etabloc syt operating instructions

Thermal Oil / Hot Water Pump

Etabloc SYT/ Etaline SYT

Close-coupled or in-line design

Installation/OperatingManual

Order number:

Legal information/Copyright Installation/Operating Manual Etabloc SYT/ Etaline SYTOriginal operating manual KSB Aktiengesellschaft All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, editedor processed for any other purpose, nor otherwise transmitted, published or made available to a thirdparty without KSB´s express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 19.04.2011

Contents

Glossary ................................................................................................ 5

1 General ................................................................................................ 6

1.1 Principles .......................................................................................................... 6

1.2 Installation of partly completed machinery .................................................. 6

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

1.4 Other applicable documents .......................................................................... 6

1.5 Symbols ............................................................................................................ 6

2 Safety ................................................................................................... 8

2.1 Key to safety symbols/markings ..................................................................... 8

2.2 General ............................................................................................................ 8

2.3 Intended use .................................................................................................... 8

2.4 Personnel qualification and training ............................................................. 9

2.5 Consequences and risks caused by non-compliance with these operatinginstructions ...................................................................................................... 9

2.6 Safety awareness ............................................................................................. 9

2.7 Safety information for the operator/user .................................................... 10

2.8 Safety information for maintenance, inspection and installation work ... 10

2.9 Unauthorised modes of operation ............................................................... 10

2.10 Explosion protection ..................................................................................... 10

3 Transport/Temporary Storage/Disposal ........................................... 13

3.1 Checking the condition upon delivery ......................................................... 13

3.2 Transport ....................................................................................................... 13

3.3 Storage/preservation ..................................................................................... 14

3.4 Return to supplier ......................................................................................... 14

3.5 Disposal .......................................................................................................... 15

4 Description of the Pump (Set) .......................................................... 16

4.1 General description ....................................................................................... 16

4.2 Designation .................................................................................................. 16

4.3 Name plate .................................................................................................... 16

4.4 Design details ................................................................................................ 16

4.5 Configuration and function ......................................................................... 17

4.6 Noise characteristics ...................................................................................... 18

4.7 Scope of supply ............................................................................................. 18

4.8 Dimensions and weights ............................................................................... 18

5 Installation at Site ............................................................................. 19

5.1 Safety regulations ......................................................................................... 19

5.2 Checks to be carried out prior to installation ............................................. 19

5.3 Installing the pump set ................................................................................. 19

Contents

Etabloc SYT/ Etaline SYT 3 of 50

5.4 Piping ............................................................................................................. 19

5.5 Protective equipment ................................................................................... 21

5.6 Electrical connection ..................................................................................... 22

5.7 Checking the direction of rotation .............................................................. 23

6 Commissioning/Start-up/Shutdown ................................................. 24

6.1 Commissioning/start-up ................................................................................ 24

6.2 Operating limits ............................................................................................ 27

6.3 Shutdown/storage/preservation ................................................................... 28

6.4 Returning to service ...................................................................................... 29

7 Servicing/Maintenance ...................................................................... 30

7.1 Safety regulations ......................................................................................... 30

7.2 Maintenance/inspection ............................................................................... 31

7.3 Drainage/cleaning ......................................................................................... 33

7.4 Dismantling the pump set ............................................................................ 33

7.5 Reassembling the pump set .......................................................................... 36

7.6 Tightening torques ....................................................................................... 39

7.7 Spare parts stock ........................................................................................... 39

8 Trouble-shooting ............................................................................... 42

9 Related Documents ........................................................................... 44

9.1 Exploded views and list of components ...................................................... 44

10 EC Declaration of Conformity ......................................................... 46

11 Certificate of Decontamination ....................................................... 47

Index .................................................................................................. 48

Contents

4 of 50 Etabloc SYT/ Etaline SYT

Glossary

Back pull-out designThe complete back pull-out unit can be pulledout without having to remove the pump casingfrom the piping.

Back pull-out unitPump without pump casing; partly completedmachinery

Certificate of DecontaminationA certificate of decontamination certifies thatthe pump (set) has been properly drained toeliminate any environmental and healthhazards arising from components in contactwith the fluid handled.

Close-coupled designMotor directly fitted to the pump via a flangeor a drive lantern

Hydraulic systemThe part of the pump in which the kineticenergy is converted into pressure energy

In-line designSuction and discharge nozzle are arrangedopposite each other on the same axis

Pool of pumpsPumps which are purchased and storedindependently of their later use

PumpMachine without drive, additional componentsor accessories

Pump setComplete pump set consisting of pump, drive,additional components and accessories

Suction lift line/suction head lineThe line which is connected to the suctionnozzle

Glossary


1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicatedon the front cover. It describes the proper and safe use of this equipment in allphases of operation.

The name plate indicates the type series and size, the main operating data, the ordernumber and the order item number. The order number and order item numberclearly identify the pump (set) and serve as identification for all further businessprocesses.

In the event of damage, contact your nearest KSB service centre immediately tomaintain the right to claim under warranty.

Noise characteristics (⇨ Section 4.6 Page 18)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, refer to the sub-sectionsunder Servicing/Maintenance. (⇨ Section 7.5.5 Page 37)

1.3 Target group

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

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsData sheet Description of the technical data of the pump

(set)General arrangement drawing/outline drawing

Description of mating and installation dimensionsfor the pump (set), weights

Drawing of auxiliary connections Description of auxiliary connectionsHydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power inputGeneral assembly drawing1) Sectional drawing of the pump

Sub-supplier product literature1) Operating manuals and other documentation ofaccessories and integrated machinery components

Spare parts lists1) Description of spare parts

Piping layout1) Description of auxiliary piping

List of components1) Description of all pump components

1.5 Symbols

Table 2: Symbols used in this manual

Symbol Description✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions⊳ Safety instructions⇨ Result of an action⇨ Cross-references

1) If agreed to be included in the scope of supply

1 General


Symbol Description1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General


2 SafetyAll the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.Explosion protectionThis symbol identifies information about avoiding explosions inpotentially explosive atmospheres in accordance with EC Directive94/9/EC (ATEX).General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies informationabout protection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent personal injuryand 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 specialistpersonnel/operators prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pump must always be complied with and bekept 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 whichare not taken into account in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits described in theother applicable documents.

▪ Only operate pumps/pump sets which are in perfect technical condition.

▪ Do not operate the pump (set) in partially assembled condition.

! DANGER

2 Safety


▪ Only use the pump to handle the fluids described in the data sheet or productliterature of the pump model.

▪ Never operate the pump without the fluid 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 productliterature (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 preventcavitation damage).

▪ Consult the manufacturer about any use or mode of operation not described inthe data sheet or product literature.

Prevention of foreseeable misuse

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

– The maximum flow rate specified in the data sheet or product literaturewould be exceeded.

– Risk of cavitation damage

▪ Never exceed the permissible operating limits specified in the data sheet orproduct literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain andinspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved ininstallation, operation, maintenance and inspection must be clearly defined by theoperator.

Deficits in knowledge must be rectified by sufficiently trained specialist personneltraining and instructing the personnel who will carry out the respective tasks. Ifrequired, the operator can commission the manufacturer/supplier to train thepersonnel.

Training on the pump (set) must always be supervised by technical specialistpersonnel.

2.5 Consequences and risks caused by non-compliance with these operatinginstructions

▪ Non-compliance with these operating instructions will lead to forfeiture ofwarranty cover and of any and all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

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

2 Safety


▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and checkthat the guards function properly.

▪ Do not remove any contact guards during operation.

▪ 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 nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

▪ If shutting down the pump does not increase potential risk, fit an emergency-stop control device in the immediate vicinity of the pump (set) during pump setinstallation.

2.8 Safety information for maintenance, inspection and installation work

▪ Modifications or alterations of the pump are only permitted with themanufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughlyfamiliar with the manual.

▪ Only carry out work on the pump (set) during standstill of the pump.

▪ 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 proceduredescribed in the manual. (⇨ Section 6.1.5 Page 26) (⇨ Section 6.3 Page 28)

▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3Page 33)

▪ As soon as the work is completed, re-install and/or re-activate any safety-relevantand protective devices. Before returning the product to service, observe allinstructions on commissioning. (⇨ Section 6.1 Page 24)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in thismanual.

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)

2.10 Explosion protection

Always observe the information on explosion protection given in this section whenoperating the pump in potentially explosive atmospheres.

! DANGER

2 Safety


Only pumps/pump sets marked as explosion-proof and identified as such in the datasheet may be used in potentially explosive atmospheres.

Special conditions apply to the operation of explosion-proof pump sets to ECDirective 94/9/EC (ATEX). Especially adhere to the sections in this manual marked with the Ex symbol and thefollowing sections (⇨ Section 2.10.1 ) to (⇨ Section 2.10.4 Page 12) . The explosion-proof status of the pump set is only assured if the pump set is used inaccordance with its intended use. Never operate the pump set outside the limits stated in the data sheet and on thename plate.Prevent impermissible modes of operation at all times.

2.10.1 Marking

The marking on the pump refers to the pump part only. Example of such marking: II 2 G c TX Refer to the Temperature limits table for the temperatures permitted for theindividual pump variants. (⇨ Section 2.10.2 Page 11)

An EC manufacturer's declaration is required for the shaft coupling; the shaftcoupling must be marked accordingly.

The motor has its own marking. The marking is maintained on the condition that thetemperatures the pump causes to develop at the motor flange and motor shaft arepermitted by the motor manufacturer.The motors fitted by KSB on pumps with ATEX certification meet this condition.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on thesurface of the pump casing and at the shaft seal. The surface temperature at the pump casing corresponds to the temperature of thefluid handled. If the pump is heated, the operator of the system is responsible forobserving the specified temperature classes and fluid temperature (operatingtemperature). The table below lists the temperature classes and the resulting theoreticaltemperature limits of the fluid handled. (A possible temperature rise in the shaft sealarea has already been taken into account).

The temperature class specifies the maximum permissible temperature at the surfaceof the pump set during operation. For the permissible operating temperature of thepump in question refer to the data sheet.

Table 4: Temperature limits

Temperature class as per EN 13463-1 Max. permissible fluidtemperature

T1 Temperature limit of the pumpT2 280 °CT3 185 °CT4 120 °CT5 85 °CT6 Only after consultation

with the manufacturer

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

If a pump is supplied without motor (as part of a pool of pumps), the motor specifiedin the pump data sheet must meet the following conditions:

▪ The permissible temperature limits at the motor flange and motor shaft must behigher than the temperatures generated by the pump.

▪ Contact the manufacturer for the actual pump temperatures.

Pump

Shaft coupling

Motor

Motor supplied by theoperator

2 Safety


2.10.3 Monitoring equipment

The pump (set) must only be operated within the limits specified in the data sheetand 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 setfunctions properly.

Contact KSB for further information on monitoring equipment.

2.10.4 Operating limits

The minimum flow rates indicated in (⇨ Section 6.2.3.1 Page 27) refer to water andwater-like fluids. Longer operating periods with these fluids and at the flow ratesindicated will not cause an additional increase in the temperatures at the pumpsurface. However, if the physical properties of the fluids handled are different fromwater, it is essential to check whether an additional heat build-up may occur and ifthe minimum flow rate must therefore be increased. The calculation formula in (⇨Section 6.2.3.1 Page 27) can be used to check whether an additional heat build-upmay lead to a hazardous temperature increase at the pump surface.

2 Safety


3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it andnotify KSB about the damage in writing immediately.

3.2 Transport

DANGERThe pump (set) could slip out of the suspension arrangementDanger to life from falling parts!

▷ Always transport the pump (set) in the specified position.

▷ Never attach the suspension arrangement to the free shaft end or the motoreyebolt.

▷ Give due attention to the weight data and the centre of gravity.

▷ Observe the applicable local health and safety regulations.

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

CAUTIONIncorrect transport of the pumpDamage to the shaft seal!

▷ For transport, lock the pump shaft with a suitable transport lock to prevent anymovement of the shaft.

When transporting the pump without motor, shaft 210 must be locked.

1. Undo screws 914.3.

2. Remove guards 680.3 and 680.4.

3. Insert lockwashers 931 into the shaft groove.

4. Tighten nuts 920.

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

Fig. 1: Transporting the pump without motor



1170:8

Fig. 2: Transporting the complete pump set

1170:9

Fig. 3: Transporting the motor with back pull-out unit

3.3 Storage/preservation

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

CAUTIONDamage during storage by humidity, dirt, or verminCorrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessorieswith waterproof material.

CAUTIONWet, contaminated or damaged openings and connectionsLeakage or damage to the pump set!

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

Store the pump (set) in a dry, protected room where the atmospheric humidity is asconstant 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 relevantinstructions. (⇨ Section 6.3.1 Page 28)

3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 33)

2. Always flush and clean the pump, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.



3. If the fluids handled by the pump (set) leave residues which might lead tocorrosion when coming into contact with atmospheric humidity, or which mightignite when coming into contact with oxygen, the pump set must be neutralised,and anhydrous inert gas must be blown through the pump for drying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set). (⇨ Section 11 Page 47)Always indicate any safety and decontamination measures taken.

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

3.5 Disposal

WARNINGFluids posing a health hazard and/or hot fluidsHazard to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any liquid residues.

▷ Wear safety clothing and a protective mask, if required.

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

1. Dismantle the pump (set).Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:- Metals- Plastics- Electronic waste- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another controlledmanner.



http://www.ksb.com/GRAS-Cert

4 Description of the Pump (Set)

4.1 General description

▪ Close-coupled pump with shaft seal

Pump for handling thermal oil or hot water

4.2 Designation

Example: Etabloc 80-160 / 150 2 S Y T

Table 5: Key to the designation

Code DescriptionEtabloc Type series80 Nominal discharge nozzle diameter [mm]160 Nominal impeller diameter [mm]150 Motor rating: kW x 10 (example 15 kW)2 Number of motor polesS Casing made of nodular cast ironY T Thermal oil/hot water variant

4.3 Name plate

991234567 000100 / 01Q 100 m3/h l H 9 m

1 mm2/s In 2900 U/min l 2008

AktiengesellschaftD-67227 Frankenthal

Id-No. 00 117 385 ZN 3804 - C 37 x 52

Etabloc SYT 80-160 / 150 2 SYT 1

2

5

4

3

9

8

76

Fig. 4: Etabloc SYT/Etaline SYT name plate (example)

1 Type series, size and version 2 KSB order number (ten digits)3 Flow rate 4 Speed5 Kinematic viscosity of the fluid

handled6 Order item number (six digits)

7 Consecutive number (two digits) 8 Head9 Year of construction

4.4 Design details

Design

▪ Volute casing pump

▪ Close-coupled design/in-line design

▪ Single-stage

▪ Horizontal/vertical installation

▪ Back pull-out design

▪ Ratings to EN 733

▪ Rigid connection between pump and motor



Pump cas ing

▪ Radially split volute casing

▪ Replaceable casing wear rings

▪ Volute casing with integrally cast pump feet

▪ In-line design

Impel ler type

▪ Closed radial impeller

Shaft seal

▪ Standardised mechanical seal to EN 12756

Bearings

▪ Grease-packed radial ball bearing

▪ Product-lubricated plain bearing

4.5 Configuration and function

1 2 53 4

6 7 8 9 10

Fig. 5: Etaline SYT sectional drawing

1 Clearance gap 2 Discharge nozzle3 Casing cover 4 Drive lantern5 Motor housing 6 Suction nozzle7 Impeller 8 Plain bearing9 Shaft seal 10 Stub shaft

The pump is designed with a radial fluid inlet (suction nozzle) and a radial outlet(discharge nozzle) arranged on the same axis. The hydraulic system is rigidlyconnected to the motor by a shaft coupling.

The fluid enters the pump via the suction nozzle (6) and is accelerated outward bythe rotating impeller (7). In the flow passage of the pump casing the kinetic energyof the fluid is converted into pressure energy. The fluid is pumped to the dischargenozzle (2), where it leaves the pump. The clearance gap (1) prevents any fluid fromflowing back from the casing to the suction nozzle. The hydraulic system is closedwith a casing cover (3) at the rear side of the impeller; the stub shaft (10) enters thecasing via the casing cover (3). The shaft passage through the cover is sealed to theatmosphere with a dynamic shaft seal (9). The stub shaft runs in a plain bearing (8)and the motor's rolling element bearings. The motor housing (5) is linked with thepump casing and the casing cover via the drive lantern (4).

The pump is sealed by a standardised mechanical seal.

Etabloc SYT

Etaline SYT

Design

Function

Sealing



4.6 Noise characteristics

Table 6: Surface sound pressure level LpA2) 3)

Rated power input PN[kW] Pump set1450 rpm

[dB]2900 rpm

[dB]0.55 55 -0.75 56 661.1 57 661.5 58 672.2 59 673 60 684 61 68

5.5 62 707.5 64 7111 65 7315 67 74

18.5 68 7522 69 76

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Pump

▪ Surface-cooled IEC three-phase current squirrel-cage motor

▪ Drive lantern guard to EN 294

4.8 Dimensions and weights

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

Drive

Contact guard

2) Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.80 - 1.1 range and for non-cavitating operation. If noise levels are to be warranted: Add +3 dB for measuring and constructional tolerance.

3) Increase for 60 Hz operation, 3500 rpm: +3 dB, 1750 rpm: +1 dB



5 Installation at Site

5.1 Safety regulations

DANGERImproper installation in potentially explosive atmospheresExplosion 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 andmotor.

5.2 Checks to be carried out prior to installation

Place of instal lat ion

WARNINGInstallation on mounting surface which is unsecured and cannot support the loadPersonal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets therequirements of exposure class XC1 to EN 206-1.

▷ The mounting surface must have set and must be completely horizontal andeven.

▷ Observe the weights indicated.

1. Check the structural requirements. All structural work required must have been prepared in accordance with thedimensions stated in the outline drawing/general arrangement drawing.

5.3 Installing the pump set

CAUTIONDry running / Ingress of leakage into the motorDamage to the pump!

▷ Never install the pump set with the "motor below".

1. Position the pump set on the foundation and fasten it.

2. Use a spirit level to align the pump set with the discharge nozzle.

5.4 Piping

5.4.1 Connecting the piping

DANGERExcessive loads acting on the pump nozzlesDanger 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 withouttransmitting any stresses or strains.

▷ Take appropriate measures to compensate thermal expansion of the piping.



CAUTIONIncorrect earthing during welding work at the pipingDestruction 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.

NOTEIt is recommended to install check and shut-off elements in the system, depending on thetype of plant and pump. However, such elements must not obstruct proper drainage orhinder disassembly of the pump.

✓ The suction lift line has been laid with a rising slope, the suction head line with adownward slope towards the pump.

✓ A flow stabilisation section having a length equivalent to at least twice thediameter of the suction flange has been provided upstream of the suction flange.

✓ The nominal diameters of the pipelines are at least equal to the nominaldiameters of the pump nozzles.

✓ Adapters to larger diameters have a diffuser angle of approx. 8° to preventexcessive pressure losses.

✓ The pipelines have been anchored in close proximity to the pump and connectedwithout transmitting any stresses or strains.

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections(especially of new installations).

2. Before installing the pump in the piping, remove the flange covers on the suctionand discharge nozzles of the pump.

CAUTIONWelding beads, scale and other impurities in the pipingDamage to the pump!

▷ Free the piping from any impurities.

▷ If necessary, install a filter.

▷ Comply with the instructions set out in (⇨ Section 7.2.2.2 Page 32) .

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

1

2Fig. 6: Filter in the piping

1 Differential pressure gauge 2 Filter

NOTEIt is recommended to install a fine filter made of corrosion-resistant material for the run-inphase of the system.Use a filter with a filter area three times the cross-section of the piping.Conical filters have proved suitable.



NOTEUse a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) ofcorrosion-resistant material.Use a filter with a filter area three times the cross-section of the piping.Conical filters have proved suitable.

1. Connect the pump nozzles to the piping.

CAUTIONAggressive flushing and pickling agentsDamage to the pump!

▷ Match the cleaning operation mode and duration for flushing and picklingservice to the casing and seal materials used.

5.4.2 Permissible forces and moments at the pump nozzles

No piping-induced forces and moments (from warped pipelines or thermalexpansion, for example) must act on the pump.

5.4.3 Auxiliary connections

CAUTIONFailure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing liquid,etc.)Malfunction of the pump!

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

▷ Use the auxiliary connections provided.

5.5 Protective equipment

DANGERExplosive atmosphere forming due to insufficient ventingExplosion hazard!

▷ Make sure the space between the casing cover/discharge cover and the motorflange is sufficiently vented.

▷ Do not cover the perforated holes of the contact guards at the drive lantern(e.g. by insulation).

WARNINGThe volute casing and casing/discharge cover take on the same temperature as the fluidhandledRisk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

CAUTIONHeat build-up inside the drive lanternDamage to the bearing!

▷ Never insulate the casing cover and the drive lantern.



5.6 Electrical connection

DANGERIncorrect electrical installationExplosion hazard!

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

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

DANGERWork on the pump set by unqualified personnelDanger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualifiedelectrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

1. Check the available mains voltage against the data on the motor name plate.

2. Select an appropriate start-up method.

NOTEIt is recommended to fit a motor protection device.

5.6.1 Setting the time relay

CAUTIONSwitchover between star and delta on three-phase motors with star-delta starting takestoo long.Damage to the pump (set)!

▷ Keep switch-over intervals between star and delta as short as possible.

Table 7: Time relay settings for star-delta starting:

Motor rating Y time to be set≤ 30 kW < 3 s> 30 kW < 5 s

5.6.2 Earthing

DANGERElectrostatic chargingExplosion hazard!Fire hazard!Damage to the pump set!

▷ Connect the PE conductor to the earthing terminal provided.



5.6.3 Connecting the motor

NOTEIn compliance with DIN VDE 0530 - Part 8, three-phase motors are always wired forclockwise rotation (looking at the motor shaft stub).The pump's direction of rotation is indicated by an arrow on the pump.

1. Match the motor's direction of rotation to that of the pump.

2. Observe the manufacturer's product literature supplied with the motor.

5.7 Checking the direction of rotation

DANGERTemperature increases resulting from contact between rotating and stationarycomponentsExplosion hazard!Damage to the pump set!

▷ Never check the direction of rotation by starting up the unfilled pump.

WARNINGHands or objects inside the pump casingRisk 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.

CAUTIONDrive and pump running in the wrong direction of rotationDamage to the pump!

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

▷ Check the direction of rotation. If required, check the electrical connection andcorrect the direction of rotation.

The correct direction of rotation of motor and pump is clockwise (seen from themotor end).

1. Start the pump set and stop it again immediately to determine the motor'sdirection of rotation.

2. Check the direction of rotation The motor's direction of rotation must match the arrow indicating the directionof rotation on the pump.

3. If the motor runs in the wrong direction of rotation, check the electricalconnection of the motor and the control system, if applicable.



6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the followingconditions are met:

▪ The pump set has been properly connected to the electric power supply and isequipped with all protection devices.

▪ The pump has been primed with the fluid to be handled.

▪ The direction of rotation has been checked. (⇨ Section 5.7 Page 23)

▪ 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 29) have been carried out.

▪ The lockwashers have been pulled out of the shaft groove.

6.1.2 Priming and venting the pump

DANGERFormation of an explosive atmosphere inside the pumpExplosion hazard!

▷ The pump internals in contact with the fluid to be handled, including the sealchamber and auxiliary systems must be filled with the fluid to be handled at alltimes.

▷ Provide sufficient inlet pressure.

▷ Provide an appropriate monitoring system.

DANGERShaft seal failure caused by dry runningHot or toxic fluid could escape!Damage to the pump!

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

NOTEIn the run-in phase of the system, it is recommended to vent the pump repeatedly via thescrew plug on the bearing bracket.

1. Vent the pump and suction line and prime both with the fluid to be handled.The pump can be primed with the fluid handled from the system via the inletline.Remove screw plug 903.1 to prime and vent the bearing housing.

2. Fully open the shut-off element in the suction line.

3. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc).

WARNINGHot water escaping under pressure when the vent plug is openedRisk of electric shock!Risk of scalding!

▷ Protect the electric components against escaping fluid.

▷ Wear protective clothing (e.g. gloves).



4. Close the vent hole (connection 6D or 6D.1/.2/.3) with screw plug 903.1 or 903.2(see table below).

Table 8: Installation of Etabloc SYT/Etaline SYT

Installation examples ConnectionsInstallation of Etabloc SYT

1170:2/2 1170:4/2

1M 6D

6B

8B

8B 1M 6B

6D

1M Connection for pressure gauge6B Fluid drain6D Fluid priming and venting8B Leakage drain

Installation of Etaline SYT

1170:3/21170:5/2

1M.16D.1

1M.26B.1 8B

6D.36D.3 8B

1M.26D.2

6B.2

1M.16D.1

1M.1/.2 Connection for pressure gauge6B1/.2. Fluid drain6D.1/.2/.3 Fluid priming and venting8B Leakage drain

6.1.3 Start-up

DANGERThe permissible pressure and temperature limits will be exceeded if the pump isoperated with the suction and discharge lines closed.Explosion hazard!Leakage of hot or toxic fluids!

▷ Never operate the pump with the shut-off elements in the suction line and/ordischarge line closed.

▷ Only start up the pump set with the discharge-side gate valve slightly or fullyopen.

DANGERExcessive temperatures due to dry running or excessive gas content in the fluid handledExplosion hazard!Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Prime the pump as specified.

▷ Always operate the pump within the permissible operating range.

CAUTIONAbnormal noises, vibrations, temperatures or leakageDamage to the pump!

▷ Switch off the pump (set) immediately.

▷ Eliminate the causes before returning the pump set to service.



✓ The system piping has been cleaned.

✓ The pump, suction line and inlet tank, if any, have been vented and primed withthe fluid to be handled.

✓ The filling and venting lines have been closed.

CAUTIONStart-up against open discharge lineMotor overload!

▷ Make sure the motor has sufficient power reserves.

▷ Use a soft starter.

▷ Use speed control.

1. Fully open the shut-off element in the suction head/suction lift line.

2. Close or slightly open the shut-off element in the discharge line.

3. Start up the motor.

4. Immediately after the pump has reached full rotational speed, slowly open theshut-off element in the discharge line and adjust it to the duty point.

6.1.4 Checking the shaft seal

The mechanical seal only leaks slightly or invisibly (as vapour) during operation.Mechanical seals are maintenance-free.

6.1.5 Shutdown

CAUTIONHeat build-up inside the pumpDamage to the shaft seal!

▷ Depending on the type of installation, the pump set requires sufficient after-runtime – with the heat source switched off – until the fluid handled has cooleddown.

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

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

2. Switch off the motor and make sure the pump set runs down smoothly to astandstill.

NOTEIf the discharge line is equipped with a non-return or check valve, the shut-off elementmay remain open.

For prolonged shutdown periods:

1. Close the shut-off element in the suction line.

2. Close the auxiliary connections. If the fluid handled is fed in under vacuum, also supply the shaft seal with barrierfluid during standstill.

CAUTIONRisk of freezing during prolonged pump shutdown periodsDamage to the pump!

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

Mechanical seal



6.2 Operating limits

DANGERNon-compliance with operating limits for pressure, temperature, fluid handled and speedExplosion hazard!Hot or toxic fluid could 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 datasheet or on the name plate unless the written consent of the manufacturer hasbeen obtained.

6.2.1 Ambient temperature

CAUTIONOperation outside the permissible ambient temperatureDamage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table 9: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °CMinimum See data sheet.

6.2.2 Frequency of starts

DANGERExcessive surface temperature of the motorExplosion hazard!Damage to the motor!

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

The frequency of starts is usually determined by the maximum temperature increaseof the motor. This largely depends on the power reserves of the motor in steady-state operation and on the starting conditions (d.o.l., star-delta, moments of inertia,etc). Provided that the start-ups are evenly spaced over the period indicated, thepump set can be started not more than 15 times per hour with the discharge-sidegate valve slightly open.

CAUTIONRe-starting while motor is still running downDamage to the pump (set)!

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

6.2.3 Fluid handled

6.2.3.1 Flow rate

Table 10: Flow rate

Minimum flow rate Maximum flow rate≈ 15 % of Qopt. 4) See hydraulic characteristic curves



The calculation formula below can be used to check if an additional heat build-upcould lead to a dangerous temperature increase at the pump surface.

Table 11: Key

Symbol Description Unitc Specific heat capacity J/kg Kg Gravitational constant m/s²H Pump head mTf Temperature of the fluid handled °C

To Temperature at the casing surface °C

Pump efficiency at duty point -Temperature difference °C

6.2.3.2 Density of the fluid handled

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

CAUTIONImpermissibly high density of the fluid handledMotor overload!

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

▷ Make sure the motor has sufficient power reserves.

6.2.3.3 Abrasive fluids

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

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains instal led

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

1. Start up the pump (set) regularly between once a month and once every threemonths for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pumpintake area.

The pump (set) i s removed from the pipe and stored

✓ The pump has been properly drained (⇨ Section 7.3 Page 33) and the safetyinstructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page33)

1. Spray-coat the inside wall of the pump casing, and in particular the impellerclearance areas, with a preservative.

2. Spray the preservative through the suction and discharge nozzles.It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).

4) Duty point at maximum efficiency



3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil orgrease, food-approved, if required) to protect them against corrosion.Observe the additional instructions. (⇨ Section 3.3 Page 14)

If the pump set is to be stored temporarily, only preserve the wetted componentsmade of low alloy materials. Commercially available preservatives can be used for thispurpose. Observe the manufacturer's instructions for application/removal.

Observe any additional instructions and information provided. (⇨ Section 3 Page 13)

6.4 Returning to service

For returning the pump to service observe the sections on commissioning/start-up (⇨Section 6.1 Page 24) and the operating limits. (⇨ Section 6.2 Page 27)

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. (⇨ Section 7 Page 30)

WARNINGFailure to re-install or re-activate protective devicesRisk of personal injury from moving parts or escaping fluid!

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

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



7 Servicing/Maintenance

7.1 Safety regulations

DANGERImproperly serviced pump setRisk of explosion!Damage to the pump set!

▷ Service the pump set regularly.

▷ Prepare a maintenance schedule with special emphasis on the shaft seal.

The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughly familiarwith the manual.

WARNINGUnintentional starting of pump setRisk of injury by moving parts!

▷ Make sure that the pump set cannot be started up unintentionally.

▷ Always make sure the electrical connections are disconnected before carryingout work on the pump set.

WARNINGFluids posing a health hazard and/or hot fluidsRisk of personal injury!

▷ Observe all relevant laws.

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

▷ Decontaminate pumps which handle fluids posing a health hazard.

WARNINGInsufficient stabilityRisk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to preventtipping or falling over.

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

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

Never use force when dismantling and reassembling the pump set.



https://shop.ksb.com/esales/contactfinder/contact.jsp?language=en&country=_C

https://shop.ksb.com/esales/contactfinder/contact.jsp?language=en&country=_C

7.2 Maintenance/inspection

7.2.1 Supervision of operation

DANGERFormation of an explosive atmosphere inside the pumpExplosion hazard!

▷ The pump internals in contact with the fluid to be handled, including the sealchamber and auxiliary systems must be filled with the fluid to be handled at alltimes.

▷ Provide sufficient inlet pressure.

▷ Provide an appropriate monitoring system.

DANGERIncorrectly serviced shaft sealExplosion hazard!Fire hazard!Leakage of hot, toxic fluids!Damage to the pump set!

▷ Regularly service the shaft seal.

DANGERExcessive temperatures as a result of bearings running hot or defective bearing sealsExplosion hazard!Fire hazard!Damage to the pump set!

▷ Regularly check the rolling element bearings for running noises.

CAUTIONIncreased wear due to dry runningDamage 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 duringpump operation.

CAUTIONImpermissibly high temperature of fluid handledDamage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted (heatingup of the fluid).

▷ Observe the temperature limits in the data sheet and in the section onoperating limits. (⇨ Section 6.2 Page 27)

While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.

▪ Check the shaft seal. (⇨ Section 6.1.4 Page 26)

▪ Check the static seals for leakage.

▪ Check the rolling element bearings for running noises.Vibrations, noise and an increase in current input occurring during unchangedoperating 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 uponce a week.

▪ Monitor the bearing temperature.The bearing temperature must not exceed 90 °C (measured at the motorhousing).

CAUTIONOperation outside the permissible bearing temperatureDamage to the pump!

▷ The bearing temperature of the pump (set) must never exceed 90 °C (measuredon the outside of the motor housing).

NOTEAfter commissioning, increased temperatures may occur at grease-lubricated rollingelement bearings due to the running-in process. The final bearing temperature is onlyreached after a certain period of operation (up to 48 hours depending on the conditions).

7.2.2 Inspection work

DANGERExcessive temperatures caused by friction, impact or frictional sparksExplosion hazard!Fire hazard!Damage to the pump set!

▷ Regularly check the cover plates, plastic components and other guards ofrotating parts for deformation and sufficient distance from rotating parts.

7.2.2.1 Checking the clearance gaps

For checking the clearance gaps remove the impeller, if required .If the clearance gap is larger than permitted (see the following table), fit new casingwear ring 502.1 and, if applicable, 502.2.The clearance gaps given refer to the diameter.

Table 12: Clearance gaps between impeller and casing / between impeller and casingcover

Etabloc SYT/Etaline SYTNew 0.3 mmMaximum permissible enlargement 0.9 mm

7.2.2.2 Cleaning filters

CAUTIONInsufficient inlet pressure due to clogged filter in the suction lineDamage to the pump!

▷ Monitor contamination of filter with suitable means (e.g. differential pressuregauge).

▷ Clean filter in appropriate intervals.

7.2.2.3 Checking the plain bearing clearances

The bearing clearance must not exceed the permissible maximum clearance (see thetable below).

If the permissible maximum clearance is exceeded, fit a new plain bearing 310.



Maximum clearance, plain bearing Nominal clearance, plain bearingSU 25 0.35 mm 0.08 - 0.13 mm

7.3 Drainage/cleaning

WARNINGFluids posing a health hazard and/or hot fluidsHazard to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any liquid residues.

▷ Wear safety clothing and a protective mask, if required.

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

1. Use connection 6B to drain the fluid handled (see drawing of auxiliaryconnections).

2. Always flush the pump if it has been used for handling noxious, explosive, hot orother hazardous fluids.Always flush and clean the pump before transporting it to the workshop. Providea cleaning record for the pump.

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

DANGERInsufficient preparation of work on the pump (set)Risk of injury!

▷ Properly shut down the pump set. (⇨ Section 6.1.5 Page 26)

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

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

▷ Close any auxiliary connections.

▷ Allow the pump set to cool down to ambient temperature.

WARNINGUnqualified personnel performing work on the pump (set)Risk of injury!

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

WARNINGHot surfaceRisk of injury!

▷ Allow the pump set to cool down to ambient temperature.

WARNINGImproper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, hoisting equipment and lifting tackle to moveheavy assemblies or components.



WARNINGThin metal foil used as carrier material in joint ringsRisk of injury (cuts)!

▷ Wear protective clothing.

▷ Always use an appropriate tool to remove joint rings.

Observe the general safety instructions and information (⇨ Section 7.1 Page 30) .

For any work on the motor, observe the instructions of the relevant motormanufacturer.

For dismantling and reassembly observe the exploded views and the generalassembly drawing .

In the event of damage you can always contact our service staff.

NOTEAfter a prolonged period of operation the individual components may be hard to pull offthe shaft. If this is the case, use a brand name penetrating agent and/or - if possible - anappropriate pull-off device.

NOTEIt is recommended to place a drip pan under the pump along its entire length to collectany fluid escaping during dismantling.

7.4.2 Preparing the pump set

1. Interrupt the power supply and secure the pump against unintentional start-up.

2. Reduce pressure in the piping by opening a consumer installation.

3. Disconnect and remove all auxiliary pipework.

7.4.3 Dismantling the motor

WARNINGMotor tipping overRisk 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 33) to (⇨ Section 7.4.2 Page34) have been observed/carried out.

1. Depending on the pump/motor size, unscrew the bolts that fix the motor foot tothe foundation.

2. Undo screws 914.3.

3. Remove guards 680.3 and 680.4.

4. Remove hexagon nuts 920.

5. Insert both lockwashers 931 into the groove in shaft 210 .

6. Tighten hexagon nuts 920.

7. Undo hexagon nut 920.7.

8. Remove the motor.



7.4.4 Removing the back pull-out unit

WARNINGBack pull-out unit tipping overRisk of squashing hands and feet!

▷ Suspend or support the back pull-out unit at the pump end.


1. If required, suspend or support the back pull-out unit to prevent it from tippingover.

2. Unbolt support foot (Etabloc SYT).

3. Unscrew hexagon nut 920.1 at the discharge cover.

4. Pull the back pull-out unit out of the volute casing.

5. Remove and dispose of gasket 411.4.

6. Place the back pull-out unit on a clean and level surface.

7.4.5 Removing the impeller


✓ The back pull-out unit is kept in a clean and level assembly area.

1. Undo impeller nut 920.3 (right-hand thread).

2. Remove impeller 230 with an impeller removal device.

3. Place impeller 230 on a clean and level surface.

4. Remove key 940.1 from shaft 210.

7.4.6 Removing the mechanical seal


✓ The back pull-out unit is kept in a clean and level assembly area.

1. Undo nuts 920.6.

2. Undo seal cover 471 and pull out of bearing housing 350 together with shaft 210.

3. Remove circlip 932.1 and disc 550.2.

4. Remove the rotating part of the mechanical seal (primary ring) from shaft 210.

5. Pull seal cover 471 off shaft 210.

6. Remove the stationary part of the mechanical seal (mating ring) from the sealcover.

7.4.7 Removing the plain bearing

1. Press plain bearing 310 out of bearing housing 350.



7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

WARNINGImproper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, hoisting equipment and lifting tackle to moveheavy assemblies or components.

CAUTIONImproper reassemblyDamage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of soundengineering practice.

▷ Use original spare parts only.

Always reassemble the pump in accordance with the corresponding general assemblydrawing 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 oldones.

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.

Never use quick-setting adhesives (cyanoacrylate adhesives).

Coat the locating surfaces of the individual components with graphite or similarbefore reassembly.

For reassembly, tighten all screws and bolts as specified in this manual.

7.5.2 Fitting the plain bearing

1. Press plain bearing 310 carefully into bearing housing 350 until it will not go anyfurther.

7.5.3 Installing the mechanical seal

The following rules must be observed when installing the mechanical seal:

▪ Work cleanly and accurately.

▪ Only remove the protective wrapping of the contact faces immediately beforeinstallation takes place.

▪ Prevent any damage to the sealing surfaces or O-rings.

✓ The notes and steps stated in (⇨ Section 7.5.1 ) have been observed/carried out.

✓ 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 the shaft and the mating ring holder and gently remove any deposits.

Sequence

Sealing elements

Assembly adhesives

Tightening torques

Installing the mechanicalseal



CAUTIONElastomers in contact with oil/greaseShaft seal failure!

▷ Use water as assembly lubricant.

▷ Never use oil or grease as assembly lubricant.

2. Carefully insert the mating ring into seal cover 471.Make sure to apply pressure evenly.

3. Slip the seal cover onto shaft 210. Secure shaft axially using a suitable device.

4. Slide the rotating assembly of the mechanical seal (primary ring) onto the shaft.Slip on disc 550.2 and secure with circlip 932.1.

5. Push shaft 210 into bearing housing 350 and tighten nuts 920.6.

7.5.4 Fitting the impeller


✓ The pre-assembled unit (motor, shaft, drive lantern, discharge cover) as well asthe individual parts are kept in a clean and level assembly area.

✓ All disassembled parts have been cleaned and checked for wear.



1. Insert key 940.1 and push impeller 230 onto shaft 210.

2. Fasten impeller nut 920.3, spring washer 930 and disc 550.3 (see table: Tighteningtorques for screwed connections on the pump).

7.5.5 Installing the back pull-out unit

WARNINGBack pull-out unit tipping overRisk of squashing hands and feet!

▷ Suspend or support the back pull-out unit at the pump end.




1. If required, suspend or support the back pull-out unit to prevent it from tippingover.

2. Fit new gasket 411.4 into the recess of volute casing 102.

3. Push the back pull-out unit into volute casing 102.

4. Depending on the pump size and motor size, fit support foot 183.

5. Fasten hexagon nut 920.1 at volute casing 102.

7.5.6 Mounting the motor

DANGERIncorrect shaft connectionExplosion hazard!

▷ Connect the shafts between pump and motor as described in this manual.



54

1 2 3

6

1167:455/4

Fig. 7: Fitting the motor shaft stub on the shaft

1 Shaft slot 2 Keyway of the motor shaft end3 Slot of the taper lock ring 4 Taper lock ring5 Motor shaft 6 Shaft


1. Fit the motor shaft stub on shaft 210 and make sure that the keyway of themotor shaft end aligns with the slot in shaft 210 and that both are locatedopposite the slot of taper lock ring 515 (see illustration: Fitting the motor shaftstub on the shaft).

2. Tighten hexagon socket head cap screws 914.1.

3. Remove hexagon nuts 920.

902 920

931

Fig. 8: Removing the lockwashers

902 Studs 920 Hexagon nuts931 Lockwasher

1. Pull both lockwashers 931 out of the groove in shaft 210.

2. Tighten hexagon nuts 920.

3. Fit guards 680.3 and 680.4.



7.6 Tightening torquesA X F E

AXB EFig. 9: Tightening points at the pump

Table 13: Tightening torques for screwed connections at the pump

Position Thread size Rated torque

[Nm]A M8

M10

M12

20

38

55B M12 x 1.5

M24 x 1.5

M30 x 1.5

55

130

170C M8

M10

20

38D M12 125E M8

M10

M12

M16

20

38

55

130F M6

M8

M10

M12

15

38

38

55X 1/8

1/4

3/8

1/2

3/4

25

55

80

130

220

7.7 Spare parts stock

7.7.1 Ordering spare parts

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 16)

Also supply the following data:

▪ Description

▪ Part No.

▪ Quantity of spare parts

▪ Shipping address

▪ Mode of dispatch (freight, mail, express freight, air freight)

Refer to the exploded view or general assembly drawing for part numbers anddescriptions. (⇨ Section 9.1 Page 44)

7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296

Table 14: Quantity of spare parts for recommended spare parts stock

Part No. Description Number of pumps (including stand-by pumps)2 3 4 5 6 and 7 8 and 9 10 and more

Quantity of spare parts210 Shaft 5) 1 1 2 2 2 3 30 %230 Impeller (including casing wear ring

502.2)1 1 1 2 2 3 30 %

310 Plain bearing 2 3 4 5 7 9 100 %350 Bearing housing 6) - - - - - 1 2 off433 Mechanical seal 2 3 4 5 6 7 90 %502.1/.2 Casing wear ring 1 1 2 2 2 3 25 %- Joint ring (set) 7) 4 6 8 8 9 12 150 %

5) Shaft 210 complete, consisting of shaft 210, taper lock ring 515, hexagon nut 920.3, key 940.16) Bearing housing 350 complete, consisting of plain bearing 310, bearing housing 350, joint ring 411.1, screw plug 903.17) Joint rings (set) consisting of joint ring 411.1-.5



7.7.3 Interchangeability of Etabloc SYT/Etaline SYT pump components

Components featuring the same number in a column are interchangeable.

Etabloc SYT Etaline SYT

Shaf

t u

nit

Description

Vo

lute

cas

ing

Dis

char

ge

cove

r

Shaft (with taper lock ring)

Imp

elle

r

Plai

n b

eari

ng

Bea

rin

g h

ou

sin

g

Mec

han

ical

sea

l

Seal

co

ver

Cas

ing

wea

r ri

ng

(su

ctio

n s

ide)

Cas

ing

wea

r ri

ng

(d

isch

arg

e si

de)

Part No.

102

163 210

230

310

350

433

471

502.

1

502.

2

Motor 80 90 100/112 132 160 180 32-125.1/... 25 ○ 1 2 3 ⃞ ￭￭￭ ○ 1 1 1 1 1 x32-160.1/... 40-160/... 25 ○ 2 ⃞ 3 4 ⃞ ⃞ ⃞ 1 1 1 1 1 1 232-200.1/... 40-200/... 25 ○ 4 2 ⃞ 4 5 ⃞ ⃞ 2 1 1 1 1 1 232-160/... 50-160/... 25 ○ 2 2 ⃞ 4 5 ⃞ ⃞ 1 1 1 1 1 1 232-200/... 50-200/... 25 ○ 4 2 3 ⃞ 5 ⃞ ⃞ 2 1 1 1 1 1 240-160/... 65-160/... 25 ○ 2 2 3 4 5 ⃞ ⃞ ○ 1 1 1 1 ○ 240-200/... 65-200/... 25 ○ 4 2 3 ⃞ 5 6 ⃞ ○ 1 1 1 1 ○ 250-160/... 80-160/... 25 ○ 2 ⃞ 3 ⃞ 5 6 ⃞ ○ 1 1 1 1 2 250-200/... 80-200/... 25 ○ 4 ⃞ 3 4 ⃞ 6 7 ○ 1 1 1 1 2 265-160/... 100-160/... 25 ○ 3 ⃞ 3 4 ⃞ 6 ⃞ ○ 1 1 1 1 3 465-200/... 25 ○ ○ ⃞ ⃞ 4 ⃞ 6 7 ○ 1 1 1 1 3 480-160/... 100-170/... 25 ○ 3 ⃞ 3 4 ⃞ 6 7 ○ 1 1 1 1 ○ 4

Table 15: Key to the symbols

Symbol Descriptionx Component not fitted○ Components differ1 Same number in a column means same component⃞ When other frequencies or power reserves are required for this

pump/motor combination, please contact KSB.￭ This pump/motor combination is not possible Components interchangeable with Etabloc

Table 16: Motor/rating

Motor Rating80 .../054, .../074, .../072, .../11290 .../114, .../154, .../152, .../222

100 .../224, .../304, .../302112 .../404, .../402132 .../554, .../754, .../552, .../752160 .../1104, .../1504, .../1102, .../1502, .../1852180 .../1854, .../2204, .../2202



8 Trouble-shootingPump delivers insufficient flow rate

Motor is overloaded

Excessive pump discharge pressure

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Impermissible rise of temperature inside the pump

Table 17: Trouble-shooting

A B C D E F G H Possible cause Remedy 8)

X Pump delivers against an excessivelyhigh pressure

Re-adjust to duty point.

Check system for impurities.Fit a larger impeller. 9)

X X X Pump and/or piping are not completelyvented and/or primed.

Vent and/or prime.Clean vent hole.

X Suction line or impeller clogged. Remove deposits in the pump and/or piping.X Formation of air pockets in the piping Alter piping layout.

Fit vent valve.X X X Suction lift is too high/NPSH available

(positive suction head) is too low.Check/alter fluid level.Install pump at a lower level.Fully open the shut-off element in the suctionline.Change suction line, if the friction losses inthe suction line are too high.Check any strainers installed.Observe permissible speed of pressure fall.

X Wrong direction of rotation Interchange two phases of the power supply.X X Wear of internal pump parts Replace worn parts by new ones. X X X Pump back pressure is lower than

specified in the purchase order.Adjust duty point accurately. In the case of persistent overloading, turndown impeller. 9)

X Density or viscosity of fluid handledhigher than stated in purchase order

9)

X Defective seal Fit new seal between volute casing anddischarge cover.

X Worn shaft seal Replace shaft seal. X X X Pump warped or sympathetic vibrations

in the pipingCheck the piping connections and securefixing of pump; if required, reduce distancesbetween the pipe clamps.Fix the pipelines using anti-vibration material.

X X Motor is running on two phases only. Replace the defective fuse.Check the electric cable connections.

X Rotor out of balance Clean the impeller.Re-balance the impeller.

X Defective bearing Fit new bearing. X X Flow rate is too low. Increase minimum flow rate.

A

B

C

D

E

F

G

8) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.9) Contact KSB.

8 Trouble-shooting


A B C D E F G H Possible cause Remedy 8)

X Defective seal Fit new seal between volute casing anddischarge cover or between discharge coverand bearing bracket.

X Joint ring not pre-loaded sufficiently Increase pre-loading of the joint ring atoperating temperature:

1. Close the valves on the discharge andsuction side.

2. Allow the pump set to cool down to atemperature below the boiling point ofthe fluid handled.

3. Re-tighten hexagon nuts 920.1 at thedischarge cover.

4. Start up the pump set. (⇨ Section 6 Page24)

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

8 Trouble-shooting


9 Related Documents

9.1 Exploded views and list of components

9.1.1 Etabloc SYT exploded view

UG1279174:001/2

Fig. 10: Etabloc SYT exploded view

[ Supplied in packaging units only( ) Not available as individual spare part

Table 18: List of components

Part No. Description Part No. Description102 Volute casing 720.1/.2 Special part163 Discharge cover 732.1 Holder183 Support foot 800 Motor210 Shaft 831 Fan impeller230 Impeller 901.3/.4 Hexagon head bolt310 Plain bearing 902.1-.4 Stud341 Drive lantern 903.1/.2 Screw plug350 Bearing housing 914.1/.2 Socket head cap screw411.1-.5 Joint ring 914.3 Pan head screw433 Mechanical seal 920.1-.3/.5-.8 Hexagon nut471 Seal cover 920.4 Blind rivet nut502.1./.2 Casing wear ring 930 Spring washer515 Taper lock ring 931 Lockwasher550.2/.3/.5 Disc 932.1 Circlip554 Lockwasher 940.1 Key680.1-.4 Guard

9 Related Documents


9.1.2 Etaline SYT exploded view

UG1283814:001/2

Fig. 11: Etaline SYT exploded view

[ Supplied in packaging units only( ) Not available as individual spare part

Table 19: List of components

Part No. Description Part No. Description102 Volute casing 720.1/.2 Special pipe part163 Discharge cover 732.1 Holder210 Shaft 800 Motor230 Impeller 831 Fan impeller310 Plain bearing 902.1-.4 Stud341 Drive lantern 903.1/.2 Screw plug350 Bearing housing 914.1/.2 Socket head cap screw411.1/-.5 Joint ring 914.3 Pan head screw433 Mechanical seal 920.1-.3/.5-.7 Hexagon nut471 Seal cover 920.4 Blind rivet nut502.1/.2 Casing wear ring 930 Spring washer515 Taper lock ring 931 Lockwasher550.2/.3/.5 Disc 932.1 Circlip554 Lockwasher 940.1 Key680.1-.4 Guard

9 Related Documents


10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Etabloc, Etabloc SYT, Etaline, Etaline SYT, Etaline Z,Etachrom NC, Etachrom BC, Etanorm, Etanorm SYT,

Etanorm GPV/CPV, Etaprime L, Etaprime B/BN, Vitachrom

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

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Pump (set): Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100,

– EN 809/A1

Person authorised to compile the technical file: Name

Function Address (company)Address (Street, No.)Address (post or ZIP code, city)

The EC Declaration of Conformity was issued in/on:

Place, date

..............................10) .............................

Name

FunctionCompanyAddress

Address

10) A signed, legally binding declaration of conformity is supplied with the product.

10 EC Declaration of Conformity


11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number11) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled11) : ................................................................................................................................

Please tick where applicable11) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return11) : ................................................................................................................................ Comments: ................................................................................................................................ ................................................................................................................................ The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal.

On seal-less 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 withthe relevant legal provisions.

.................................................................... ....................................................... .......................................................Place, date and signature Address Company stamp

11) Required fields

11 Certificate of Decontamination


Index

AAbrasive fluids 28

BBearing temperature 32

CCertificate of Decontamination 47Clearance gaps 32Commissioning/start-up 24

DDesign 16Designation 16Direction of rotation 23Dismantling 34Disposal 15

EExplosion protection 11, 19, 21, 22, 23, 24, 25, 27, 30,31, 32, 37

FFilter 32Frequency of starts 27

IInstallation

Installation on foundation 19Installation at site 19Intended use 8Interchangeability of pump components 41

MMechanical seal 26Misuse 9Monitoring equipment 12

NNoise characteristics 18

OOperating limits 8, 27Order number 6Ordering spare parts 39Other applicable documents 6

PPartly completed machinery 6Permissible forces at the pump nozzles 21Piping 20Preservation 14, 29Priming and venting 24Product description 16

RReassembly 34, 36Return to supplier 14Returning to service 29

SSafety 8Safety awareness 9Scope of supply 18Servicing/Maintenance 30Shaft seal 17Shutdown 29Spare parts stock 40Start-up 26Storage 14, 29

TTemperature limits 11Tightening torques 39Transport 13Trouble-shooting 42

Index


KSB Aktiengesellschaft67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)Tel. +49 6233 86-0 • Fax +49 6233 86-3401www.ksb.com

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-EN