Etanorm KSB PUMP O&M Manual

Standardised Pump

Order number:

Installation/Operating Manual Etanorm Original operating manual KSB Aktiengesellschaft Pegnitz All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, processed for any other purpose, nor otherwise transmitted to a third party without KSB´s express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 01.02.2010

1.1

Princi Principle pless ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 6

1.2 1.2

Inst Instal alla lati tion on of part partly ly comp comple lete ted d machi machine nery ry .... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 6

1.3

Target Target group group ........ ........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 6

1.4

Other Other applic applicabl able e doc docume uments nts .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 6

1.5

Symbo Symbols ls ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 6

2.1

Key to safety safety symbol symbols/m s/mark arking ingss ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 8

2.2

Genera Generall ......... ............ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 8

2.3

Intend Intended ed use ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 8

2.4

Person Personnel nel qualif qualifica icatio tion n and traini training ng ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 9

2.5 2.5

Cons Conseq eque uenc nces es and and risk riskss ccau ause sed d by by nonnon-co comp mpli lian ance ce with with thes these eo ope pera rati ting ng instructions ...................................................................................................... ...................................................................................................... 9

2.6

Safety Safety awaren awareness ess ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 9

2.7

Safety Safety inform informati ation on for the operat operator/ or/use userr ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 10

2.8 2.8

Safe Safety ty info inform rmat atio ion n for for main mainte tena nanc nce, e, insp inspec ecti tion on and and inst instal alla lati tion on work work ... 10

2.9

Unauth Unauthori orised sed modes modes of operat operation ion ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 10

2.10 2.10

Explos Explosion ion prote protecti ction on ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 10

3.1

Transp Transport ort ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 13

3.2

Storag Storage e and preser preservat vation ion .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 13

3.3

Return Return to suppli supplier er ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 14

3.4

Dispos Disposal al ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 14

4.1

Genera Generall descri descripti ption on ........ ........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 15

4.2

Design Designati ation on ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 15

4.3

Name Name plate plate ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 15

4.4

Design Design detail detailss ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 15

4.5

Design Design and functi function on ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 16

4.6

Noise Noise charac character terist istics ics ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 17

4.7

Scope Scope of supply supply ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 17

4.8

Dimens Dimension ionss and weight weightss ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 18

5.1

Safety Safety regula regulatio tions ns ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 19

5.2

Checki Checking ng the site site before before instal installat lation ion ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 19

5.3

Instal Installin ling g the pump pump set .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 19

5.4

Piping Piping ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 21

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5.5

Protec Protectiv tive e equipm equipment ent .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 24

5.6

Checki Checking ng the cou coupli pling ng alignm alignment ent ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 25

5.7

Aligni Aligning ng the pump pump and motor motor .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 26

5.8

Electr Electrica icall con connec nectio tion n ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 27

5.9

Checki Checking ng the direct direction ion of rotati rotation on ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 29

6.1

Commis Commissio sionin ning/s g/star tart-u t-up p ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 30

6.2

Operat Operating ing limits limits ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 34

6.3

Shutdo Shutdown/ wn/sto storag rage/p e/pres reserv ervati ation on ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 36

6.4

Return Returning ing to servic service e after after storag storage e ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 36

7.1

Safety Safety regula regulatio tions ns ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 37

7.2

Servic Servicing ing/in /inspe specti ction on ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 37

7.3

Draina Drainage/ ge/dis dispos posal al ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 42

7.4

Disman Dismantli tling ng the pump pump set ..... ........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 42

7.5

Reasse Reassembl mbling ing the pump pump set ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 45

7.6

Tighte Tightenin ning g torque torquess ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 50

7.7

Spare Spare parts parts stock stock ....... .......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 52

9.1

Explod Exploded ed view view / List List of compon component ents: s: ........ ........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 57

The complete back pull-out unit can be pulled out without having to remove the pump casing from the piping.

Pump without pump casing; partly completed machinery

A certificate of decontamination certifies that the pump (set) has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled.

Pumps which are purchased and stored independently of their later use

Machine without drive, additional components or accessories

Complete pump set consisting of pump, drive, additional components and accessories

The line which is connected to the suction nozzle

The line which is connected to the discharge nozzle

The part of the pump in which the kinetic energy is converted into pressure energy

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This manual is supplied as an integral part of the type series and variants indicated on the front cover. This 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. Noise characteristics (⇨ Section 4.6 Page 17)

To install partly completed machinery supplied by KSB, please refer to the subsections under Servicing/Maintenance. Servicing/Maintenance. (⇨ Section 7.5.5 Page 49)

This manual is aimed at the target group of trained and qualified specialist technical personnel. (⇨ Section 2.4 Page 9)

Overview of other applicable documents Data sheet

Description of the technical data of the pump (set) General arrangement drawing/ Description of mating and installation dimensions Outline drawing for the pump (set) Drawing of auxiliary auxiliary connections connections Description of auxiliary auxiliary connections connections Hydra Hydrauli ulicc char charact acteri eristi sticc curv curve e Charac Character terist istic ic curves curves showin showing g head head,, NPSH NPSH required, efficiency and power input Sectional drawing of the pump General assembly drawing1) 1) Operating manuals and other product literature Sub-supplier product literature of accessories and integrated machinery components 1) Description of spare parts Spare parts lists 1) Description of auxiliary piping Piping layout 1) Description of all pump components List of components

Symbols used in this manual ✓ ⊳ ⇨

1)

If agreed to be included in the scope of supply

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Conditions which need to be fulfilled before proceeding with the step-by-step instructions Safety instructions Result of an action Cross-references

1.

Step-by-step instructions

2. Note Recommendations and important information on how to handle the product

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!

DANGER

Definition of safety symbols/markings

!

!

DANGER

WARNING

CAUTION

This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury. This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury. This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions. This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with EC Directive 94/9/EC (ATEX). In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury. In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage. In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions.

This manual contains general installation, operating and maintenance instructions that must be observed to ensure safe pump operation and prevent personal injury and damage to property. The safety information in all sections of this manual must be complied with. This manual must be read and completely understood by the responsible specialist personnel/operators prior to installation and commissioning. The contents of this manual must be available to the specialist personnel at the site at all times. Information attached directly to the pump must always be complied with and be 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 which are not taken into account in this manual.

The pump (set) must only be operated within the operating limits which are described in the other applicable documents. ▪ Only operate pumps/pump sets which are in perfect technical condition. ▪ Do not operate partially assembled pumps/pump sets.

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▪ Only use the pump to handle the fluids specified in the data sheet or product literature of the respective design variant. ▪ Never operate the pump without the fluid to be handled. ▪ Observe the minimum flow rates indicated in the data sheet or product literature (to prevent overheating, bearing damage, etc). ▪ Observe the maximum flow rates indicated in the data sheet or product literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc). ▪ Do not throttle the flow rate on the suction side of the pump (to prevent cavitation damage). ▪ Consult the manufacturer about any use or mode of operation not described in the data sheet or product literature.

▪ Never open discharge-side shut-off elements further than permitted.

– The maximum flow rate rate specified in the data sheet or product product literature would be exceeded. – Risk Risk of cavi cavitat tation ion dama damage ge ▪ Never exceed the permissible operating limits specified in the data sheet or product literature regarding pressure, temperature, etc. ▪ Observe all safety information and instructions in this manual.

All personnel involved must be fully qualified to install, operate, maintain and inspect the machinery this manual refers to. The responsibilities, competence and supervision of all personnel involved in installation, operation, maintenance and inspection must be clearly defined by the operator. Deficits in knowledge must be rectified by sufficiently trained specialist personnel training and instructing the personnel who will carry out the respective tasks. If required, the operator can commission the manufacturer/supplier manufacturer/supplier to train the personnel. Training on the pump (set) must always be supervised by technical specialist personnel.

▪ Non-compliance with these operating instructions will lead to forfeiture of warranty cover and of any and all rights to claims for damages. ▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons persons due to electrical, electrical, thermal, mechanical and chemical chemical effects and explosions – Failure Failure of impor important tant produc productt functions functions – Failure Failure of prescribed prescribed maintenanc maintenance e and servicing servicing practices practices – Hazard Hazard to the environm environment ent due to leakage leakage of hazardous hazardous substanc substances es

In addition to the safety information contained in this manual and the intended use, the following safety regulations shall be complied with: ▪ Accident prevention, health and safety regulations ▪ Explosion protection regulations

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▪ Safety regulations for handling hazardous substances ▪ Applicable standards and laws

▪ The operator shall fit contact guards for hot, cold or moving parts and check that the guards function properly. ▪ Do not remove the contact guard while the pump is running. ▪ Connect an earth conductor to the metal jacket if the fluid handled is electrostatically charged. ▪ Provide the personnel with protective equipment and make sure it is used. ▪ Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g. explosive, toxic, hot) so as to avoid any danger to persons and the environment. Adhere to all relevant laws. ▪ Eliminate all electrical hazards. (In this respect refer to the applicable national safety regulations and/or regulations issued by the local energy supply companies.)

▪ Modifications or alterations of the pump are only permitted with the manufacturer's prior consent. ▪ Use only original spare parts or parts authorised by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for consequential damage. ▪ The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual. ▪ Carry out work on the pump (set) during standstill only. ▪ The pump casing must have cooled down to ambient temperature. ▪ Pump pressure must have been released and the pump must have been drained. ▪ When taking the pump set out of service always adhere to the procedure described in the manual. manual. (⇨ Section 6.1.7 Page 33) ▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3 Page 42) ▪ As soon as the work is completed, re-install and/or re-activate any safety-relevant and protective devices. Before returning the product to service, observe all instructions on commissioning. (⇨ Section 6.1 Page 30)

Never operate the pump (set) outside the limits stated in the data sheet and in this manual. The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use. (⇨ Section 2.3 Page 8)

!

DANGER

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Only pumps/pump sets marked as explosion-proof identified as such in the data sheet may be used in potentially explosive atmospheres. Special conditions apply to the operation of explosion-proof pump sets to EC Directive 94/9/EC (ATEX). Especially adhere to the sections in this manual marked with the Ex symbol and the following sections (⇨ Section 2.10.1 Page 11) to (⇨ Section 2.10.4 Page 12). 12). The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. Never operate the pump (set) outside the limits stated in the data sheet and on the name plate. Prevent impermissible modes of operation at all times.

The marking on the pump refers to the pump only. Example of such marking: II 2 G c TX Refer to the Temperature limits table for the temperatures permitted for the individual pump variants. (⇨ Section 2.10.2 Page 11) An EC manufacturer's declaration is required for the shaft coupling; the shaft coupling must be marked accordingly. The motor must be considered separately.

In normal pump operation, the highest temperatures are to be expected on the surface of the pump casing, at the shaft seal and in the bearing areas. The surface temperature at the pump casing corresponds to the temperature of the fluid handled. If the pump is heated, the operator of the system is responsible for observing the specified temperature classes and fluid temperature (operating temperature). The table below lists the temperature classes and the resulting theoretical temperature limits of the fluid handled. (A possible temperature rise in the shaft seal area has already been taken into account). The temperature class specifies the maximum permissible temperature at the surface of the pump set during operation. For the permissible operating temperature of the pump in question refer to the data sheet. Temperature limits

T1 T2 T3 T4 T5 T6

Temperature limit of the pump 280 ℃ 185 ℃ 120 ℃ 85 ℃ Only after consultation with the manufacturer

In the following cases, and if ambient temperatures are higher, contact the manufacturer. Compliance with temperature class T5 is warranted for the area of the rolling element bearings based on an ambient temperature of 40°C, assuming that the pump set is properly serviced and operated and that the surfaces in the bearing area are freely exposed to the atmosphere. If temperature class T6 has to be complied with, special measures may have to be taken with regard to the bearing temperatures. Misuse, malfunctions or non-compliance with the instructions may result in substantially higher temperatures.

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If the pump is to be operated at a higher temperature, the data sheet is missing or if the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature.

The pump (set) must only be operated within the limits specified in the data sheet and on the name plate. If the system operator cannot warrant compliance with these operating limits, appropriate monitoring devices must be used. Check whether monitoring equipment is required to ensure that the pump set functions properly. Contact KSB for further information on monitoring equipment.

The minimum flows indicated in (⇨ Section 6.2.3 Page 35) refer to water and waterlike fluids. Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface. However, if the physical properties of the fluids handled are different from water, it is essential to check whether an additional heat build-up may occur and if the minimum flow rate must therefore be increased. The calculation formula in (⇨ Section 6.2.3 Page 35) can be used to check whether an additional heat build-up may lead to a hazardous temperature increase at the pump surface.

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Danger to life from falling parts! ▷

Always transport the pump (set) in horizontal position.

▷

Never attach the suspension arrangement to the free shaft end or the motor eyebolt.

▷

Refer to the weights given in the general arrangement drawing.

▷

Observe the local accident prevention regulations.

▷

Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.

To transport the pump/pump set suspend it from the lifting tackle as shown below.

Transporting the pump

max. 90 °

Transporting the complete pump set

max. 90 °

Transporting the pump on baseplate

If commissioning is to take place some time after delivery, we recommend that the following measures be taken for pump (set) storage.

Corrosion/contamination of the pump (set)! ▷

For outdoor storage cover the pump (set) or the packaged pump (set) and accessories with waterproof material.

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Leakage or damage to the pump set! ▷

Only remove caps/covers from the openings of the pump set at the time of installation.

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, observe the relevant instructions. (⇨ Section 6.3.1 Page 36)

1. Drain Drain the pump pump as per operating operating instru instruction ctions. s. (⇨ Section 7.3 Page 42) 2. Always flush and clean the pump, particularly particularly if it has been been used for for handling noxious, explosive, hot or other hazardous fluids. 3. If the fluids handled by the pump leave residues which which might lead to corrosion corrosion damage when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the pump set must also be neutralised, and anhydrous inert gas must be blown through the pump for drying purposes. 4. Always complete and and enclose a certificate certificate of decontamination when returning returning the pump set. (⇨ Section 11 Page 64) It is imperative to indicate any safety and decontamination measures taken.

If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination

Hazardous to persons and the environment! ▷

Collect and properly dispose of flushing liquid 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.

1. Disman Dismantle tle the pump pump (set) (set).. Collect greases and other lubricants during dismantling. 2. Separate Separate and and sort the the pump materials, materials, e.g. e.g. by: by: - Metals - Plastics - Electronic waste - Greases and other lubricants 3. Dispose of materials in accordance with local regulations or in another controlled manner.

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▪ Standardised water pump with shaft seal

Pump for handling clean or aggressive fluids which are not chemically or mechanically aggressive to the pump materials.

Key to the designation Etanorm G 40 160 G10

Type series Casing material, e.g. G = grey cast iron Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Seal code, e.g. G10 = mechanical seal Q1Q1X4GG

Aktiengesellschaft D-67227 Frankenthal

1

ETANORM G 40-160 G10 9971234567 000100 / 01 Q 40 m3 /h l H 50 m n 2900 1/min l 2007 1 mm2 /s

2 3 4 5

Id-No.

00 117 385

6 7 8 9

ZN 3804 - C 37 x 52

Name plate Etanorm 1 3 5 7 9

Type Type seri series es,, pum pump p siz size e and and desi design gn (⇨ Section 4.2 Page 15) Flow rate Kine Kinema mati ticc vis visco cosi sity ty of the the flu fluid id handled Con Consec secutiv utive e numb number er (two digits) Year Year of cons onstruc tructi tio on

2 4 6 8

KSB order number (ten digits) Speed Order it item nu number (six digits) Head

▪ Volute casing pump ▪ Back pull-out design ▪ Horizontal installation ▪ Single-stage ▪ Ratings and dimensions in accordance with EN 733

▪ Radially split volute casing

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▪ Replaceable casing wear rings ▪ Volute casing with integrally cast pump feet

▪ Closed radial impeller with multiply curved vanes

▪ Radial ball bearings ▪ Grease lubrication ▪

oil lubrication

▪ Shaft equipped with replaceable shaft sleeve/shaft protecting sleeve in the shaft seal area ▪ Standardised mechanical seal to EN 12756 ▪ Gland packing

Risk of explosion! ▷

Never operate a pump (set) with gland packing in potentially explosive atmospheres.

Sectional drawing 1 3

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Clearance gap Casing cover

2 4

Discharge nozzle Shaft

5 7 9

Bearing bracket Impeller Roll Rollin ing g ele eleme ment nt bear bearin ing, g, pump pump end end

6 Suction nozzle 8 Shaft seal 10 Roll Rollin ing g ele eleme ment nt bear bearin ing, g, mo moto torr end

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. The fluid enters the pump axially via a suction nozzle (6) and is accelerated outward in a cylindrical flow by the rotating impeller (7). The flow profile of the pump casing converts the kinetic energy of the fluid 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 into the inlet. 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 towards the atmosphere by 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. The pump is sealed by a shaft seal. Standardised mechanical seal or packed gland

Sound pressure level measured at surfaces LpA2) 3)

0.55 0.75 1.1 1.5 2.2 3 4 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110

47 48 50 52 54 55 57 59 60 62 64 65 66 67 68 69 70 72 73 74

48 50 52 54 56 57 59 61 62 64 66 67 68 70 71 72 73 75 76 77

55 56 57 58 59 60 61 62 64 65 67 68 69 70 71 73 74 75 76 77

64 66 66 67 67 68 68 70 71 73 74 75 76 77 78 78 79 80 81 81

Depending on the model, the following items are included in the scope of supply: ▪ Pump ▪ Surface-cooled IEC three-phase current squirrel-cage motor ▪ Flexible coupling with or without spacer 2)

3)

Spatial average to ISO 3744 and EN 12639. Applies to non-cavitating pump operation in the range Q/Qopt = 0.8 - 1.1. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance. Increase for 60 Hz operation: 3500 rpm, +3 dB; 1750 rpm +1 dB

17 of 66

▪ Coupling guard to EN 294

Risk of explosion! ▷

Choose a coupling guard material that is non-sparking in the event of mechanical contact (see DIN EN 13463-1).

▷

If any coupling parts are made of aluminium, a brass coupling guard must be used.

▪ Channel section steel or folded steel plate ▪ Cast baseplate (to ISO 3661) ▪ As required

For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump (set).

18 of 66

Explosion hazard! Damage to the pump set! ▷

Comply with the applicable local explosion protection regulations.

▷

Observe the information in the data sheet and on the name plates of pump and motor.

Personal injury and damage to property! ▷

Make sure the foundation concrete is of sufficient strength (min. X0 to DIN 1045).

▷

Only place the pump set on a foundation whose concrete has set firmly.

▷

Only place the pump set on a horizontal and level surface.

▷

Refer to the weights given in the general arrangement drawing.

1. Check Check the the struct structural ural requiremen requirements. ts. All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing/general arrangement drawing.

Always install the pump set in horizontal position.

Explosion hazard! ▷

Install the pump in horizontal position to ensure self-venting of the pump.

2

1

3

4

Fitting the shims 1 3

Bolt-to-bolt clearance Shim Shim for for bolt bolt-t -too-bo bolt lt clea cleara ranc nce e> 800 mm

2 4

Shim Foundation bolt

✓ The foundation has the required strength and characteristics.

19 of 66

✓ 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 foundation and use a spirit level to align shaft shaft and discharge nozzle. Permissible deviation: 0.2 mm/m 2. If required required,, use shims shims (2) to to adjust adjust the height. height. Always fit shims immediately to the left and right of the foundation bolts (4) between the baseplate/foundation frame and the foundation itself. For a bolt-to-bolt clearance > 800 mm, fit additional shims (3) halfway between the adjoining holes. All shims must lie perfectly flush. 3. Insert Insert the foundatio foundation n bolts (4) (4) into the the holes provid provided. ed. 4. Use concret concrete e to set the foundation foundation bolts bolts (4) into the the foundation foundation.. 5. Wait until until the concrete concrete has set set firmly, firmly, then align the the baseplate. baseplate. 6. Tighten Tighten the foundat foundation ion bolts bolts (4) evenly evenly and firmly firmly..

For baseplates more than 400 mm wide it is recommended to grout the baseplate with low-shrinkage concrete.

For baseplates made of grey cast iron it is recommended to grout the baseplate with lowshrinkage concrete.

For low-noise operation contact KSB to check whether the pump set can be installed on anti-vibration mounts.

1

2

3

4 Levelling elements 1, 3 4

Locknut Levelling el element

2

Levelling nut

✓ The installation surface has the required strength and characteristics.

1. Position Position the pump set set on the leveling leveling elements elements (4) and align align it with the help help of a spirit level (on the shaft/discharge nozzle). 2. To adjust any differences differences in height, loosen the bolts and locknuts (1, 3) of the leveling elements (4). 3. Turn the levelling nut (2) until any differences differences in height height have been compensated. compensated. 4. Re-tighte Re-tighten n the locknuts locknuts (1, (1, 3) at the levellin levelling g elements elements (4).

20 of 66

Danger to life from leakage of hot, toxic, corrosive or flammable fluids! ▷

Do not use the pump as an anchorage point for the piping.

▷

Anchor the pipelines in close proximity to the pump and connect them without transmitting any stresses or strains.

▷

Observe the permissible forces and moments at the pump nozzles. (⇨ Section 5.4.2 Page 22)

▷

Take appropriate measures to compensate thermal expansion of 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.

It is recommended to install check and shut-off elements in the system, depending on the type of plant and pump. However, such elements must not obstruct proper drainage or hinder disassembly of the pump. ✓ The suction lift line/suction head line has been laid with a rising/downward slope towards the pump. ✓ The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump nozzles. ✓ To prevent excessive pressure losses, adapters to larger diameters have a diffuser angle of approximately 8°. ✓ The pipelines have been anchored in close proximity to the pump and connected without transmitting any stresses or strains.

1. Thoroughly clean, flush and blow through all vessels, pipelines pipelines and connections (especially of new installations). 2. Before installing installing the pump pump in the the piping, remove the flange covers covers on the the suction and discharge nozzles of the pump.

Damage to the pump! ▷

Free the piping from any impurities.

▷

If necessary, install a filter.

▷

Observe the instructions in (⇨ Section 7.2.2.3 Page 39). 39).

3. If required, required, install install a filter filter in the piping (see (see drawing: drawing: Filter Filter in the piping). piping).

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1

2 Filter in the piping 1

Differential pressure gauge

2

Filter

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 three times the diameter of the piping. Conical filters have proved suitable.

4. Conn Connect ect the the pump nozzles nozzles with with the the piping. piping.


Match the cleaning operation mode and duration for flushing and pickling service to the casing and seal materials used.

FV FH FH FH

FV

FV FVmax

FH

2

FH FHmax

+

2

+

Mt Mtmax

2

-1

Forces and moments at the pump nozzles The following condition must be met: ∑IFVI, ∑IFHI, and ∑IMtI are the sums of the absolute values of the respective loads acting on the nozzles. Neither the load direction nor the load distribution among the nozzles are taken into account in these sums.

Forces and moments at the pump nozzles

32-125.1 32-160.1 32-200.1 32-250.1 32-125

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2.6 2.5 2.5 2.5 2.6

1.8 1.7 1.7 1.7 1.8

0.55 0.5 0.5 0.5 0.55

3.65 3.56 3.60 ---

2.59 2.51 2.43 ---

0.58 0.51 0.51 ---

4.16 4.10 4.10 4.25 4.16

2.95 2.87 2.78 2.96 2.95

0.85 0.80 0.80 0.95 0.85

1.93 1.89 1.89 ---

1.37 1.33 1.30 ---

0.41 0.36 0.36 ---

32-160 32-200 32-250 40-125 40-160 40-200 40-250 40-315 50-125 50-160 50-200 50-250 50-315 65-125 65-160 65-200 65-250 65-315 80-160 80-200 80-250 80-315 80-400 100-160 100-200 100-250 100-315 100-400 125-200 125-250 125-315 125-400 150-200 150-250 150-315 150-400

2.5 2.5 2.5 2.6 2.6 2.6 2.6 2.7 2.7 2.7 2.7 2.7 2.9 3.0 3.0 3.0 3.2 3.2 3.5 4.0 4.0 4.0 4.3 5.4 5.4 5.2 4.6 5.2 6.3 6.7 6.7 6.7 7.4 7.4 7.4 7.4

1.7 1.7 1.7 1.8 1.8 1.8 1.8 1.9 2.0 1.9 1.9 1.9 2.1 2.2 2.2 2.2 2.4 2.4 2.8 2.9 2.9 2.9 3.2 4.4 4.4 4.0 3.7 4.3 5.6 5.8 6.0 5.8 6.85 6.85 6.85 6.85

0.5 0.5 0.5 0.6 0.6 0.6 0.6 0.7 0.75 0.7 0.7 0.7 0.75 0.85 0.85 0.85 1.05 1.05 1.2 1.45 1.45 1.45 1.75 2.4 2.4 2.3 1.9 2.35 3.3 3.4 3.4 3.4 4.0 4.0 4.0 4.0

3.56 3.65 3.73 -3.81 3.81 4.21 4.09 -3.97 4.21 4.58 4.54 -4.42 5.27 5.27 5.43 5.43 6.08 6.16 6.28 -7.70 7.70 7.86 7.57 -9.50 9.84 9.32 9.23 --10.53 10.53

2.51 2.43 2.59 -2.67 2.67 2.92 2.84 -2.67 2.92 3.32 3.24 -3.04 3.89 3.89 4.05 4.05 4.74 4.78 4.86 -6.28 6.28 6.48 6.16 -8.50 8.71 8.10 7.90 --9.72 9.72

0.51 0.51 0.58 -0.81 0.81 0.58 0.55 -1.11 1.11 0.87 0.84 -1.16 1.79 1.79 1.62 1.91 2.44 2.44 2.78 -3.60 3.60 3.47 3.18 -5.10 5.10 4.75 4.63 --5.67 5.67

4.10 4.10 4.25 4.34 4.34 4.46 4.70 4.66 4.53 4.53 4.81 5.22 5.18 5.04 5.04 6.00 6.00 6.20 6.19 6.94 7.03 7.16 7.58 8.78 8.78 8.97 8.65 9.62 10.50 11.23 10.63 10.52 12.00 12.02 12.02 12.00

2.87 2.78 2.96 3.04 3.04 3.04 3.33 3.24 3.15 3.05 3.33 3.80 3.69 3.47 3.47 4.44 4.44 4.62 4.62 5.41 5.45 5.55 6.01 7.16 7.16 7.40 7.03 8.17 9.50 9.94 9.25 9.00 11.00 11.10 11.10 11.00

0.80 0.80 0.95 1.26 1.26 1.26 0.90 0.85 1.35 1.27 1.27 1.57 1.35 1.34 1.34 2.08 2.08 2.17 2.18 2.77 2.77 2.86 3.23 4.32 4.32 4.25 3.97 4.70 5.70 5.87 5.41 5.30 6.47 6.47 6.47 6.47

1.89 1.89 --2.02 2.02 2.20 --2.10 2.23 2.42 --2.34 2.80 2.80 -2.88 3.22 3.26 --4.08 4.08 4.17 4.02 -4.90 5.22 4.94 --5.59 5.59 5.59

1.33 1.30 --1.40 1.40 1.54 --1.40 1.54 1.76 --1.61 2.06 2.06 -2.15 2.51 2.53 --3.33 3.33 3.44 3.26 -4.46 4.62 4.30 --5.16 5.16 5.16

0.36 0.36 --0.45 0.45 0.60 --0.59 0.60 0.73 --0.62 0.96 0.96 -1.01 1.29 1.29 --1.89 1.89 1.97 1.84 -2.64 2.73 2.51 --3.00 3.00 3.00

Where fluid has to be pumped out of a vessel under vacuum, it is recommended to install a vacuum balance line.

The following rules apply to vacuum balance lines: ▪ Minimum nominal line diameter 25 mm. ▪ The line extends above the highest permissible fluid level in the vessel.

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1

2

3

5 Vacuum balance line 1 3 5

Vessel under vacuum Shut-off valve Main shut-off valve

4

6

2 4 6

Vacuum balance line Swing check valve Vacuum-tight shut-off valve

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.

Malfunction of the pump! ▷

Refer to the general arrangement drawing, the piping layout and pump markings (if any) for the dimensions and locations of auxiliary connections.

▷

Use the auxiliary connections provided.


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).

Risk of burning!

24 of 66

▷

Insulate the volute casing.

▷

Fit protective equipment.

Damage to the bearing! ▷

Never insulate the bearing bracket, bearing bracket lantern and casing cover.


Make sure that the coupling is correctly aligned at all times.

Damage to pump, motor and coupling!

a)

▷

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.

1

1

b)

A

B

A

B

A

B

A

B

1

1

2

2

a) Checking the coupling alignment and b) Aligning a spacer-type coupling 1

Straight-edge

2

Wedge gauge

✓ The coupling guard and step guard, if any, have been removed.

1. Loosen the support foot foot and re-tighten re-tighten it without transmitting any stresses stresses and strains. 2. Place the the straightstraight-edge edge axially axially on on both couplin coupling g halves. halves. 3. Leave Leave the straight-e straight-edge dge in this positio position n and turn the couplin coupling g by hand. The coupling is correctly aligned if the distances A) and B) to the respective shafts are the same at all points around the circumference. The radial and axial deviation of both coupling halves must not exceed 0.1 mm during standstill as well as at operating temperature and under inlet pressure. 4. Check the distance between between the two coupling 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 of both coupling halves must not exceed 0.1 mm during standstill as well as at operating temperature and under inlet pressure.

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After having installed the pump set and connected the piping, check the coupling alignment and, if required, re-align the pump set (at the motor).

1 2 3

Motor with levelling screw 1 3

Hexagon head bolt Locknut

2

Levelling screw


1. Check Check the the couplin coupling g alignme alignment. nt. 2. Unscrew the hexagon head bolts (1) at the motor and the locknuts locknuts (3) at the baseplate. 3. Turn the levelling screws screws (2) by hand or by means of an open-jawed open-jawed wrench until the coupling alignment is correct. 4. Re-tighten the the hexagon head bolts (1) at the the motor and the locknuts (3) at the baseplate. 5. Check Check that the coupli coupling ng and shaft shaft can easily easily be rotated rotated by hand. hand.

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.



6. Re-install Re-install the the coupling coupling guard guard and and step guard, guard, if any. any. 7. Check Check the distance distance betwee between n coupling coupling and couplin coupling g guard. The coupling guard must not touch the coupling.

Any differences in the centre heights of the pump and motor shafts are compensated by means of shims.

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1 Pump set with shim 1

Shim


1. Check Check the the couplin coupling g alignme alignment. nt. 2. Unscrew Unscrew the the hexagon hexagon head head bolts bolts at the motor motor.. 3. Insert shims underneath the the motor feet until the difference difference in shaft shaft centre height has been compensated. 4. Re-tighte Re-tighten n the the hexagon hexagon head bolts. bolts. 5. Check Check that the coupli coupling ng and shaft shaft can easily easily be rotated rotated by hand. hand.

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.



6. Re-install Re-install the the coupling coupling guard guard and and step guard, guard, if any. any. 7. Check Check the distance distance betwee between n coupling coupling and couplin coupling g guard. The coupling guard must not touch the coupling.


For electrical installation, also observe the requirements of IEC 60079-14.

▷

Always connect explosion-proof motors via a motor protection switch.

Danger of death from electric shock! ▷

Always have the electrical connections installed by a trained electrician.

▷

Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pump sets, IEC 60079 (DIN VDE 0165).

27 of 66

Damage to the mains network, short circuit! ▷

Observe the technical specifications of the local energy supply companies.

1. Check Check the available available mains voltag voltage e against against the data on the motor motor name plate. plate. 2. Select Select an appropriat appropriate e start-u start-up p method. method.

It is recommended to fit a motor protection device.

Damage to the pump (set)! ▷

Keep switch-over intervals between between star and delta as short as possible (see table: Time relay settings for star-delta starting). Time relay settings for star-delta starting: ≤ 30 kW > 30 kW

<3s <5s


Connect PE conductor to the earthing terminal provided.

▷

On belt-driven pump sets use belts made of conductive material.

In compliance with DIN VDE 0530 - Part 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.

1. Change Change the motor's motor's direction direction of rotation rotation to match match that of the the pump. 2. Observe the manufacturer's manufacturer's product product literature literature supplied supplied with with the motor.

28 of 66


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.

Risk of injuries, damage to the pump! ▷

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

▷

Check that the inside of the pump is free from any foreign objects.

Damage to the mechanical seal and leakage! ▷

Separate the pump from the motor to check the direction of rotation.


Refer to the arrow indicating the direction of rotation on the pump.

▷

Check the direction of rotation. If required, interchange any two phases to correct the direction of rotation.

The correct direction of rotation of motor and pump is clockwise (seen from the motor end). 1. Start Start the pump set and and stop it again immediat immediately ely to determine determine the the motor's motor's direction of rotation. 2. Check Check the the direct direction ion of rotati rotation. on. 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 check the electrical connection of the motor and the control system, if necessary.

29 of 66

Before starting up the pump set make sure that the following requirements are met: ▪ The pump set has been properly connected to the electric power supply and is equipped with all protection devices. ▪ The pump has been primed with the fluid to be handled. (⇨ Section 6.1.3 Page 31) ▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 29) ▪ All auxiliary connections required are connected and operational. ▪ The lubricants have been checked. ▪ After prolonged shutdown of the pump (set), the activities described in (⇨ Section 6.4 Page 36) have been carried out.

Grease-lubricated bearings have been packed with grease at the factory.

Fill the bearing bracket with lubricating oil. Oil quality see (⇨ Section 7.2.3.1.2 Page 40) Oil quantity see (⇨ Section 7.2.3.1.3 Page 40)

✓ Constant-level oiler has been fitted.

If no constant-level oiler is provided on the bearing bracket, the oil level can be read in the middle of the oil level sight glass arranged at the side of the bearing bracket.

Damage to the bearings! ▷

Regularly check the oil level.

▷

Always fill the oil reservoir completely.

▷

Keep the oil reservoir properly filled at all times. 1

2

3 4 5 Bearing bracket with constant-level oiler

30 of 66

1 3 5

Constant-level oiler Connec Con nectio tion n elbo elbow w of the con consta stantnt-lev level el oiler Bearing br bracket

2 4

Vent plug Screwed plug

1. Pull Pull out the vent vent plug plug (2). (2). 2. Hinge down down the reservoir reservoir of the constant-level constant-level oiler (1) from the bearing bracket (5) and hold in this position. 3. Fill in oil through the hole for the vent plug until the oil reaches the connection connection elbow of the constant-level oiler (3). 4. Completely Completely fill fill the reservoi reservoirr of the constantconstant-level level oiler oiler (1). 5. Snap the the constant-le constant-level vel oiler oiler (1) back into its its operating operating position. position. 6. Fit the vent vent plug plug (2) (2) again again.. 7. After approximately approximately 5 minutes, check check the oil oil level in the glass reservoir of of the constant-level oiler (1). The oil reservoir must be properly filled at all times to provide an optimum oil level. Repeat steps 1-6, if necessary. 8. To check the function of the constant-level constant-level oiler (1), slowly drain drain some oil via the the screwed plug (4) until air bubbles can be seen in the oil reservoir.

An excessively high oil level can lead to a temperature rise and to leakage of the fluid handled or oil.


Before starting up the pump, vent the suction line and the pump and prime with the fluid to be handled.

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 the pump and sucti suction on line and and fill both both with the the fluid handled handled.. Connection 6B can be used for venting (see drawing of auxiliary connections). 2. Fully open the the shut-off shut-off valve valve in the suctio suction n line. 3. Fully open open any auxiliary feed lines (barrier fluid, fluid, flushing flushing liquid, etc). 4. Open the shut-off valve, valve, if any, in the vacuum balance line and close the vacuumvacuumtight shut-off valve, if any. (⇨ Section 5.4.3 Page 23)

For design-inherent reasons a remaining gas 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.

1. Remove Remove the couplin coupling g guard guard and step step guard, guard, if any. any.

31 of 66

2. Check Check the coupling coupling alignment; alignment; re-alig re-align n the coupling, coupling, if required. required.((⇨ Section 5.6 Page 25) 3. Check Check that the coupli coupling ng and shaft shaft can easily easily be rotated rotated by hand. hand. 4. Re-install Re-install the the coupling coupling guard guard and and step guard, guard, if any. any. 5. Check Check the distance distance betwee between n coupling coupling and couplin coupling g guard. The coupling guard must not touch the coupling.

Explosion hazard! Leakage of hot or toxic fluids! ▷

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 gate valve slightly or fully open.



▷

Prime the pump as specified. (⇨ Section 6.1.3 Page 31)

▷

Always operate the pump within the permissible operating range.


Switch off the pump (set) immediately.

▷

Eliminate the causes before returning the pump set to service.

✓ The system piping has been cleaned. ✓ Pump, suction line and inlet tank, if any, have been vented and filled with the fluid to be pumped. ✓ The filling and venting lines have been closed.

Overloading of the motor! ▷

Use a soft starter.

▷

Use speed control.

▷

Make sure the power reserve of the motor is sufficient.

1. Fully open open the shut-off shut-off valve valve in the suction suction head/suc head/suction tion lift lift line. 2. Close or slightl slightly y open the shut-of shut-offf valve in the discharg discharge e line. 3. Switc Switch h on on the the motor. motor. 4. Immediately after after the pump has reached full rotational speed, speed, slowly open the shut-off element in the discharge line and adjust it to comply with the duty point.

32 of 66

Hot or toxic fluid may escape! ▷

Once the operating temperature has been reached, re-tighten the hexagon nuts at the casing/discharge cover.

▷

Check the coupling alignment. Re-align the coupling if required.

5. After After the operating operating temperat temperature ure has been been reached reached and/or in the event event of leakage, switch off the pump set and retighten the bolts between lantern and casing. 6. Check Check the coupling coupling alignment. alignment. Re-alig Re-align n the coupling coupling if required. required.

The mechanical seal only leaks slightly or invisibly (as vapour) during operation. Mechanical seals are maintenance-free. The packed gland must leak slightly during operation. If a pure graphite packing ring is used, there must always be leakage. Leakage rate of the pure graphite packing ring Minimum Maximum

10 cm³ /min /min 20 cm³ /min /min

1. Only lightly lightly tighte tighten n the nuts nuts of the gland gland follower follower by hand. hand. 2. Use a feeler gauge to verify that the gland follower follower is mounted mounted centred centred and at a right angle to the shaft. The gland must leak after the pump has been primed. The leakage can be reduced. 1. Tighten Tighten the nuts nuts of the the gland gland follower follower by 1/6 turn. turn. 2. Monitor Monitor the the leakage leakage for another another five five minutes minutes.. Repeat steps 1 and 2 until the minimum value has been reached. Slightly loosen the nuts at the gland follower. Switch off the pump set immediately! Loosen the gland follower and repeat start-up. After the leakage has been adjusted, monitor the leakage for about two hours at maximum fluid temperature. Check that enough leakage occurs at the gland at minimum fluid pressure.

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.

✓ The shut-off element in the suction line is and remains open.

1. Close the the shut-off shut-off element element in the disch discharge arge line. line.

33 of 66

2. Switch Switch off the motor motor and make sure sure the pump set runs runs down smooth smoothly ly to a standstill.

If the discharge line is equipped with a non-return or check valve, the shut-off element may remain open as long as there is back pressure.

For prolonged shutdown periods: 1. Close the the shut-off shut-off element element in the sucti suction on line. line. 2. Close the auxiliary auxiliary conn connectio ections. ns. If the fluid handled is fed in under vacuum, also supply the shaft seal with barrier fluid during standstill.


Drain the pump and the cooling/heating chambers (if any) or otherwise protect them against freezing.

Explosion hazard! Hot or toxic fluid may escape! ▷

Comply with the operating data indicated in the data sheet.

▷

Avoid prolonged operation against a closed shut-off element.

▷

Never operate the pump at temperatures exceeding those specified in the data sheet or on the name plate unless the written consent of the manufacturer has been obtained.


Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation: Permissible ambient temperatures Maximum Minimum

40 °C See data sheet.

Explosion hazard! Damage to the motor! ▷

34 of 66

In case of explosion-proof motors, observe the frequency of starts specified in the manufacturer's product literature.

The frequency of starts is usually determined by the maximum temperature increase of the motor. This largely depends on the power reserves of the motor in steadystate operation and on the starting conditions (d.o.l., star-delta, moments of inertia, etc). If the start-ups are evenly spaced over the period indicated, the following limits can be used for orientation for start-up with the discharge-side gate valve slightly open: Switching frequency

Etanorm G, M, S Etanorm B, C

15 6


Do not re-start the pump set before the pump rotor has come to a standstill.

Flow rate -30 to +70 ℃

≈ 15 % of QOpt4)

> 70 to +140 °C

≈ 25 % of QOpt4)

See hydraulic characteristic curves

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.

Key c g H Tf

Specific heat capacity Gravitational constant Pump head Temperature of the fluid handled

J/kg K m/s² m °C

To

Temperature at the casing surface Pump efficiency at duty point Temperature difference

°C °C

The power input of the pump increases in proportion to the density of the fluid handled.

Motor overload!

4)

▷

Observe the information on fluid density indicated in the data sheet.

▷

Make sure the power reserve of the motor is sufficient.

Operating point of highest efficiency

35 of 66

Do not exceed the maximum permissible solids content specified in the data sheet. When the pump handles fluids containing abrasive substances, increased wear of the hydraulic system and the shaft seal are to be expected. In this case, reduce the intervals commonly recommended for servicing and maintenance.

✓ Sufficient fluid is supplied for the operation check run of the pump.

1. Start up the pump (set) regularly once a month or once every three months for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pump intake area. ✓ The pump has been properly drained (⇨ Section 7.3 Page 42) and the safety instructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page 42)

1. Spray-coat the inside wall of the pump casing, and in particular the impeller clearance areas, with a preservative. 2. Spray Spray the preservativ preservative e through through the suction and dischar discharge ge nozzles. nozzles. It is advisable to then close the pump nozzles (e.g. with plastic caps or similar). 3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil and grease, food-approved if required) to protect them against corrosion. Observe the additional instructions. (⇨ Section 3.2 Page 13) If the pump set is to be stored temporarily, only preserve the wetted components made of low alloy materials. Commercially available preservatives can be used for this purpose. Observe the manufacturer's instructions for application/removal. Observe any additional instructions and information provided. (⇨ Section 3 Page 13)

For returning the pump to service observe the sections on commissioning/start-up (⇨ Section 6.1 Page 30) and the operating limits (⇨ Section 6.2 Page 34) . In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. (⇨ Section 7 Page 37)

Risk of personal injury from moving parts or escaping fluid! ▷

As soon as the work is complete, re-install and/or re-activate any safety-relevant and protective devices.

If the pump has been out of service for more than one year, replace all elastomer seals.

36 of 66


Service the pump set regularly.

▷

Prepare a maintenance schedule with special emphasis on lubricants, shaft seal and coupling.

The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

Risk of injury by moving parts! ▷

Always make sure the electrical connections are disconnected before carrying out work on the pump set.

▷

Make sure that the pump set cannot be started up accidentally.

Risk of personal injury! ▷

Observe all relevant laws.

▷

When draining the fluid take appropriate measures to protect persons and the environment.

▷

Decontaminate pumps handling fluids posing a health hazard.

A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pump (set) with a minimum of maintenance expenditure and work.

All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/ contact". contact ".

Never use force when dismantling and reassembling a pump set.


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.

37 of 66

Explosion hazard! Fire hazard! Leakage of hot, toxic fluids! Damage to the pump set! ▷

Regularly service the shaft seal.

Explosion hazard! Fire hazard! Damage to the pump set! ▷

Regularly check the lubricant level.

▷

Regularly check the rolling element bearings for running noises.

Damage to the pump set! ▷


▷

Never close the shut-off element in the suction line and/or supply line during pump operation.


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. (⇨ Section 6.2 Page 34)

While the pump is in operation, observe and check the following: ▪ The pump must run quietly and free from vibrations at all times. ▪ In case of oil lubrication, ensure the oil level is correct. (⇨ Section 6.1.2 Page 30) ▪ Check the shaft seal. (⇨ Section 6.1.6 Page 33) ▪ Check the static seals for leakages. ▪ Check the rolling element bearings for running noises. Vibrations, noise and an increase in current input occurring during unchanged operating conditions indicate wear. ▪ Monitor the correct functioning of any auxiliary connections. ▪ Monitor the stand-by pump. To make sure that the stand-by pumps are ready for operation, start them up once a week. ▪ Monitor the bearing temperature. The bearing temperature must not exceed 90 °C (measured on the outside of the bearing bracket).


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The bearing temperature of the pump (set) must never exceed 90 °C (measured on the outside of the bearing bracket).

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 h depending on the conditions).


Regularly check the coupling guard, plastic components and other guards of rotating parts for deformation and sufficient distance from rotating parts.

Check the flexible elements of the coupling. Replace these parts in due time if there is any sign of wear.

For checking the clearance gaps remove the impeller, if required (⇨ Section 7.4.5 Page 44). 44). If the clearance gap is larger than permitted (see the following table), replace casing wear ring 502.1and/or 502.2 with a new one. The clearances given refer to the diameter. Clearance gaps between impeller and casing /between impeller and casing wear ring New Maximum permissible expansion

0.3 mm 0.9 mm

0.5 mm 1.5 mm


Monitor contamination of filter with suitable means (e.g. differential pressure gauge).

▷

Clean filter in appropriate intervals.

Risk of explosion! Damage to the pump set! ▷

Check correct seating of axial sealing rings mounted on the shaft. Only gentle contact of the sealing lip shall be established.

39 of 66


Regularly check the condition of the lubricant.

The rolling element bearings are usually lubricated with mineral oil.

Oil change intervals Initial oil change Further oil changes

after 300 operating hours after 3000 operating hours5)

Oil quality6)

Lubricating oil C 46 CL 46 CLP 46

□

Kinematic viscosity at 40 °C Flash point (to Cleveland) Soli Solidi difi fica cati tion on poi point nt (po (pour ur poi point nt)) 7) Application temperature

46 ± 4 mm² /s /s +175 °C -15 -15 °C Higher than permissible bearing temperature

Oil quantity for oil-lubricated radial ball bearings to DIN 625

25 35 55

6305 C3 6307 C3 6311 C3

0.2 0.35 0.65

Hazard to persons and the environment!

5) 6) 7) 8)

▷

When draining the lubricant take appropriate measures to protect persons and the environment.

▷

Observe all legal regulations on the disposal of liquids posing a health hazard.

At least once a year To DIN 51517 For ambient temperatures below -10 °C use a different suitable type of lubricant oil. Request particulars. Refer to the data sheet for the shaft type.

40 of 66

2 3 1 Bearing bracket with constant-level oiler 1 3

Constant-level oiler Bearing br bracket

2

Screwed plug

✓ A suitable container for the used oil is on hand.

1. Place the the containe containerr underneath underneath the the screwed screwed plug. plug. 2. Undo the the screwed screwed plug (2) (2) at the bearing bearing bracket bracket (3) and and drain the the oil. 3. Once the bearing bracket bracket (3) has been drained, re-insert and re-tighten the the screwed plug (2). 4. Re-f Re-fil illl wit with h oil oil.. (⇨ Section 6.1.2 Page 30)

The bearings are supplied packed with high-quality lithium-soap grease.

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, dustladen air, aggressive industrial atmosphere etc.), check the bearings earlier and clean and relubricate them, if required.

▪ High melting point lithium soap base grease ▪ Free of resin and acid ▪ Not liable to crumble ▪ With good rust-preventive rust-preventive characteristics ▪ Penetration number between 2 and 3 (corresponding to a worked penetration of 220 to 295 mm/10) ▪ Drop point ≥ 175 °C

If required, the bearings may be lubricated with greases of other soap bases. Make sure to remove any old grease and rinse the bearings thoroughly.

41 of 66

Grease quantity for grease-lubricated radial ball bearings to DIN 625

25 35 55

6305 Z C3 6307 Z C3 6311 Z C3

5 10 15

Changed lubricating qualities! ▷

Thoroughly clean the bearings.

▷

Adjust the re-lubrication intervals to the grease used.

1. Only half-f half-fill ill the bearin bearing g cavities cavities with with grease. grease.

Hazardous to persons and the environment! ▷

Collect and properly dispose of flushing liquid 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.

1. For draining draining the fluid fluid handled use connection connection 6B (see (see drawing of auxiliary connections). 2. If noxious, explosive, hot hot or other other hazardous hazardous fluids have been handled, flush the pump. Always flush and clean the pump before transporting it to the workshop. Provide a cleaning record for the pump.


Always have repair and maintenance work performed by specially trained, qualified personnel.


Allow the pump set to cool down to ambient temperature.

Observe the general safety instructions and information. (⇨ Section 7.1 Page 37)

9)

Refer to the data sheet for the shaft type.

42 of 66

For any work on the motor, observe the instructions of the relevant motor manufacturer. For dismantling and reassembly observe the exploded view and the general assembly drawing. (⇨ Section 9.1 Page 57)

All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/ contact". contact ".


Properly shut down the pump set. (⇨ Section 6.1.7 Page 33)

▷

Close the shut-off elements in the suction and discharge line.

▷

Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 42)

▷

Close any auxiliary connections.

▷

Allow the pump set to cool down to ambient temperature.

After a prolonged period of operation the individual parts 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 pull-off device.

1. Disconnec Disconnectt the power power supply supply (e.g. (e.g. at the the motor). motor). 2. Disconnec Disconnectt and remove remove all all auxiliary auxiliary pipework. pipework. 3. Remove Remove the the coupl coupling ing guar guard. d. 4. Remove Remove the the couplin coupling g spacer, spacer, if any. any. 5. Drain Drain the oil fill fill of oil-lub oil-lubrica ricated ted bearings bearings.. (⇨ Section 7.2.3.1.4 Page 40)

For pump sets with spacer-type couplings, the back pull-out unit can be removed while the motor remains bolted to the baseplate.

1. Disconnec Disconnectt the motor motor from from the power power supply supply.. 2. Unbolt Unbolt the the motor motor from from the the basepla baseplate. te. 3. Shift Shift the motor motor to to separate separate it it from from the pump.

Risk of squashing hands and feet! ▷

Suspend or support the motor to prevent it from tipping over.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.3 Page 43) have been observed/carried out. ✓ For pump sets without spacer-type coupling, the motor has been removed.

43 of 66


Suspend or support the bearing bracket at the pump end.

1. If required, suspend or support bearing bearing bracket 330 to prevent prevent it from tipping over. 2. Unbolt Unbolt support support foot foot 183 183 from from the basepl baseplate. ate. 3. Undo nut nut 920.3 (with (with bolted-on bolted-on discharge discharge cover) cover) or 920.5 920.5 (with clamped clamped discharge cover) at the volute casing. 4. Pull the the back pull-ou pull-outt unit out out of the the volute volute casing. casing. 5. Remove Remove and and dispose dispose of gasket gasket 400.1. 6. Place the the back pull-ou pull-outt unit on a clean clean and level level surface. surface.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.4 Page 43) have been observed/carried out. ✓ The back pull-out unit is kept in a clean and level assembly area.

1. Undo impeller impeller nut nut 920.1 920.1 (right-h (right-hand and thread) thread).. 2. Remove Remove impeller impeller 230 with with a puller. puller. 3. Place impeller impeller 230 230 on a clean clean and and level level surface. surface. 4. Remove Remove keys keys 940.2 940.2 from shaft 210.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.5 Page 44) have been observed/carried out. ✓ The back pull-out unit is kept in a clean and level assembly area.

1. Remove the rotating part part of the the mechanical seal (spring-loaded (spring-loaded ring) from shaft sleeve 523. 2. Remove Remove nuts 920.4 920.4 from dischar discharge ge cover cover 163.2, if any. any. 3. Remove Remove discharge discharge cover cover 163.2 163.2 from bearing bearing bracke brackett 330. 4. Remove the stationary part of the mechanical mechanical seal (seat (seat ring) from discharge discharge cover 163.2. 5. Pull shaft sleeve sleeve 523 523 off shaft 210. 6. Remove Remove and and dispose dispose of gasket gasket 400.3.

✓ The steps stated in (⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.5 Page 44) have been observed/carried out. ✓ The back pull-out unit is kept in a clean and level assembly area.

1. Undo nuts nuts 920.2 at the packed packed gland and and loosen gland gland follower follower 452. 452. Remove nuts from discharge cover, if any. 2. Remove Remove discharge discharge cover cover 163.1 163.1 from bearing bearing bracke brackett 330. 3. Remove gland follower 452 from discharge discharge cover 163.1 and remove remove the packing. 4. Remove Remove stuf stuffin fing g box ring ring 454. 454. 5. Remove Remove packing packing rings rings 461 and and lantern lantern ring ring 458, if any. any. 6. Pull shaft shaft protect protecting ing sleeve sleeve 524 off off shaft shaft 210.

44 of 66

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.6 Page 44) have been observed/carried out. ✓ The bearing bracket has been placed on a clean and level surface.

1. Undo the grub grub screw screw in in the coupli coupling ng hub hub.. 2. Pull the the coupling coupling hub hub off pump pump shaft shaft 210 with with a puller. puller. 3. Remo Remove ve key key 940 940.3 .3.. 4. Remo Remove ve thr throw ower er 507. 507. 5. Remove Remove bearing bearing covers covers 360.2 360.2 on the the pump and and motor motor end. 6. Remove Remove socket socket head cap screw screwss 901.1 and gasket gasketss 400.2. 7. Press shaft 210 out out of the shaft shaft seat. 8. Place radial radial ball ball bearing bearing 321 on a clean clean and level level surface. surface. 9. Dispos Dispose e of gask gaskets ets 400.2. 400.2.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.6 Page 44) have been observed/carried out. ✓ The bearing bracket has been placed on a clean and level surface.

1. Undo the grub grub screw screw in in the coupli coupling ng hub hub.. 2. Pull the the coupling coupling hub hub off pump pump shaft shaft 210 with with a puller. puller. 3. Remo Remove ve key key 940 940.3 .3.. 4. Remove Remove axia axiall sealin sealing g rings rings 411. 411. 5. Remove Remove bear bearing ing cove coverr 360.1. 360.1. 6. Remove Remove circli circlips ps 932. 932. 7. Press shaft 210 out out of the the bearing bearing seats. seats. 8. Place radial radial ball ball bearing bearing 321 on a clean clean and level level surface. surface.


Reassemble the pump (set) in accordance with the general rules of sound engineering practice.

▷

Use original spare parts only.

Always reassemble the pump in accordance with the corresponding general assembly drawing or exploded view. 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). 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.

45 of 66

Never use quick-setting adhesives (cyanoacrylate (cyanoacrylate adhesives). Coat the locating surfaces of the individual components with graphite or similar before reassembly. For reassembly, tighten all screws as specified in this manual. (⇨ Section 7.6 Page 50)

✓ The individual parts are kept in a clean and level assembly area. ✓ All disassembled parts have been cleaned and checked for wear. ✓ Any damaged or worn parts have been replaced by original spare parts. ✓ The sealing surfaces have been cleaned.

1. Press radial radial ball bearin bearing g 321 onto onto shaft shaft 210. 210. 2. Push the the pre-assemb pre-assembled led shaft shaft into bearing bearing brack bracket et 330. 3. Insert Insert new gasket gasket 400.2. 400.2. 4. Fasten Fasten bearing bearing cover 360.2 360.2 with hexago hexagon n head bolts 901.1; 901.1; take care care not to damage radial shaft seal 421. 5. Fit Fit thr throw ower er 507. 507. 6. Inse Insert rt key keyss 940. 940.3. 3. 7. Fit the the coupling coupling half half on the the motor-end motor-end shaft shaft stub. stub. 8. Secure Secure the the coupling coupling hub hub with with a grub grub screw. screw.

1 2

3 4

Fitting the radial ball bearing 1 3

Bearing bracket Radial ball bearing

2 4

Cover plate Shaft

✓ The individual parts are kept in a clean and level assembly area. ✓ All disassembled parts have been cleaned and checked for wear. ✓ Any damaged or worn parts have been replaced by original spare parts. ✓ The sealing surfaces have been cleaned.

1. Press radial radial ball bearin bearing g 321 onto onto shaft shaft 210. 210. Make sure that the bearing side with the cover plate rests against the shaft shoulder (see illustration: Fitting the radial ball bearing). 2. Push the the pre-assemb pre-assembled led shaft shaft into bearing bearing brack bracket et 330. 3. Fit Fit cir circl clip ipss 932 932.. 4. Fit bearin bearing g cover cover 360.1. 360.1. 5. Fit axial axial seali sealing ng rings rings 411. 411. 6. Inse Insert rt key keyss 940. 940.3. 3. 7. Fit the the coupling coupling half half on the the motor-end motor-end shaft shaft stub. stub. 8. Secure Secure the the coupling coupling hub hub with with a grub grub screw. screw.

46 of 66

Always observe the following rules when installing the mechanical seal: ▪ Work cleanly and accurately. ▪ Only remove the protective wrapping of the contact faces immediately before assembly takes place. ▪ Prevent any damage to the sealing surfaces or O-rings. ✓ The notes and steps stated in (⇨ Section 7.5.1 Page 45) to (⇨ Section 7.5.2 Page 46) have been observed/carried out. ✓ The assembled bearing as well as the individual parts are kept in a clean and level assembly area. ✓ All disassembled parts have been cleaned and checked for wear. ✓ Any damaged or worn parts have been replaced by original spare parts. ✓ The sealing surfaces have been cleaned.

1. Clean shaft shaft sleeve sleeve 523, and touch touch up any score score marks or scratc scratches hes with a polishing cloth. If the socre marks or scratches are still visible, replace shaft sleeve 523. 2. Push shaft shaft sleeve sleeve 523 with with new gasket gasket 400.3 400.3 onto shaft shaft 210. 3. Clean the the seat ring ring in discharg discharge e cover 163.2 163.2 or seat ring ring holder holder 476.

Shaft seal failure! ▷

Use water as assembly lubricant.

▷

Never use oil or grease as assembly lubricant.

4. Carefully Carefully fit fit seat seat ring/sea ring/seatt ring holder holder 476. Press seat ring in evenly. 5. Place dischar discharge ge cover 163.2 163.2 into the locatin locating g fit of bearing bearing bracket bracket 330. 6. Fit and tighte tighten n nuts nuts 920.4, 920.4, if any. any.

To reduce friction forces when assembling the seal, wet the shaft sleeve and the seat ring location with water.

7. Mount the rotating part part of the the mechanical seal (spring-loaded (spring-loaded ring) on shaft sleeve 523. Observe the following installation dimension b for mechanical seals with installation dimension L1k to EN 12756 (design KU): b

1 2 3 4 Installation dimension b of mechanical seal 1 3

Impeller Mechanical seal

2 4

Shaft sleeve Discharge cover

47 of 66

Installation dimensions of the mechanical seal 25 35 55

7.5 mm 10 mm 15 mm

l

i

d

a

d

Gland packing chamber Gland packing chamber

25

30

46

45

□ 8 x 126

3 packing rings

35

40

60

56

□ 10 x 165

1 lantern ring 3 packing rings

□ 10 x 196

1 lantern ring 3 packing rings

55

50

70

56

1 lantern ring ✓ The notes and steps stated in (⇨ Section 7.5.1 Page 45) to (⇨ Section 7.5.2 Page 46) have been observed/carried out. ✓ The assembled bearing/gland packing as well as the individual parts are kept in a clean and level assembly area. ✓ All disassembled parts have been cleaned and checked for wear. ✓ Any damaged or worn parts have been replaced by original spare parts. ✓ The sealing surfaces have been cleaned.

1. Clean Clean the the packi packing ng cham chamber ber.. Packing ring cut to size

2. Insert Insert packing packing ring 461 into the the packing chambe chamberr of discharge discharge cover cover 161.1. 3. Use stuffing stuffing box box ring 454 454 to push home home packing packing ring 461. 461. Insert lantern ring 458, if any (see drawing above). Insert each subsequent packing ring with its joint displaced by approximately 90° in relation to the previous one. Use stuffing box ring 454 to push each packing ring separately into the packing chamber. 4. Place gland gland follower follower 452 on studs studs 902.2 and tighten tighten gently gently and evenly evenly with with hexagon nuts 920.2, so that packing rings 461 are not compressed yet. 5. Use a feeler gauge to verify that gland follower 452 is mounted centred and at a right angle to the shaft.

10)

Shaft unit see data sheet.

11)

Shaft unit see data sheet. For operation with positive suction head and suction pressure > 0.5 bar, the lantern ring is replaced by two additional packing rings.

12)

48 of 66

6. Tighten Tighten gland gland follower follower 452 452 lightly lightly and evenly evenly.. It must be easy to rotate the rotor. 1. Clean Clean the the packi packing ng cham chamber ber.. 2. Insert Insert pure pure graphite graphite packing packing ring ring 461. 461.

Pure graphite packing ring

3. Use stuffing stuffing box box ring 454 to push push home pure graphit graphite e packing ring ring 461. There must be a visible gap between shaft protecting sleeve 523 and the packing rings. Insert each subsequent pure graphite packing ring 461 with its joint displaced by approximately 90° in relation to the previous one. Use stuffing box ring 454 to push each packing ring separately into the packing chamber. The pure graphite packing rings 461 must always fit snugly in the stuffing box. 4. Position Position gland follow follower er 452 on studs 902.2. 902.2. Fasten Fasten by tightenin tightening g nuts 920.2 920.2 lightly and evenly. 5. Use a feeler gauge to verify that gland follower 452 is mounted centred and at a right angle to the shaft. 6. Tighten Tighten gland gland follower follower 452 452 lightly lightly and evenly evenly.. It must be easy to rotate the rotor.

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 45) to (⇨ Section 7.5.3 Page 47) have been observed/carried out. ✓ The assembled bearing bracket as well as the individual parts are kept in a clean and level assembly area. ✓ All disassembled parts have been cleaned and checked for wear. ✓ Any damaged or worn parts have been replaced by original spare parts. ✓ The sealing surfaces have been cleaned.

1. Insert Insert key 940.1 940.1 and push push impeller impeller 230 230 onto shaft shaft 210. 210. 2. Fasten impeller impeller nut 920.3, 920.3, spring washer 930 and disc 550.3, if any any (see table: Tightening torques for screwed connections at the pump (⇨ Section 7.6 Page 50)). 50)).


Suspend or support the bearing bracket at the pump end.

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 45) to (⇨ Section 7.5.4 Page 49) have been observed/carried out. ✓ Any damaged or worn parts have been replaced by original spare parts. ✓ The sealing surfaces have been cleaned. ✓ For back pull-out units without coupling, install the coupling in accordance with the manufacturer's instructions.

1. Insert Insert new gasket gasket 400.1 400.1 in volute volute casing casing 102. 2. If required, prevent the the back pull-out pull-out unit from tipping tipping over, e.g. by suspending or supporting it. Then push it into volute casing 102. 3. Tighten nut 920.3 or 920.5 920.5 at the volute casing. casing. Observe Observe the tightening tightening torques. torques. (⇨ Section 7.6.1 Page 50) 4. Fasten Fasten support support foot 183 to the the baseplate baseplate with a foundati foundation on bolt.

49 of 66

Steps 1 and 2 do not apply to versions with spacer-type coupling.

1. Shift Shift the motor motor to connect connect it to the the pump via via the coupling coupling.. 2. Fasten Fasten the the motor motor to the the basepl baseplate. ate. 3. Alig Align n the the pum pump. p. (⇨ Section 5.7 Page 26) 4. Connect the the motor to the power supply supply (refer to manufacturer's manufacturer's product product literature).

b)

a)

A

A

C

C C

X D

D

B

X B Bolts to be tightened: Variant with bolted-on discharge cover (a) and oil lubrication (a) and variant with clamped discharge cover (b) and grease lubrication (b) X

Tightening torques of screwed connections at the pump

50 of 66

M10

38

M12 M12 x 1.5

55 55

M24 x 1.5

130

M30 x 1.5 M8

170 20

M10 M 12 M8

38 125 20

M10

38

M12

55

M16

130

M6

15

M8

38

M10

38

M12 1/8

55 25

1/4

55

3/8

80

1/2

130

3/4

220

5

6

1

2

3

4

Tightening points of the pump set Tightening torques for the pump set

M12

30

Pump on baseplate

M16

75

M20 M12 M24 x 1.5

75 30 140

Levelling screws in baseplate

M36 x 1.5 M6

140 10

Motor on baseplate or

M8

10

motor on levelling screws or shims

M10

15

M12

30

M16

75

M20

140

M24 M6

140 13

M8

18

Coupling (only for spacer-type coupling made by Flender)

M10 M6

44 10

Coupling guard

51 of 66

Always quote the following data when ordering replacement or spare parts: ▪ Type series ▪ Material variant ▪ Size ▪ Seal code ▪ KSB order number ▪ Order item number ▪ Consecutive number ▪ Year of construction

Refer to the name plate for all data. (⇨ Section 4.3 Page 15) Also supply the following data: ▪ Description ▪ Part No. ▪ Quantity of spare parts ▪ Delivery address ▪ Mode of dispatch (freight, mail, express freight, air freight)

Refer to the exploded view or general assembly drawing for part numbers and descriptions. (⇨ Section 9.1 Page 57)

Quantity of spare parts for recommended spare parts stock

210 230 321 330 502.1 -

Shaft Impeller13) Radial ball bearing (set) Bearing bracket Casing wear ring Gaskets (set)

1 1 1 2 4

1 1 1 2 6

1 1 2 2 8

2 2 2 3 8

2 2 2 3 9

2 2 3 1 4 10

20 % 20 % 25 % 2 50 % 100 %

433 523

Mechanical seal Shaft sleeve

1 2

1 2

2 2

2 3

2 3

3 4

25 % 50 %

4 2

4 2

6 2

6 3

6 3

8 4

100 % 50 %

14)

461 524

13) 14)

Gland packing (set) Shaft protecting sleeve

including casing wear ring 502.2 Parts 433, 523 are not used

52 of 66

Components featuring the same number in a column are interchangeable. Interchangeability of pump components

32-125.1 32-160.1 32-200.1 32-250.1 3 2- 1 2 5 3 2- 1 6 0 3 2- 2 0 0 3 2- 2 5 0 4 0- 1 2 5 4 0- 1 6 0 4 0- 2 0 0 4 0- 2 5 0 4 0- 3 1 5 5 0- 1 2 5 5 0- 1 6 0 5 0- 2 0 0 5 0- 2 5 0 5 0- 3 1 5 6 5- 1 2 5 6 5- 1 6 0 6 5- 2 0 0 6 5- 2 5 0 6 5- 3 1 5 8 0- 1 6 0 8 0- 2 0 0 8 0- 2 5 0 8 0- 3 1 5 8 0- 4 0 0 1 0 0- 1 6 0 1 0 0- 2 0 0 1 0 0- 2 5 0 1 0 0- 3 1 5 1 0 0- 4 0 0 1 2 5- 2 0 0 1 2 5- 2 5 0 1 2 5- 3 1 5 1 2 5- 4 0 0 1 5 0- 2 0 0 1 5 0- 2 5 0 1 5 0- 3 1 5 1 5 0- 4 0 0

25 25 25 25 25 25 25 25 25 25 25 25 35 25 25 25 25 35 25 25 25 35 35 25 35 35 35 55 35 35 35 35 55 35 35 55 55 35 35 55 55

○* ○* ○* ○ ○ ○* ○* ○* ○ ○* ○* ○* ○ ○ ○* ○* ○* ○ ○ ○* ○* ○* ○ ○* ○* ○* ○ ○ ○* ○* ○* ○* ○ ○* ○* ○ ○ ○ ○* ○ ○

1 1 4 6 1 1 4 6 1 1 4 6 ○ 1 1 4 6 9 1 2 ○ ○ 9 2 3 7 9 11 3 3 7 9 11 5 8 10 11 5 8 10 11

12* 12* 15* 17* 12* 12* 15* 17* 12* 12* 15* 17* ○* 12* 12* 15* 17* 20* 12* 13* ○* ○* 20* 13* 14* 18* 20* 22* 14* 14* 18* 20* 22* 16* 19* 21* 22* 16* 19* 21* 22

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 1 2 2 2 3 2 2 2 2 3 2 2 3 3 2 2 3 3

○* 1* 2* 3* ○* 1* 2* 3* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○* ○

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 1 2 2 2 3 2 2 2 2 3 2 2 3 3 2 2 3 3

1* 1* 1* 1* 1* 1* 1* 1* 1* 1* 1* 1* 2* 1* 1* 1* 1* 2* 1* 1* 1* 2* 2* 1* 2* 2* 2* 3* 2* 2* 2* 2* 3* 2* 2* 3* 3* 2* 2* 3* 3

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 1 2 2 2 3 2 2 2 2 3 2 2 3 3 2 2 3 3

1* 1* 1* 1* 1* 1* 1* 1* 2* 2* ○* 2* 2* 3* 3* 3* 3* 5* 5* 5* 5* 9* 9* 6* 6* 6* 6* 10* 7* 7* 7* 7* 7* 8* 8* 8* 8* ○* 12* 12* 12

X 3* 3* 4* X 3* 3* 4* X 3* 3* 4* 13* 3* 3* 3* 4* 10* 3* 9* 9* 13* 10* 9* 10* 10* 10* 8* 10* 10* 10* 10* 8* 11* 14* 8* 8* 11* 14* 8* 8

1* 1* 1* 1* 1* 1* 1* 1* 1* 1* 1* 1* 2* 1* 1* 1* 1* 2* 1* 1* 1* 2* 2* 1* 2* 2* 2* 3* 2* 2* 2* 2* 3* 2* 2* 3* 3* 2* 2* 3* 3

1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 1 2 2 3 3 2 2 2 2 3 2 2 3 3 2 2 3 3

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Key to the symbols * ○ X

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Component interchangeable with Etabloc Components differ Component not fitted

Pump delivers insufficient flow rate Motor is overloaded Excessive pump discharge pressure Excessive bearing temperature Leakage at the pump Excessive leakage at the shaft seal Vibrations during pump operation Impermissible rise of temperature inside the pump Trouble-shooting Pump delivers against an excessively high discharge pressure.

Pump or piping are not completely vented or primed. Supply pply lin line or or imp impe eller ller clog logged. ged. Forma Formatio tion n of air pock pockets ets in the the pipi piping. ng.

Re-adjust to duty point. Check plant for impurities. Fit a larger impeller.16) Increase the speed (turbine, I.C. engine). Vent and/or prime.

Rem Remove ove dep depos osit itss in in the the pump pump and/o nd/orr pip pipin ing g. Modify Modify the pip piping ing.. Fit a vent valve. Suction head is too high, NPSHavailable Check/alter liquid level. (positive suction head) is too low. Install pump at a lower level. Fully open shut-off valve 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. Clean flushing liquid duct, supply external flushing liquid, if necessary, or increase flushing liquid pressure. Replace the shaft seal. Wrong direction of rotation Interchange two of the phases of the power supply cable. Speed is too low. - Increase voltage/frequency at the frequency inverter in the permissible range. - operation without frequency inverter - Check the voltage. Wear of internal pu pump pa parts Replace wo worn co 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) Density or viscosity of the fluid pumped Contact KSB. is higher than stated in the purchase order. Wrong shaft seal materials Change the material combination. 16) Gland ffo ollower to too ttiight o orr askew. Correct. Speed is too high. Reduce speed.16) Tie bolt/gasket defective. Fit new gasket between volute casing and discharge cover. Re-tighten the bolts. Worn shaft seal Replace the shaft seal. Check flushing liquid/barrier fluid. - operation with frequency inverter

15) 16)

Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. Contact KSB.

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Score marks or roughness on shaft protecting sleeve / shaft sleeve Dismantle to find out. Vibr Vibrat atio ions ns dur durin ing g pump pump ope opera rati tion on..

Pump set is misaligned. Pump is warped or sympathetic vibrations in the piping.

Increased axial thrust16)

Replace shaft protecting sleeve / shaft sleeve. Replace the shaft seal. Remedy fault. Replace the shaft seal, if required. Corr Correc ectt suct suctio ion n cond condit itio ions ns.. Re-align the pump set. Re-balance the impeller. Increase pressure at the pump suction nozzle. Re-align the pump set. Check pipeline connections and secure fixing of pump; if required, reduce the distances between the pipe clamps. Fix the pipelines using anti-vibration material. Clean balancing holes in the impeller. Fit new wear rings. Top up, reduce or change lubricant.

Insufficient or excessive quantity of lubricant or unsuitable lubricant. Non-compliance with specified coupling Correct distance according to the general distance. arrangement drawing. Motor Motor is runn running ing on two two phases phases onl only. y. Replac Replace e the the defe defecti ctive ve fuse. fuse. Check the electric cable connections. Rotor is out of balance. Clean the impeller. Re-balance the impeller. Defective bearing(s). Fit new bearing(s). Insufficient flow rate Increase the minimum flow rate. Inco Incorr rrec ectt inf inflo low w of of cir circu cula lati tion on liqu liquid id Incr Increa ease se the the fre free e pas passa sage ge..

15)

Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

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This view applies to the following sizes: 32-200.1 32-250.1 32-200 32-250

40-200 40-250 40-315

50-200 50-250 50-315

65-200 65-250 65-315

80-250 80-315 80-400

100-250 100-315 100-400

125-250 125-400

150-250 150-400

[ Supplied in packaging units only

Etanorm with standardised mechanical seal and bolted discharge cover List of components 102 163.2 183 210 230 321 330

Volute casing Discharge cover Support foot Shaft Impeller Radial ball bearing Bearing bracket

412 433 476 502.1/.2 523 5 50 81-92

O-ring17) Mechanical seal Seat ring holder17) Casing wear ring Shaft sleeve Disc19) Cover plate

17)

Etanorm B, S only

18)

For Etanorm with shaft unit 55 = 2 keys (shaft unit see data sheet) For Etanorm pumps with shaft unit 25 only (shaft unit see data sheet).

19)

920.1/.3/.4 930.3 932 940.2 940.3

Nut Safety device Circlip Key18) Key

1M

Connection for pressure gauge

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360.1 400.1/.3

Bearing cover Gasket

901.1-3 902.1/.2

Hexagon head bolt Stud

6B 6D

411

Joint ring

903.1

Screwed plug20)

8B

20)

Fluid drain Filler opening for the fluid Leakage drain

Bei Etanorm C,S zusätzlich Dichtring 411.5 (in Zeichnung nicht enthalten)( zutreffender Werkstoff siehe Datenblatt)

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40-125 40-160

50-125 50-160

65-125 65-160

80-160 80-200

100-160 100-200

125-200 125-315

150-200 150-315


Standardised mechanical seal and clamped discharge cover List of components 102 163.2 183 210 230

Volute casing Discharge cover Support foot Shaft Impeller

433 476 502.1/.2 523 550

Mechanical seal Seat ring holder24) Casing wear ring Shaft sleeve Disc22)

9 32 940.2 940.3

Circlip Key21) Key

1M

321 330 360.1 400.1/.3 411 412

Radial ball bearing Bearing bracket Bearing cover Gasket Joint ring O-ring24)

81-92 901.1-3 902.1-3 903.1 920.1/.5 930.3

Cover plate Hexagon head bolt Stud Screwed plug23) Nut Safety device

6B 6D 8B

Connection for pressure gauge Fluid drain Fluid filling Leakage drain

21) 22) 23) 24)

For Etanorm with shaft unit 55 = 2 keys (shaft unit see data sheet) For Etanorm pumps with shaft unit 25 only (shaft unit see data sheet). Etanorm C,S: additional joint ring 411.5 (not shown in drawing) (relevant material see data sheet) Etanorm B, S only

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40-200 40-250 40-315

50-200 50-250 50-315

65-200 65-250 65-315

80-250 80-315 80-400

100-250 100-315 100-400

125-250 125-400

150-250 150-400


Gland packing and bolted discharge cover List of components 903.1 920.1-.4 930.3 932 940.1-.3

Screwed plug25) Nut Safety device Circlip Key

550

Gland follower Stuffing box ring Lantern ring Gland packing Casing wear ring Shaft protecting sleeve Disc26)

1M

81-92 901.1-3 902.1/.2/.4

Cover plate Hexagon head bolt Stud

6B 6D 8B


102 163.1 183 210 230 321

Volute casing Discharge cover Support foot Shaft Impeller Radial ball bearing

452 454 458 461 502.1/.2 5 24

330

Bearing bracket

360.1 400.1 411

Bearing cover Gasket Joint ring

25) 26)

Etanorm C,S: additional joint ring 411.5 (not shown in drawing) (relevant material see data sheet) For Etanorm pumps with shaft unit 25 only (shaft unit see data sheet).

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40-125 40-160

50-125 50-160

65-125 65-160

80-160 80-200

100-160 100-200

125-200 125-315

150-200 150-315


1211:113/4

Gland packing and clamped discharge cover List of components 903.1 920.1/.2/.5 930.3 932.1-.3 940.1-.3

Screwed plug28) Nut Safety device Circlip Key

550

Gland follower Stuffing box ring Lantern ring Gland packing Casing wear ring Shaft protecting sleeve Disc27)

1M

81-92 901.1-3 902.3/.4

Cover plate Hexagon head bolt Stud

6B 6D 8B


102 163.1 183 210 230 321

Volute casing Discharge cover Support foot Shaft Impeller Radial ball bearing

452 454 458 461 502.1/.2 524

330

Bearing bracket

360.1 400.1 411

Bearing cover Gasket Joint ring28)

27) 28)

For Etanorm pumps with shaft unit 25 only (shaft unit see data sheet). Etanorm C: additional joint ring 411 (not shown in drawing) (relevant material see data sheet)

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1211:172

B

Constant-level oiler List of components 183 210 321 330 360.2 400.2 421 507

Support foot Shaft Radial ball bearing Bearing bracket Bearing cover Gasket Lip seal Thrower

550 638 6 72 81-92 901.1-.3 903.3 920.1/.5 930.330)

Disc29) 30) Constant-level oiler Venting Cover plate Hexagon head bolt Screwed plug Nut Safety device

29)

For Etanorm pumps with shaft unit 55 only (shaft unit see data sheet).

30)

Not shown in drawing. For Etanorm with shaft unit 55 = 2 keys

31)

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932 940.2 940.3 940.3

Circlip Key 29) Key31) Key

8B 13 B 13D

Leakage drain Oil drain Oil – filling and venting

Manufacturer:

The manufacturer herewith declares that

:

KSB order number: ........................................ ............................................................................... ........................................................... ....................

▪ is in conformity with the provisions of the following directives as applicable in their current version:

– EC Machin Machinery ery Directive Directive 2006/42/EC 2006/42/EC The manufacturer also declares that ▪ the following harmonised international standards have been applied:

– ISO 12100-1/A1, 12100-1/A1, ISO 12100-2/A1 12100-2/A1,, – ISO ISO 141 14121 21-1 -1,, – EN 80 809/A1

Frankenthal, 29 December 2009 ........................................................... Name Function Responsible for compiling the technical documentation KSB Aktiengesellschaft Johann-Klein-Straße Johann-Klein-Straße 9 67227 Frankenthal (Germany)

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Type Order number/ Order item number32)

................................................................................................................................ ................................................................................ ........................................ ............................................................................... ................................................ .........

Deliv eliver ery y date date

.... ...... .... .... .... ........ ...... ........ ...... .... .... .... ........ ...... ........ ...... .... .... .... ........ ...... ........ ...... .... .... .... ........ ...... ........ ...... .... .... .... ........ ...... .... .... .... ........ ...... ........ ...... .... .... .... ......

Fiel Field d of appl applic icat atio ion: n:

.... ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ..

Fluid handled32) :

............................................................................... ....................................... ................................................................................ ................................................. .........

Please tick where applicable 32) :

⃞⃞⃞⃞ radioactive

⃞⃞⃞⃞ harmful

explosive

corrosive

toxic

bio-hazardous

highly flammable

safe

Reason for return32) :

............................................................................... ........................................ ............................................................................... ................................................. .........

Comments:

................................................................................................................................ ............................................................................... ....................................... ................................................................................ ................................................. .........

The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal. On sealless pumps, the rotor has been removed from the pump for cleaning. ⃞ ⃞

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.

........... ................. ............ ............ ........... ........... ............ ............ ........... ........... ........... ..... Place, date and signature

32)

Required fields

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........... ................. ............ ........... ........... ............ ............ ........... ......... .... Address

............ .................. ............ ........... ........... ............ ............ ........... ........ ... Company stamp

Abrasive fluids 36

Maintenance/ repair 37 Mechanical seal 33 Misuse 9 Monitoring equipment 12

Bearing temperature 38 Bearings 16 Name plate 15 Noise characteristics 17 Certificate of decontamination 64 Clearance gaps 39 Code 15 Commissioning/start-up 30 Constant-level oiler 30 Coupling 39 Coupling alignment 25

Design 15, 15, 16 Direction of rotation 29 Dismantling 43 Disposal 14

Exploded view 57, 57, 59, 59, 60, 60, 61 Explosion protection 11, 11, 16, 16, 18, 18, 19, 19, 24, 24, 25, 25, 26, 26, 27, 27, 28, 28, 29, 29, 31, 31, 32, 32, 34, 34, 37, 37, 38, 38, 39, 39, 40

Filter 21, 21, 39 Final check 31 Frequency of starts 34 Function 16

Gland packing 33 Grease lubrication Grease quality 41 Intervals 41

Impeller type 16 Installation Installation on the foundation 19 Installation without foundation 20 Installation at site 19 Intended use 8 Interchangeability of pump components 53

Oil lubrication Intervals 40 Oil quality 40 Oil quantity 40 Operating limits 8, 34 Order number 6 Ordering spare parts 52 Other applicable documents 6

Partly completed machinery 6 Permissible forces and moments at the pump nozzles 22 Piping 21 Preservation 14, 14, 36 Priming and venting 31 Product description 15 Pump casing 15 Pure graphite packing ring 33

Reassembly 43, 43, 45 Return to supplier 14 Returning to service 36 Running noises 38

Safety 8 Safety awareness 9 Scope of supply 17, 17, 18 Shaft seal 16 Shutdown 36 Spare parts stock 52 Start-up 32 Storage 14, 14, 36

Temperature limits 11 Tightening torques 50, 50, 51 Transport 13 Trouble-shooting 55

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0 1 -

6 1 / 8 . 1 1 2 1

KSB Aktiengesellschaft 67225 Frankenthal • Johann-Klein-Str. Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com

Etanorm KSB PUMP O&M Manual

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