaseous liq-uids containing solids, without fibres li-able to twist and bunch.

4.3.5 Installation types-- 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 givenby our Sales Office.

Caution

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5 Assembly / Installation5.1 Safety regulations

It is not permitted for any person to enter the tankduring operation of the pump unless special safety

precautions have been taken in accordance with currentsafety regulations.

5.2 Checking procedure prior tocommencement of the installation

Construction layout must be in accordance with measurementsset out on the table of dimensions.The construction of the concrete foundations should besufficiently strong (min. 3000 psi / min. B 25 DIN 1045) to ensurea secure and functionally correct installation in compliance withDIN 1045 or equivalent standard. Concrete foundations musthave set before installation of the unit. Its surface must be leveland 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 thescope of supply. This nameplate must be fixed in a clearly visibleposition outside the tank (for example switch panel, pipework,mounting bracket).

5.3.1 Checking of operating dataA check must be carried out to ensure that the details stated onthe nameplate correspond to the order and pump data (forexample operating voltage, frequency and pumped mediatemperature etc.).

5.3.2 Oil level controlThe oil chambers of our submersible pumps were filled withenvironmentally safe non--toxic paraffin oil at the factory.

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 directionof rotation 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 shall be connected taking into account thepermissible flange loads as given in the table ”Permissible flangeloads”.

Y

Z

X

UG10466387

Table ”Permissible flange loads”

Forces [N] Moments [Nm]

DN Fy Fz Fx ∑F My Mz Mx ∑M

100 2700 3350 3000 5250 1250 1450 1750 2600

150 4050 5000 4500 7850 1750 2050 2500 3650

200 5400 6700 6000 10450 2300 2650 3250 4800

250 6750 8350 7450 13050 3150 3650 4450 6550

300 8050 10000 8950 15650 4300 4950 6050 8900

Forces [lb] Moments [lb-ft]

DN Fy Fz Fx ∑F My Mz Mx ∑M

100 605 750 675 1180 920 1070 1290 1915

150 910 1125 1010 1760 1290 1510 1840 2690

200 1210 1505 1345 2345 1695 1950 2400 3540

250 1515 1875 1675 2930 2320 2690 3280 4830

300 1810 2245 2010 3515 3170 3650 4460 6565

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 ensurethat the pump does not come under undue stress due to pipelineforces and torques.

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

endanger life.

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Toxic and hot media can endanger life.When emptying objects on a lower level, a non-return valve mustbe fitted into the discharge pipe to avoid backflow from thechannel, which could be led via the backflow level (road level)upwards and only then into the sewage channel.

Screwed pipeline joints where plastic partswere used, must not be damaged by careless

handling of tools during the installation of pump andpipeline.

Fitting of a non-return valve is also essential for longer risingpipes to avoid excessive backflow when the pump is turnedoff. Ensure that ventilation is taken into account when fittinga non-return valve.

5.5 Electrical connection

The electrical connection must be carried out by atrained electrician and in compliance with local

regulations.The voltage must comply with the voltage indicated on thenameplate.Electrical installation must be in accordance with the Appendix”Electrical connection diagram” for the appropriate motorsizes. The pump is delivered with cable.

Do not remove the protective cover, which issituated at the cable end until immediately

before installation.

The individual cores of the cable ends bear marking tapes (e.g.U(T1). V(T2), W(T3), U2(T4), V2(T5), W2(T6) 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 yellow tags and reaffix itafterwards.

When laying a conduit between the pumpstation and the electrical switchgear,

additional control cable (min. AWG 15 / 1.5 mm2) must beinstalled for pump monitoring equipment. Adjust cores tosuit requirement.

5.5.1 Monitoring equipmentThe unit has been supplied internal sensors to prevent damage.Installation, description and functioning of the sensors to preventdamage can be taken from appendix ”Electrical connectiondiagrams”.

5.5.2 Fitting of electric cabling

After installing the unit, it is advised toposition the motor cable straight upward in

order not to have it affected by the swirl created by thepumped liquid.

For correct installation of the electric cabling within the pumpsump (appendix ”General pump outline” Fig. 4) werecommend using kellum grips, which can be supplied for anadditional cost (paragraph 4.4). Slack installation of cables couldcause damage to the electric cabling 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 instructionsgiven in the supplementary operating manual ”Assembly ofprotection sheath”.

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

5.5.4 Level control switchPumping stations with automatic pump operation should be fittedwith a level control switch. The cut--off point should be set as ’R’in accordance with appendix ”Dimension tables”.

5.5.5 Checking of the direction of rotationOnce the electrical connections are complete, the followingshould be checked:

The pump cannot reach its duty point if thedirection of rotation is incorrect.

Non--observance can lead to damaging the pump set.

Never put hands or any objects into the pump whenthe pump can be accidentally started. Prior to

carrying out rotation check, make sure no foreign objects arein the pump casing.

The running time should be as short aspossible (max. 1 minutes).

Correct direction of rotation:If the right phase sequence of the circuit is known, the correctdirection of rotation will occur automatically, providing theinstructions in 5.5 have been carried out correctly (rotating of themotor to the left).The direction of rotation is checked by bumping the pump andobservations of the impeller.When looking at the pump mouth, the impeller must move to theleft (with some pumps, the direction of rotation is marked by anarrow).(See appendix ”General pump outline” Fig. 5).If the direction of rotation is incorrect, interchange 2 of the 3phases in the switch cabinet.

5.5.6 Connection of a potential equalizerFor potential equalization use the external connection terminal atthe cable 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 installation kit is available for installation of the KRTpump unit:-- 5.6.1 Stationary wet--well 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 stainlesssteel cables the pump slides into the well or tank and attachesitself to the discharge elbow which has been fitted to the bottom.The weight of the pump acts to seal the connection betweenpump and discharge elbow. A profile gasket between pump anddischarge elbow achieves a pressure--proof elastic connection.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 with guidecables.

5.6.1.3 Installation of pump with claw connectionUse appendix ”Wet--well installation” for guidance.

1. Prior to lowering the pump fit claw part # 732 to the dischargeflange of the pump housing.Screws have to be tightened in accordance with theinstructions. This is described under item 7.5.1 in the table”Bolt tightening torque”.

2. Fit profile seal part # 410.35 or 99--6 into the groove of theclaw / pump casing flange. This profile seal will serve to sealthe discharge elbow during installation.

5.6.1.4 Fitting of the mounting bracket /discharge elbow / guide cable

Construction of the base foundations should be sufficiently strong(min. 3000 psi) to ensure a functionally correct fixing of guidecable equipment and discharge elbow.Refer to the drawing as illustrated in appendix ”Wet--wellinstallation” for all installation tasks outlined below.1. Secure mounting bracket part # 894 using anchor bolt part #

90--3.37 (supplied by others) at the sump opening rim.Borehole diameter and depth for the anchor bolt to be takenfrom appendix ”Dimension tables”. Bolt tighteninginstructions are outlined in the tables below.Up to size 200--401, all means of fixation are part of the scopeof supply. Fixations for larger sizes have to be carefullyselected by the owner of the plant and must be adapted to hisconditions at site.For the bolt of the mounting bracket refer to appendix”Dimension tables”.

2. Fit threaded bolt part # 904 with clamping piece part # 571 /support piece part # 572 to the mounting bracket. Do notunscrew hexagonal nut part # 920.36 too much, just enoughto allow sufficient play for tightening the cable 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 cableto run off the vertical, then a maximum angle of 5°should beadhered to, thus ensuring safe fitting function. Securing of thedischarge elbow is carried out by using steel anchor bolts part# 90--3.38 or foundation bolts part # 900.38 regardless ofpump size or material combination. Units larger than approx.2,000 kg in weight are supplied complete with foundation sliderails. Refer to appendix ”Dimension tables” and appendix”Wet--well installation” for details relating to appropriatefitting instructions and hole dimensions.

4. Insertion of cable part # 59-24.01 and fitting. Lift thrust plugand clamp and insert one end of the cable. Lead the cablearound the discharge elbow part # 72--1 and back againtowards the guide bracket and insert into clamp of thrust plug.Manually tension the cable and secure by using hex. nuts part# 920.37.

5. Tighten the cable by fastening the hexagonal nut part #920.36 situated on top of the mounting bracket(s). Tighten thehexagonal nut with a torque of MA as outlined in the table”Guide cable tension” to achieve sufficient cable tension.Subseqently secure by using a second hexagonal nut.

6. The loose end of the cable at the clamp part # 572 can eitherbe twisted into a ring or the end can be cut off. After lengthadjustment, seal off ends to avoid fraying.

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

Table Bolt tightening torque ”Steel anchor bolt”

Size (Ø) [in/mm] Torque [lbf-ft/Nm]

0.39 / 10 7.5 / 10

0.71 / 18 60 / 80

Table Bolt tightening torque ”Foundation bolt”

Size (Ø) [in/mm] Torque [lbf-ft/Nm]

0.47 / 12 20 / 25

0.63 / 16 50 / 65

0.79 / 20 95 / 125

0.94 / 24

Table ”Guide cable -- tension”

DN MA[lbf-ft/Nm]

P(N)

100

150 10 / 14 1350 / 6.000

200

10 / 14 1350 / 6.000

25022 / 30 2250 / 10 000

30022 / 30 2250 / 10.000

MA = tightening torque

P = 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 canbe found in ”Wet--well installation”.This type of assembly permits the fitting of the pump to thedischarge elbow.

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 overthe support piece part # 572. It is then attached to the guide cableor rails and slowly lowered into the sump. Once the pump islowered, it will attach itself to the discharge elbow part # 72--1 andis then securely fixed to the outlet pipe ready for use. Finally,attach the chain or rope to the shackle part # 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 DescriptionPumps for transportable installation are supplied with a pumpstand. The outlet flange can be used for fitting either rigid orflexible piping.Examples for typical installation possibilities can be taken fromappendix ”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 installation

For parts supplied and detailed illustration, see appendix”Wet--well installation -- 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 installingthe pump. All screws must be tightened according to instructions.Refer to table ”Bolt tightening torque” paragraph 7.5.1 forinstructions.

5.6.2.4 Assembly chain or lifting ropetransportable installation

Fitting of chain / lifting rope should be installed out as outlined inappendix ”Wet--well installation--transportable.Always use the lifting point which is closes to the pump dischargeon top of the motor, see appendix ”General pump outline” Fig.1b.

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

draining mines,the emergency draining of canals,pumping 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 bas.

6 Start up / shut downIt is important to follow these requirements.Any damage incurred as a result of

non-compliance is not covered by the guarantee.

Do not pump any media which is unsuitablefor the material outlined in the technical

documentation.

6.1 Initial start up of pumpPrior to starting the pump it has to be ascertained that thefollowing points have been checked and executed:-- Operating data (see 5.3.1), oil level (see 6.1.1) and direction

of rotation (see 5.5.5).-- Check that the installation of the electrical supply was carried

out correctly in accordance with appendix ”Electricalconnection diagrams”.

Temperature monitoring in the windingprotects the motor in case of insufficient

cooling conditions. Reliable operation and explosionprotection can only be guaranteed if the circuits fortemperature monitoring function properly.

-- Ensure that the pump has been installed correctly to complywith 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 outline” Fig.2. Remove fill plug part # 903.03 with joint ring part # 411.03. Theoil level must be at the height of the oil inlet. If it is lower, fill the oilchamber via feed opening until overflow. Regarding oil quality andquantity, see point 7.2.4 (Oil change). Tighten the fill plug with jointring again.

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6.1.2 Start--UpThe pump must be started up against a closed discharge sidecheck valve and open shut--off valve. If the discharge pipe is notfitted with a check valve, the pump must be started up with theshut--off valve slightly open and slowly opening further.

Pump start--up against a closed shut--offelement will result in increased wear.

Suitable valves must be installed to ensure that any high pointsin the discharge piping are properly vented.When the pump is started up via frequency inverter, short startramps must be ensured (approx. 3--5 s) for the motor to reach therotational speed corresponding to the mains frequency.Speed controlled operation shall only start after approx. 2--5minutes.

Pump start--up with long start ramps and lowfrequency may cause clogging.

6.2 Limitation 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 topumping stations with automatic pump operation.

(Appendix ”General pump outline” Fig. 7).Built--in temperature controls within the winding will protect themotor from overheating. If the motor overheats (for exampleduring long operation with a completely exposed motor), thebuilt--in temperature controls will switch off the motor and turn iton again automatically after cooling down. The control systemmust provide a protection against dry running by stopping thepump automatically at water levels ”R” and below (cut--offcontact, see 5.5.4).

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: 104 °F/ 60 °C.

1) Can be operated up to 176 °F / 80 °C for a limited period (3--5min. until the thermal protection equipment is activated).

Do not operate the equipment attemperatures higher than those indicated

above, unless KSB has given written consent. Damagecaused due to non--observance of this warning will not becovered by the guarantee.

6.2.3 Density of pumped mediaPower input of the pump increases directly with the density of thepumped medium. To avoid overloading of the motor this densitymust comply with the data stated in the order.

6.2.4 Abrasive mediaWhen pumping media containing abrasive particles, increasedwear of 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 the pipe to the rising mainto > 4.9 ft/s <16 ft/s >1.5 m/sec < 5 m/sec in order to achieve themaximum operating periods possible.

6.2.5 Starting 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 / 7.5 kW max. 30 / hr.Motor ratings up to 125 Hp / 90 kW max. 20 / hr.5.000 switching operations per year as maximum.

6.2.6 Operating voltageThe maximum admissible deviation of the operating voltageamounts to ±10% of the rated voltage. The maximum admissiblevoltage difference between the single phases amounts to +/-- 1%.

6.2.7 Frequency converter operationThe output frequency is limited at 60 Hz.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,-- inatural frequency ranges of pipe system.

6.3 Shut down / 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 oilthrough inlet and outlet flanges. It is then recommended tocover the flanges with plastic caps or similar.

-- Store the pump in an upright position in a dry place. Supportall electrical cables at cable entry points to avoid permanentdistortion.

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

6.3.2 Measures for prolonged shut down periods1. The pump remains installed ready for operation when

required.In order to maintain pump availability, the pump should beswitched on for brief periods (approx. 10 sec) once everymonth.

2. The pump is dismantled and stored.Prior to storage the pump should be checked and maintainedin accordance with paragraph 7.1 and 7.2. Subsequently, thepreservation outlined in paragraph 6.3.1 must be carried out.

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11

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 from being

started accidentally. Otherwise, there will be danger to life.

In addition, free-running of the impeller should bechecked. This can be done by putting one hand into

the pump casing and manually turning the impeller.

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

Immediately after completion of the maintenancework, all safety and protection equipment has to be

installed expertly and must be set working.

7 Service and maintenance7.1 General instructionsThe operator must ensure that all maintenance, inspection andrepair work is carried out by qualified, authorized staff who arefamiliar with the equipment and who have read the operatinginstructions.By compiling a maintenance plan it is possible to cut maintenanceexpenses and avoid extensive down--time, thus achievingtrouble--free and reliable operating of the pump.

Always disconnect all electricity supplies prior toworking on the pump. Safeguard the pump from being

started accidentally. Otherwise, there will be danger to life.

If the pumped media are harmful, the pump must bedecontaminated. Special care should be taken to

prevent an endangering of personnel and environment whendraining oil, leakage or coolant liquid.All official regulations must be adhered to.

Special regulations apply to repair work onexplosions-proof pumps. Modifications or alteration

of the pump may affect explosion protection and are onlypermitted after consultation with the manufacturer. Onlyoriginal spare parts and accessories authorized by themanufacturer must be used for explosion-proof pumps.

7.2 Service / Inspection

The following points must be observed to ensure reliableoperation:This work must only be carried out by experiencedpersonnel!

Item Maintenance work Maintenanceinterval

7.2.1 Insulation resistance test Every 4.0007.2.2 Checking the electric cables

Every 4.000operating

7.2.3 Visual inspection of lifting chain /rope

operatinghours; at leastonce a year

7.2.4 Check of monitoring equipment Every 10.0007.2.5 Checking the mechanical seal

leakage

Every 10.000operatinghours; at least

7.2.6 Oil changehours; at leastevery three

7.2.7 Lubrication of bearings

yyears

General overhaul Every fiveyears

7.2.1 Checking of the insulation resistance

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 motor cable ends(disconnected at the starting panel). The measurement should betaken by using a megger.

-- Measuring voltage: max 1,000 V d.c.

The measurements to be taken are:

a. Winding against ground-- All winding leads connected together, and measured to

ground lead (green--yellow),

b. Winding temperature sensors against ground-- All cable ends of the winding temperature sensors (21/22 or

10/11) must be connected to one another. Otherwise thesensors will be damaged; measure to ground lead(green--yellow).

The insulation resistance of the motor winding with cable endstied together must not be less than 1 MΩ. If measurements areless, then cable and motor must be checked separately. Duringthe measurement procedure the supply cables must bedisconnected from the motor.If the insulation resistance for the electric supply cable is lessthan 1 MΩ, this indicates a damaged cable and needsreplacement.Low reading of the insulation resistance values of the motorindicates that there is a fault in the winding. If this is the case,contact KSB.

Caution

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12

7.2.2 Checking the electric cable-- Visual inspection of the electric cable:

Whenever the pump is inspected, the electrical supply cablesshould also be checked with regard to damage such as cracksor bubbles, due to either mechanical or chemical causes. Ifsuch damage is detected, then all electric cables must bereplaced.

-- Checking the protective grounding conductor:Measurement of the resistance between green-yellow coresand exposed metal surface on pump.Resistance should be < 1Ω.

Never switch on a pump with a defective groundconductor!

If the given values are exceeded, disconnect the electric cable atthe motor and check again directly at the motor. If values areexceeded here also, the motor must be repaired; contact KSB.

7.2.3 Visual inspection 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 manufacturer’s originalspare parts.This also refers to the correct fixing of the lifting chain / lifting ropeto the pump.

7.2.4 Check of monitoring equipmentThe sensors shall be checked every 10,000 operating hours or atleast every three years during general maintenance work.

The tests described below measure the resistance at theconductor ends of the control cable. The actual function of thesensors is not tested.

Never use voltages higher than 30V to checkthe sensors!

a. Bimetal switchMeasure the resistance between terminals 21 and 22. Theresistance must be lower than 1 Ω.

b. Thermistors (PTC)Measure the resistance between terminals 10 and 11. Theresistance measured must be between 200 Ω and 1000 Ω.

If the tolerances given are exceeded disconnect the control cableat the pump and check again directly at the terminals inside themotor. If tolerances are still exceeded, the winding will have to bereplaced.

c. Leakage sensor in the motorMeasure the resistance between terminal 9 and the earthconductor (PE).The resistance measured must be higher than 60kΩ. Lowerresistance values would suggest water ingress into the motor. Inthis case the motor must be opened and overhauled.

d. Float switch (Mechanical seal leakage)(only motors 35 4, 50 4, 65 4, 40 6, 50 6, 26 8, 35 8)

Measure the resistance between terminals 3 and 4. Theresistance must be lower than 1Ω.If the readings suggest an open switch, check for mechanical sealleakage.

7.2.5 Checking the mechanical seal leakage

See “General assembly drawing”.Slight wear of the mechanical seals is unavoidable and will beincreased by abrasive substances contained in the fluid pumped.The leakage chamber must be drained every 10,000 operatinghours or at least every three years during general maintenancework.The leakage shall be drained with the pump in vertical position.Remove screwed plug part # 903.04 and joint ring part # 411.04(indicated by plate ”Liquid leakage drain”). Drain the leakage andfit the screwed plug with joint ring again.If more than approx. three litres of leakage should escape werecommend to replace the mechanical seals.

Pumps handling liquids posing health hazards mustbe decontaminated. When draining the leakage see to

it that there is no risk to persons or the environment. Allrelevant laws must be heeded.

7.2.6 Oil changeThe oil chamber of our submersible pump has been filled withenvironmentally friendly, non--toxic paraffin oil of medical qualityon the pump end.After every 10,000 hours of use, or three years, whichevercomes first, the oil must be changed.

Pumped liquid might enter the oil chamber when it iswarm after operation, which can cause a pressure rise

within the chamber. It is, therefore, advisable to cover thefilling plug part # 903 (with a cloth) during the openingprocess to avoid hot liquid (squirting out) escaping.

Procedure: See appendix ”General pump outline”.Erect the pump as shown in Fig. 2 and put a suitable containerunder the plug. Unscrew screwed plug part # 903.03 with joint ringpart # 411.03 ”oil filler plug” and part # 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 orsmall leakage of dirt via the pumped media will have no adverseeffect. Severe contamination of the oil by the pump media,however, indicates damaged mechanical seals. In this case,replace the mechanical seal.Screw in screwed plug part # 903.05 with joint ring part # 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 plugpart # 903.03 and fit a new gasket part # 411.03.

Caution

Caution

Caution

KRT

13

Oil quantity:The quantity of oil required amounts to 6.9 liq qt / 6.5 liters.D hydraulics only 2.2 liq qt / 2.1 liters.

Recommended quality of oil:Trade name: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 upto SAE 20 W can be used for lubrication of the mechanical seals.With regard to disposal all general Government regulations mustbe observed.

Regional regulations have to be observed tothe extent that the oil does not contaminate

the pumped media (for example drinking water) and that safedisposal is guaranteed. Otherwise, it is not permitted to fillthe pump with oil, but paraffin oil must be used for thispurpose.

7.2.7 Lubrication of bearingsThe pump / motor shaft is supplied with grease-lubricated ballbearings.On pumps equipped with D--type impellers, the rolling elementbearings of motors 35 4, 50 4, 65 4, 32 6, 40 6, 50 6, 26 8 and 358 can be re--lubricated.An encapsulated water--tight lubricating nipple allowsre--lubrication of the angular contact ball bearings withoutopening the pump.The bearings should be re--lubricated after 10,000 operatinghours, but at least every three years.

Procedure:(Appendix “General assembly drawing”).To re--lubricate the bearings, remove screwed plug part # 903.46and joint ring part # 411.46. Please note the sign “Lubricationantifriction bearing” next to the screwed plug. Fill in grease viathe lubricating nipple part # 636.02 located below the sign.After re--lubrication fit the screwed plugs with joint rings again.

Re--lubrication must be carried out while themachine is running!

The machine must be electrically connected for thispurpose. Before starting up the pump make sure it is

positioned on a level surface and secured against tippingover.

Make sure that there is no foreign matter in the pump casing.

Never hold your hands or any other objects into the pump.

Grease quality: lithium soap grease suitable for hightemperatures.

Recommended commercial greases:ESSO UNIREX N3FAG ARCANOL L40TEXACO HYTEX EP3/DEA Pragon

Grease quantity: 60 g.

7.3 Drainage / disposal

If the pump has been used to pumphazardous media, care must be taken that,

when draining the leakage liquid/ oil filling, personnel andenvironment are not endangered. All governmentregulations have to 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 7.4.4have to be observed.

Dismantling and reassembly may only be carried out in linewith the appropriate sectional drawing. The sectionaldrawing and other instructions are detailed in the appendix.The dismantling sequence should be carried out as outlinedin the sectional drawing.If there are any problems, please contact our servicedepartment for advice.

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”). Specialtools are not required. The only exceptions relate to the impellerdismantling / assembly process for the following sizes.

7.4.3.1 Special points relating to the dismantling of theimpeller

F, E and K impellers

The impeller--shaft connection is achieved by a parallel seat withlocating key. The impellers have been prepared to accept aspecial impeller withdrawing device. This can be purchased as aspecial tool from KSB.Further details relating to procedures and references relating tospecial tools are outlined in the assembly instructions appendix”Impeller mounting / dismantling device”.

D impellersImpeller and shaft are connected by means of a cone interferencefit. For dismantling, a forcing screw is needed which can byprovided by KSB as special tool.

Size Jacking screw / Material number

D 150--400

D 150-401 01 115 548D 200-400

01 115 548

D 250-400

D 300-400

KRT

14

7.4.3.2 Dismantling of mechanical sealExact instructions relating to fitting positions of the mechanicalseals, either motor side or pump side, are outlined in appendix”Installation plan mechanical seal”.

7.4.4 Dismantling the motor componentPlease ensure, when dismantling the motor and the electriccable, that core identifications are clearly marked for futurereference during re-assembly.

Special points for exlosion proof:All other work affecting the flameproofness, such asnew windings and mechanical repairs at the motor

section, require a subsequent acceptance test by anapproved engineer or have to be carried out at the premisesof the manufacturer or factory certified repair center.

7.5 Reassembly

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 usingmanufacturer’s original spare parts. Ensure that all sealingsurfaces are clean and the O--rings or flat seals fit perfectly. Werecommend the use of O--rings/seals at all times. O--rings madefrom continuous strips which were glued together must not beused.Assembly of the pump takes place in reverse order of dismantling.The drawing combined with the individual parts index should beused as a guide. All screws must be tightened during assemblyas outlined in the instructions. General instructions in this respectare outlined in the table below ”bolt tightening torque” andspecial points are stated in the installation instructions.Assure bolts are lubricated prior to tightening.

Table: Bolt tightening torque

Thread Torque [lbf-ft / Nm]A 276 Type 316 Ti (A4--70)/ A 276 S 31803 (1.4462)

M 5 3 / 4

M 6 5 / 7

M 8 13 / 17

M 10 26 / 35

M 12 44 / 60

M 16 110 / 150

M 20 215 / 290

M 24 205 / 278

M 27 300 / 409

M 30 415 / 554

7.5.2 Special points relating to components forre-assembly

7.5.2.1 Mechanical sealIn principle, we recommend to use new KSB spare parts formechanical 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 takenduring the fitting of the mechanical seal. Protectors of the movingsurfaces must not be removed until immediately before fitting thepart. The surface of the shaft must be perfectly clean andundamaged.In principle to assist with the fitting of the bellows mechanical seal,the inside of the bellows should be wetted with soapy water (donot use oil).

Fitting of the bellows mechanical seal at the motor end:To avoid damage to the rubber bellows by a keyway or shaftrecess, the shaft stub should be covered with a thin sheet of foil(approx. 5...15 mils thick). Push the rotating unit over foil coverand place into fitting position. Then remove the foil.

7.5.2.2 Impeller assemblySee section 7.4.3.

7.5.2.2.1 KRT D-Wear plateThe clearance between impeller part # 230 and wear plate part# 135 must be set to 0.012 + 0.008 in / 0.3 + 0.2 mm. Use screwspart # 914.12 and part # 914.24 for initial adjustment andre-adjustment of the clearance.

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

Procedure:(Appendix ”General pump outline” Fig. 7).The oil fill / drain hole is used to test for leaks. Securely screw thetesting device into the hole.

Test media: Compressed air.

Test pressure: max. 7.25 psi / 0.5 bar.

Test duration: 2 min.

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

7.5.2.4 MotorEnsure prior to reassembly of explosionproof motors that all thespecial points outlined in paragraph 7.4.4 were observed. Allmotors must be tested electrically in line with paragraph 6.1, 6.2and 7.2.

7.6 Spare partsAlways quote the following data when ordering spare parts:

Pump type: e.g. KRTF 100--401/504XG--S

Works-No. / Serial No.(e.g. 5M07-777222/3or 888999) fill in

Motor-No. (e.g. 015234 or blank)

This data can be taken from the nameplate.

Caution

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15

8 Trouble-shooting

Unit not pumpingPump delivers insufficientlyCurrent / power consumption too highHead too lowPump operation is uneven and noisy

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 an 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 discharge elbow andlowering it back again.

Pump inlet blocked by deposits Clean inlet, pump parts and non return valveInlet pipe or impeller blocked -- rotor runningsluggishly

Remove deposits from within the pump and / orpipelines

Dirt / fibres in impeller chambers Check impeller ensuring that it rotates slightly -- ifnecessary clean hydraulic

Wear 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 KSB.

Oscillations caused by plant Contact KSB.Wrong 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 are defective Replace by new original KSB cabling or contact your

nearest authorized KSB agentRadial bearing in the motor defective Contact KSB.Water level dropping excessively during operation Check supply and capacity of system -- (sump depth)

check level controlTemperature 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

If working inside the pump is necessary whilst the pump is under warranty, then contact your nearestauthorized KSB agent prior to commencement of work. Non-observance will negate any warranty claims.

Non-observance will negate any warrentydaims.

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16

Appendix

Appendix 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General pump outline 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General assembly drawing with parts list -- impeller type D 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General arrangement drawing with parts list -- impeller types F, E and K 20. . . . . . . . . . . . . . . . . . . . . . . . .

Installation plan -- mechanical seal with parts list 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General outline-installation set 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wet-well installation with guide cable 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wet-well installation transportable 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical connection diagram 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical connection diagram 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function chart -- Leakage detection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impeller mounting / dismantling device 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supplement 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KSB Spare Parts Service 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KRT

17

General pump outline

Motors: 23 4...65 420 6...50 610 8...35 8

DN 100-300

903.03 Oil-priming plug411..03

903..05 Oil-drain plug411..05

B

Fig. 1a Fig. 1b

Fig. 2

ABA

A

A

81-29.03

Fig. 3

Fig. 4

KRT

18

Fig. 5

Fig. 6

Fig. 7

KRT

19

General assembly drawing with parts list -- impeller type D

Motors: 23 4...65 420 6...50 6

150-400150-401200-400250-400300-400

914.03920.01902.01

B - B81-45411.26

903.04411.04

UG1032623

KRT

20

General arrangement drawing with parts list -- impeller types F, E and K

Motors: 23 4...65 420 6...50 610 8...35 8

100-401150/151-401

200-330200-401250-370250-401300-380

OW 382429--00

KRT

21

Part No. Part description

59-17 Shackle69-14 Leakage detector81-18 Cable socket81-45 Float switch81-59 Stator101 Pump casing135 Wear plate163 Discharge cover230 Impeller260 Impeller hub cap320 Anti-frict bear321 Radial ball bearing322 Radial roller bearing330 Bearing bracket360 Bearing cover411 Gasket412 O-ring421 Radial shaft seal ring433 Mechanical seal500 Ring502 Casing wear ring550 Washer636 Grease nipple647 Grease regulator811 Motor casing818 Rotor834 Cable duct900 Screw902 Stud903 Screwed plug914 Socket head cap screw920 Nut932 Circlip940 Key

Standard-mechanical seal

Special mechanical seal

433.01

932.03

433.02

550.44

550.03

433.02

KRT

22

Installation plan -- mechanical seal with parts list

Motors: 23 4...65 420 6...50 610 8...35 8

100/150/151-401200-330200-401250-370250-401300-380

Part No. Part description433 Mechanical seal550 Washer932 Circlip

KRT

23

General outline-installation set

KRT

24

Wet-well installation with guide cable

Motors: 23 4, 29 4, 35 4, 50 4, 65 420 6, 26 6, 32 6, 40 6, 50 610 8, 17 8, 21 8, 26 8, 35 8

DN 100/150/200

Epoxy resin tarcoatingG, GH, H

Motors:35 4...65 4 59-1722 6...50 6

902.35920.35

90-3.38

OW 380772-00

99-6

Counter nut

StandardStandard variants

DN 100/150/200

KRT

25

DN 250/300

Z V

OW 380772-00

900.38

72-1

59-24.01

KRT

26

Part No. Part description

59-17 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

KRT

27

Wet-well installation transportable

Motors: 23 4, 29 4, 35 4, 50 4, 65 420 6, 26 6, 32 6, 40 6, 50 610 8, 17 8, 21 8, 26 8, 35 8

DN 100/150/200/250/300

920.26

914.26

88559-24.0259-17

914.26920.26

59-17

88559-24.02

Z

Z

Special coating

Motors:23 4, 29 420 6, 26 610 8, 17 821 8

Motors:35 4, 50 4, 65 432 6, 40 6, 50 626 8, 35 8

88559-24.02

59-17

902.04920.04

182

OW 309307-00

KRT

28

Part No. Part description

182 Foot59-17 Shackle59-24 Rope885 Chain902 Stud914 Socket head cap screw920 Nut

KRT

29

Electrical connection diagram

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

Description -- Thermal motor monitoring

The winding is protected by two independent temperaturemonitoring circuits:F4, F5 = 2 bimetallic switches in the motor winding

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

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

It is necessary to use one of both circuits to protect thewinding.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 windingtemperature is reached and automatically on again after themotor have cooled down.

Optional use of thermistors (PTC):A thermistor control unit with manual / auto reset may be installedin the control circuit of the motor.It must switch off the pump when the maximum windingtemperature is reached.In this case no additional equipment is necessary.

Temperature monitoring protects the motor in theevent of insufficient cooling. Safe and

reliableoperation and explosion protection can only beensured if the temperature monitoring equipment isoperational.

12x...mm2

7x...+5x1.5mm2

T1 T2 T3 T6 T4 T521 22 10 11 9 PE

(1)

(1)

(2)

(2)

(3)

(3)

(6)

(6)

(4)

(4(

(5)

(5)

(1)

(1)

(1)

(1)

(2)

(2)

(3)

(3)

(10)

(4)

(11)

(5)

12

∆∆ 230 V

∆ 460 V

KRT

30

Electrical connection diagram

Motors: 35 4, 50 4, 65 4, 32 6, 40 6, 50 6, 26 8, 35 8

Description -- Thermal motor monitoring

The winding is protected by two independent temperaturemonitoring circuits:F4, F5 2 bimetallic switches in the motor winding

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

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

It is necessary to use one of both circuits to protect thewinding.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 windingtemperature is reached and automatically on again after themotor have cooled down.Optional use of thermistors (PTC):If frequency converter with motor--protection unit are installed, itis recommanded to use thermistors (PTC).In this case no additional equipment is necessary.

Temperature monitoring protects the motor in theevent of insufficient cooling. Safe and reliable

operation and explosion protection can only be ensured ifthe temperature monitoring equipment is operational.

T1

T6

T2

T4

T3

T5

PE

PE 21 22

3 4

L1 L2 L3 PE

PE

T1

T2

T3

21 22 3 4 10 11 PE

T6

T5

T4

PE

Yel

low

/Gre

enB

lack

Bro

wn

Blu

e

Yel

low

/Gre

en

Yel

low

/Gre

enB

lack

Bro

wn

Blu

e

KRT

31

Function chart -- Leakage detection

M

PE

B2

K 1

9

Leakage inside the motorAn electrodes fitted inside the motor monitor the winding andconnection space for leakage. It must be connected to anelectrode relay. Tripping of the electrode relay must result in thepump being cut out. The electrode relay (K1) must meet thefollowing requirements: Sensor circuit 10 to 30V~, tripping current0.5 to 3 mA.

Check of the Leakage sensorMeasure the resistance between terminal 9 and the earthconductor (PE).The resistance measured must be higher than 60 kΩ. Lowerresistance values would suggest water ingress into the motor. Inthis case the motor must be opened and overhauled.

B2 = Leakage sensor inside the motorCore identification: 9,

K1 = Electrode relay.

Mechanical seal leakageMotors: 35 4, 50 4, 65 4, 32 6, 40 6, 50 6, 26 8, 35 8The chamber for mechanical seal leakage is equipped with a floatswitch. The contact (max. 250V~/2A) opens when leakage isdetected in the leakage chamber. Opening of the contact shalltrigger an alarm signal.

Check of the float switch:Measure the resistance between terminals 3 and 4. Theresistance must be lower than 1Ω.In the readings suggest an open switch, check for mechanicalseal leakage.

KRT

32

Impeller mounting / dismantling device

100/150/151-401200-330200-401

250-370/401300-380

Mounting / dismantling of impeller

Tools required:Dismantling device Material-No. 19 138 913

Offset screwdriverDIN 911 Material-No. 00 588 089

The impeller is mounted / dismantled by using the special deviceillustraded in Fig. 2.

Dismantling1. Loosen impeller fixation according to the appertaining

appendix ”General drawing”.

Fig. 1 Unscrew impeller screw 914.10 and remove impellerhub cap 260.

Dismantling the impeller Fig. 2b2. Impeller 230 is removed by means of the mounting /

dismantling device.For this purpose, screw hex. bolt, part 4, into shaft end to avoiddamage to the shaft thread.

Fit special impeller mounting/dismantling device by screwingin part 2.After that, screw down threaded bolt, part. 1, and removeimpeller.

Assembly Fig. 2a

1. Screw part 1of the impeller mounting device into the shaft endof the pump unit in order to mount impeller 230.

2. After that, fit part 2 by screwing it down onto the threaded boltpart 1.

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

Fig. 1

230 914.10 260

Fig. 2

Fig. 2a Fig. 2b

KRT

33

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110

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25

M12

150

18

89

50

M10

85

10

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0106

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292

427

80N

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SW

19

45N

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17

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inm

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(Dim

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inm

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1. Works No. / Item No.

KRT-F 100-250/7 4 UG-2492--M01--753328

enter here

2. Required part with part No.

enterhere

Sample

34

. . . and should something have to be replaced,

KSB’s competent Spare Parts Service is at your disposal for the products

D Amarex/KRT D Amamix/AmapropD Sewatec D AmajetD Amacan D GetecD Omega

To: KSB Aktiengesellschaft Postfach 200743 Date:Turmstr. 92 D-06008 Halle/SaaleD-06110 Halle/SaaleErsatzteilabteilung

Fax: (+49) 345/48 26 4691 Tel: (+49) 345/48 26--0

From:

In order to ensure the smooth processing of your spare parts inquiry, we request that you let us have the following data:

D The works No. is given on the name plateof your pumpe.g. 2--M01--753328

or9970428626 000100 2

in addition:

Pump typee.g. KRT-F 100-250/7 4 UG-S

D The description of the parts is givenin the operating instructionse.g. Impeller, Part no. 230

in addition:

for multi--vane impeller:impeller diameter in mm

for terminal gland:cable length in mm

KRT

2553

.804

1/2-

1406

.12.

2006

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tom

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KSB Pumps Inc5885 Kennedy Road . Mississauga . Ontario L4Z 2G3Phone: (905) 568--9200 . Fax: (905) 568--3740 . www.ksb.ca

KSB, Inc.4415 Sarellen Road . Richmond, VA23231Phone: (804) 222--1818 . Fax: (804) 226--6961 . www.ksb--inc.com

KRT