SEO-91SEO001PO/002PO-OM-C-18/04/2011

COMMENTS :
Sign.
N.
Sign.
N.
Sign.
N.
Sign.
N.
18/04/2011
Sign.
N.
13/12/2010
Sign.
N.
11/10/2010
REV
ETABLI
ESTABLISHED
VERIFIE
CHECKED
Approved
APPROUVE
APPROVED
DATE
Approved as noted
Date : ..
MODIFICATIONS
Returned for correction
STAT
For information
Signature : .
LAHMEYER INTERNATIONAL
GOVERNMENT OF THE REPUBLIC OF THE SUDAN

MINISTRY OF IRRIGATION AND WATER RESOURCES
MEROWE DAM PROJECT IMPLEMENTATION UNIT
MEROWE DAM PROJECT

10 x 140MVA
CONTRACTS 3A, 3B, 3C, 3E
ENGINEER:
CONTRACTOR:
OPERATING & MAINTENANCE MANUAL
DOMESTIC SEWAGE SYSTEM SEWER SHAFT PUMPS

-SEO(91SEO001PO / 002PO)
SCALE
1/1
Subcontractor:
Power Environment
Hydro
REV
AHS MRW00SEO.OM.109.08
SH/SH END N of SH
1/
INTERNAL USE
Ce document proprit de ALSTOM ne doit pas tre utilis, copi ou communiqu des tiers sans son autorisation
This document is the exclusive property of ALSTOM and shall not be used copied or communicated to third parties without their prior authorization
AHS-MRW00SEO.OM.109.08
REVISION: C
Rev. Date: 18.04.2011
page: 1 of 81
OPERATION & MAINTENANCE MANUAL

PAGE
CHAPTER
B)
List of Illustrations
C)
Introduction:
C1)
General Description of Equipment
C2)
Brief Description of Equipment Use
C3)
C4)
Definitions and Technical Terms Used

List of items used
D)
Detailed Description of Equipment

FLOWDIAGRAM
12
TECHNICALDATASHEETSPUMP
13
15
PUMPDATASHEET
16
GENERALPUMPOUTLINE
21
GENERALARRANGEMENTDRAWING
22
INSTALLATIONPLANMECHANICALSEAL
27
DIMENSIONTABLES
28
GENERALOUTLINEINSTALLATIONSET
29
GENERALARRANGEMENTDRAWINGWETWELLINSTALLATION
28
ELECTRICALCONNECTIONDIAGRAM
34
OPERATIONALDIAGRAMMOISTUREMONITORING
36
ASSEMBLYINSTRUCTIONSIMPELLER
37
ASSEMBLYINSTRUCTIONSCUTTER
40
DISMANTLING/ASSEMBLYSIMPELLER
40
FITTINGINSTRUCTIONSFORSTEELDOWELS
41
PUMPFLOWCURVES
42
E)
Operating Principles and Characteristics
F)
G)
Operating Instructions
Testing and Adjustment
50
GENERAL
SAFETY
TRANSPORT&STORAGE
DESCRIPTIONOFPUMP
ASSEMBLYINSTALLATION
STARTUPSHUTDOWN
TROUBLESHOOTING
51
51
52
52
53
53
58
Maintenance Instructions:
H)
7
11
43
59
H1)
Preventive Maintenance
60
H2)
Repair and Adjustment
63
69
H3)
Spare Parts Lists

STOCKAGEOFSPAREPARTS
GENERALARRANGEMENTDRAWINGSWITHPARTSLIST
H4)
H5)
J)
Special Tools Lists

List of Suppliers
As Built Drawings
REVISION: C
Rev. Date: 18.04.2011
71
73
79
80
81
page: 2 of 81
B) LIST OF ILLUSTRATIONS
SITE TEST REPORTS
SEO DOMESTIC SEWAGE SANITARY

WASTEWATER TREATMENT SYSTEM
REVISION: C
Rev. Date: 18.04.2011
page: 3 of 81
C) INTRODUCTION
REVISION: C
Rev. Date: 18.04.2011
page: 4 of 81
C1) BRIEF DESCRIPTION OF EQUIPMENT

SEWER SHAFT SEAL PUMPS
LIST OF MAIN EQUIPMENT:
REFERENCE
DESCRIPTION
MODEL
91SEO001PO/002PO
DOMESTIC SEWAGE PUMPS
AMAREX KRTS
40-250/62UG-S
SUPPLIER
MANUF: KSB
SUPPLIER:
HYTEC
*)
The INSTRUMENTS AND
VALVES are described in the OMM of
Valves and Instruments (ITY system)
REVISION: C
Rev. Date: 18.04.2011
page: 5 of 81
C2) DESCRIPTION OF USE OF EQUIPMENT
REVISION: C
Rev. Date: 18.04.2011
page: 6 of 81
C3) DEFINITION OF TECHNICAL TERMS

Centrifugal Submersible Pump: A pump and its electric motor together in a protective
housing which permits the unit to operate under water. Centrifugal pump is a rotodynamic
pump that uses a rotating impeller to increase the pressure and flow rate of a fluid.
Centrifugal pumps are the most common type of pump used to move liquids through a piping
system. The fluid enters the pump impeller along or near to the rotating axis and is
accelerated by the impeller, flowing radially outward or axially into a diffuser or volute
chamber, from where it exits into the downstream piping system. Centrifugal pumps are
typically used for large discharge through smaller heads.
Head(1) A measure of the energy possessed by water at a given location in the water
system expressed in feet; (2) a measure of the pressure or force exerted by water expressed
in feet.
Velocity HeadA measurement of the amount of energy in water due to its velocity or
motion.
Pressure HeadA measurement of the amount of energy in water due to water pressure.
EfficiencyA ratio of total energy output to the total energy input expressed as a percent.
PrimingThe action of starting the flow in a pump or siphon. With a centrifugal pump, this
involves filling the pump casing and suction pipe with water.
Impeller: The moving element in a pump that drives the fluid.The bladed member of the
rotating assembly of the pump which applies the principal force to the liquid being pumped
Backwash: The process of flow reversal to clean a filter and to restore it to the normal clean
condition for filtering with a minimum resistance to flow through the media.
Cavitation: A condition that occurs in pumps when the water/liquid entering the pump is
changed from a liquid state to a gaseous state and back to liquid that is generally caused by
too high of flow rate or from pipe that is too small for the flow rate. The formation of vapor
bubbles in areas of low pressure in a liquid.
Cavitation damage: The pitting or wearing away of a solid surface caused by the collapse
of vapor bubbles created by low pressure prior to the damage.
Centrifugal Pump: a type of kinetic energy pump using centrifugal force(slinging motion) to
accomplish it's work. A pump containing a rotation impeller or rotating vanes mounted on a
shaft in a casing and turned by a power source. The rotating impeller uses centrifugal force
to deliver water in a steady stream.
REVISION: C
Rev. Date: 18.04.2011
page: 7 of 81
Dead head: Operating point on the curve where unit is pumping zero GPM - also known as
Shut-off Head.
Diffuser: Operating point on the curve where unit is pumping zero GPM - also known as
Shut-off Head.
Discharge: Where the water exits the pump
Discharge Head: The total head, including static head and friction head, on the discharge
side of the pump.
Effluent: The output stream exiting the system, filter or other device - often the waste stream
Explosion proof: A type of motor enclosure that will prevent sparks generated by the motor
from reaching the atmosphere outside of the motor enclosure. As a general rule our
company does not sell this kind of motor.
Flange: A device used to couple to a pipe on the suction or discharge of a pump
Nozzle: An ejector part/device that increases the velocity of the liquid flowing through it by
creating a partial vacuum at it's throat. Atmospheric pressure causes the increase in velocity.
NPSH: Net Positive Suction Head. There are two types of NPSH. NPSHR is the amount of
head required by the pump to keep the liquid being pumped in a liquid state. The only way
NPSHR can be changed is by changing the pumps' rotational speed or its impeller diameter.
NPSHA is the amount of head available to the pump to overcome the NPSHR. NPSHA
should be a larger number than NPSHR. NPSHA is affected by atmospheric pressure
changes, altitude, pipe and fitting sizes, and elevation to the liquid being pumped.
Operating Pressure: The manufacturer's specified range of pressure expressed in pounds

per square inch (PSI) in which a water processing device or water system is designed to
function.
Pressure Differential:
The difference is pressure between two parts of a hydraulic system (influent and effluent of a
filter, suction and discharge of a pump, the up and down-stream sides of a venturi or orifice).
Pump Strainer: A device, placed on the suction side of a pump, which contains a removable
strainer basket designed to trap debris in the waterflow with a minimum of flow restriction
Pumping Level: The lowest water level reached during pumping operation.
REVISION: C
Rev. Date: 18.04.2011
page: 8 of 81
Rated pressure: That pressure that is equal to or less than the designed pressure and
appears on the dataplate of the equipment
Rate of flow: The measurement of the volume of flow per unit of time (m3/s)
Recirculating system: The entire system including the suction piping, pump, strainer, filter,
face piping and return piping.
Self Priming: A pump designed to have the ability to prime itself automatically, after being
initially filled, when operating under a suction lift; to free itself of entrained gas without losing
prime; and to continue normal pumping operation without attention.
Service Factor: A factor indicating the degree to which an electric motor can be operated
over the specified horsepower without danger of overloading or failure.
Service Pressure: The range of pressure in the pressure tank during the pumping cycle,
usually expressed in pounds per square inch gauge (P.S.I.G.).
Setting: The vertical distance from the level at which the discharge pipe leaves the well to
the bottom of the pump or jet assembly in the well.
Shut off head: The head created by a pump that is running against a closed discharge.
Static Head: The vertical distance between the free level of the source of the supply and the
point of free discharge, or to the level of the free surface of the discharged water.
Suction: Where the water enters the pump
Suction Head: The total head on the suction side of the pump, including suction lift and
friction head.
TDH: Total Dynamic Head
TDSL: Total Dynamic Suction Lift
TEFC: Totally Enclosed Fan Cooled - a type of motor enclosure
REVISION: C
Rev. Date: 18.04.2011
page: 9 of 81
Total Discharge Head: The total pressure or head the pump must develop on the
discharge side. It is the sum of THE ELEVATION, THE SERVICE PRESSURE, and THE
FRICTION LOSS. Of course, all of these measurements must be expressed in the same
units, usually feet of head, before adding them together
Vacuum: Negative pressure; a region in a pump or a pipe that is below atmospheric

pressure
Venturi: A cylindrical tube that gradually increases in size. When used in conjunction with a
nozzle, it converts the velocity of the liquid being pumped to pressure.
Volute Casing: A pump housing that is spiral or scroll shaped where the suction and
discharge pipes screw into the unit.
Watts: A measurement of electrical power where watts = volts x amps. One watt is the rate
of energy expended when a steady current of one amp flows under a pressure of one volt.
1HP = 746 Watts.
Wastewater
Wastewater is "used" water, the water leftover after its use in numerous application such as
industrial, agricultural, municipal, domestic and on
REVISION: C
Rev. Date: 18.04.2011
page: 10 of 81
C4) List of Items Used
UNIT SYS. NUM
TYPE
DESIGNATION
SUPP.
ROOM
91
SEO 001
PO
SEWER SHAFT SERVICE PUMP
AHS
outdoor
91
SEO 002
PO
SEWER SHAFT STAND BY PUMP
AHS
outdoor
REVISION: C
Rev. Date: 18.04.2011
page: 11 of 81
D) DETAILED DESCRIPTION
REVISION: C
Rev. Date: 18.04.2011
page: 12 of 81
FLOW DIAGRAM
REVISION: C
Rev. Date: 18.04.2011
page: 13 of 81
REVISION: C
Rev. Date: 18.04.2011
page: 14 of 81
TECHNICAL DATASHEETS
PUMPS
REVISION: C
Rev. Date: 18.04.2011
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REVISION: C
Rev. Date: 18.04.2011
page: 16 of 81
REVISION: C
Rev. Date: 18.04.2011
page: 17 of 81
REVISION: C
Rev. Date: 18.04.2011
page: 18 of 81
Operating instructions
2553.804/8-10
Amarex KRT
Submersible motor pumps
Series
Size
Motor sizes
Material types
Works-No.:
Amarex KRT
DN 40...DN 200
5 2...23 2 (2pol.)
5 4...29 4 (4pol.)
4 6...12 6 (6pol.)
G, GH, H
C1, C2
see data plate:
The
operating
manual
contains
important
information
and
hazard/danger warnings.
It is imperative to read the instructions
set out in the manual prior to installation, making electrical
connections and commissioning. Additional operating instructions relating
to the components of this plant will also have to be 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.
01 055 329
KSB
REVISION: C
Rev. Date: 18.04.2011
page: 19 of 81
KSB
Amarex
These operat ing i nstructions contain important notes f or the

individual material versions of the below sizes:
Type Size
Material version
S, F, E, K, D =
impeller type
Cast iron
G
G1
G2
GH
S, F, K
40 - 250
S, F, K
F, K
F, K
F, E
80 - 250
F, E
F, E, K
80 - 315
F, E, K
F, K
F, K
100 - 240
F, E, K
100 - 250
F, E, K
F, K
F, K
F, E, K
100 - 315
F, E, K
F, K
F, K
150 - 251
--
--
--
F, E, K, D
150 - 315
F, E, K,
D
F, K
F, K
200 - 280
--
200 - 281
--
200 - 315
--
Type Size
Material version
F, K =
impeller type
Industrial material
H
C1
C2
40 - 250
F, K
80 - 315
F, K
F, K
F, K
100 - 240
F, K
100 - 250
F, K
F, K
F, K
F, K
100 - 315
F, K
F, K
F, K
F, K
150 - 315
F, K
F, K
F, K
F, K
200 - 280
Contents
KRT
Page
General
2
2.1
2.2
2.3
2.4
2.5
2.6
3
3
3
3
3
3
2.8
Safety
Marking of Instruction in the Manual
Personnel Qualification and Training
Noncompliance with safety instructions
Safety Awareness
Safety instructions for the operator / user
Safety instructions for maintenance,
inspection and installation work
Unauthorised modification and manufacture
of spare parts
Impermissible modes of operation
3
3.1
3.2
Transport and interim storage

Transport
Interim storage / Preservation
4
4
4
4
4.1
4.2
4.3
4.4
Description of the product and accessories

Technical specification
Designation
Configuration
Accessories
4
4
4
4
5
5
5.1
5.2
5.3
5.4
5.5
5.6
Installation at site
Safety regulations
Checks to be carried out prior to installation
Installation of the pump/unit
Connecting the piping
Electrical connection
Assembly of the installation kit
5
5
5
5
5
6
7
6
6.1
6.2
6.3
6.4
Commissioning, Startup / Shutdown

Commissioning
Operating limits
Shutdown / Storage / Preservation
Returning to service after storage
8
8
8
9
9
7
7.1
7.2
7.3
7.4
7.5
7.6
Maintenance / Repair
General instructions
Maintenance / Inspection
Drainage / Disposal
Dismantling
Reassembly
Spare parts stock keeping
9
9
10
11
11
12
13
Troubleshooting
14
Annexe (survey)
15
2.7
2
REVISION: C
Rev. Date: 18.04.2011
page: 20 of 81
3
4
4
4
KSB
Amarex KRT
General pump outline

DN 40...DN 200
Motor
52...23 2;
46...12 6
5 4...29 4;
Diagram data plate

Pump type
Works No. / Identity No.
Motor No.
Important information for ordering spare parts
explosionproof version
Pump type
Works No. / Identity No.

Motor No.
Identity No of
explosionproof certificate
Fig. 1
16
REVISION: C
Rev. Date: 18.04.2011
page: 21 of 81
KSB
Amarex KRT
Fig. 2a
Fig. 2b
Motor:
23 2,
23 4, 29 4
Motor:
52,62,82,122,172
54,74,114,164
46,66,96,126
903
411.03
903
411.03
M=70
M=25
Fig. 3
81-29.03
A
Fig. 4
B
A
81-29.02
17
REVISION: C
Rev. Date: 18.04.2011
page: 22 of 81
KSB
Amarex KRT
Fig. 6
Motor:
52,62,82,122,172
54,74,114,164
46,66,96,126
Motor:
232
234,294
Fig. 8
Fig. 9
18
REVISION: C
Rev. Date: 18.04.2011
page: 23 of 81
KSB
Amarex KRT
General arrangement drawing

Motor:
5 2...23 2
4 6...12 6
40-250
80-250
80-315
100-240/250
100-315
150-251
150-315
200-280/281
200-315
5 4...29 4
OW 382 436-00
19
REVISION: C
Rev. Date: 18.04.2011
page: 24 of 81
KSB
Amarex KRT
Cable entry
H07RN-F 12x5
H07RN-F 12x2,5
Z1
(only D 150-251)
D 150-251
D 150-315
D 100-315
20
REVISION: C
Rev. Date: 18.04.2011
page: 25 of 81
KSB
Amarex KRT
S 40-250
s=0.20.1 mm
321.02
Part-No.
Part description
Part-No.
Part description
23-7
Impeller body
421
Radial shaft seal ring
69-14
Leakage detector
433
Mechanical seal
80-1
Submersible motor
441
Seal casing
81-17
Butt joint
500
Ring
81-39
Clamp
502
Casing wear ring
81-51
Shim
503
Impeller wear ring
81-59
Stator
529
Bearing sleeve
99-17
Desiccant
550
Washer
101
Pump casing
561
Grooved pin
113
Intermediate casing
811
Motor casing
131
Inlet ring
818
Rotor
135
Wear plate
834
Cable duct
162
Suction cover
852
Screwed coupling
163
Discharge cover
900
Screw
230
Impeller
901
Hexagon head bolt
321
Radial ball bearing
903
Screwed plug
322
Radial roller bearing
914
Socket head cap screw
330
Bearing bracket
920
Nut
410
Profile joint
930
Safety device
411
Gasket
931
Lockwasher
412
O-Ring
932
Circlip
21
REVISION: C
Rev. Date: 18.04.2011
page: 26 of 81
KSB
Amarex KRT
Installation plan - mechanical seal

Motor:
5 2...17 2
5 4...16 4
40-250, 80-250
100-240, 100-250
Part No.
433
515
Part description
Mechanical seal
Clamping ring
G, GH, C1
433.01
(Balg-mechanical seal)
515
433.02
H, C2
G, GH, C1
0W 309130-00
GLRD HJ
433.01
515
433.02
(Mechanical seal with
covered springs)
29
0W309130-05
Standard
Standard-Varianten
22
REVISION: C
Rev. Date: 18.04.2011
page: 27 of 81
Amarex KRT
Matabelle / Dimension table / Tableau de dimensions
Stationre Aufstellung / Stationary installation / Installation stationnaire
Seilfhrung / Guide wire / Guidage du cble
G, G1, G2, GH, H, C1, C2

B
10
Baugre / Size / Taille : KRT 40-250

Werkstoffausfhrung / Material variant / Excution matriaux :
DN3
100
4 x 18
60
85
85
670
153
555
102
7 (C2)
125
a1
448
165
DN 3
165
DIN EN 1092-2, PN 16
100
C2
170
200
260
300
M16 x 200
50
1)
DN1
110
5o
V 70
18
150
780
600min
A-A
175
220
40
1)
40-250
Motor
Motor
Moteur
345
Gewicht /
Weight / Poids
[kg]
DN1
DN3
a1
H, C1, C2
65*
50
545
125
167
62
133
175
82
142
184
157
204
168
215
136
178
150
192
52
12 2
575
17 2
54
74
545
* bei / only / pour KRT K 40-250

0W 382 529
24
450min
600min
300
Mindestwasserstand
Min. water level
Niveau deau mini.
Hydraulik
Hydraulics
y
q
Hydraulique
S
K
200
150
20
Mae in mm / Dimensions in mm / Cotes en mm

REVISION: C
Rev. Date: 18.04.2011
page: 28 of 81
Amarex KRT
Matabelle / Dimension table / Tableau de dimensions
Transportable Aufstellung / Transportable installation / Installation transportable
Baugre / Size / Taille : KRT 40-250; 80-250; 80-315; 100-240; 100-250
Werkstoffausfhrung / Material variant / Excution matriaux : G, G1, G2, GH, H, C1,
C2
b2
e2
z f x lf
DN2
a2
1)
DN2
R2
gf
f2
Kf
Df
DIN EN 1092-2, PN 16
DN1
T
DN2
1)
Mindestwasserstand
Min. water level
Niveau deau mini.
Hydraulik
Hydraulics
y
q
Hydraulique
K
S
40-250
gf
Kf
Df
zf
l f
40
88
110
150
18
80
138
160
200
18
100
158
180
220
18
Gewicht /
Weight / Poids
[kg]
Motor
Motor
Moteur
52
DN1
DN2
a2
b2
e2
f2
R2
H, C1, C2
65*
40
685
445
225
240
300
400
200
125
167
133
175
142
184
157
204
168
215
136
178
150
192
136
----
150
----
165
----
62
C1: 540
82
12 2
C1: 270
715
17 2
54
685
74
F
E
80-250
54
100
80
717
475
255
225
325
400
200
74
11 4
747
16 4
F
E
K
80-315
52
80
80
715
470
250
220
320
62
82
12 2
400
200
C1: 540
C1: 270
745
17 2
23 2
F
100-240
11 4
100
100
885
505
755
475
255
255
380
16 4
F
E
K
100-250
54
100
100
725
475
255
74
11 4
755
255
380
32
----
134
210
142
218
151
227
166
242
177
253
254
300
400
C1 540
C1:
200
C1 270
C1:
165
225
175
235
400
200
141
205
C1: 540
C1: 270
155
219
170
234
180
244
16 4
* bei / only / pour KRT K 40-250
0W 382 528
175
Mae in mm / Dimensions in mm / Cotes en mm

REVISION: C
Rev. Date: 18.04.2011
page: 29 of 81
KSB
Amarex KRT
General outline installation set
35
REVISION: C
Rev. Date: 18.04.2011
page: 30 of 81
KSB
Amarex KRT
Wet-well installation with guide wire

Motor:
DN
5 2...23 2, 5 4...29 4, 4 6...12 6
40/80/100/150/200
Counter nut
Epoxy resin tar

coating
Standard
Standard variants
200-280
200-281
200-315
36
REVISION: C
Rev. Date: 18.04.2011
page: 31 of 81
KSB
Amarex
Part No.
59-17
59-18
KRT
Part description
Shackle
Hook
59-24.01/02
Rope
72-1
Flanged bend
90-3
Dowel
99-6
Round cord
410
Profile joint
550
Washer
571
Clamp
572
Clamp
732
Holder
885
Chain
894
Bracket
900
Screw
902
Stud
904
Threaded pin
914
920
Nut
970
Plate
37
REVISION: C
Rev. Date: 18.04.2011
page: 32 of 81
KSB
Amarex KRT
Wet-well installation transportable

Motor:
DN
5 2...23 2, 5 4...29 4, 4 6...12 6
40/80/100/150/200
Epoxy resin tar coating
200-280/281/315
Standard
Standard variants
0W 309308-00
38
REVISION: C
Rev. Date: 18.04.2011
page: 33 of 81
KSB
Amarex KRT
40-250 (G ...H)
80-250 (G)
89-315
100-240, 100-250
D 150-251
D 150-315
100-315, 150-315
Part
No.
182
183
59-17
59-24
595
885
892
901
902
914
920
932
Part description
Foot
Support foot
Shackle
Rope
Buffer
Chain
Foot plate
Hexagon head bolt
Stud
Nut
Circlip
80-315, 100-240, 100-250, 100-315, 150-315
200-280/281/315
39
REVISION: C
Rev. Date: 18.04.2011
page: 34 of 81
KSB
Amarex KRT
Electrical diagram
Motor:
5 2...23 2, 5 4...29 4, 4 6...12 6
Description - Thermal cutout Amarex KRT,

explosionproof
Power cable
With explosionproof motors, t he w indings are prot ected by t wo

independent temperature monitoring circuits.
Two bi metal s witches F4, F5 (i dentification t ape 21, 22) s erve as
temperature monitoring devices which, as soon as the max. winding
temperature is reac hed, s witch of f t he pum p and aut omatically on
again after the windings have cooled down.
This requi res t hat t he c onductors are di rectly c onnected to the
control circuit of the motor contactor.
Three P TC t hermistors R1, R2, R3 (identification tape 10, 11) are
fitted as addi tional t emperature c ontrolslimiters w hich, in the event
of t emperature s witch f ailure, s hut dow n t he pum p bef ore the
temperature permissible f or ex plosionproof appl ications i s
exceeded. Automatic reset is not allowed.
A thermistor control unit T with manual reset must be installed in
the control circuit of the motor contactors.
This equipment is of a c ommercial brand, w hich c an al so be
purchased via KSB.
Control cable
Motor version X, Y
Motor version U, W
For operation with frequency converter, a release device bearing the

test mark PTB 3.53-PTC/A must be used.
If the pump has been shut down by thermistors, it is necessary to
overhaul it.
In urgent c ases t he res et m ay be us ed af ter the motor has cooled
down. The thermistor must not be shut off at any time.
Explosionproof requirements for the pumps are only
met if the built-in temperature monitoring devices
(bimetal switches and thermistors) including
conductors 21, 22, 10, and 11 are connected.
Temperature switch
F4, F5 = Monitoring circuit =2 bimetal switches in the motor
winding
Identification tape 21, 22
max. operating voltage of switch: 250 V
max. current: 2 A
R1,R2,R3 = Temperature control circuit = 3 PTC thermistors in
the m
otor winding
Identification tape: 10, 11
max.operating voltage on terminals
Umax = 30 V =
resistance between terminals 10/11
- at ambient temperature R 10-750
- at shutdown temperature R > 4000
Attention
Do not test monitoring circuits by means of a

hand megger. Use an ohmmeter.
Description - thermal cutout Amarex KRT, non-explosionproof

The winding is protected by one temperature monitoring circuit.
Bimetal switches F4, F5 (identifications tape 21,22) are used for
temperature monitoring. It switches off the pump as soon as the
max. winding temperature is reached, and automatically switches it
on again after the winding has cooled down.
The bimetal switch must be directly connected to the control circuit
of the motor contactor.
Conductors 10 and 11 (used for explosionproof version only) will be
connected to dummy terminals.
40
REVISION: C
Rev. Date: 18.04.2011
page: 35 of 81
KSB
Amarex KRT
Function chart moisture detection
PE
K1
B2
Function chart - moisture detection

(see also wiring diagram)
The motor chamber of t he pum p i s f itted w ith a m oisturesensitive electrode, which is to be m onitored by m eans of a
electrode rel ay. I n c ase of m oisture penet rating i n t he m otor
interior, a current will flow from te rminal 9 to e arth v ia th e
moisture electrode.
B2 =
electrode in motor chamber

Core identification: 9
K1 =
electrode relay
Sensor circuit 10 - 30 V~
Release current 0,5 - 3 mA.
KSB c an provi de you w ith an appropri ate el ectrode relay. This

relay needs a power supply 230V~.
Tripping of t he el ectrode rel ay K 1 m ust res ult i n a shutdown of
the motor. Subsequently a revision of t he m otor w ill be
necessary.
Check of moisture-sensitive electrode

An i nsulation res istance m easurement has to be effected in
conformity with para 7. 2.1. If the measured insulation resistance
is < 1 the motor has to be opened and overhauled.
41
REVISION: C
Rev. Date: 18.04.2011
page: 36 of 81
KSB
Amarex KRT
Assembly instructions-Impeller dismantling/fitting with tapered connection

40-250, 80-250,100-240/250
150-251
80/100/150-315
200-280/281/315
11 8
M20x95
M16
M20
11 197 784
11 197 135
M16x95
M20x155
M20x180
R6
min30
50.5
11197135
45
M16x60
118
min20
F,E,K 80-315
F,E,K 100-315
F,E,K 150-315
K 200-280
K 200-281
D 150-251
D 150-315
D 200-315
Ident-No.
32
S,F,K 40-250
F, E
80-250
F 100-240
F,E,K 100-250
Jacking screw
25
Size
11 197 784
11 305 849
11 305 959
11 306 084
Jacking screw
Jacking screw
42
REVISION: C
Rev. Date: 18.04.2011
page: 37 of 81
KSB
Amarex KRT
Assembly instructions-Impeller dismantling/fitting with tapered connection

40-250, 80-250,100-240/250
150-251
80/100/150-251/150-315
200-280/281/315
Jacking screw
43
REVISION: C
Rev. Date: 18.04.2011
page: 38 of 81
KSB
Amarex
Removing impellers with taper fit

The f ollowing s equence of operat ions must be observed
whenremoving the impeller:
1.
Remove impeller screw 914.10.
2.
Use jacking screw to pull off impeller

(Tight taper fit-impeller may be firmly locked on shaft).
Screw jacking screw either directly into the impeller 230
or into locking sleeve 531, see drawing details opposite
and relevant sectional drawing.
Installation of S/F/E/K/D-Impeller (without locking sleeve

1.
Having i nstalled t he pum p-side mechanical seal

433.02, pus h t he i mpeller 230 (S/F/E/K/D-impeller)
onto the shaft end.
For D 150-251, s crew t hreaded c oupling 852 i nto t he
shaft first.
L
2.
Apply Loc tite 243 to t he t hread of i mpeller s crew

914.10.
Observe Loctite handling instructions. Screw in impeller
screw 914.10 and tighten with a torque wrench.
S/K/F
F/E
F
F/K/E/D
F/K/E
F/K/E/D
D
F/K/E
K
D
3.
40-250
80-250
100-240
100-250
80-315
100-315
150-251
150-315
200-280/281
200-315
(M10)
(M10)
(M10)
(M10)
(M16)
(M16)
(M10)
(M16)
(M16)
(M16)
50 Nm
50 Nm
50 Nm
50 Nm
150 Nm
150 Nm
50 Nm
150 Nm
150 Nm
150 Nm
Mount pump casing 101 with bolts 901.14, square nuts

920.01 w ith l ockwasher 931 and O-ri ngs 412. 15. Us e
torque wrench to t ighten hex . head bol ts 901. 14 For
data, see installation of E/K-impellers, para 2.
S/K/F
F/E
F
F/K/E
D
F/K/E
F/K/E
F/K/E/D
D
K
40-250
80-250
100-240
100-250
150-251
80-315
100-315
150-315
200-315
200-280/281
(M12)
(M12)
(M12)
(M12)
(M12)
(M16)
(M16)
(M16)
(M16)
(M16)
65 Nm
65 Nm
65 Nm
65 Nm
65 Nm
150 Nm
150 Nm
150 Nm
150 Nm
150 Nm
Adjustment of axial clearance

If an axial casing w ear ri ng i s f itted at t he pum p c asing, t he
clearance between the casing and t he i mpeller s hould be
adjusted t o 0. 5 m m (K 40-250 0. 2 mm) by tightening the bolts
901.14. For t he A marex K RT 200-280/ 281 (radi al clearance) an
adjustment is not necessary.
44
REVISION: C
Rev. Date: 18.04.2011
page: 39 of 81
KRT
KSB
Amarex KRT
Assembly instruction - Cutter
Dismantling of the S-impeller (Amarex KRT S 40-250)
Dismantling of the S-impeller (Amarex KRT S 40-250)
1. After fitting the pum p-side m echanical s eal 433. 02, pus h
impeller 230 ont o t he s haft, f it grooved pin 561.01 into the
impeller.
The impeller body 23-7 is f itted ont o t he c entering devi ce.
Then f it i mpeller s crew 914. 10 and t ighten it by using a
torque wrench.
Tightening torque: M 10; 50 Nm
Dismantling t akes pl ace i n res erve order. The impeller can be

pulled of f f rom t he s haft by m eans of t he s ame forcing screws
used for the Amarex KRT K 40-250 (Attention: tight cone seat!)
Pay attention t o as sembly i nstruction Impeller dismantling /
assembly with tapered connection.
2. Fit pum p c asing w ith j oint O-ri ng 412.16 using hex. screws
901.14 and tighten it by a torque wrench.
Tightening torque: M 12; 60 Nm.
3. Insert j oint O-ri ng 412. 16 i nto s uction c over 162 and m ount
ring 500.02 w ith c ylindrical pi n 914. 07 i n t he s uction
cover.Insert s uction c over i nto t he pum p casing until it
borders on t he i mpeller bl ades (cylindrical pin 914.15 must
not prot rude f rom t he t hreads of t he s uction c over!) - but do
not yet tighten!
4. Measure the di stance bet ween pum p c asing and s uction
cover and shift the suction cover with cylindrial pin 914.15 by
S = 0,2 0,1 mm vis--vis the pump casing.
Tightening torque: M 12; 30 Nm
5. Make sure t hat t he i mpeller i s runni ng s moothly by t urning
itsbody (sliding between s uction c over and i mpeller i s not
admissible).
45
REVISION: C
Rev. Date: 18.04.2011
page: 40 of 81
46
10
18
REVISION: C
50
150
80
85
110
89
Rev. Date: 18.04.2011
M 10
(Dimensions in mm)
M 12
(Dimensions in mm)
...25
Supplement
Ident-No.:
01 066 974
45 NM ! SW 17
80 NM ! SW 19
R 292 247
Amarex KRT
page: 41 of 81
Baureihe-Gre
Type-Size
Modle
Tipo
Serie
Tipo
Nenndrehzahl
Nom. speed
Vitesse nom.
Velocit di rotazione nom.

Nominaal toerental
Revoluciones nom.
Laufrad-
Impeller dia.
Diamtre de roue
Amarex KRT 40-250F
2900 1/min
160 mm
Projekt
Project
Projet
Angebots-Nr.
Quotation No.
N de l'offre
Pos.-Nr.
Item No.
N de pos.
Progetto
Projekt
Proyecto
0
39
50
N offerta
Offertenr.
N oferta
US.gpm
50
100
IM.gpm
girante
Waaier
rodete
N pos
Pos. nr.
N de art
Agence Ile-de-France
4, alle des Barbanniers
92635 Gennevilliers Cedex
150
200
100
250
150
200
Qmin
120
35
100
30
Frderhhe
TDH
Hauteur
Prevalenza
Opvoerhoogte
Altura
ft
25
80
20
1
60
16
0
10
m/h
20
5
30
l/s
40
50
10
15
10
Leistungsbedarf
Power Input
Puiss. abs.
Potenza ass.
Opgenomen
vermogen
Potencia nec.
8
hp
kW
6
4
2
0
10
m/h
20
30
40
50
Frdermenge/Flow/Dbit/Portata/Capaciteit/Caudal
Laufradaustrittsbreite/Impeller outlet width/Largeur la sortie de la roue
Luce della girante/Waaier uittredebreedte/Anchura de salida rodete
42 mm
42 mm
REVISION: C
Rev. Date: 18.04.2011
Aus Kurve K42908/2 gerechnet

T222-Ge, Douaud Nicolas, 2007-09-17
page: 42 of 81
E) OPERATING PRINCIPLES AND

CHARACTERISTICS
REVISION: C
Rev. Date: 18.04.2011
page: 43 of 81
PURPOSE OF THE DOCUMENT

The purpose of this document is to describe the general function, the main
components, the control principles and the interfaces to other systems of the
domestic sewage disposal system pertaining to the MEROWE project.
REFERENCE DOCUMENT
2.1
CONTRACT DOCUMENTS
Particular Technical Specification Contract 3E - 36
2.2
ASSOCIATED DOCUMENTS
AHS MRW 00 SEO-SP100: DOMESTIC SEWAGE SYSTEM _ FLOW DIAGRAM
AHS MRW 00 SEP-SP100: DRINKING WATER SUPPLY SYSTEM FLOW
DIAGRAM
AHS MRW 00 ITY-MS100: PIPING SPECIFICATION
GENERAL DESCRIPTION OF THE DOMESTIC SEWAGE SYSTEM

Domestic sewage from the sanitary facilities of the administration and service
building, the power house, the substation control building and the service area will
be collected in the domestic sewage tank at EL. 241,500 m. Sludge and filter
backwash water originating from the drinking water system will also be directed into
this tank.
Two submergible wastewater pumps (one duty one stand by) of at least 25m/h
capacity transfer the wastewater via a pressure pipe to the outdoor domestic
sewage network at the service area. From this point, the effluents will be directed by
gravity to the sewage treatment plant.
The main components of the domestic sewage disposal system are:
- Domestic sewage tank
- Submergible domestic sewage pumps
- Domestic sewage pressure pipe
- Flushing connections
AA
M-1145-A40215.4/A
REVISION: C
Rev. Date: 18.04.2011
page: 44 of 81
- Valves
- Instrumentation
4
SYSTEMS MANAGEMENT AND OPERATION PRINCIPLES
4.1
DOMESTIC SEWAGE TANK

The domestic sewage tank (00SEO001BA) is a concrete basin integrated into the
service and administration building at El. 241.5. It is accessible via a manhole from
El. 247.600.
The usable volume is 20 m.
It is equipped with
- Support, guiding rope and pressure pipe to install two submergible sewage
pumps. The pumps are accessible by a manhole from El. 247.6.
- A basket with a mesh size equal to the free passage of the pump (>75mm) at the
inlet, accessible by the manhole from El. 247.6. This is only a safety device to
protect the pumps from extraordinary big parts, which are normally not expected
in the network
- a vent pipe going outside the building
A slight slope at the bottom of about 4% will direct domestic sewage to the
submergible pumps.
4.2
DOMESTIC SEWAGE PUMPS

Two pumps 00 SEO 001PO and 00 SEO 002PO are installed as domestic sewage
pumps to transfer domestic sewage from the domestic sewage tank 00 SEO 001 BA
to the outdoor sewage network.
These are submergible centrifugal pumps specially designed for wastewater. They
are placed inside the domestic sewage tank.
The pumps are equipped with special impellers allowing a free passage of at least
75 mm.
This enables to do without strainers or rakes, which would require maintenance.
AA
M-1145-A40215.5/A
REVISION: C
Rev. Date: 18.04.2011
page: 45 of 81
The pumps are connected to the pressure pipe using a specially designed bend.
The weight of the pump acts as a seal between the pump and the bend. For
maintenance, each pump can be removed and repositioned without emptying the
domestic sewage tank.
One pump is working in normal operation mode and the other pump is working in
stand-by operation mode. The permutation of the pump is automatic, while the
pumps electric supply is ensured from the auxiliary board 20LKA001TB.
- A low level detector 00SEP001SN detects a low level in the tank. The pump in
operation is stopped by the main auxiliaries controller 20KKM001AR.
- A high level detector 00SEO002SN detects a high level in the tank. The normal
pump is started by the main auxiliaries controller 20KKM001AR.
- A very high level detector 00SEP003SN detects a very high level in the tank. An
alarm is transmitted to the control room and both pumps are started by the main
auxiliaries controller 20KKM001AR.
The following table provides a summary of the main operation principles:
Sensor identification
Automatic consequences
00SEP003N
: Start of both pumps by the

controller 20KKM001AR, alarm
00SEP002SN
: Start of one pump by the

controller 20KKM001AR
00SEP001SN
: Stop of the pumps in operation by

the controller 20KKM001AR
Note : represents a level rising in the tank

represents a level decreasing in the tank.
Operating volumes (between start and stop) are defined for operating sequences
compatible with the maximum number of start/stop of pumps. Final levels shall be
defined after detailed calculation taking into account minimum level and pump
curves to be given by supplier.
At the outlet of the two pumps 00SEO001PO and 00SEP002PO, two manometers,
respectively 00SEP001LP and 00SEP002LP, allow the local verification of the
pressure levels.
Two pressure logical sensors, respectively 00SEP001SP and 00SEP002SP, ensure
the hydraulic supervision of the flow presence at the outlet of the pumps.
The pumps 00 SEO 001 PO and 00 SEO 002 PO can be isolated for maintenance
purpose respectively by the valve 002 VE as well as 004 VE. Each of these valves is
normally open.
AA
M-1145-A40215.6/A
REVISION: C
Rev. Date: 18.04.2011
page: 46 of 81
Two non-return valves 001 VE and 003 VE prevent respectively counter flows on the
pumps 00 SEO 001PO and 00 SEO 002 PO.
4.3
DOMESTIC SEWAGE PIPING

Domestic sewage piping will either be PVC or cast iron according to piping
specification AHS MRW00 ITY MS 100.
The piping shall have continuous slope as far as possible. If high points or low
points cannot be avoided, venting valves or draining valves will be installed at such
locations.
In order to avoid sedimentation during stand still, the pipe diameter will be selected
to assure a minimum velocity of 0,8 m/s.
4.4
FLUSHING CONNECTIONS
A drinking water tap ND 50 with a hose connection and a hose is installed near the
pumps. Flushing connections with ND 50 hose connections will be supplied to
enable flushing each pump backwards as well as the pressure pipe in case of
blockage or prior to dismantling of the system.
4.5
VALVES
All valves used in the domestic sewage system will be gate valves to avoid any
obstacles that may lead to a blockage.
All check valves will also be of free flow type without restrictions or obstacles when
open.
SYSTEM CONTROL PRINCIPLES
5.1.1
Remote control
This system is controlled from the main auxiliaries controller 20KKM001AR.
The selector switches for the pumps 00SEO001PO/00SEO002PO on the auxiliary
board 20LKA001TB must be set to Remote.
Based on levels in the tank, detected by level sensors, the sewage control box
00SEO001CR sends a starting order to the pump to be started.
AA
M-1145-A40215.7/A
REVISION: C
Rev. Date: 18.04.2011
page: 47 of 81
In case the pump to be started is in electrical fault, detected on the auxiliary board
20LKA001TB, or in hydraulic fault, detected after a time delay by the pressure
logical sensors, the pump to be started is stopped. This pump is then set to fault
mode and the other pump is started in replacement.
5.1.2
Maintenance and manual control

The pumps are controlled from the auxiliary board 20LKA001TB.
The selector switches for the pumps 00SEO001PO/00SEO002PO on the auxiliary
board 20LKA001TB must be set to Local and all operation must be done through
this auxiliary board.
The pumps electrical safety devices are in operation.
All operations are done manually under plant personnel responsibility.
Regularly in order to maintain the pumps in the optimal condition, all pumps must be
set to Local mode, and each of them must be successfully started from the auxiliary
board 20LKA001TB.
5.2
ELECTRICAL INTERFACES TO OTHER SYSTEMS

Domestic sewage tank 00SEO003BA very high level sensor (00SEO003SN) will
interlock sludge discharge and filter backwashing of the drinking water system.
AA
M-1145-A40215.8/A
REVISION: C
Rev. Date: 18.04.2011
page: 48 of 81
INTERFACE DATA
Interface
Maximum instantaneous
flow rate
Domestic sewage in
Flow by gravity into
domestic sewage tank 20
m
Domestic sewage out
Sludge (0,5-1% solids)

from sedimentation tank
from the drinking water
unit to the domestic
sewage tank by gravity
Back wash waste water
from the drinking water
unit to the domestic
sewage tank by gravity
Drinking Water from
drinking water network
Electrical power
6.1
Average flow rate

50 m/d
25 m/h (about 45 m/h in

case both pumps operate
in parallel)
30 m/h
50 m/d
10 m/h
1,5 m/d
15 m/h
Maintenance and
cleaning only
4,5 m/d
Max 17 KW per pump
INSTRUMENTATION
Sensor
Designation
00SEO001LP
00SEO001PO pump
outlet pressure
indicator
00SEO002PO pump
outlet pressure
indicator
00SEO001PO pump
outlet pressure logical
sensor
00SEO002PO pump
outlet pressure logical
sensor
Domestic sewage tank
00SEO001BA low
level sensor
00SEO001BA high
level sensor
00SEO003BA very
high level sensor
00SEO002LP
00SEO001SP
00SEO002SP
00SEO001SN
00SEO002SN
00SEO003SN
Connection to
controller
/
Purpose
00SEO001PO pump
local pressure indication
00SEO002PO pump
local pressure indication
20KKM001AR 00SEO001PO pump

automatic control and
running supervision
20KKM001AR 00SEO002PO pump
automatic control and
running supervision
20KKM001AR Domestic sewage
transfer pumps control
AA
M-1145-A40215.9/A
REVISION: C
Rev. Date: 18.04.2011
page: 49 of 81
F) OPERATING INSTRUCTIONS
&
G) TESTING AND ADJUSTMENT
REVISION: C
Rev. Date: 18.04.2011
page: 50 of 81
KSB
1
Amarex
2.2
General
This KSB pump has been devel oped in accordance with the latest
technology, it was manufactured w ith great c are and i s subject to
constant quality control.
The operating manual is designed to introduce the pump to you to
make operation easier and to make full use of all its applications.
The operat ing manual contains i mportant i nformation to ensure
safe, correct and ec onomic operat ion. It i s i mperative to ob serve
the contents of the operat ing manual to ensure rel iability and l ong
operating life of the pump and to avoid dangerous practices.
The operat ing manual does not t ake i nto a ccount any local
regulations w hich have to be complied w ith by the operat or or by
any hired installation staff.
This pump must never be operat ed out side the limits l aid down in
the technical documentation with regard t o pumped media, rat e of
flow, s peed, dens ity, pre ssure and temperature, i ncluding motor
rating or contrary t o any other i nstructions stipulated in t he
operating manual or contract documentation.
The data plate states series/size, the most important operating data
and t he Works No. /Serial No., which must always be stated when
making enquiries, subsequent orders and especially when ordering
spare/replacement part
s.
Should any addi tional i nformation or i nstructions be required, or if
there i s any damage t o t he equipment, then please c ontact your
nearest KSB service.
Safety
2.1
Identification of symbols used within the

operating manual
The s ymbols c ontained w ithin t his m anual calling at tention t o

situations w here nonobs ervance c ould endanger l ives, are
especially identified such as:
Warning sign in accordance with DIN 4844 W9

Calling attention to electric current with
2.3
Attention
Any instructions which are actually printed on the machine such as:
- Arrow indicating the direction of rotation
- Identification for fluid connections
Dangerous practices - nonobservance of

safety instructions
Noncompliance with the safety instructions can endanger peoples

lives, the environment and the pumps. Non-observance will negate
any warrenty daims.
In detail, noncompliance could, for example, cause the following:
- Failure of pump/plant to operate
- Failure of servicing and maintenance methods
- Endangering peopl e by c ontact w ith el ectrical, mechanical and
chemical matters
- Contamination of
substances.
the envi ronment by l eakage of dangerous
Safe working methods
The operat or must obs erve al l s afety instructions out lined i n this
leaflet, the ex isting na tional s afety precautions to prevent
accidents, and also any i ntercompany w orking, operat ing and
safety 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 c ontact w ith hot or cold movable
parts must not be removed whilst the machine is in operation.
- Leakages (for example at shaft seals) of dangerous m edia (e.g.
explosive, poisonous, hot liquids) must be di sposed of in such a
manner as to avoid any danger to personnel and environment.
- Danger c aused by el ectric s upply m ust be el iminated (i n t his
respect, see de tails of any regul ations en forced by individual
countries of the VDE and/or local power supply stations).
2.6
Warning sign in accordance with DIN 4844 W8

Safety instructions rel ating t o s ituations where nonobservance
could damage the machine and i ts functions are i dentified with the
word
Personnel skills and training
Operators, as w ell as service, i nspection and ass embly personnel

must have proof of havi ng the appropri ate sk ills t o c arry out s uch
work. A rea of res ponsibility, al location and s upervision of t he
personnel must be controlled by the operator. Should the personnel
not have t he requi red knowledge, t raining must be arranged. I f
required, t he operat or c an arrange s uch training t o be carried out
by the manufacturer/supplier. The operat or must al so ens ure t hat
the instruction manual is fully understood by the personnel.
2.4
This operating manual c ontains basi c i nstructions, w hich must be

observed during installation, operation and servicing. Therefore it is
imperative t hat this manual i s read pri or to a ssembly by the fitter
and relevant skilled staff/and operators, and it must always be kept
within the locality of the machine/plant.
Do not only ob serve t he general safety not es under this section,
but as w ell any ot her not es regardi ng safety i ncluded in t he
manual.
KRT
Safety instructions during maintenance,

inspection and installation
The operat or bears the re sponsibility t o ensure that all s ervice,

inspection and maintenance work i s carried out by aut horised and
fully trained personnel, who have read and are f amiliar w ith t he
operating instructions.
Basically, all work to the plant should only be carried out when the
machine is not operating. The operat ing instructions relating to the
method of switching off the equipment must be adhered to without
fail.
Pumps or pl
ants pu mping dangerous m edia m ust be
decontaminated.
Once maintenance w ork is c ompleted, all s afety equipment m ust
be reinstated again and checked to ensure they function correctly.
Read and f ollow t he poi nt l isted i n the paragraph First
commissioning prior to installation.
must be observed without fail and be kept clean and legible.
3
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2.7
Amarex
Unauthorised modifications to the pump and
fitting of spare parts
Modifications to the pu mp c an onl y be

carried out af ter
authorisation has been obt ained f rom t he m anufacturer. Original
spare part s and an cillary equipment supplied by the manufacturer
provide s afety. I nstallation of any o ther equipment c ancels the
guarantee for any pump failure which occurs as a result of installing
nonmanufacturers parts.
2.8
Impermissible modes of operation
Operating safety of the equi pment i s onl y guarant eed i f al l

operating i nstructions as out lined i n paragraph 1 - General - are
observed. The l imits gi ven i n t he da ta sheet must under no
circumstances be exceeded.
Transport and interim storage

The chain or lifting wire which is supplied
must only be 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 pu mp must be handl ed carefully during
transport. The chain or l ifting w ire m ust be
attached securely at t he pu mp and crane end.
Personnel can be i njured and the pump unit
damaged s hould t he pump s lip out of the
chain/guide wire.
3.1
Transport
The motor hous ing/cover of t he pum p has been prepared f or

attaching the chain supplied with the unit. For lifting the unit during
unpacking onl y t his prepared f ixing s hould be u sed for at taching
the lifting chain.
4.2
KRT
Identification data
Identification can be found on the dat a pl ate, which is f itted to t he

motor. I llustration dat a pl ate f or nonf lameproof and f lameproof
design see appendix: General pump outline Fig 1.
KRT F 100-240 / 17 2 X 1 G - 190
Series
Impeller type (D,E,F,K,S)

D = diagonal single vane impeller
E = single-vane impeller
F = free-flow impeller
K = non-clogging impeller
S = with cutter
Hydraulic size
Motor size
Number of poles
2-pole
4-pole
6-pole
Motor version (U, W, X, Y)

U
W
X
Y
=
=
=
=
standard version
hot water design (max. 60OC)
explosionproof version T3
explosionproof version T4
Identity No.
Material version / variants
(G, G1, G2, GH/H, C1/C2)
G
G1
G2
GH/H
C1/C2
=
=
=
=
=
Pump complete in cast

GG Pump with impeller in duplex steel 1.4517
GG Pump with impeller in chilled casting 0.9635
Pump manufactured in chilled casting 0.9635
Pump manufactured in duplex steel 1.4517
Impeller diameter in mm
4.3
4.3.1
Construction
Driver
KSB submersible pu mp s ets are supplied w ith t hree-phase

asynchronous motors c omplete with c onnecting c able.
Electrical dat
ai
n
compliance w
ith dat
a pl
ate.
Starting method standard: direct or Y.
4.3.1.1
Motors in explosionproof design
In accordance with EN 50014/ EN 50018;

Protection type EEx d IIB T3 or T4.
4.3.2
Shaft seal
The shaft seal consists of a mechanical seal which is independent

of the di rection o f rot ation a t pu mp and motor end. The oi l
chamber which is fitted between the two mechanical seals ensures
cooling and lubrication.
3.2
Storage/conservation
4.3.3
The procedure has been outlined in the paragraph 6.3 Shutdown
4.
Description of pump
4.1
General description
Bearing assembly
All sizes are fitted with grease-lubricated, m aintenance-free deepgroove anti-friction bearings.
KSB submersible pumps are s ubmersible, close-coupled uni ts

which are non-self-priming. The impellers in these pumps can vary,
depending on t he impeller type required by t he customers to suit a
particular appl ication. U sually, t he pu mps are operated f ully
submerged. For short periods, they may run dry un til the minimum
filling level is reached.
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4.3.4
Amarex KRT
5.3
Impeller types
Cutter (S) for f aeces, dom estic s ewage and
sewage containing long fibrous admixtures.
Free-flow i mpeller (F-i mpeller) f or pumping

liquids c ontaining l arger s olid part icles and
fibres liable to twist and bunc h and al so gas
and air inclusions.
Single-vane i mpeller (E -impeller)

for
pumping l iquids c ontaining larger solid
particles and fibres liable to twist and bunch,
and also for t he dam age-free t ransport of
solids.
Open, diagonal single vane impeller
(D-impeller) f or s ewage w ith s olid and long
fibrous admixtures and with coarser solids.
Installation
Examine the uni t c arefully pri or t o c ommencement of i nstallation

regarding any dam age i ncurred t o t he unit and cabling during
transport. B efore i nstallation of t he pum p al l i tems l isted i n
paragraph 6.1 have to be checked i n s equence. A s eparate dat a
plate stating pump and motor dat a i s s upplied within t he s cope of
supply. Thi s dat a pl ate m ust be f ixed in a clearly visible position
outside t he t ank (f or ex ample s witch panel , pipework, mounting
bracket).
5.3.1 Checking of operating data

A c heck m ust be c arried out t o ens ure t hat t he det ails s tated on
the data plate correspond to the order and pump data (for example
operating voltage, frequency and pumped media temperature etc.).
5.3.2 Oil level control

The oi l c hambers of our s ubmersible pum ps were filled with
environmentally friendly nontoxic paraffin oil at works.
The oil level must be checked prior to initial operation of the
unit.
Procedure see item 6.1.1
5.3.3 Checking of the direction of rotation

Closed non-clogging impeller (K-impeller) for
contaminated, non-gas
eous l
iquids
containing s olids, w ithout f ibres liable to
twist and bunch.
4.3.5
Installation methods
Connection of the pipeline
Attention
For detailed installation description, see item 5.6.
Dimensions
Information regardi ng di mensions and w eight c an be found in

Appendix 4 Dimension Tables.
4.4
5.4
(Appendix General arrangement of installation sets Fig 1)

The discharge pipe must be c onnected t o t he pum p w ithout
tension.
- stationary wet-well installation

- transportable installation
4.3.6
Before starting with the installation, make sure that the direction of
rotation is the correct one, acc. to para. 5.5.6.
Under no circumstances must the pump be used

as an anchoring point for the pipeline.
Any expansion of the pipes caused by hi gh temperatures m ust be

adjusted by t aking appropriate corrective measures, to ensure that
the pump does not come under undue stress due to pipeline forces
and torques.
Excessive pipeline forces can cause leakages of
pumped media for example.
Toxic and hot media can endanger life.
Ancillary equipment
Suitable K SB s witchgears are avai lable t o ens ure t rouble-free

functioning of the m onitoring equi pment. Rec ommended
equipment i s des cribed i n Appendix Electrical connection
diagram
When emptying objects on a l ower l evel, a non-ret urn val ve m ust

be f itted i nto t he di scharge pi pe t o avoi d bac kflow f rom the
channel, which could be led vi a t he bac kflow l evel (road l evel)
upwards and only then into the sewage channel.
Any inf ormation relat ing t o ot her anc illary equipm ent will be giv en
by our Sales Office.
Screwed pipeline joints where plastic parts were

used, must not be dam aged by c areless
handling of tools during the installation of pum p
and pipeline.
Fitting of a non-return valve is also essential for longer rising
pipes to avoid excessive backflow when the pump is turned
off. Ensure that ventilation is taken into account when fitting
a non-return valve.
Assembly/Installation
5.1
Safety regulations
It is not permitted f or any pers on t o ent er t he
tank during operation of the pump unless special
safety prec autions have been t
aken i n
accordance with current safety regulations.
5.2
Attention
Checking procedure prior to commencement of

the installation
Construction l ay-out m ust be i n ac cordance with measurements

set out on the table of dimensions.
The construction of the concrete foundations should be sufficiently
strong (Min. B25 in accordance with DIN 1045) t o ensure a s ecure
and functionally correct installation in compliance with DIN 1045 or
equivalent standard. Concrete foundations m ust have s et bef ore
installation of the unit. Its surface must be level and even.
5
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5.5
Amarex KRT
Electrical connection
5.5.4
General
The electrical connection must be c arried out by
a trained electrician and in compliance with local
regulations.
The voltage must comply with the voltage
indicated on the data plate.
Electrical i nstallation m ust be i n ac cordance w ith t he annex es
Electrical installation and Performance layout fo r th e
appropriate motor sizes. The pump is delivered with cable.
.
Attention
Do not remove the protective cover, which is

situated at the cable gland until immediately
before installation.
The i ndividual c ores of t he c able ends bear m arking t apes (e. g.

U(T1). V (T2), W (T3), 21,
22,
or
10,
11,
...)
If cables have to be s hortened, t ake c are of t he c ore i ndex or
colour i mprints. I n s uch a c ase, rem ove t he c ore marking and
reaffix it afterwards.
Attention
5.5.1
5.5.5
Level control switch
Pumping stations with automatic pump operation should be fitted

with a level control switch. The cutoff point should be set as R in
accordance with Appendix Table of dimensions.
This prevents an interruption of the delivery by the pump which
would cause dry running.
5.5.6
Checking of the direction of rotation
Once the electrical connections are c omplete, the following should

be checked:
Attention
Frequency inverter operation
Fitting of electric cabling
Attention
After installing the uni t, i t i s advi sed t o pos ition

the m otor c able s traight upw ard i n order not to
have i t af fected by t he s wirl c reated by the
pumped liquid.
For correct installation of t he el ectric c abling w ithin t he pum p

sump (Appendix General pump outline Fig. 5) we recommend
to use ca ble so cks, which ca n b e s upplied as an addi tional ex tra
(paragraph 4. 4). S lack i nstallation of c ables could cause damage
to t he el ectric c abling bec ause of vi brations when the pump is
operating.
Attention
Fitting of cable protection sheath
If a protection sheath is included i n t he s cope of s upply f or t he

electric c abling, i t has t o be f itted ac cording t o t he i nstructions
given i n t he s upplementary operating m anual Assembly of
protection sheath.
The pum p c annot reac h i ts dut y poi nt i f t he

direction of rot ation i s i ncorrect.
Nonobservance can lead to damaging the pump set.
Prior t o c arrying out any tests check that there

are no foreign obj ects w ithin t he pum p c asing.
Never put hands or any objects into the
pump.
Monitoring equipment
The gi ven m otor c apacity of P2 c an onl y be us ed up t o 85% .

Other s pecial c haracteristics f or t his m ethod of operat ion c an be
taken f rom Appendix Electrical connections diagram/circuit
diagram.
5.5.3
The motor is protected against overloading by a t hermally retarded

overcurrent rel ay t o c omply w ith V DE 0660 / IEC 947 and
regulations which are in accordance with local requirements. This
should be adjusted t o t he nom inal m otor c urrent i ndicated on t he
data plate.
When l aying an eart h c able bet ween t he

pumping s tation and t he el ectrical s witchgear,
an addi tional m ulti-core c ontrol
cable
(min. 1. 5 m m2) m ust be i nstalled for motor
monitoring equipment and f loat s witch c ontrol.
Adjust cores to suit requirement.
The unit has been s upplied w ith m onitoring equi pment t o prevent
overloading. I nstallation, des cription and f unctioning of the
monitoring equipment can be t aken f rom Appendix Electrical
connections diagrams/circuit diagrams.
5.5.2
Overcurrent relay
Attention
The running time should be as short as possible

(max 3 minutes).
Correct direction of rotation:

If the phase sequence of the circuit is known, the correct direction
of rotation will occur automatically, providing the instructions in 5.5
have been carried out correctly (rotating of t he m otor t o t he l eft).
The di rection of rot ation i s c hecked by s hort s tarts and
observations of the impeller.
When l ooking at t he pum p m outh, t he impeller must move to the
left (w ith s ome pum ps, t he di rection of rot ation i s marked by an
arrow).
(compare Annexe General Pump Outline Fig. 6).
If the direction of rotation is incorrect, interchange 2 of the
3 phases in the switch cabinet.
5.5.7
Connection of a potential equaliser
For potential equalisation, follow the instructions to EN 60 204.

The potential-equalising conductor is c onnected t o t he ex ternal
connection terminal at the cable entry.
(Annexe General Pump Outline)
Special requirements for chemically corrosive media
Do not us e t he out side t erminal i f t he uni t i s us ed f or c hemically
corrosive media and with a flameproof pump.
Instead, the potential equaliser s hould be f itted t o a f lange at t he
discharge pipe, which does not come into contact with the media.
Please ens ure t hat t here i s an el ectrical c onnection bet ween the
newly created potential equaliser and the pump.
(Appendix General pump outline Fig. 5).
6
REVISION: C
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5.6
Amarex KRT
2. Fit threaded bolt 904 with clamping piece 553/ support piece
572 to the mounting bracket. Do not unscrew hexagonal nut
920.36 too much, just enough to allow sufficient play for
tightening the wire subsequently. Ensure that the two clamping
pieces 553 are fitted correctly to a support piece.
Assembly kit installation
The following assembly kits are available for assembly/installation

of the KRT pump unit.
- 5.6.1 Stationary wet-well installation
- 5.6.2 Transportable installation
5.6.1
Stationary installation/guide wire
5.6.1.1
Description
(Appendix General outline installation set Fig. 1).

Stationary installation provides the facility t o ins ert and lif t out t he
pump unit at any t ime regardless of liquid level within the sump by
means of a double guide wire.
Guided s ecurely by t wo paral lel, previously tightened stainless
steel wires the pump slides into the well or tank and attaches itself
to the duckfoot bend which has been fitted to the bottom.
The weight of the pum p acts as seal between pum p and duckfoot
bend. A profile joint between pum p and duc kfoot bend ac hieves a
pressureproof el astic c onnection. W alking on t he w ell i s not
permitted during inspection and maintenance work.
5.6.1.2
Scope of supply for stationary wet-well

installation
Please ref er t o t he Appendix Wet-well installation with parts

list.
5.6.1.3
Installation of pump with claw connection
3. The duc kfoot bend s hould be pos itioned and secured to the
base of the sump s o t hat t he t ightened w ire w ill run v ertically
later on.
Should construction/pipework etc. require t he w ire t o run of f
the vertical, then a maximum angle of 5o should be adhered to,
thus ens uring s afe f itting f unction.Securing of t he duckfoot
bend is c arried out by us ing bol ts or f oundation bol ts
regardless of
pum p s ize or m
aterial
variation.
Units l arger t han approx . 2, 000 k g i n weight are supplied
complete with foundation s lide rai ls. Ref er t o Appendix
Dimension Table and Appendix Wet-well installation
with parts list f or det ails rel ating t o appropri ate f itting
instructions and hole dimensions.
4. Insertion of w ire and f itting. Li ft t hrust pl ug and clamp and
insert one end of the wire. Lead t he wire around t he duc kfoot
bend 72-1 and back again towards the guide bracket and insert
into clamp of thrust plug. Manually tension the wire and secure
by using hex. nuts 920.37.
5. Tighten t he w ire by f astening t he hex agonal nut 920.36
situated on top of t he m ounting brac ket(s). Ti ghten t he
hexagonal nut w ith a t orque of M A as outlined i n t he t able
Appendix Guide wire tension to ac hieve s ufficient w ire
tension. Subseqently secure by using a second hexagonal nut.
6. The loose end of the w ire at t he c lamp 572 c an ei ther be
twisted i nto a ri ng or t he end c an be c ut of f. A fter l ength
adjustment, seal off ends to avoid fraying.
7. Place s hackle 59-18 i nto t he m ounting bracket 894 to

enable the lifting chain to be attached at a later stage.
1. Prior to lowering the pump fit claw 732 to the discharge flange
of the pump housing.
Screws have t o be t ightened i n ac cordance w ith t he
instructions. This is described under i tem 7. 5.1 i n t he t able
Bolt tightening torque.
Please obs erve t he f itting i nstructions f or steel bolts given in

Appendix "Stationary wet-well installation with guide wire".
Use appendix Wet-well installation w

guidance.
ith p arts list fo
2. Fit profile seal 410.35 or 996 into the groove of the claw/pump
casing flange. This profile seal will serve to seal the duckfoot
bend during installation.
5.6.1.4
Fitting of the mounting bracket/

duckfoot bend/guide wire
Construction of t he bas e/concrete f oundations should be

sufficiently s trong (m in. B 25 i n accordance with DIN 1045) to
ensure a f unctionally c orrect f ixing of gui de wire equipment and
duckfoot bend.
Refer to th e d rawing a s illu strated in Appendix Wet-well
installation with parts list for all installation tasks outlined below.
1. Secure mounting bracket 894 us ing anchor bolt 90-3.37 at the
sump opening rim. B orehole di ameter and dept h f or t he
anchor bol t have t o be t aken f rom Appendix Table of
dimensions. Bolt tightening i nstructions are out lined i n t he
table bel ow. Bolt tightening torque for steel anchor bolts
or foundation bolts.
As for the hole pattern of t he m ounting brac ket ref er t o A ppendix
Table of dimensions.
Table Bolt tightening torque Steel anchor bolt

Size ()
10
18
Torque (Nm)
10
80
Table Bolt tightening torque Foundation bolt

Size ()
12
16
20
Torque (Nm)
25
65
125
Table Guide wire - tension

Size
40-250
80-250
80-315
100-240
100-250
150-251
100315
150315
200-280
200281
200-315
MA
(Nm)
14
P
(N)
6 000
MA = tightening torque
P = wire tension
7
REVISION: C
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5.6.1.5
Amarex KRT
Fitting of chain/lifting wire
stationary wet well installation
Start up/shut down
Installation of this equipment should be c arried out i n ac cordance

with th e General pump outline, Fig. 2a by i nserting t he
chain/lifting wire into t he l oop oppos ite t he out let branc h. Furt her
details can be found in Wetwell installation with parts list.
Attention
It is important to fulfil the following requirements.

Any dam age i ncurred as a res ult of non
compliance is not covered by the guarantee.
This t ype of f ixing ac hieves a f orward i nclination of t he pum p

towards the outlet branch and permits the fitting of the pump to the
duckfoot bend.
Attention
Do not pum p any m edia w hich i s uns uitable f or

the m aterial out lined i n the technical
documentation.
5.6.1.6
6.1
Installation of the pump
(Appendix General outline installation set Fig. 1)

The pump is lowered i nto t he s ump by gui ding i t f rom above over
the c lamp 572. I t i s t hen at tached t o the guide wire and slowly
lowered in to th e s ump. On ce th e p ump is lo wered, it will attach
itself t o t he duc kfoot bend 72-1 and i s t hen securely fixed to the
outlet pi pe ready f or us e. Fi nally, at tach t he chain or wire to the
shackle 59-18 on the mounting bracket
5.6.1.7
Connection of the pipeline
Initial start up of pump
Prior to starting the pump it has to be ascertained that the following

points have been checked and executed:
-
Operating data must be checked to comply with paragraph

5.3.1,Oil level, paragraph 6.1.1 and Direction of rotation,
paragraph 5.5.6
- Check that the installation of the electrical supply was carried

out correctly in accordance with Appendix: Electrical
connection diagram / operating plans
(Appendix General outline installation set , Fig. 1)
Attention
For procedure, see para. 5.4.
5.6.2
Transportable installation
5.6.2.1
Description
Temperature monitoring in t he w inding prot ects

the m otor i n c ase of i nsufficient c ooling
conditions (e.g. i f pum p i s part ially not
submerged). Rel iable operat ion and explosion
protection can onl y be guarant eed i f t he c ircuits
for temperature monitoring function properly.
Pumps f or t ransportable i nstallation are s upplied w ith a pum p

stand. The outlet branch with DIN connections lends itself for fitting
either ri gid or f lexible pi ping. Examples for typical installation
possibilities can be taken from Appendix General arrangement
of installation parts Fig. 2. A ncillary equipm ent c an be
requested and purchased from our sales offices.
5.6.2.2
Procedure acc. to Appendix General Pump outline Fig. 3.
Components/extent of supply for

transportable installation
For part s s upplied and detailed illustration, see Appendix Wetwell transportable installation with parts list
5.6.2.3
Assembly kit installation
Please ref er t o drawing in Appendix Wetwell transportable

installation with parts list for assembly.
1. The base pl ate or t he pum p s tand m ust be f itted pri or t o
installing the pump. All screws must be t ightened according to
instructions. Ref er t o t able Bolt tightening torque
paragraph 7.4.1 for instructions.
5.6.2.4
Assembly chain/lifting wire /

transportable installation
Fitting of c hain/lifting w ire s hould be c arried out as out lined i n

Appendix Wet-well installation transportable with parts list.
For P umps w ith a m otor c apacity of 4 kW, always use the loop
which i s f itted on t he di scharge s ide, s ee Appendix General
pump outline Fig. 2b.
5.6.2.5
Installation of pump
Transportable installation permits to operate the pumps in different

locations.
For example, they can be used for:
draining mines
the emergency draining of canals
pumping water out of rivers etc.
Ensure t hat t he pum p has been i nstalled c orrectly t o c omply

with installation kit paragraph 5.6.
Should the pump have been out of service for a long period,
then the steps outlined in paragraph 6.3 must be carried out.
6.1.1
Oil level check
Remove screwed plug 903.03 with joint ring 411.03. The minimum
oil level must not fall short of measure M. If it is lower, fill th e oil
chamber via feed opening until overflow. Regarding oil quality and
quantity, see point 7.2.5 (Oil change).
Tighten screwed plug with joint ring again.
6.2
6.2.1
Limitations of the operating range

Minimum liquid level
The pump is ready f or operation when the liquid level has reached
measuring mark R.
This m inimum l iquid l evel al so appl ies t o pum ping s tations with
automatic pump operation.
(Appendix General pump outline Fig. 7)
R = Lowest switch-off point for automatic operation
M = Minimum liquid level for constant operation
Built-in te mperature c ontrols w ithin th e w inding w ill p rotect the
motor f rom overheat ing. I f t he m otor overheat s (for example
during l ong operat ion w ith a c ompletely ex posed motor), the
built-in temperature c ontrols will s witch of f t he m otor and t urn it
on again automatically after cooling down.
The c ontrol s ystem m ust provi de a prot ection against dry
running by stopping the pump automatically (cut-off contact, see
5.5.5).
Attention
Dry running leads to increased wear and

should be avoided.
For such applications the pump m ust be i nstalled i n a vert ical

position with the motor on the top and fitted to a firm base.
8
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6.2.2
Amarex KRT
Temperature of pumped media and
surroundings
KRT .... type X,Y
KRT .... type U 1)
KRT .... type W
40 OC or
as indicated
on data plate
1)
60 OC or
as indicated
data plate
on
1)
40 OC
Can be operated up to 80 C for a limited period (35 min. or until

the thermal protection equipment is activated)
Attention
6.2.3
Do not operate the equipment at temperatures

higher than those indicated above, unless the
manufacturer has given written consent.
Damage caused due to non-observance of this
warning will not be covered by the guarantee.
Switching frequency
6.3.2
Measures for prolonged shutdown periods
1. The pump remains installed ready for operation when

required.
In order t o s ecure pum p av ailability as and w hen required and t o
avoid f ormation of depos its w ithin t he pum p and the immediate
pump surroundings, the pl ant s hould be s witched on f or bri ef
periods (approx. 5 m inutes) onc e every m onth or every t hree
months as required. It i s es sential t hat t here i s enough pum ped
media i n t he i nlet area or t hat enough l iquid can be fed into the
pump.
2. The pump is dismantled and stored
Prior to storage t he pum p s hould be c hecked and m aintained i n
accordance with paragraph 7. 1 and 7. 2. S ubsequently, t he
preservation outlined in paragraph 6.3.1 must be carried out.
6.4
Re-starting pump after storage
Prior to r estarting th e p ump, a ll checks and m aintenance s teps

outlined i n paragraphs 7.1 and 7.2 have t o be c arried out .
In order to avoid intolerably high temperature rises within the motor

and ex cessive overl oading of m otor, s eals and beari ngs, t he
following num ber of s witching operat ions per hour (S ) should not
be exceeded:
Motor capacity
(kW)
up to 7.5
above 7.5
6.2.4
Operating voltage
Abrasive media
When pum ping m edia c ontaining abras ive part icles, i ncreased
wear of hydraul ic and m echanical s eals must be expected. The
maintenance intervals m ust be hal ved c ompared t o t hose us ually
recommended (as outlined in paragraph 8). I n addi tion, i t i s
recommended to limit the flow velocity in relation to the rising main
to > 1. 5 m /sec < 5 m s ec i n order t o ac hieve t he m aximum
operating periods possible.
6.3
When restarting the pump the items outlined in Initial operation

paragraph 6.1 and Operating limits paragraph 6.2 have t o be
observed.
Immediately after completion of the maintenance
work, all safety and prot ection equipment has to
be installed expertly and must be set working.
Density of pumped media
Power input of the pum p increases proportionally to the density of

the pum ped m edium. To avoi d overl oading of the motor this
density must comply with the data stated in the order.
6.2.6
In addi tion, f ree-running of t he i mpeller s hould

be checked. This can be done by putting one
hand into the pump casing and manually
turning the impeller.
max. S
(Switching operations/h)
30
10
The m aximum adm issible devi ation of t he operat ing vol tage
amounts t o 10%, with ex plosionproof vers ions t o 5% of t he
rated voltage. The m aximum adm issible vol tage di fference
between the single phases amounts to 1%.
6.2.5
Always disconnect all electricity supplies

prior to working at the pump. Safeguard the
pump from being started accidentally.
Otherwise, there will be danger to life.
7.
Service and maintenance
7.1
The operat or m ust ens ure t hat al l m aintenance, inspection and

repair w ork i s c arried out by qual ified, aut horised s taff w ho are
familiar w ith t he equipm ent and w ho hav e read t he operating
instructions.
By compiling a m aintenance plan it is possible to cut maintenance
expenses and avoid extensive repair costs, thus achieving troublefree and reliable operating of the pump.
prior to working on the pump. Safeguard the
Shutdown/storage/preservation
If operation is not requi red unt il s ome t ime af ter del ivery, w e
recommend the following steps for storage of the pump:
6.3.1
Storage of new pumps
If t he pum ped m edia are harmful, the pump

must be decontaminated. Special care should be
taken t o prevent an endangeri ng of personnel
and envi ronment w hen drai ning leakage
liquid/oil. All official regulations must be adhered
to.
- Spray the inside of t he pum p hous ing w ith oi l by payi ng s pecial

attention t o t he area around t he i mpeller gap. S pray oi l t hrough
inlet and out let branc hes. I t i s t hen rec ommended t o prot ect t he
branches (with plastic caps or similar).
- Store t he pum p i n an upri ght pos ition i n a dry pl ace. S upport al l
electrical cables at c able ent ry poi nts t o avoi d perm anent
distortion.
- Electric c onnecting c ables are c apped s ecurely f or protection
purposes prior to delivery. This protection must not be removed.
9
REVISION: C
Rev. Date: 18.04.2011
page: 57 of 81
KSB
8
Amarex KRT
Trouble-shooting
Unit not pumping
Pump delivers insufficiently
Current/power consumption too high
Head too low
Pump operation is uneven and noisy
Cause
Pump delivers against excessively high discharge

pressure
Valve in discharge pipe not fully open
Pump not running within operating limits
Pump and/or pipeline are not completely vented or
primed
Pump inlet blocked by deposits
Inlet pipe or impeller blocked - rotor running sluggishly
Dirt/fibres in impeller chambers
Wear of internal pump parts
Damaged column pipe (pipe and seal)
Unacceptable air or gas content within the pumped
media
Oscillations caused by plant
Wrong direction of rotation
Insufficient operating voltage
Motor not running due to no voltage supply
Motor running on two phases only
Motor winding or electric cable defective
Radial bearing in the motor defective
With star delta connection - Motor only running in star
position
Water level dropping excessively during operation
Remedy:
Prior to carrying out work to the pressure containing
parts - release pressure from the pump!
Disconnect power supply to the pump.
Open discharge valve further until duty point is reached
Open gate valve completely
Check operating data of the pump
Vent - by lifting the pump off the duckfoot bend and
lowering it back again.
Clean inlet, pump parts and non return valve
Remove deposits from within the pump and/or
pipelines
Check impeller ensuring that it rotates slightly - if
necessary clean hydraulic
Replace worn parts
Replace defective column pipe
Renew seals
Contact your nearest authorised KSB agent
Switch two phases of the circuit cabling
Check electric supply
Check cable connections
Check electrical installation
Inform electrical company
Replace defective fuses
Check electric cable connections
Replace by new original KSB cabling or contact your
nearest authorised KSB agent
Check star delta connection
Check supply and capacity of system - (sump depth)

check level control
Temperature monitor for winding control has ceased to The motor will switch on automatically after cooling
operate due to excessively high winding temperature
down
Thermistor release unit without automatic restart facility Check the pump.
for temperature limit (flameproof) has been released
due to exceeding the permissible winding temperature
Moisture protection relay has been released due to
Check the pump.
moisture within the motor
Attention:
If working inside the pump is necessary whilst the pump is under warranty, then contact your nearest
authorised KSB agent prior to commencement of work. Non-observance will negate any warrenty daims.
14
REVISION: C
Rev. Date: 18.04.2011
page: 58 of 81
H) MAINTENANCE INSTRUCTIONS
REVISION: C
Rev. Date: 18.04.2011
page: 59 of 81
H1) PREVENTIVE MAINTENANCE
REVISION: C
Rev. Date: 18.04.2011
page: 60 of 81
OPERATION AND MAINTENANCE MANUAL
As Specified
As Required
5 Years
2 Years
Yearly
6 Months
3 Months
Daily
Monthly
System /Equipment
Nr.
Weekly
PREVENTIVE MAINTENANCE SCHEDULE
SEO
91SEO001PO
91SEO002PO
SEWER SHAFT
PUMPS
INSULATIONRESISTANCECHECKOFMOTORWINDING:
1.1
Takemeasurementatthecableendswithamegger:
Measuringvoltage:max1,000Vdc
4000hrsbut
atleast
once/yr
1.2
Checktheinsulationresistanceofhemotorwindingwith
thecableendstiedtogether(Mustnotbelessthan5
megaohm)
4000hrsbut
atleast
once/yr
1.3
Ifmeasurementsareless,thencheckcableandmotor
separately(withsupplycabledisconnectedfromthe
motor)
4000hrsbut
atleast
once/yr
1.4
Measurementstobetaken:
4000hrsbut
atleast
once/yr
1.4.1
Windingagainstearthallwindingendsconnectedto
eachother
4000hrsbut
atleast
once/yr
1.4.2
Windingtemperaturesensoragainstearthallcable
endsofthewindingtemperaturesensorsshouldbe
connectedtooneanotherandallwindingendsbe
connectedtoearth.
4000hrsbut
atleast
once/yr
1.4.3
Ambientandpumpedliquidtemperature
4000hrsbut
atleast
once/yr
1.4.4
Iftheinsulationresistancefortheelectricsupplycableis
lessthan5megaohm,thisindicatesdamageandneeds
replacement.
4000hrsbut
atleast
once/yr
1.4.5
Lowreadingoftheinsulationresistancevaluesindicates
thatthereisafaultinthewinding.Contact
manufacturer.
4000hrsbut
atleast
once/yr
VISUALINSPECTIONOfTHEELECTRICCABLES:
2.1
Checkforcracks,bubbles.
2.2
Replacecablesifdamageisdetected
2.3
Checktheprotectioncable,measurementofthe
resistancebetweenthecoresshouldbeR<1
REVISION: C
X
X
Rev. Date: 18.04.2011
page: 61 of 81
OPERATION AND MAINTENANCE MANUAL
As Specified
As Required
5 Years
2 Years
Yearly
6 Months
3 Months
Daily
Monthly
System /Equipment
Nr.
Weekly
PREVENTIVE MAINTENANCE SCHEDULE
SEO
SEWER SHAFT
PUMPS
91SEO001PO
91SEO002PO
CHECKOFMONITORINGEQUIPMENT:
3.1
TemperatureSwitch:Checkresistancebetweenthe
connectionends21&22:R<1
4000hrsbut
atleast
once/yr
3.2
PTCResistorSensorResistancemeasuringresistance
betweenconnectionends10&11:10<R<
750
4000hrsbut
atleast
once/yr
3.3
Ifthegiventolerancesareexceededdisconnectthe
electricsupply/controlcableattheunit&checkagain
directlyattheterminalsofunit.Ifexceededagainthe
windingmustbereplaced.
4000hrsbut
atleast
once/yr
3.4
MoistureProtectionelectrode:Insulationresistance
check.Iftheinsulationresistancemeasuredatthe
electrodeis>1Mitisok.Ifitislowerthanthereis
intrusionofmoistureorwaterintothemotor.Motor
needstobeopenedandoverhauled
4000hrsbut
atleast
once/yr
3.5
Replacethemoistureprotectionelectrodeintheeventof
damage
4000hrsbut
atleast
once/yr
OILCHANGE:
4000hrsbut
atleast
once/yr
4.1
Followprocedureinchapter2)foroilchange,refilling
andoilspecifications.
4000hrsbut
atleast
once/yr
4.2
Replacemechanicalsealalsoifoilisseverely
contaminated.
4000hrsbut
atleast
once/yr
5
5.1
6
6.1
4000hrsbut
atleast
once/yr
BEARINGSANDLUBRICATION:
Thepumpmotorshaftissuppliedwithgreaselubricated
ballbearings.
4000hrsbut
atleast
once/yr
VISUALCHECKOFLIFTINGCHAIN/LIFTINGWIRE:
4000hrsbut
atleast
once/yr
Verifyfordamageandreplaceifdamaged.
GENERALOVERHAUL:
REVISION: C
Rev. Date: 18.04.2011
page: 62 of 81
4000hrsbut
atleast
once/yr
H2) REPAIR AND ADJUSTMENT
REVISION: C
Rev. Date: 18.04.2011
page: 63 of 81
KSB
6.2.2
Amarex KRT
Temperature of pumped media and
surroundings
KRT .... type X,Y
KRT .... type U 1)
KRT .... type W
40 OC or
as indicated
on data plate
1)
60 OC or
as indicated
data plate
on
1)
40 OC
Can be operated up to 80 C for a limited period (35 min. or until

the thermal protection equipment is activated)
Attention
6.2.3
Do not operate the equipment at temperatures

higher than those indicated above, unless the
manufacturer has given written consent.
Damage caused due to non-observance of this
warning will not be covered by the guarantee.
Switching frequency
6.3.2
Measures for prolonged shutdown periods
1. The pump remains installed ready for operation when

required.
In order t o s ecure pum p av ailability as and w hen required and t o
avoid f ormation of depos its w ithin t he pum p and the immediate
pump surroundings, the pl ant s hould be s witched on f or bri ef
periods (approx. 5 m inutes) onc e every m onth or every t hree
months as required. It i s es sential t hat t here i s enough pum ped
media i n t he i nlet area or t hat enough l iquid can be fed into the
pump.
2. The pump is dismantled and stored
Prior to storage t he pum p s hould be c hecked and m aintained i n
accordance with paragraph 7. 1 and 7. 2. S ubsequently, t he
preservation outlined in paragraph 6.3.1 must be carried out.
6.4
Re-starting pump after storage
Prior to r estarting th e p ump, a ll checks and m aintenance s teps

outlined i n paragraphs 7.1 and 7.2 have t o be c arried out .
In order to avoid intolerably high temperature rises within the motor

and ex cessive overl oading of m otor, s eals and beari ngs, t he
following num ber of s witching operat ions per hour (S ) should not
be exceeded:
Motor capacity
(kW)
up to 7.5
above 7.5
6.2.4
Operating voltage
Abrasive media
When pum ping m edia c ontaining abras ive part icles, i ncreased
wear of hydraul ic and m echanical s eals must be expected. The
maintenance intervals m ust be hal ved c ompared t o t hose us ually
recommended (as outlined in paragraph 8). I n addi tion, i t i s
recommended to limit the flow velocity in relation to the rising main
to > 1. 5 m /sec < 5 m s ec i n order t o ac hieve t he m aximum
operating periods possible.
6.3
When restarting the pump the items outlined in Initial operation

paragraph 6.1 and Operating limits paragraph 6.2 have t o be
observed.
Immediately after completion of the maintenance
work, all safety and prot ection equipment has to
be installed expertly and must be set working.
Density of pumped media
Power input of the pum p increases proportionally to the density of

the pum ped m edium. To avoi d overl oading of the motor this
density must comply with the data stated in the order.
6.2.6
In addi tion, f ree-running of t he i mpeller s hould

be checked. This can be done by putting one
hand into the pump casing and manually
turning the impeller.
max. S
(Switching operations/h)
30
10
The m aximum adm issible devi ation of t he operat ing vol tage
amounts t o 10%, with ex plosionproof vers ions t o 5% of t he
rated voltage. The m aximum adm issible vol tage di fference
between the single phases amounts to 1%.
6.2.5

prior to working at the pump. Safeguard the
7.
Service and maintenance
7.1
The operat or m ust ens ure t hat al l m aintenance, inspection and

repair w ork i s c arried out by qual ified, aut horised s taff w ho are
familiar w ith t he equipm ent and w ho hav e read t he operating
instructions.
By compiling a m aintenance plan it is possible to cut maintenance
expenses and avoid extensive repair costs, thus achieving troublefree and reliable operating of the pump.
prior to working on the pump. Safeguard the
Shutdown/storage/preservation
If operation is not requi red unt il s ome t ime af ter del ivery, w e
recommend the following steps for storage of the pump:
6.3.1
Storage of new pumps
If t he pum ped m edia are harmful, the pump

must be decontaminated. Special care should be
taken t o prevent an endangeri ng of personnel
and envi ronment w hen drai ning leakage
liquid/oil. All official regulations must be adhered
to.
- Spray the inside of t he pum p hous ing w ith oi l by payi ng s pecial

attention t o t he area around t he i mpeller gap. S pray oi l t hrough
inlet and out let branc hes. I t i s t hen rec ommended t o prot ect t he
branches (with plastic caps or similar).
- Store t he pum p i n an upri ght pos ition i n a dry pl ace. S upport al l
electrical cables at c able ent ry poi nts t o avoi d perm anent
distortion.
- Electric c onnecting c ables are c apped s ecurely f or protection
purposes prior to delivery. This protection must not be removed.
9
REVISION: C
Rev. Date: 18.04.2011
page: 64 of 81
KSB
7.2
Amarex KRT
Service/Inspection
7.2.3
The following points must be observed to ensure reliable

operation:
This work must only be carried out by experienced personnel!
Item
Maintenance tasks
7.2.1
Insulation resistance check
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
Visual inspection of electric cables

Check of monitoring equipment
Oil change
Bearings and lubrication
Visual check of lifting chain / rope
General overhaul
7.2.1
Maintenance to
be carried out
at following
intervals
every
4,000 hours
but at least
once a year
every 5 years
Checking the monitoring equipment
The performance tests should form part of general periodic

maintenance work, carried out every 4,000 hours or at least
annually.
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:
10 < R < 750
If t he gi ven t olerances are ex ceeded, di sconnect the electric
supply/control c able at t he uni t and c heck agai n di rectly at t he
terminals of t he uni t. I f t olerances are exceeded here, too, the
winding must be replaced.
c) Moisture protection electrode - Insulation resistance check
The motor area is being monitored by a l eakage detector which is
fitted into the motor area. It is fitted as standard.
Instructions rel ating t o perf ormance and technical data can be
found in Appendix Moisture protection monitoring.
Insulation resistance check
The insulation resistance of the motor winding has to be

checked every 4,000 hours but at least once a year during
general maintenance.
Measurements should be taken at the cable ends (disconnected at
the starting panel). The measurement s hould be t aken by us ing a
megger.
Measuring voltage: max 1,000 V d.c. voltage
The moisture monitoring el ectrode i s ok ay i f t he i nsulation

resistance measured at t he el ectrode i s > 1 M . Lower val ues
indicate moisture or even intrusion of water into the motor. In such
cases, the motor needs to be opened and overhauled.
A NEW MOISTURE PROTECTION ELECTRODE MUST BE
FITTED IN THE EVENT OF DAMAGE.
The insulation resistance of the motor winding with cable ends tied
together must not be l ess t han 5 m egohm. I f m easurements are
less, then cable and motor must be checked separately. During the
measurement proc edure t he s upply c able m ust be disconnected
from the motor.
7.2.4
The measurements to be taken are:
However, the oil should be changed after 4,000 operating

hours, but at least annually.
a) Winding against earth

- All winding ends connected with each other
b) Winding temperature sensor against earth
- All cable ends of the winding temperature sensors should be
connected to one another and all winding ends be connected
to earth
Ambient and pumped liquid temperature
If the insulation resistance for the electric supply cable is less than
5 megohm, this indicates damage and needs replacement.
Low reading of the i nsulation res istance val ues of t he m otor
indicates that there i s a f ault i n t he w inding. I f t his i s t he c ase,
contact ei ther t he m anufacturer or t
he neares t K SB
Agent/Distributor.
7.2.2
-
Inspection of the electric cable
Visual inspection of the electric cable.

Whenever the pump is inspected, the electrical supply cables
should also be checked with regard to damage such as cracks
or bubbles, due to either mechanical or chemical causes.
If such damage is detected, then all electric cables must be
replaced.
Oil change
The oil c hamber of our s ubmersible pum p has been filled with
environmentally friendly, non-toxic paraffin oil of medical quality on
the pump end.
Pumped liquid might enter the oil chamber when

it i s w arm af ter operat ion, w hich c an cause a
pressure rise within the chamber. It is, therefore,
advisable t o c over t he f illing plug 903 (with a
cloth) duri ng t he openi ng proc ess t o avoi d hot
liquid (squirting out) escaping.
Procedure
(Appendix 1 - General pump arrangement).
Erect t he pum p as s hown i n Fig. 8 and put a s uitable c ontainer
under t he plug. Rem ove f illing plug 903.03 with gasket 411 and
drain the oil.
The oi l i s l ight i n c olour and t ransparent in appearance. Slight
discolouring, caused by running in of new mechanical seal or small
leakage of dirt via t he pum ped m edia will have no adv erse ef fect.
Severe c ontamination of t he oi l by t he pum p media, however,
indicates dam aged m echanical s eals. I n t his c ase, repl ace t he
mechanical seal.
Checking the protection cable. Measurement of the resistance

between the cores should be R < 1 Ohm.
10
REVISION: C
Rev. Date: 18.04.2011
page: 65 of 81
KSB
Amarex KRT
Refilling
Erect the pump as demonstrated in Fig. 3 and fill the oil chamber with
oil until overflow (see also paragraph 6.1.1). Replace the plug 903.03
and fit a new gasket 411.03.
Quantity of oil:
Details regarding the quantity of oil can be taken from the table in
paragraph 7.2.4.1 Lubricating instructions
Recommended quality of oil:

Trade name:
Paraffin oil, freeflowing, Messrs. Merck No. 7174; With-oil
Merkur Pharma 40 Messrs. DEA or equivalent, non-toxic.
This quality is harmless and as such complies with the regulations
applicable to food.
Alternative:
All non-alloyed and alloyed motor oils of classes SAE 10W can be
used for lubrication of the mechanical seals. With regard to disposal
all general Government regulations must be observed.
Regional regulations have to be obs erved to the
Attention
extent t hat t he oi l does not contaminate the
pumped m edia (for example drinking water) and
that safe disposal is guaranteed. Otherwise, it is
not permitted to fill the pump with oil, but paraffin
oil must be used for this purpose.
7.2.4.1 Table Lubricating instructions

Size
S, K 40-250
F, E, K
F, E 80-250
F, E, K 100-315
F 100-240
80-315
D, F, E, K 150-315
F, E, K 100-250
K 200-280/281
D 150-251
D 200-315
Motor sizes
2-pole
5 2, 6 2, 8 2, 12 2,17 2
4-pole
5 4, 7 4,11 4, 16 4
6-pole
4 6, 6 6, 9 6, 12 6
Oil quantity:
(l )
23 2
23 4, 29 4
2,1
4,6
7,0
For recommended quality of oil, see paragraph 7.2.4
7.2.5
7.4.1
Bearing and lubrication
The pum p/motor s haft i s s upplied w ith greas e-lubricated bal l

bearings.
7.2.6
Visual check of lifting chain/lifting wire
Maintenance c hecks to th e p ump s hould al so i nclude t he l ifting

chain/lifting wire i nclusive of f itting t o t he pum p w ith regard t o
possible damage - caused ei ther m echanically or c hemically.
Damaged parts must be repl aced by m anufacturers ori ginal
spare parts.
This also refers to the correct fixing of the lifting chain/lifting wire
to the pump.
7.3
Dismantling and re-assembly
Attention
Basic guidelines and instructions
All repai r and m aintenance w ork t o t he pum p must only be

carried out by especially trained straff, and original replacement
parts must be used.
The safety precautions as outlined in paragraph 7. 4.4 have to be
observed.
Dismantling and re-assembly may only be carried out in line
with the appropriate sectional drawing. The sectional
drawing and other instructions are detailed in the appendix .
The dismantling sequence should be carried out as outlined
in the sectional drawing.
If there are any problems, please contact our service
department for advice.
If t he pum p has been us ed to pump hazardous

media, c are m ust be t aken t hat, w hen drai ning
the leakage liquid/oil f illing, pers onnel and
environment
are not
endangered.
A ll
government regulations have to be observed.
11
REVISION: C
Rev. Date: 18.04.2011
page: 66 of 81
KSB
Amarex KRT
7.4.2
Preparing for dismantling
Prior to dismantling the oil chamber is to be emptied.
7.4.3
Dismantling the pump section
Dismantling the pump section is c arried o ut a s illu strated in th e

drawing ( Appendix Sectional drawing with part list). S pecial
tools are not required. The only exceptions relate to the impeller
dismantling/assembly process for the following sizes.
7.4.3.1
Special points relating to the dismantling of

the impeller
- Size: KRT S 40250

see Appendix Impeller dismantling/assembly with cutter
-
Sizes:
KRT
40250
80250
80315
D 150-251
100240
100315
200280
D 150-315
100250
150315
200281
D 200-315
The i mpeller/shaft c onnection i s m ade by

using a cone
seat/tapered s eat. A ppendix Impeller dismantling / assembly
with taper connection.
- Remaining sizes:
The impeller/shaft c onnection i s ac hieved by a paral lel s eat w ith
locating key. The impellers have been prepared to accept a special
impeller with drawing device. This can be purc hased as a special
tool from KSB.
Further details rel ating t o proc edures and ref erences rel ating t o
special tools are out lined i n t he as sembly i nstructions Appendix
Impeller fitting/with drawing device.
7.4.3.2
Dismantling of mechanical seal
Exact instructions relating t o f itting pos itions of t he m echanical

seals, ei ther m otor s ide or pum p s ide, are outlined in Appendix
Mechanical seal arrangement with parts list.
7.4.4
Dismantling the motor component
Please ensure, when di smantling t he m otor part and t he el ectric

connecting cabling, that core identifications are clearly marked for
future reference during reassembly.
- Special points for versions X , Y eplosionproof
All ot her w ork af fecting t he ex plosionproofness,
such as new w indings and mechanical repairs
at t he m otor s ection, requi re a subsequent
acceptance test by an approved engi neer or
have to be carried out at t he prem ises of t he
manufacturer.
7.5
Re-assembly
7.5.1
Assembly of the pump takes place in reverse order of dismantling.

The drawing combined w ith t he i ndividual part s i ndex s hould be
used as a guide. All screws must be t ightened during assembly as
outlined in the instructions. General instructions in this respect are
outlined in the table below bolt tightening torque and special
points are stated in the installation instructions.
Table Bolt tightening torque

A4-70 / 1.4462
4
7
17
35
60
150
290
M5
M6
M8
M 10
M 12
M 16
M 20
7.5.2
Special points relating to components for

re-assembly
7.5.2.1
Mechanical seal
In principle, we recommend to use new manufacturers spare parts

for mechanical seals. In this respect it should be noted:
To ac hieve perf ect perf ormance, i t i s i mportant t o ens ure t hat all
parts are immaculately clean and that greatest care is taken during
the f itting of t he m echanical s eal. P rotectors of the moving
surfaces m ust not be rem oved unt il immediately before fitting the
part. The s urface of t he s haft m ust be perf ectly clean and
undamaged.
In principle to assist with the fitting of the bellows mechanical seal,
the i nside of t he bel lows t o avoi d any dam age t o the mechanical
seal should be wetted with soapy water (do not use oil).
Fitting of t he bel lows m echanical s eal at the
motor end.
Attention:
To avoid damage t o t he rubber bel lows by a k eyway or s haft

recess, the shaft stub should be c overed w ith a t hin s heet of f oil
(approx. 0.1...0.3 mm thick). Push t he rot ating uni t over f oil c over
and place into fitting position. Then remove the foil.
7.5.2.2
Impeller assembly
Instructions and proc edures are out lined i n Appendix Impeller

dismantling/fitting. Paragraph 7.4.3 outlines appropriate size.
7.5.2.2.1 KRT D-Wear plate

The clearance between i mpeller 230 and w ear pl ate 135 m ust be
set t o 0. 4 +0. 2 m m (m easured approx . 5 cm from the vane tip).
Use screws 914.12 and 914. 24 f or i nitial adj ustment and readjustment of the clearance.
7.5.2.3
Assembly of the pump must be c arried out in accordance with the

current m echanical engi neering regul ations. A ll part s which were
dismantled m ust be c leaned and t ested w ith regard to wear.
Damaged or w
orn part s m ust be
replaced by using
manufacturers spare parts. Ensure that all sealing surfaces are
clean and the O-rings or flat seals fit perfectly. We recommend the
use of O-ri ngs/seals at al l t imes.O-rings m ade from continuous
strips which were glued together must not be used.
Torque (Nm)
Thread
Checking seals/oil level
After as sembly t he m echanical s eal part/oil chamber should be

tested for leaks.
Procedure:
(Appendix 1 General pump outline Fig. 9).
The oil inlet tapping should be used to test for leaks.
Securely screw the testing device into the oil inlet opening.
Test media:
Test pressure:
Test duration:
Compressed air
max. 0.5 bar
2 min.
Make s ure t hat t he pres sure does not decrease during the test.
Afterwards, the oil level is to be checked (compare para. 7.2.4).
12
REVISION: C
Rev. Date: 18.04.2011
page: 67 of 81
KSB
7.5.2.4
Amarex KRT
Motor / electrical connections
Ensure prior to re-assembly of explosionproof motors that all the

special poi nts out lined i n paragraph 7. 4.4 were observed.
All motors must be tested electrically in line with paragraph 6.1, 6.2
and 7.2.
7.6
Stockkeeping of spare parts
Always quote the following data when ordering spare parts:

Pump type:e.g. KRTF100-240/172X1G-190
Works-No./Identity-No.
Motor-No.
fill in
This dat a c an be t aken f rom t he dat a pl ate ( appendix General

pump diagram Fig. 1)
7.6.1
Part
No.
801
834
818
230
502
433.01
Recommended stock of spare parts for a

two-year operation in accordance with VDMA
24296
(applicable for continuous operation)
Part description
Part motor
Cable entry
Rotor
Impeller
Wear ring
Mechanical seal
motor side
433.02 Mechanical seal
pump side
321.01 Grooved ball
/322
bearing
motor side
320/
Grooved ball
321.02 bearing
pump side
Set of seals
motor
Set of seals
hydraulic
Number of pumps
(including stand-by pumps)
2 3 4 5 6 8
10
and
more
- - - 1 1 2
3
1 1 2 2 2 3
40%
- - - 1 1 2
3
1 1 1 2 2 3
30%
2 2 2 3 3 4
50%
2 3 4 5 6 7
90%
2 3 4 5 6 7
90%
1 1 2 2 3 4
50%
1 1 2 2 3 4
50%
4 6 8 8 9 10
100%
4 6 8 8 9 10
100%
13
REVISION: C
Rev. Date: 18.04.2011
page: 68 of 81
H3) SPARE PARTS LIST
REVISION: C
Rev. Date: 18.04.2011
page: 69 of 81
OPERATION & MAINTENANCE MANUAL
a) Spare Parts to be supplied under the current contract:
(UNAVAILABLE AT THIS TIME)

List is being prepared by Alstom in Paris, and will be included in this chapter after
finalization and approval.
REVISION: C
Rev. Date: 18.04.2011
page: 70 of 81
STOCKAGE OF SPARE PARTS
REVISION: C
Rev. Date: 18.04.2011
page: 71 of 81
KSB
7.5.2.4
Amarex KRT
Motor / electrical connections
Ensure prior to re-assembly of explosionproof motors that all the

special poi nts out lined i n paragraph 7. 4.4 were observed.
All motors must be tested electrically in line with paragraph 6.1, 6.2
and 7.2.
7.6
Stockkeeping of spare parts
Always quote the following data when ordering spare parts:

Pump type:e.g. KRTF100-240/172X1G-190
Works-No./Identity-No.
Motor-No.
fill in
This dat a c an be t aken f rom t he dat a pl ate ( appendix General

pump diagram Fig. 1)
7.6.1
Part
No.
801
834
818
230
502
433.01
Recommended stock of spare parts for a

two-year operation in accordance with VDMA
24296
(applicable for continuous operation)
Part description
Part motor
Cable entry
Rotor
Impeller
Wear ring
Mechanical seal
motor side
433.02 Mechanical seal
pump side
321.01 Grooved ball
/322
bearing
motor side
320/
Grooved ball
321.02 bearing
pump side
Set of seals
motor
Set of seals
hydraulic
Number of pumps
(including stand-by pumps)
2 3 4 5 6 8
10
and
more
- - - 1 1 2
3
1 1 2 2 2 3
40%
- - - 1 1 2
3
1 1 1 2 2 3
30%
2 2 2 3 3 4
50%
2 3 4 5 6 7
90%
2 3 4 5 6 7
90%
1 1 2 2 3 4
50%
1 1 2 2 3 4
50%
4 6 8 8 9 10
100%
4 6 8 8 9 10
100%
13
REVISION: C
Rev. Date: 18.04.2011
page: 72 of 81
GENERAL ARRANGEMENT DRAWINGS

WITH PARTS LIST
REVISION: C
Rev. Date: 18.04.2011
page: 73 of 81
KSB
Amarex KRT
General arrangement drawing

Motor:
5 2...23 2
4 6...12 6
40-250
80-250
80-315
100-240/250
100-315
150-251
150-315
200-280/281
200-315
5 4...29 4
OW 382 436-00
19
REVISION: C
Rev. Date: 18.04.2011
page: 74 of 81
KSB
Amarex KRT
Cable entry
H07RN-F 12x5
H07RN-F 12x2,5
Z1
(only D 150-251)
D 150-251
D 150-315
D 100-315
20
REVISION: C
Rev. Date: 18.04.2011
page: 75 of 81
KSB
Amarex KRT
S 40-250
s=0.20.1 mm
321.02
Part-No.
Part description
Part-No.
Part description
23-7
Impeller body
421
Radial shaft seal ring
69-14
Leakage detector
433
Mechanical seal
80-1
Submersible motor
441
Seal casing
81-17
Butt joint
500
Ring
81-39
Clamp
502
Casing wear ring
81-51
Shim
503
Impeller wear ring
81-59
Stator
529
Bearing sleeve
99-17
Desiccant
550
Washer
101
Pump casing
561
Grooved pin
113
Intermediate casing
811
Motor casing
131
Inlet ring
818
Rotor
135
Wear plate
834
Cable duct
162
Suction cover
852
Screwed coupling
163
Discharge cover
900
Screw
230
Impeller
901
Hexagon head bolt
321
Radial ball bearing
903
Screwed plug
322
Radial roller bearing
914
330
Bearing bracket
920
Nut
410
Profile joint
930
Safety device
411
Gasket
931
Lockwasher
412
O-Ring
932
Circlip
21
REVISION: C
Rev. Date: 18.04.2011
page: 76 of 81
KSB
Amarex KRT

Motor:
5 2...17 2
5 4...16 4
40-250, 80-250
100-240, 100-250
Part No.
433
515
Part description
Mechanical seal
Clamping ring
G, GH, C1
433.01
515
433.02
H, C2
G, GH, C1
0W 309130-00
GLRD HJ
433.01
515
433.02
covered springs)
29
0W309130-05
Standard
Standard-Varianten
22
REVISION: C
Rev. Date: 18.04.2011
page: 77 of 81
KSB
Amarex KRT

Motor:
5 2...23 2
5 4...29 4
4 6...12 6
80-315/100-315/150-315
200-280/200-281
D 150-251/150-315/200-315
Part No.
433
515
932
G, GH, C1
433.01
Part description
Mechanical seal
Clamping ring
Circlip
932.03(=55)
515 (=33)
433.02
0W309131-00
H, C2
433.02
covered springs)
0W309131-05
Standard
Standard-Varianten
23
REVISION: C
Rev. Date: 18.04.2011
page: 78 of 81
H4) SPECIAL TOOLS LIST
- Not applicable
REVISION: C
Rev. Date: 18.04.2011
page: 79 of 81
H5) LIST OF SUPPLIERS
HYTEC Industrie
28 av des Bthunes
BP19060
95071 CergyPontoise
CEDEX
T: +33 1 34 30 84 37
sav@hytecindustrie.com
REVISION: C
Rev. Date: 18.04.2011
page: 80 of 81
J) AS BUILT DRAWINGS
REFERENCE
DESCRIPTION
AHS MRW
00 SEO NF
100 DOMESTIC SEWAGE SYSTEM - PROCESSING NOTICE
AHS MRW
00 SEO SP
100 DOMESTIC SEWAGE SYSTEM - FLOW DIAGRAM
REVISION: C
Rev. Date: 18.04.2011
page: 81 of 81

SEO-91SEO001PO/002PO-OM-C-18/04/2011

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GOVERNMENT OF THE REPUBLIC OF THE SUDAN

MEROWE DAM PROJECT

OPERATING & MAINTENANCE MANUAL

DOMESTIC SEWAGE SYSTEM SEWER SHAFT PUMPS

Rev. Date: 18.04.2011

OPERATION & MAINTENANCE MANUAL

General Description of Equipment

Brief Description of Equipment Use

Definitions and Technical Terms Used

Detailed Description of Equipment

Operating Principles and Characteristics

Repair and Adjustment

Spare Parts Lists

Special Tools Lists

Rev. Date: 18.04.2011

SITE TEST REPORTS

SEO DOMESTIC SEWAGE SANITARY

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

C1) BRIEF DESCRIPTION OF EQUIPMENT

DOMESTIC SEWAGE PUMPS

Rev. Date: 18.04.2011

C2) DESCRIPTION OF USE OF EQUIPMENT

Rev. Date: 18.04.2011

C3) DEFINITION OF TECHNICAL TERMS

Rev. Date: 18.04.2011

Discharge: Where the water exits the pump

Operating Pressure: The manufacturer's specified range of pressure expressed in pounds

Rev. Date: 18.04.2011

Suction: Where the water enters the pump

TDSL: Total Dynamic Suction Lift

TEFC: Totally Enclosed Fan Cooled - a type of motor enclosure

Rev. Date: 18.04.2011

Vacuum: Negative pressure; a region in a pump or a pipe that is below atmospheric

Rev. Date: 18.04.2011

C4) List of Items Used

UNIT SYS. NUM

SEWER SHAFT SERVICE PUMP

SEWER SHAFT STAND BY PUMP

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Rev. Date: 18.04.2011

Submersible motor pumps

see data plate:

Rev. Date: 18.04.2011

These operat ing i nstructions contain important notes f or the

Transport and interim storage

Description of the product and accessories

Commissioning, Startup / Shutdown

Rev. Date: 18.04.2011

General pump outline

Diagram data plate

Works No. / Identity No.

Important information for ordering spare parts

Works No. / Identity No.

Rev. Date: 18.04.2011