KSB Catalogue
KSB Catalogue
KSB Catalogue
Etanorm
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual Etanorm
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
Contents
Glossary .................................................................................................................................................. 6
1 General.................................................................................................................................................... 7
1.1 Principles ........................................................................................................................................................... 7
1.2 Installation of partly completed machinery.................................................................................................... 7
1.3 Target group..................................................................................................................................................... 7
1.4 Other applicable documents............................................................................................................................ 7
1.5 Symbols ............................................................................................................................................................. 7
1.6 Key to safety symbols/markings....................................................................................................................... 8
2 Safety ...................................................................................................................................................... 9
2.1 General.............................................................................................................................................................. 9
2.2 Intended use ..................................................................................................................................................... 9
2.3 Personnel qualification and training............................................................................................................... 9
2.4 Consequences and risks caused by non-compliance with this manual ....................................................... 10
2.5 Safety awareness ............................................................................................................................................ 10
2.6 Safety information for the operator/user ..................................................................................................... 10
2.7 Safety information for maintenance, inspection and installation .............................................................. 10
2.8 Unauthorised modes of operation ................................................................................................................ 11
2.9 Explosion protection ...................................................................................................................................... 11
2.9.1 Marking .............................................................................................................................................. 11
2.9.2 Temperature limits............................................................................................................................. 11
2.9.3 Monitoring equipment...................................................................................................................... 12
2.9.4 Operating limits ................................................................................................................................. 12
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Contents
6 Commissioning/Start-up/Shutdown................................................................................................... 37
6.1 Commissioning/Start-up ................................................................................................................................. 37
6.1.1 Prerequisites for commissioning/start-up ......................................................................................... 37
6.1.2 Filling in the lubricants ...................................................................................................................... 37
6.1.3 Priming and venting the pump......................................................................................................... 38
6.1.4 Final check .......................................................................................................................................... 39
6.1.5 Start-up............................................................................................................................................... 40
6.1.6 Checking the shaft seal...................................................................................................................... 41
6.1.7 Shutdown ........................................................................................................................................... 42
6.2 Operating limits.............................................................................................................................................. 42
6.2.1 Ambient temperature........................................................................................................................ 43
6.2.2 Frequency of starts............................................................................................................................. 43
6.2.3 Fluid handled ..................................................................................................................................... 44
6.3 Shutdown/storage/preservation .................................................................................................................... 44
6.3.1 Measures to be taken for shutdown ................................................................................................ 44
6.4 Returning to service ....................................................................................................................................... 45
8 Trouble-shooting.................................................................................................................................. 66
9 Related Documents .............................................................................................................................. 68
9.1 General Assembly Drawings .......................................................................................................................... 68
9.1.1 Standardised mechanical seal and bolted casing cover................................................................... 68
9.1.2 Standardised mechanical seal and clamped casing cover ............................................................... 70
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Contents
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Glossary
Glossary
ACS UBA
French drinking water regulations (ACS = German drinking water regulations to German
Attestation de Conformité Sanitaire) Environment Agency
Certificate of decontamination
A certificate of decontamination is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Discharge line
The pipeline which is connected to the discharge
nozzle
FM
Certification by FM Global (FM = Factory Mutual)
regarding property insurance in industry and risk
management; FM Approved products
Hydraulic system
The part of the pump in which the kinetic energy
is converted into pressure energy
Pool of pumps
Customers/operators’ pumps which are purchased
and stored regardless of their later use.
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
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1 General
1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover.
The manual describes the proper and safe use of this equipment in all phases of
operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the pump set and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB Service centre to
maintain the right to claim under warranty.
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
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1 General
Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
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2 Safety
2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
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2 Safety
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2 Safety
▪ When taking the pump set out of service always adhere to the procedure
described in the manual. (ð Section 6.1.7, Page 42) (ð Section 6.3, Page 44)
▪ Decontaminate pumps which handle fluids posing a health hazard.
(ð Section 7.3, Page 53)
▪ As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ð Section 6.1, Page 37)
2.9.1 Marking
Pump The marking on the pump refers to the pump part only.
Example of such marking:
II 2 G c TX (EN 13463-1) or EX II 2G Ex h IIC T5-T1 Gb (ISO 80079-36)
Refer to the individual Temperature Limits table for the temperatures permitted for
the individual pump variants. (ð Section 2.9.2, Page 11)
The pump complies with the requirements of type of protection constructional safety
"c" to ISO 80079-37.
Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor The motor must be considered separately.
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2 Safety
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3 Transport/Temporary Storage/Disposal
3 Transport/Temporary Storage/Disposal
3.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in the specified position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Observe the information about weights, centre of gravity and fastening points.
▷ Observe the applicable local accident prevention regulations.
▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
To transport the pump/pump set or back pull-out unit suspend it from the lifting
tackle as shown.
≤ 90 °
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3 Transport/Temporary Storage/Disposal
≤ 90 °
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage due to humidity, dirt or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the pump (set) or the packaged pump (set) and
accessories with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump!
▷ Clean and cover pump openings and connections as required prior to putting
the pump into storage.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, the shutdown measures
must be adhered to. (ð Section 6.3.1, Page 44)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
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3 Transport/Temporary Storage/Disposal
3.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing fluid and any fluid residues.
▷ Wear safety clothing and a protective mask if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
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4 Description of the Pump (Set)
4.2 Product Information as per Regulation No. 547/2012 (for water pumps
with a maximum shaft power of 150 kW) implementing "Ecodesign"
Directive 2009/125/EC
▪ Minimum efficiency index: see name plate, key to name plate
▪ The benchmark for the most efficient water pumps is MEI ≥ 0.70.
▪ Year of construction: see name plate, key to name plate
▪ Manufacturer’s name or trade mark, commercial registration number and place
of manufacture: see data sheet or order documentation
▪ Product’s type and size identificator: see name plate, key to name plate
▪ Hydraulic pump efficiency (%) with trimmed impeller: see data sheet
▪ Pump performance curves, including efficiency characteristics: see documented
characteristic curve
▪ The efficiency of a pump with a trimmed impeller is usually lower than that of a
pump with full impeller diameter. Trimming of the impeller will adapt the pump
to a fixed duty point, leading to reduced energy consumption. The minimum
efficiency index (MEI) is based on the full impeller diameter.
▪ Operation of this water pump with variable duty points may be more efficient
and economic when controlled, for example, by the use of a variable speed drive
that matches the pump duty to the system.
▪ Information on dismantling, recycling and disposal after decommissioning:
(ð Section 3.5, Page 15)
▪ Information on benchmark efficiency or benchmark efficiency graph for
MEI = 0.70 (0.40) for the pump based on the model shown in the Figure are
available at: https://www.europump.org/efficiencycharts
4.3 Designation
Table 5: Designation example
Position
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
E T N 0 5 0 - 0 3 2 - 1 2 5 1 G G S A S 1 1 G B 2 1 3 2 0 2 B P D 2 E M
See name plate and data sheet See data sheet
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4 Description of the Pump (Set)
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4 Description of the Pump (Set)
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4 Description of the Pump (Set)
2 ETN 050-032-160 GB X A 10 G A 2
7
8
3 Etanorm 47132456 Ø 174 mm
4 9
9971234567 000100 / 01
5 10
Q 30,00 m³/h H 34,00 m
11
6 v 1,0 mm²/s n 2900 1/min 2018
12
MEI ≥ 0,60 η --,-%
Mat. No. 01216137 ZN 3823 - 217
Design
▪ Volute casing pump
▪ Horizontal installation
▪ Back pull-out design
▪ Single-stage
▪ Dimensions and ratings to EN 733
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4 Description of the Pump (Set)
Pump casing
▪ Radially split volute casing
▪ Volute casing with integrally cast pump feet
▪ Replaceable casing wear rings (optional for casing material C)
Impeller type
▪ Closed radial impeller with multiply curved vanes
Bearings
▪ Standard bearings
– Floating bearings: deep groove ball bearings
▪ Reinforced bearings
– Floating bearings: deep groove ball bearings
▪ Bearings with bearing pedestal
– Floating bearings: deep groove ball bearings
Shaft seal
▪ Gland packing
▪ Single mechanical seals and double mechanical seals to EN 12756
▪ Shaft equipped with replaceable shaft sleeve in the shaft seal area
Example: WS_25_LS
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4 Description of the Pump (Set)
Lubrication:
▪ Grease lubrication
▪ Oil lubrication
6 7 8 9 10
Fig. 6: Sectional drawing
1 Clearance gap 2 Discharge nozzle
3 Casing cover 4 Shaft
5 Bearing bracket 6 Suction nozzle
7 Impeller 8 Shaft seal
9 Rolling element bearing, pump end 10 Rolling element bearing, motor end
Design The pump is designed with an axial fluid inlet and a radial outlet. The hydraulic
system runs in its own bearings and is connected to the motor by a shaft coupling.
Function The fluid enters the pump axially via the suction nozzle (6) and is accelerated
outward by the rotating impeller (7). In the flow passage of the pump casing the
kinetic energy of the fluid is converted into pressure energy. The fluid is pumped to
the discharge nozzle (2), where it leaves the pump. The clearance gap (1) prevents
any fluid from flowing back from the casing to the suction nozzle. At the rear side of
the impeller, the shaft (4) enters the casing via the casing cover (3). The shaft passage
through the cover is sealed to atmosphere with a shaft seal (8). The shaft runs in
rolling element bearings (9 and 10), which are supported by a bearing bracket (5)
linked with the pump casing and/or casing cover.
Sealing The pump is sealed by a shaft seal (standardised mechanical seal or gland packing).
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4 Description of the Pump (Set)
3) Surface sound pressure level; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.8 - 1.1 range and
for non-cavitating operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.
4) Increase for 60 Hz operation: 3500 rpm: +3 dB, 1750 rpm: +1 dB
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5 Installation at Site
5 Installation at Site
DANGER
Excessive temperatures in the shaft seal area
Explosion hazard!
▷ Never operate a pump (set) with gland packing in potentially explosive
atmospheres.
Place of installation
WARNING
Installation on mounting surface which is unsecured and cannot support the load
Personal injury and damage to property!
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN 206-1.
▷ The mounting surface must be set, flat, and level.
▷ Observe the weights indicated.
DANGER
Excessive temperatures due to improper installation
Explosion hazard!
▷ Install the pump in a horizontal position to ensure self-venting of the pump.
DANGER
Static charging due to insufficient potential equalisation
Explosion hazard!
▷ Make sure that the connection between pump and baseplate is electrically
conductive.
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5 Installation at Site
2 3
Fig. 7: Fitting the shims
L Bolt-to-bolt distance 1 Shim
2 Shim if (L) > 800 mm 3 Foundation bolt
ü The foundation has the required strength and characteristics.
ü The foundation has been prepared in accordance with the dimensions given in
the outline drawing/general arrangement drawing.
1. Position the pump set on the foundation and level it with the help of a spirit
level placed on the shaft and discharge nozzle.
Permissible deviation: 0.2 mm/m
2. Use shims (1) for height compensation, if necessary.
Always fit shims, if any, immediately to the left and right of the foundation
bolts (3) between the baseplate/foundation frame and the foundation.
For a bolt-to-bolt distance (L) > 800 mm fit additional shims (2) halfway between
the bolt holes.
All shims must lie perfectly flush.
3. Insert the foundation bolts (3) into the holes provided.
4. Use concrete to set the foundation bolts (3) into the foundation.
5. Wait until the concrete has set firmly, then level the baseplate.
6. Tighten the foundation bolts (3) evenly and firmly.
NOTE
For baseplates more than 400 mm wide grouting the baseplate with low-shrinkage
concrete is recommended.
NOTE
For baseplates made of grey cast iron grouting the baseplate with low-shrinkage
concrete is recommended.
NOTE
For low-noise operation contact the manufacturer to check whether the pump set
can be installed on anti-vibration mounts.
NOTE
Expansion joints can be fitted between the pump and the suction/discharge line.
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5 Installation at Site
4
Fig. 8: Adjusting the levelling elements
1, 3 Locknut 2 Adjusting nut
4 Machine mount
ü The installation surface has the required strength and characteristics.
1. Position the pump set on the machine mounts (4) and align it with the help of a
spirit level (on the shaft/discharge nozzle).
2. To adjust any differences in height, loosen the locknuts (1, 3) of the machine
mounts (4).
3. Turn the adjusting nut (2) until any differences in height have been
compensated.
4. Re-tighten the locknuts (1, 3) at the machine mounts (4).
5.4 Piping
DANGER
Impermissible loads acting on the pump nozzles
Danger to life from escaping hot, toxic, corrosive or flammable fluids!
▷ Do not use the pump as an anchorage point for the piping.
▷ Anchor the pipes in close proximity to the pump and connect them properly
without transmitting any stresses or strains.
▷ Observe the permissible forces and moments at the pump nozzles.
▷ Take appropriate measures to compensate for thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.
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5 Installation at Site
NOTE
Installing check and shut-off elements in the system is recommended, depending on
the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
ü Suction lift lines have been laid with a rising slope, suction head lines with a
downward slope towards the pump.
ü A flow stabilisation section having a length equivalent to at least twice the
diameter of the suction flange has been provided upstream of the suction flange.
ü The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
ü Adapters to larger diameters have a diffuser angle of approximately 8° to
prevent excessive pressure losses.
ü The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Remove any impurities from the piping.
▷ If necessary, install a filter.
▷ Observe the information in (ð Section 7.2.2.3, Page 49) .
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the
suction and discharge nozzles of the pump.
3. Check that the inside of the pump is free from any foreign objects. Remove any
foreign objects.
4. If required, install a filter in the piping (see figure: Filter in the piping).
1
2
Fig. 9: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of
corrosion-resistant material.
Use a filter with a filter area three times the cross-section of the piping.
Conical filters have proved suitable.
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5 Installation at Site
CAUTION
Aggressive flushing liquid and pickling agent
Damage to the pump!
▷ Match the cleaning operation mode and duration of flushing and pickling to
the casing materials and seal materials used.
Mz
applicable if the pump is installed on a baseplate and bolted to a rigid and level
foundation.
My
Fy
Fx Fx Mx
Fy
Fz
Fx Fy
Table 10: Forces and moments at the pump nozzles for casing material G (JL1040/ A48CL35B)
Size Suction nozzle Discharge nozzle
DN Fx Fy Fz ∑F Mx My Mz DN Fx Fy Fz ∑F Mx My Mz
[N] [N] [N] [N] [Nm] [Nm] [Nm] [N] [N] [N] [N] [Nm] [Nm] [Nm]
040-025-160 40 450 400 350 696 450 320 370 25 265 250 300 472 315 210 245
040-025-200 40 450 400 350 696 450 320 370 25 265 250 300 472 315 210 245
050-032-125.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-032-160.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-032-200.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-032-250.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-032-125 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-032-160 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-032-200 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-032-250 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
065-040-125 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-040-160 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-040-200 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-040-250 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-040-315 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-050-125 65 740 650 600 1153 530 390 420 50 530 470 580 916 500 350 400
065-050-160 65 740 650 600 1153 530 390 420 50 530 470 580 916 500 350 400
065-050-200 65 740 650 600 1153 530 390 420 50 530 470 580 916 500 350 400
065-050-250 65 740 650 600 1153 530 390 420 50 530 470 580 916 500 350 400
065-050-315 65 740 650 600 1153 530 390 420 50 530 470 580 916 500 350 400
080-065-125 80 880 790 720 1385 560 400 460 65 650 600 740 1153 530 390 420
080-065-160 80 880 790 720 1385 560 400 460 65 650 600 740 1153 530 390 420
080-065-200 80 880 790 720 1385 560 400 460 65 650 600 740 1153 530 390 420
080-065-250 80 880 790 720 1385 560 400 460 65 650 600 740 1153 530 390 420
080-065-315 80 880 790 720 1385 560 400 460 65 650 600 740 1153 530 390 420
100-080-160 100 1180 1050 950 1843 620 440 510 80 790 720 880 1385 560 400 460
100-080-200 100 1180 1050 950 1843 620 440 510 80 790 720 880 1385 560 400 460
100-080-250 100 1180 1050 950 1843 620 440 510 80 790 720 880 1385 560 400 460
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5 Installation at Site
1,2 S
1,1
1 G
0,9
0,8 B
0,7 °C
-30 20 70 120 140
Fig. 11: Temperature/material correction diagram for casing materials G (EN-GJL-250/
A48CL35B), S (EN-GJS-400-15/A536 GR 60-40-18) and B (CC480K-GS/B30 C90700)
Table 11: Forces and moments at the pump nozzles for casing material C (1.4408/ A743 GR CF8M)
Size Suction nozzle Discharge nozzle
DN Fx Fy Fz ∑F Mx My Mz DN Fx Fy Fz ∑F Mx My Mz
[N] [N] [N] [N] [Nm] [Nm] [Nm] [N] [N] [N] [N] [Nm] [Nm] [Nm]
040-25-160 40 970 780 650 1404 500 280 410 25 460 410 600 860 370 185 280
040-25-200 40 970 780 650 1404 500 280 410 25 460 410 600 860 370 185 280
050-32-125.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-160.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-200.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-250.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-125 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-160 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-200 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-250 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
065-40-125 65 1600 1300 1050 2314 1050 550 780 40 780 640 1000 1421 500 280 415
065-40-160 65 1600 1300 1050 2314 1050 550 780 40 780 640 1000 1421 500 280 415
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5 Installation at Site
NOTE
Where fluid has to be pumped out of a vessel under vacuum, installing a vacuum
balance line is recommended.
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5 Installation at Site
1 2 3 4
5 6
Fig. 12: Vacuum balance system
1 Vessel under vacuum 2 Vacuum balance line
3 Shut-off element 4 Swing check valve
5 Main shut-off element 6 Vacuum-tight shut-off element
NOTE
An additional line fitted with a shut-off valve (from the pump discharge nozzle to
the balance line) facilitates venting of the pump before start-up.
DANGER
Risk of potentially explosive atmosphere by mixing of incompatible fluids in the
auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid
handled.
WARNING
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing
liquid, etc.)
Risk of injury from escaping fluid!
Risk of burns!
Malfunction of the pump!
▷ Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the quantity, dimensions and locations of auxiliary
connections.
▷ Use the auxiliary connections provided.
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5 Installation at Site
5.5 Enclosure/insulation
DANGER
Risk of potentially explosive atmosphere due to insufficient venting
Explosion hazard!
▷ Make sure the space between the casing cover/discharge cover and the bearing
cover is sufficiently vented.
▷ Never close or cover the perforation of the bearing bracket guards (e.g. by
insulation).
WARNING
The volute casing and casing/discharge cover take on the same temperature as the
fluid handled
Risk of burns!
▷ Insulate the volute casing.
▷ Fit protective equipment.
CAUTION
Heat build-up in the bearing bracket
Damage to the bearing!
▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover.
DANGER
Inadmissible temperatures at the coupling or bearings due to misalignment of the
coupling
Explosion hazard!
Risk of burns!
▷ Make sure that the coupling is correctly aligned at all times.
CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷ Always check the coupling after the pump has been installed and connected to
the piping.
▷ Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
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5 Installation at Site
a) 1 b) 1
A B A B
A B A B
1 2 1 2
Fig. 13: Checking the coupling alignment: Coupling without spacer sleeve (a) or Coupling with spacer sleeve (b)
1 Straight-edge 2 Gauge
ü The coupling guard and its footboard, if any, have been removed.
1. Loosen the support foot and re-tighten it without transmitting any stresses and
strains.
2. Place the straight-edge axially on both coupling halves.
3. Leave the straight-edge in this position and turn the coupling by hand.
The coupling is aligned correctly if the distances A and B to the respective shafts
are the same at all points around the circumference.
The radial and axial deviation between the two coupling halves must not exceed
0.1 mm, during standstill as well as at operating temperature and under inlet
pressure.
4. Check the distance (dimension see general arrangement drawing) between the
two coupling halves around the circumference.
The coupling is correctly aligned if the distance between the two coupling
halves is the same at all points around the circumference.
The radial and axial deviation between the two coupling halves must not exceed
0.1 mm, during standstill as well as at operating temperature and under inlet
pressure.
5. If alignment is correct, re-install the coupling guard and its footboard, if any.
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5 Installation at Site
1
2
3
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact.
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5 Installation at Site
1
Fig. 15: Pump set with shim
1 Shim
ü The coupling guard and its footboard, if any, have been removed.
1. Check the coupling alignment.
2. Loosen the hexagon head bolts at the motor.
3. Insert shims underneath the motor feet until the difference in shaft centreline
height has been compensated.
4. Re-tighten the hexagon head bolts.
5. Check proper functioning of coupling/shaft.
Check that coupling/shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact.
DANGER
Electrical connection work by unqualified personnel
Risk of fatal injury due to electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.
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5 Installation at Site
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate starting method.
NOTE
A motor protection device is recommended.
CAUTION
Switchover between star and delta on three-phase motors with star-delta starting
takes too long.
Damage to the pump (set)!
▷ Keep switch-over intervals between star and delta as short as possible.
5.8.2 Earthing
DANGER
Electrostatic charging
Explosion hazard!
Damage to the pump set!
▷ Connect the PE conductor to the earthing terminal provided.
▷ Provide for potential equalisation between the pump set and foundation.
NOTE
In compliance with IEC 60034-8, three-phase motors are always wired for clockwise
rotation (looking at the motor shaft stub).
The pump's direction of rotation is indicated by an arrow on the pump.
Etanorm 35 of 84
5 Installation at Site
DANGER
Temperature increase resulting from contact between rotating and stationary
components
Explosion hazard!
Damage to the pump set!
▷ Never check the direction of rotation by starting up the unfilled pump set.
▷ Separate the pump from the motor to check the direction of rotation.
WARNING
Hands inside the pump casing
Risk of injuries, damage to the pump!
▷ Always disconnect the pump set from the power supply and secure it against
unintentional start-up before inserting your hands or other objects into the
pump.
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
▷ Separate the pump from the motor to check the direction of rotation.
CAUTION
Drive and pump running in the wrong direction of rotation
Damage to the pump!
▷ Refer to the arrow indicating the direction of rotation on the pump.
▷ Check the direction of rotation. If required, check the electrical connection and
correct the direction of rotation.
The correct direction of rotation of the motor and pump is clockwise (seen from the
drive end).
1. Start the motor and stop it again immediately to determine the motor's
direction of rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction
of rotation on the pump.
3. If the motor is running in the wrong direction of rotation, check the electrical
connection of the motor and switchgear, if any.
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6 Commissioning/Start-up/Shutdown
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/Start-up
Grease-lubricated bearings
Grease-lubricated bearings have been packed with grease.
Oil-lubricated bearings
Fill the bearing bracket with lubricating oil.
Oil quality see (ð Section 7.2.3.1.2, Page 50)
Oil quantity see (ð Section 7.2.3.1.3, Page 51)
Filling the constant level oiler with lubricating oil (oil-lubricated bearings only)
ü The constant level oiler has been fitted.
NOTE
If no constant level oiler is provided on the bearing bracket, the oil level can be
read in the middle of the oil level gauge arranged at the side of the bearing
bracket.
CAUTION
Insufficient quantity of lubricating oil in the reservoir of the constant level oiler
Damage to the bearings!
▷ Regularly check the oil level.
▷ Always fill the oil reservoir completely.
▷ Keep the oil reservoir properly filled at all times.
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6 Commissioning/Start-up/Shutdown
1 2
3 4 5
Fig. 16: Bearing bracket with constant level oiler
1 Constant level oiler 2 Vent plug
3 Connection elbow of the constant level 4 Screw plug
oiler
5 Bearing bracket
1. Pull out the vent plug (2).
2. Hinge down the reservoir of the constant level oiler (1) from the bearing
bracket (5) and hold it in this position.
3. Fill in oil through the hole for the vent plug until the oil reaches the connection
elbow of the constant level oiler (3).
4. Completely fill the reservoir of the constant level oiler (1).
5. Snap the constant level oiler (1) back into its operating position.
6. Fit the vent plug (2) again.
7. After approximately 5 minutes, check the oil level in the glass reservoir of the
constant level oiler (1).
The oil reservoir must be properly filled at all times to ensure that the correct oil
level is maintained. Repeat steps 1 - 6, if necessary.
8. To check the function of the constant level oiler (1), slowly drain some oil via the
screw plug (4) until air bubbles can be seen in the oil reservoir.
NOTE
An excessively high oil level can lead to a temperature rise and to leakage of the
fluid handled or oil.
DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.
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6 Commissioning/Start-up/Shutdown
DANGER
Risk of potentially explosive atmosphere by mixing of incompatible fluids in the
auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid
handled.
DANGER
Shaft seal failure caused by insufficient lubrication
Hot or toxic fluid could escape!
Damage to the pump!
▷ Before starting up the pump set, vent the pump and suction line and prime
both with the fluid to be handled.
CAUTION
Increased wear due to dry running
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during
pump operation.
1. Vent the pump and suction line and prime both with the fluid to be handled.
Connection 6D can be used for venting (see drawing of auxiliary connections).
2. Fully open the shut-off element in the suction line.
3. Fully open all auxiliary feed lines (barrier fluid, flushing liquid, etc.), if any.
4. Open the shut-off element, if any, in the vacuum balance line and close the
vacuum-tight shut-off element, if any. (ð Section 5.4.3, Page 29)
NOTE
For design-inherent reasons some unfilled volume in the hydraulic system cannot be
excluded after the pump has been primed for commissioning/start-up. However,
once the motor is started up the pumping effect will immediately fill this volume
with the fluid handled.
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6 Commissioning/Start-up/Shutdown
6.1.5 Start-up
DANGER
Non-compliance with the permissible pressure and temperature limits if the pump
is operated with the suction and/or discharge line closed.
Explosion hazard!
Hot or toxic fluids escaping!
▷ Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷ Only start up the pump set with the discharge-side shut-off element slightly or
fully open.
DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid
handled
Explosion hazard!
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▷ Prime the pump as per operating instructions. (ð Section 6.1.3, Page 38)
▷ Always operate the pump within the permissible operating range.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
CAUTION
Start-up against open discharge line
Motor overload!
▷ Make sure the motor has sufficient power reserves.
▷ Use a soft starter.
▷ Use speed control.
1. Fully open the shut-off element in the suction head/suction lift line.
2. Close or slightly open the shut-off element in the discharge line.
3. Start up the motor.
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6 Commissioning/Start-up/Shutdown
4. Immediately after the pump has reached full rotational speed, slowly open the
shut-off element in the discharge line and adjust it to comply with the duty
point.
CAUTION
Misalignment of pump and coupling
Damage to pump, motor and coupling!
▷ When the operating temperature has been reached, switch off the pump set
and check the coupling alignment.
WARNING
Unprotected rotating parts
Risk of personal injury!
▷ Do not touch rotating parts.
▷ When the pump is running, perform any work with utmost caution.
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6 Commissioning/Start-up/Shutdown
6.1.7 Shutdown
CAUTION
Heat build-up inside the pump
Damage to the shaft seal!
▷ Depending on the type of installation, the pump set requires sufficient after-
run time – with the heat source switched off – until the fluid handled has
cooled down.
CAUTION
Backflow of fluid handled is not permitted
Motor or winding damage! Mechanical seal damage!
▷ Close the shut-off elements.
NOTE
If the discharge line is equipped with a non-return or check valve, the shut-off
element may remain open provided that the system conditions and system
regulations are considered and observed.
CAUTION
Risk of freezing during prolonged pump shutdown periods
Damage to the pump!
▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect
them against freezing.
DANGER
Non-compliance with operating limits for pressure, temperature, fluid handled and
speed
Explosion hazard!
Hot or toxic fluid could escape!
▷ Comply with the operating data indicated in the data sheet.
▷ Never use the pump for handling fluids it is not designed for.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures, pressures or rotational speeds
exceeding those specified in the data sheet or on the name plate unless the
written consent of the manufacturer has been obtained.
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6 Commissioning/Start-up/Shutdown
DANGER
Formation of a potentially explosive atmosphere inside the pump
Explosion hazard!
▷ When draining tanks take suitable measures to prevent dry running of the
pump (e.g. fill level monitoring).
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
▷ Observe the specified limits for permissible ambient temperatures.
DANGER
Excessive surface temperature of the motor
Explosion hazard!
Damage to the motor!
▷ In case of explosion-proof motors, observe the frequency of starts specified in
the manufacturer's product literature.
CAUTION
Re-starting while motor is still running down
Damage to the pump (set)!
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
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6 Commissioning/Start-up/Shutdown
The calculation formula below can be used to check if an additional heat build-up
could lead to a dangerous temperature increase at the pump surface.
×
×
×
Table 17: Key
Symbol Description Unit
c Specific heat capacity J/kg K
g Gravitational constant m/s²
H Pump discharge head m
Tf Fluid temperature °C
TO Temperature at the casing surface °C
Pump efficiency at duty point -
Temperature difference K
CAUTION
Impermissibly high density of the fluid handled
Motor overload!
▷ Observe the information about fluid density in the data sheet.
▷ Make sure the motor has sufficient power reserves.
6.3 Shutdown/storage/preservation
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6 Commissioning/Start-up/Shutdown
WARNING
Failure to re-install or re-activate protective devices
Risk of injury from moving parts or escaping fluid!
▷ As soon as the work is completed, re-install and re-activate any safety-relevant
devices and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer
seals.
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7 Servicing/Maintenance
7 Servicing/Maintenance
DANGER
Improper cleaning of coated pump surfaces
Explosion hazard by electrostatic discharge!
▷ When cleaning coated pump surfaces in atmospheres of Explosion group IIC,
use suitable anti-static equipment.
DANGER
Sparks produced during servicing work
Explosion hazard!
▷ Observe the safety regulations in force at the place of installation!
▷ Always perform maintenance work at an explosion-proof pump (set) outside of
potentially explosive atmospheres.
DANGER
Improperly serviced pump set
Explosion hazard!
Damage to the pump set!
▷ Service the pump set regularly.
▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.
WARNING
Unintentional starting of the pump set
Risk of injury by moving components and shock currents!
▷ Ensure that the pump set cannot be started unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Risk of injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps which handle fluids posing a health hazard.
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7 Servicing/Maintenance
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump, pump set and pump parts with a
minimum of servicing/maintenance expenditure and work.
NOTE
All maintenance work, service work and installation work can be carried out by KSB
Service or authorised workshops. For contact details please refer to the enclosed
"Addresses" booklet or visit "www.ksb.com/contact" on the Internet.
Never use force when dismantling and reassembling the pump set.
7.2 Servicing/Inspection
DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.
DANGER
Incorrectly serviced shaft seal
Explosion hazard!
Hot, toxic fluid escaping!
Damage to the pump set!
Risk of burns!
Fire hazard!
▷ Regularly service the shaft seal.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing
seals
Explosion hazard!
Fire hazard!
Damage to the pump set!
Risk of burns!
▷ Regularly check the lubricant level.
▷ Regularly check the rolling element bearings for running noises.
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7 Servicing/Maintenance
DANGER
Incorrectly serviced barrier fluid system
Explosion hazard!
Fire hazard!
Damage to the pump set!
Hot and/or toxic fluids escaping!
▷ Regularly service the barrier fluid system.
▷ Monitor the barrier fluid pressure.
CAUTION
Increased wear due to dry running
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during
pump operation.
CAUTION
Impermissibly high temperature of fluid handled
Damage to the pump!
▷ Prolonged operation against a closed shut-off element is not permitted
(heating up of the fluid).
▷ Observe the temperature limits in the data sheet and in the section on
operating limits. (ð Section 6.2, Page 42)
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured
on the outside of the bearing bracket).
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7 Servicing/Maintenance
NOTE
After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is
only reached after a certain period of operation (up to 48 hours depending on the
conditions).
DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
Damage to the pump set!
▷ Regularly check the coupling guard, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.
DANGER
Static charging due to insufficient potential equalisation
Explosion hazard!
▷ Make sure that the connection between pump and baseplate is electrically
conductive.
Table 18: Clearances between impeller and casing / between impeller and casing
cover
Impeller material Permissible clearance
New Maximum
G (JL1040/ A48CL35B) 0,3 mm 0,9 mm
B (CC480K-GS/B30 C90700)
I (LTB 2)
C (1.4408/ A743 GR CF8M) 0,5 mm 1,5 mm
CAUTION
Insufficient inlet pressure due to clogged filter in the suction line
Damage to the pump!
▷ Monitor contamination of filter with suitable means (e.g. differential pressure
gauge).
▷ Clean filter at appropriate intervals.
Etanorm 49 of 84
7 Servicing/Maintenance
DANGER
Excessive temperatures caused by mechanical contact
Risk of explosion!
Damage to the pump set!
▷ Check correct seating of axial seal rings mounted on the shaft.
Only gentle contact of the sealing lip shall be established.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing
seals
Explosion hazard!
Fire hazard!
Damage to the pump set!
▷ Regularly check the condition of the lubricant.
7.2.3.1.1 Intervals
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7 Servicing/Maintenance
WARNING
Lubricants posing a health hazard and/or hot lubricants
Hazard to persons and the environment!
▷ When draining the lubricant take appropriate measures to protect persons and
the environment.
▷ Wear safety clothing and a protective mask if required.
▷ Collect and dispose of any lubricants.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1 2 3
Fig. 17: Bearing bracket with constant level oiler
1 Constant level oiler 2 Screw plug
3 Bearing bracket
ü A suitable container for the used oil is on hand.
1. Place the container underneath the screw plug.
2. Undo the screw plug (2) at the bearing bracket (3) and drain the oil.
3. Once the bearing bracket (3) has been drained, re-insert and re-tighten the
screw plug (2).
4. Re-fill with oil. (ð Section 6.1.2, Page 37)
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7 Servicing/Maintenance
7.2.3.2.1 Intervals
Under normal conditions the grease-lubricated bearings will run for 15,000 operating
hours or 2 years. Under unfavourable operating conditions (e.g. high room
temperature, high atmospheric humidity, dust-laden air, aggressive industrial
atmosphere etc.), check the bearings earlier and clean and relubricate them if
required.
CAUTION
Mixing greases of differing soap bases
Changed lubricating qualities!
▷ Thoroughly clean the bearings.
▷ Adjust the re-lubrication intervals to the grease used.
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7 Servicing/Maintenance
7.3 Drainage/cleaning
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing fluid and any fluid residues.
▷ Wear safety clothing and a protective mask if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set. (ð Section 6.1.7, Page 42)
▷ Close the shut-off elements in the suction line and discharge line.
▷ Drain the pump and release the pump pressure. (ð Section 7.3, Page 53)
▷ Shut off any auxiliary feed lines.
▷ Allow the pump set to cool down to ambient temperature.
WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
▷ Always have repair work and maintenance work performed by specially trained,
qualified personnel.
WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
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7 Servicing/Maintenance
For dismantling and reassembly observe the exploded views and the general
assembly drawing. (ð Section 9.1, Page 68)
In case of damage you can always contact KSB Service.
NOTE
All maintenance work, service work and installation work can be carried out by KSB
Service or authorised workshops. For contact details please refer to the enclosed
"Addresses" booklet or visit "www.ksb.com/contact" on the Internet.
NOTE
After a prolonged period of operation the individual components may be hard to
pull off the shaft. If this is the case, use a brand name penetrating agent and/or - if
possible - an appropriate puller.
NOTE
On pump sets with spacer-type couplings, the back pull-out unit can be removed
while the motor remains bolted to the baseplate.
WARNING
Motor tilting
Risk of crushing hands and feet!
▷ Suspend or support the motor to prevent it from tilting.
WARNING
Back pull-out unit tilting
Risk of crushing hands and feet!
▷ Suspend or support the bearing bracket at the pump end.
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7 Servicing/Maintenance
4. Use forcing screws 901.30 (for bolted casing covers) or 901.31 (for clamped
casing covers) to remove the back pull-out unit from its seat in the volute casing.
Pull the back pull-out unit completely out of the volute casing.
5. Remove and dispose of gasket 400.10.
6. Place the back pull-out unit on a clean and level surface.
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7 Servicing/Maintenance
Oil lubrication
ü The notes and steps stated in (ð Section 7.4.1, Page 53) to
(ð Section 7.4.6, Page 55) have been observed/carried out.
ü The bearing bracket has been placed in a clean and level assembly area.
1. Undo the grub screw in the coupling hub.
2. Pull the coupling hub off pump shaft 210 with a puller.
3. Remove key 940.02.
4. Remove thrower 507.01.
5. Remove pump-end bearing cover 360.01 and drive-end bearing cover 360.02.
6. Remove hexagon head bolts 901.01 and 901.02 as well as gaskets 400.01 and
400.02.
7. Press shaft 210 out of the shaft seat.
8. Remove radial ball bearings 321.01 and 321.02, and place them on a clean and
level surface.
9. Dispose of gaskets 400.01 and 400.02.
Grease lubrication for shaft units 25, 35, 55 (standard bearing assembly)
ü The notes and steps stated in (ð Section 7.4.1, Page 53) to
(ð Section 7.4.6, Page 55) have been observed/carried out.
ü The bearing bracket has been placed in a clean and level assembly area.
1. Undo the grub screw in the coupling hub.
2. Pull the coupling hub off pump shaft 210 with a puller.
3. Remove key 940.02.
4. Remove axial seal rings 411.01 and 411.02.
5. Remove pump-end bearing cover 360.01 and drive-end bearing cover 360.02.
6. Remove circlips 932.01 and 932.02.
7. Press shaft 210 out of the bearing seats.
8. Remove radial ball bearings 321.01 and 321.02, and place them on a clean and
level surface.
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7 Servicing/Maintenance
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
CAUTION
Improper reassembly
Damage to the pump!
▷ Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
▷ Use original spare parts only.
Sequence Always reassemble the pump in accordance with the corresponding general assembly
drawing or exploded view.
Sealing elements Check O-rings for any damage and replace by new O-rings if required.
Always use new gaskets, making sure that they have the same thickness as the old
ones.
Always fit gaskets of asbestos-free materials or graphite without using lubricants
(e.g. copper grease, graphite paste).
Assembly adhesives Avoid the use of assembly adhesives if possible.
Should an assembly adhesive be required after all, use a commercially available
contact adhesive (e.g. Pattex) or sealant (e.g. HYLOMAR or Epple 33).
Only apply adhesive at selected points and in thin layers.
Never use quick-setting adhesives (cyanoacrylate adhesives).
Coat the locating surfaces of the individual components with graphite or similar
before reassembly.
Prior to reassembly, screw back any forcing screws and adjusting screws.
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.
(ð Section 7.6, Page 63)
Oil lubrication
ü The individual parts have been placed in a clean and level assembly area.
ü All dismantled parts have been cleaned and checked for wear.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
1. Press radial ball bearings 321.01 and 321.02 onto shaft 210.
2. Slide the pre-assembled shaft into bearing bracket 330.
3. Insert new gaskets 400.01 and 400.02.
4. Fasten bearing covers 360.01 and 360.02 with hexagon head bolts 901.01 and
901.02. Watch lip seals 421.01 and 421.02.
5. Fit thrower 507.
6. Insert key 940.02.
7. Pull the coupling half onto the drive-end shaft stub.
8. Secure the coupling hub with a grub screw.
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7 Servicing/Maintenance
Grease lubrication for shaft units 25, 35, 55 (standard bearing assembly)
3
4
58 of 84 Etanorm
7 Servicing/Maintenance
CAUTION
Elastomers in contact with oil/grease
Shaft seal failure!
▷ Use water as assembly lubricant.
▷ Never use oil or grease as assembly lubricant.
NOTE
To reduce friction forces when assembling the seal, wet the shaft sleeve and the
location of the stationary ring with water.
9. Fit the rotating assembly of the mechanical seal (primary ring) on shaft sleeve
523.
Observe the following installation dimension b for mechanical seals with installation
length L1k to EN 12756 (design KU):
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7 Servicing/Maintenance
1 2 3 4
Fig. 19: Installation dimension b of mechanical seal
1 Impeller 2 Shaft sleeve
3 Mechanical seal 4 Casing cover
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7 Servicing/Maintenance
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7 Servicing/Maintenance
11. On models with a clamped casing cover, fasten cover plates 81-92.01 and
81-92.02 with transport locks 901.98 and lock washers 554.98. The casing cover is
now fastened to the bearing bracket.
12. Fit and tighten nuts 920.15, if any.
13. Tighten gland follower 452 lightly and evenly.
The rotor must be easy to rotate.
WARNING
Back pull-out unit tilting
Risk of crushing hands and feet!
▷ Suspend or support the bearing bracket at the pump end.
NOTE
Steps 1 and 2 do not apply to versions with spacer-type coupling.
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7 Servicing/Maintenance
a) X b) A
A
X A
E
c)
C
X
C C
B
D
X
X D
Fig. 23: Tightening points: model with bolted casing cover and grease lubrication (a), model with clamped casing
cover (b) and oil lubrication (c)
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7 Servicing/Maintenance
1 2 3 4
Fig. 24: Position of bolts/screws at the pump set
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7 Servicing/Maintenance
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
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8 Trouble-shooting
8 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work performed to remedy faults, observe the relevant information
given in this operating manual and/or in the product literature provided by the
accessories manufacturer.
If problems occur that are not described in the following table, consultation with the
KSB customer service is required.
A Pump delivers insufficient flow rate
B Motor is overloaded
C Excessive discharge pressure
D Increased bearing temperature
E Leakage at the pump
F Excessive leakage at the shaft seal
G Vibrations during pump operation
H Impermissible temperature increase in the pump
Table 29: Trouble-shooting
A B C D E F G H Possible cause Remedy15)
✘ - - - - - - - Pump delivers against an excessively Re-adjust to duty point.
high pressure. Check system for impurities.
Fit a larger impeller.16)
Increase the speed (turbine, I.C. engine).
✘ - - - - - ✘ ✘ Pump or piping are not completely Vent and/or prime.
vented or primed.
✘ - - - - - - - Supply line or impeller clogged Remove deposits in the pump and/or piping.
✘ - - - - - - - Formation of air pockets in the piping Alter piping layout.
Fit vent valve.
✘ - - - - - ✘ ✘ Suction lift is too high/NPSHavailable Check/alter fluid level.
(positive suction head) is too low. Install pump at a lower level.
Fully open the shut-off element in the suction
line.
Change suction line, if the friction losses in
the suction line are too high.
Check any strainers installed/suction opening.
Observe permissible speed of pressure fall.
✘ - - - - - - - Air intake at the shaft seal Supply external barrier fluid, if necessary, or
increase barrier fluid pressure.
Replace shaft seal.
✘ - - - - - - - Wrong direction of rotation Check the electrical connection of the motor
and the control system, if any.
✘ - - - - - - - Speed is too low.
- Operation with frequency inverter - Increase voltage/frequency at the frequency
- Operation without frequency inverter inverter in the permissible range.
- Check voltage.
✘ - - - - - ✘ - Wear of internal components Replace worn components by new ones.
- ✘ - - - - ✘ - Pump back pressure is lower than Re-adjust to duty point.
specified in the purchase order. In the case of persistent overloading, turn
down impeller.16)
15) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
16) Contact the manufacturer.
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8 Trouble-shooting
Etanorm 67 of 84
9 Related Documents
9 Related Documents
Fig. 25: Pump set with standardised mechanical seal and bolted casing cover
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9 Related Documents
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9 Related Documents
Fig. 26: Pump set with standardised mechanical seal and clamped casing cover
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9 Related Documents
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9 Related Documents
Fig. 27: Pump set with gland packing and bolted casing cover
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9 Related Documents
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9 Related Documents
Fig. 28: Pump set with gland packing and clamped casing cover
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9 Related Documents
920.95 360.02
321.02
930.95 901.02
210
920.95
210
930.95
360.01 940.01/.02/.09
901.01
321.01
901.04
8B 901.31
940.02 210 183
940.01/.09 920.95
210
507.01 930.95
330 940.01/.02/.09
321.01/.02
330
360.01/.02
507.01
901.01/.02/.04/.31 UG1418831_CD2_D01/03
Etanorm 75 of 84
9 Related Documents
638
920.95 903.46
930.95 411.46 360.02
731.21
550.95 13B 901.02
672
400.02
13D 321.02
210
550.95
507.01 360.01 210 920.95
930.95
421.01 400.01 940.01/.02/.09
901.01 321.01 421.02
901.04
183
940.02 901.31
8B UG1418765/CD2/D01/001/02
940.01/.09
210 210
550.95
920.95
330 930.95
940.01/.02/.09
321.01/.02
330
360.01/.02
400.01/.02
411.46
421.01/.02
507.01
638
672
731.21
901.01/.02/.04/.31
903.46
Fig. 30: Version with oil lubrication and constant level oiler
33) Some individual components might not be applicable, depending on the size and material.
34) Always supplied with constant level oiler and oil level sight glass for region B.
35) For shaft units 55 and 60 only
36) For shaft unit 25 only
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10 EU Declaration of Conformity
10 EU Declaration of Conformity
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
Person authorised to compile the technical file:
Name
Function
Address (company)
Address (Street, No.)
Address (post or ZIP code, city) (country)
The EU Declaration of Conformity was issued in/on:
Place, date
..............................37).............................
Name
Function
Company
Address
37) A signed, legally binding EU Declaration of Conformity is supplied with the product.
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11 Certificate of Decontamination
11 Certificate of Decontamination
Type: ................................................................................................................................
Order number/
Order item number38): ................................................................................................................................
Delivery date: ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled : 38)
................................................................................................................................
⃞ ⃞ ⃞ ⃞
Radioactive Explosive Corrosive Toxic
⃞ ⃞ ⃞ ⃞
Harmful Bio-hazardous Highly flammable Safe
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.
For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has been
removed from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern,
leakage barrier and bearing bracket or adapter have also been cleaned.
For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage at
the stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it has
been removed.
⃞ No special safety precautions are required for further handling.
⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:
...............................................................................................................................................................
...............................................................................................................................................................
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the
relevant legal provisions.
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Index
Index
A Installation
Installation on a foundation 24
Auxiliary connections 30 without foundation 25
Installation at site 23
B Intended use 9
Bearing temperature 48
Bearings 20 K
Key to safety symbols/markings 8
C
Certificate of decontamination 78 L
Clearances 49 Leakage rate 41
Commissioning 37 Lubrication 21
Configuration 21
Constant level oiler 37 M
Coupling 49 Maintenance 47
Coupling alignment 32 Mechanical seal 41
Monitoring equipment 12
D
Design 19 N
Direction of rotation 36 Name plate 19
Dismantling 54 Noise characteristics 22
Disposal 15
O
E Oil lubrication
Event of damage 7 Intervals 50
Ordering spare parts 64 Oil quality 50
Oil quantity 51
Exploded view 68, 70, 72, 74
Operating limits 42
Explosion protection 11, 23, 31, 33, 34, 35, 36, 38, 40,
42, 43, 46, 47, 48, 49, 50 Order number 7
Other applicable documents 7
F
Faults P
Causes and remedies 66 Partly completed machinery 7
Fields of application 9 Permissible forces at the pump nozzles 27
Filter 26, 49 Piping 26
Final check 39 Preservation 14, 45
Fluid handled
Priming and venting 39
Density 44
Product code 16
Frequency of starts 43
Product description 16
Function 21
Pump casing 20
G Pure graphite packing 41
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Index
S
Safety 9
Safety awareness 10
Scope of supply 22
Shaft seal 20
Shutdown 45
Spare part
Ordering spare parts 64
Spare parts stock 65
Start-up 40
Storage 14, 45
T
Temperature limits 11
Tightening torques 63, 64
Transport 13
W
Warnings 8
Warranty claims 7
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(01478324)
1311.8/05-EN