thermoil heater etanorm, pump

Thermal Oil / Hot Water Pump

Etanorm SYT

Installation/OperatingManual

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Legal information/Copyright

Installation/Operating Manual Etanorm SYT

Original operating manual

KSB Aktiengesellschaft

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited orprocessed for any other purpose, nor otherwise transmitted, published or made available to a third party withoutKSB's express written consent.

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft Frankenthal 07.02.2013

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 ............................................................................................................................ 6

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

2 Safety .....................................................................................................7

2.1 Key to safety symbols/markings ....................................................................... 7

2.2 General .............................................................................................................. 7

2.3 Intended use .....................................................................................................7

2.4 Personnel qualification and training ............................................................... 8

2.5 Consequences and risks caused by non-compliance with these operatinginstructions ........................................................................................................ 8

2.6 Safety awareness ..............................................................................................8

2.7 Safety information for the operator/user ....................................................... 9

2.8 Safety information for maintenance, inspection and installation work ....... 9

2.9 Unauthorised modes of operation .................................................................. 9

2.10 Explosion protection ........................................................................................ 9

3 Transport/Temporary Storage/Disposal .............................................12

3.1 Checking the condition upon delivery .......................................................... 12

3.2 Transport ......................................................................................................... 12

3.3 Storage/preservation ...................................................................................... 13

3.4 Return to supplier ........................................................................................... 13

3.5 Disposal ...........................................................................................................14

4 Description of the Pump (Set) ............................................................15

4.1 General description ........................................................................................ 15

4.2 Product Information as per Regulation No. 547/2012 (for Water Pumps witha Maximum Shaft Power of 150 kW) Implementing "Ecodesign" Directive2009/125/EC ..................................................................................................... 15

4.3 Designation ..................................................................................................... 15

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

4.5 Design details .................................................................................................. 16

4.6 Configuration and function ........................................................................... 17

4.7 Noise characteristics .......................................................................................18

4.8 Scope of supply ............................................................................................... 18

4.9 Dimensions and weights ................................................................................19

5 Installation at Site ...............................................................................20

5.1 Safety regulations ........................................................................................... 20

5.2 Checks to be carried out prior to installation ............................................... 20

Contents

Etanorm SYT 3 of 66

5.3 Installing the pump set .................................................................................. 20

5.4 Piping .............................................................................................................. 22

5.5 Enclosure/insulation .......................................................................................26

5.6 Checking the coupling alignment ................................................................. 26

5.7 Aligning the pump and motor ...................................................................... 27

5.8 Electrical connection ...................................................................................... 29

5.9 Checking the direction of rotation ................................................................ 30

6 Commissioning/Start-up/Shutdown ...................................................31

6.1 Commissioning/start-up ................................................................................. 31

6.2 Operating limits .............................................................................................. 34

6.3 Shutdown/storage/preservation .................................................................... 36

6.4 Returning to service .......................................................................................37

7 Servicing/Maintenance .......................................................................38

7.1 Safety regulations ........................................................................................... 38

7.2 Maintenance/inspection ................................................................................. 39

7.3 Drainage/cleaning ..........................................................................................42

7.4 Dismantling the pump set .............................................................................. 42

7.5 Reassembling the pump set ........................................................................... 46

7.6 Tightening torques ......................................................................................... 49

7.7 Spare parts stock ............................................................................................. 50

8 Trouble-shooting ................................................................................54

9 Related Documents ............................................................................56

9.1 Exploded views and lists of components ...................................................... 56

9.2 Wiring diagrams for double mechanical seal ............................................... 62

10 EC Declaration of Conformity ...........................................................63

11 Certificate of Decontamination .........................................................64

Index ....................................................................................................65

Contents

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Glossary

Back pull-out design

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

Back pull-out unit

Pump without pump casing; partly completedmachinery

Certificate of decontamination

A certificate of decontamination is enclosed bythe customer when returning the product tothe manufacturer to certify that the producthas been properly drained to eliminate anyenvironmental and health hazards arising fromcomponents in contact with the fluid handled.

Discharge line

The line which is connected to the dischargenozzle

Hydraulic system

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

Pool of pumps

Pumps which are purchased and storedindependently of their later use

Pump

Machine without drive, additional componentsor accessories

Pump set

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

Suction lift line/suction head line

The line which is connected to the suctionnozzle

Glossary

Etanorm SYT 5 of 66

1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variantsindicated on the front cover. The manual describes the proper and safe use of thisequipment in all phases 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 numberuniquely identify the pump (set) and serve as identification for all further businessprocesses.

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

Noise characteristics (⇨ Section 4.7 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 48)

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist technicalpersonnel.(⇨ Section 2.4 Page 8)

1.4

1.5 Symbols

Table 1: 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-references1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

6 of 66 Etanorm SYT

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

2.1 Key to safety symbols/markings

Table 2: 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 information aboutprotection 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 specialist personnel/operators responsible 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 nottaken 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.

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

! DANGER

2 Safety

Etanorm SYT 7 of 66

▪ 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 transport, install, operate, maintainand inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved intransport, installation, operation, maintenance and inspection must be clearlydefined by the operator.

Deficits in knowledge must be rectified by means of training and instructionprovided by sufficiently trained specialist personnel. If required, the operator cancommission the manufacturer/supplier to train the personnel.

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

▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2 Safety

8 of 66 Etanorm SYT

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 6.1.7 Page 34)(⇨ Section 6.3 Page 36)

▪ Decontaminate pumps which handle fluids posing a health hazard.(⇨ Section 7.3Page 42)

▪ 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 31)

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 7)

2.10 Explosion protection

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

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 Page 10) to(⇨ Section 2.10.4 Page 11) (⇨ Section2.10.3 Page 10). The explosion-proof status of the pump set is only assured if the pump set is used inaccordance with its intended use.

! DANGER

2 Safety

Etanorm SYT 9 of 66

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 )The motor must be considered separately.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected at thesurface 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 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 3: Temperature limits

Temperature class to EN 13463-1 Maximum permissible fluidtemperature

T1 Temperature limit of the pumpT2 280 ℃T3 185 ℃T4 120 ℃T5 85 ℃T6 Only after consultation

with the manufacturer

In the following cases, and if ambient temperatures are higher, contact themanufacturer.

Compliance with temperature class T5 is warranted for the area of the rollingelement bearings based on an ambient temperature of 40°C, assuming that thepump set is properly serviced and operated and that the surfaces in the bearing areaare freely exposed to the atmosphere.

If temperature class T6 has to be complied with, special measures may have to betaken with regard to the bearing temperatures.

Misuse, malfunctions or non-compliance with the instructions may result insubstantially higher temperatures.

If the pump is to be operated at a higher temperature, if there is no data sheet or ifthe pump is part of a pool of pumps, contact KSB for the maximum permissibleoperating temperature.

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.

Pump

Motor

Temperature class T5

Temperature class T6

2 Safety

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2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.2.3.1 Page 35) refer to water and water-like fluids. Longer operating periods with these fluids and at the flow rates indicatedwill not cause an additional increase in the temperatures at the pump surface.However, if the physical properties of the fluids handled are different from water, itis essential to check whether an additional heat build-up may occur and if theminimum flow rate must therefore be increased. The calculation formula in(⇨ Section6.2.3.1 Page 35) can be used to check whether an additional heat build-up may leadto a hazardous temperature increase at the pump surface.

2 Safety

Etanorm SYT 11 of 66

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 or the supplying dealer (as applicable) and the insurer about thedamage in writing immediately.

3.2 Transport

DANGER

The 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.

To transport the pump/pump set or back pull-out unit suspend it from the liftingtackle as shown below.

Fig. 1: Transporting the back pull-out unit

Fig. 2: Transporting the pump



≤ 90 °

Fig. 3: Transporting the complete pump set

≤ 90 °

Fig. 4: Transporting the pump on the baseplate

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 instructionsin(⇨ Section 6.3.1 Page 36) .

3.4 Return to supplier

1. Drain the pump as per operating instructions.(⇨ Section 7.3 Page 42)2. Always flush and clean the pump, particularly if it has been used for handling

noxious, explosive, hot or other hazardous fluids.



3. If the fluids handled by the pump set leave residues which might lead tocorrosion damage when coming into contact with atmospheric humidity, orwhich might ignite when coming into contact with oxygen, the pump set mustalso be neutralised, and anhydrous inert gas must be blown through the pumpfor drying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set).Always indicate any safety and decontamination measures taken.(⇨ Section 11Page 64)

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

3.5 Disposal

WARNINGFluids, consumables and supplies which are hot or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ 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 anothercontrolled manner.



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

4 Description of the Pump (Set)

4.1 General description

Pump for handling fluids in heat transfer systems (DIN 4754) or for hot watercirculation

4.2 Product Information as per Regulation No. 547/2012 (for Water Pumpswith a Maximum Shaft Power of 150 kW) Implementing "Ecodesign"Directive 2009/125/EC

▪ This product is designed for use above 120 °C only.

▪ Further technical data see data sheet.

4.3 DesignationExample: Etanorm SYT 80 - 160 SYT8

Table 4: Key to the designation

Code DescriptionEtanorm Type seriesS Casing material

S Nodular cast ironYT Thermal oil/hot water version80 Nominal discharge nozzle diameter [mm]160 Nominal impeller diameter [mm]SYT8 Seal code, mechanical seal

SYT8 AQ1VGG

4.4 Name plate

Etanorm SYT 80-250 SYT89970857065 000100 / 01Q 160 m3/h l H 77 m

16.5 mm2/sn 2970 1/min l 2009

AktiengesellschaftD-67227 Frankenthal

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

1

2

5

4

3

9

8

76

Fig. 5: Name plate Etanorm SYT (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 Head

9 Year of construction



4.5 Design detailsDesign

▪ Volute casing pump

▪ Back pull-out design

▪ Horizontal installation

▪ Single-stage

▪ Dimensions and ratings to EN 733

Pump casing

▪ Radially split volute casing

▪ Replaceable casing wear rings

▪ Volute casing with integrally cast pump feet

Impeller type

▪ Closed radial impeller with multiply curved vanes

Bearings

Motor-end bearing:

▪ Radial ball bearing

▪ Grease lubrication

▪ Rolling element bearing

Shaft unit Code25 6306-2RS/C3 PCP-LLG35 6309-2RS/C3 PCP-LLG55 6311-2RS/C3 PCP-LLG

▪ Grease-packed for life (high melting point grease)

Pump-end bearing:

▪ Plain bearings

▪ Product-lubricated

Shaft seal

▪ Standardised mechanical seal to EN 12756

▪ Double mechanical seal (optional)



4.6 Configuration and function

1 2 3 4 5

6 7 8 9 10

Fig. 6: Sectional drawing

1 Clearance gap 2 Discharge nozzle3 Casing cover 4 Shaft5 Bearing bracket 6 Suction nozzle7 Impeller 8 Plain bearing9 Shaft seal 10 Rolling element bearing, motor

end

The pump is designed with an axial fluid inlet and a radial outlet. The hydraulicsystem runs in its own bearings and is connected to the motor by a shaft coupling.

The fluid enters the pump axially via the suction nozzle (6) and is acceleratedoutward by the rotating impeller (7). In the flow passage of the pump casing thekinetic energy of the fluid is converted into pressure energy. The fluid is pumped tothe discharge nozzle (2), where it leaves the pump. The clearance gap (1) preventsany fluid from flowing back from the casing to the suction nozzle. At the rear side ofthe impeller, the shaft (4) enters the casing via the casing cover (3). The shaft passagethrough the bearing bracket is sealed towards the atmosphere with a shaft seal (9).The shaft runs in a plain bearing and a rolling element bearing (8 and 10); thebearings are supported by a bearing bracket (5) linked with the pump casing and/orcasing cover.

The pump is sealed by a standardised mechanical seal.If the pump is fitted with a double mechanical seal, the pump is connected to aquench pot. The unpressurised quench liquid supply serves to prevent any leakage ofthe fluid handled towards the atmosphere. It also prevents any contact between thefluid and the lubricating grease of the rolling element bearing, especially for fluidswhich have a tendency to creep.

Design

Function

Sealing



4.7 Noise characteristics

Table 5: Sound pressure level measured at surfaces LpA1)2)

Rated powerinput

PN

[kW]

Pump Pump set

1450 rpm [dB]

2900 rpm[dB]

1450 rpm[dB]

2900 rpm[dB]

0.55 47 48 55 640.75 48 50 56 661.1 50 52 57 661.5 52 54 58 672.2 54 56 59 673 55 57 60 684 57 59 61 68

5.5 59 61 62 707.5 60 62 64 7111 62 64 65 7315 64 66 67 74

18.5 65 67 68 7522 66 68 69 7630 67 70 70 7737 68 71 71 7845 69 72 73 7855 70 73 74 7975 72 75 75 8090 73 76 76 81

110 74 77 77 81

4.8 Scope of supply

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

▪ Pump

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

CAUTIONExcessive temperature due to insufficient coolingDamage to the pump set!

▷ Only use electric motors whose cooling air flows in axial direction towards thepump end.

▷ Ensure an air velocity ≥ 3 m/s measured in the area of the bearing end plate onthe drive side.

▷ If the pump is driven by a combustion engine, only use engines whose coolingair is sucked in or blown out via the coupling/flywheel.

▪ Flexible coupling with or without spacer

▪ Coupling guard

Drive

Shaft coupling

Contact guard

1) Spatial average to ISO 3744 and EN 12639. Applies to non-cavitating pump operation in the range Q/Qopt = 0.8 - 1.1. Ifnoise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.

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



DANGER

Risk of ignition by frictional sparksRisk of explosion!

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

▷ If any coupling parts are made of aluminium, a brass coupling guard must beused.

▪ Channel section steel or folded steel plate

Optional:

▪ Cast baseplate (to ISO 3661)

▪ As required

4.9 Dimensions and weights

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

Baseplate

Special accessories



5 Installation at Site

5.1 Safety regulations

DANGER

Improper 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 installationPlace of installation

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

Always install the pump set in horizontal position.

DANGER

Excessive temperatures due to improper installationExplosion hazard!

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

5.3.1 Installation on the foundation

L1

32

Fig. 7: Fitting the shims

L Bolt-to-bolt distance 1 Shim2 Shim if (L) > 800 mm 3 Foundation bolt

✓ The foundation has the required strength and characteristics.



✓ The foundation has been prepared in accordance with the dimensions given inthe outline drawing/general arrangement drawing.

1. Position the pump set on the foundation and level it with the help of a spiritlevel placed on the shaft and discharge nozzle.Permissible deviation 0.2 mm/m.

2. Use shims (2) for height compensation, if necessary. Always fit shims, if any, immediately to the left and right of the foundationbolts (3) between the baseplate/foundation frame and the foundation.For a bolt-to-bolt distance (L) > 800 mm fit additional shims (2) halfwaybetween the bolt holes. All shims must lie perfectly flush.

3. Insert the foundation bolts (3) into the holes provided.

4. Use concrete to set the foundation bolts (3) into the foundation.

5. Wait until the concrete has set firmly, then level the baseplate.

6. Tighten the foundation bolts (3) evenly and firmly.

NOTEFor baseplates more than 400 mm wide it is recommended to grout the baseplatewith low-shrinkage concrete.

NOTEFor baseplates made of grey cast iron it is recommended to grout the baseplatewith low-shrinkage concrete.

NOTEFor low-noise operation contact KSB to check whether the pump set can beinstalled on anti-vibration mounts.

5.3.2 Installation without foundation

4

1

2

3

Fig. 8: Adjusting the levelling elements

1, 3 Locknut 2 Levelling nut4 Levelling element ✓ The installation surface has the required strength and characteristics.

1. Position the pump set on the levelling elements (4) and level it with the help ofa spirit level (on the shaft/discharge nozzle).

2. To adjust any differences in height, loosen the bolts and locknuts (1, 3) of thelevelling elements (4).



3. Turn the levelling nut (2) until any differences in height have beencompensated.

4. Re-tighten the locknuts (1, 3) at the levelling elements (4).

5.4 Piping

5.4.1 Connecting the piping

DANGER

Impermissible 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.

▷ Observe the permissible forces and moments at the pump nozzles.(⇨ Section5.4.2 Page 23)

▷ 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, dependingon the type of plant and pump. However, such elements must not obstruct properdrainage or hinder 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 thesuction and 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 7.2.2.3 Page 41).

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



1

2

Fig. 9: Filter in the piping

1 Differential pressure gauge 2 Filter

NOTEIt is recommended to install a fine filter made of corrosion-resistant material for therun-in phase 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 of 0.5 mm x 0.25 mm (mesh size x wire diameter)made of corrosion-resistant material.Use a filter with a filter area three times the cross-section of the piping.Conical filters have proved suitable.

4. 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

FV

FVmax

2FH

FHmax

2

Mtmax

Mt

2

+ + - 1

FV

FH

FH

FVFH

FH

Fig. 10: 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 loadsacting on the nozzles. Neither the load direction nor the load distribution among thenozzles are taken into account in these sums.



Table 6: Forces and moments at the pump nozzles3)

Size t = 20 °C t = 300 °C

FVmax

[kN]

FHmax

[kN]

Mtmax

[kNm]

FVmax

[kN]

FHmax

[kN]

Mtmax

[kNm]32-125.1 3.65 2.59 0.58 3.15 2.24 0.532-160.1 3.56 2.51 0.51 3.08 2.17 0.4432-200.1 3.6 2.43 0.51 3.11 2.10 0.4432-160 3.56 2.51 0.51 3.08 2.17 0.4432-200 3.65 2.43 0.51 3.11 2.10 0.4432-250 3.65 2.43 0.51 3.11 2.10 0.4440-160 3.81 2.67 0.81 3.29 2.31 0.740-200 3.81 2.67 0.81 3.29 2.31 0.740-250 4.21 2.92 0.58 3.64 2.52 0.540-315 4.09 2.84 0.55 3.54 2.46 0.4850-160 3.97 2.67 1.11 3.43 2.31 0.9650-200 4.21 2.92 1.11 3.64 2.52 0.9650-250 4.58 3.32 0.87 3.96 2.87 0.7550-315 4.54 3.24 0.84 3.92 2.80 0.7365-160 4.42 3.04 1.16 3.82 2.63 165-200 5.27 3.89 1.79 4.55 3.36 1.5565-250 5.27 3.89 1.79 4.55 3.36 1.5565-315 5.43 4.05 1.62 4.69 3.5 1.480-160 5.43 4.05 1.91 4.69 3.5 1.6580-200 6.08 4.74 2.44 5.25 4.1 2.180-250 6.16 4.78 2.44 5.32 4.13 2.180-315 6.28 4.86 2.78 5.43 4.20 2.4100-160 7.7 6.28 3.6 6.65 5.43 3.1100-200 7.7 6.28 3.6 6.65 5.43 3.1100-250 7.86 6.48 3.47 6.79 5.6 3100-315 7.57 6.16 3.18 6.54 5.32 2.75125-200 9.5 8.5 5.1 8.21 7.34 4.4125-250 9.84 8.71 5.1 8.5 7.53 4.4125-315 9.32 8.1 4.75 8.05 7 4.1125-400 9.32 7.9 4.63 7.97 6.83 4150-315 10.53 9.72 5.67 9.1 8.4 4.9150-400 10.53 9.72 5.67 9.1 8.4 4.9

5.4.3 Vacuum balance line

NOTEWhere fluid has to be pumped out of a vessel under vacuum, it is recommended toinstall 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.

3) The values indicated apply to nodular cast iron JS1025.



1 2

5

43

6

Fig. 11: Vacuum balance system

1 Vessel under vacuum 2 Vacuum balance line3 Shut-off element 4 Swing check valve5 Main shut-off element 6 Vacuum-tight shut-off element

NOTEAn additional line (from the pump discharge nozzle to the balance line) fitted witha shut-off element facilitates venting of the pump before start-up.

5.4.4 Auxiliary connections

WARNINGFailure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushingliquid, etc.)Risk of injury from escaping fluid!Risk of burns!Malfunction of the pump!

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

▷ Use the auxiliary connections provided.



Fig. 12: Connections 24E and 24A

24 A Outlet quench liquid 24 E Inlet quench liquid

For designs with double mechanical seal, use connections 24A and 24E to connect thepump set to the quench system.Connect the quench pot in accordance with the manufacturer's instructions.

5.5 Enclosure/insulation

DANGER

An explosive atmosphere could form due to insufficient ventingExplosion hazard!

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

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

▷ Insulate the volute casing.

▷ Fit protective equipment.

CAUTIONHeat build-up in the bearing bracketDamage to the bearing!

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

5.6 Checking the coupling alignment

DANGER

Inadmissible temperatures at the coupling or bearings due to misalignment of thecouplingExplosion hazard!Risk of burns!

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

Double mechanical seal



CAUTIONMisalignment of pump and motor shaftsDamage to pump, motor and coupling!

▷ Always check the coupling after the pump has been installed and connected tothe piping.

▷ Also check the coupling of pump sets supplied with pump and motor mountedon the same baseplate.

BA

A B

a) b)

B

B

A

A

1

1 2 21

1

Fig. 13: Checking the coupling alignment: Coupling without spacer sleeve (a) or Coupling with spacer sleeve (b)

1 Straight-edge 2 Gauge

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

1. Loosen the support foot and re-tighten it without transmitting any stresses andstrains.

2. Place the straight-edge axially on both coupling halves.

3. Leave the straight-edge in this position and turn the coupling by hand. The coupling is aligned correctly if the distances A and B to the respective shaftsare the same at all points around the circumference.The radial and axial deviation between the two coupling halves must notexceed 0.1 mm, during standstill as well as at operating temperature and underinlet pressure.

4. Check the distance (dimension see general arrangement drawing) between thetwo coupling halves around the circumference. The coupling is correctly aligned if the distance between the two couplinghalves is the same at all points around the circumference.The radial and axial deviation between the two coupling halves must notexceed 0.1 mm, during standstill as well as at operating temperature and underinlet pressure.

5. If alignment is correct, re-install the coupling guard and its footboard, if any.

5.7 Aligning the pump and motor

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



5.7.1 Motors with levelling screw

1

3

2

Fig. 14: Motor with levelling screw

1 Hexagon head bolt 2 Levelling screw3 Locknut

✓ The coupling guard and the footboard for the coupling guard, if any, have beenremoved.

1. Check the coupling alignment.

2. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at thebaseplate.

3. Turn the levelling screws (2) by hand or by means of an open-jawed wrenchuntil the coupling alignment is correct and all motor feet rest squarely on thebaseplate.

4. Re-tighten the hexagon head bolts (1) at the motor and the locknuts (3) at thebaseplate.

5. Check that the coupling and shaft can easily be rotated by hand.

WARNINGUnprotected rotating couplingRisk 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'sdelivery, then the operator must supply one!

▷ Observe all relevant regulations for selecting a coupling guard.

DANGER

Risk of ignition by frictional sparksExplosion hazard!


6. Re-install the coupling guard and the footboard for the coupling guard, if any.

7. Check the distance between coupling and coupling guard.The coupling and coupling guard must not come into contact.

5.7.2 Motors without levelling screw

Any differences in the centreline heights of the pump and motor shafts arecompensated by means of shims.



1

Fig. 15: Pump set with shim

1 Shim

✓ The coupling guard and the footboard for the coupling guard, if any, have beenremoved.

1. Check the coupling alignment.

2. Unscrew the hexagon head bolts at the motor.

3. Insert shims underneath the motor feet until the difference in shaft centrelineheight has been compensated.

4. Re-tighten the hexagon head bolts.


WARNINGUnprotected rotating couplingRisk 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'sdelivery, then the operator must supply one!

▷ Observe all relevant regulations for selecting a coupling guard.

DANGER

Risk of ignition by frictional sparksExplosion hazard!



7. Check the distance between coupling and coupling guard.The coupling and coupling guard must not come into contact.

5.8 Electrical connection

DANGER

Incorrect electrical installationExplosion hazard!

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

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

DANGER

Work 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.

NOTEA motor protection device is recommended.

5.9 Checking the direction of rotation

DANGER

Temperature increase 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 set.

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

WARNINGHands inside the pump casingRisk of injuries, damage to the pump!

▷ Always disconnect the pump set from the power supply and secure it againstunintentional start-up before inserting your hands or other objects into thepump.

CAUTIONIncorrect direction of rotation with non-reversible mechanical sealDamage to the mechanical seal and leakage!

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

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 the motor and pump is clockwise (seen from thedrive end).

1. Start the motor 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 is running in the wrong direction of rotation, check the electricalconnection of the motor and switchgear, if any.



6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

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 isequipped with all protection devices.

▪ The pump and the bearing bracket have been primed with the fluid to behandled.(⇨ Section 6.1.3 )

▪ The quench system, if any, has been filled with the quench liquid.(⇨ Section 6.1.2Page 31)

▪ The direction of rotation has been checked.(⇨ Section 5.9 Page 30)▪ All auxiliary connections required are connected and operational.

▪ The lubricants have been checked.(⇨ Section 7.2.3 Page 41)▪ After prolonged shutdown of the pump (set), the activities described in (⇨

Section 6.4 Page 37) have been carried out.

6.1.2 Quench liquid supply

The quench liquid has to be compatible with and suitable for mixing with the fluidhandled.

For synthetic heat transfer oils, it is advisable to use a mineral oil based thermal fluidor a different mineral oil as the quench liquid.Heat transfer oils of the diphyl group are not suitable for use as quench liquids.

6.1.3 Priming and venting the pump

DANGER

Risk of potentially explosive atmosphere inside the pumpExplosion hazard!

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

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.

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

1. Remove screw plug 903.1 (connection 6D) to prime and vent the bearinghousing.

2. 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.

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

Permissible quench liquids



4. Fully open all auxiliary feed lines (barrier fluid, flushing liquid, etc), ifapplicable.

5. Open the shut-off element, if any, in the vacuum balance line and close thevacuum-tight shut-off element, if any.(⇨ Section 5.4.3 Page 24)

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).

NOTEFor design-inherent reasons some unfilled volume in the hydraulic system cannot beexcluded after the pump has been primed for commissioning/start-up. However,once the motor is started up the pumping effect will immediately fill this volumewith the fluid handled.

6. Close the vent hole (connection 6D) with screw plug 903.1.

6.1.4 Final check

1. Remove the coupling guard and the footboard for the coupling guard, if any.

2. Check the coupling alignment; re-align the coupling if required.(⇨ Section 5.6Page 26)



5. Check the distance between the coupling and coupling guard.The coupling and coupling guard must not come into contact.

NOTEThe coupling alignment check must be repeated after the pump has reachedoperating temperature.

6.1.5 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits if the pump isoperated with the suction and/or discharge line 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 shut-off element slightly orfully open.



DANGER

Excessive temperatures due to dry running or excessive gas content in the fluidhandledExplosion hazard!Damage to the pump set!


▷ 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.

CAUTIONMisalignment of pump and couplingDamage to pump, motor and coupling!

▷ When the operating temperature has been reached, switch off the pump setand check the coupling alignment.

5. Check the coupling alignment and re-align the coupling, if required.

6.1.6 Checking the shaft seal

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

NOTEMechanical seal failure may result in the fluid handled penetrating into the rollingelement bearing, where it may damage the grease fill. Whenever fluid leakageoccurs, the rolling element bearing should therefore also be replaced as aprecaution. This is particularly important when the pump is handling synthetic heattransfer fluids.

Mechanical seal



6.1.7 Shutdown

CAUTIONHeat build-up inside the pumpDamage 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 hascooled down.

✓ 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-offelement in the discharge line may remain open, provided the site's requirementsand regulations are taken into account and observed.

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 withbarrier fluid 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.

6.2 Operating limits

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled andspeedExplosion hazard!Hot or toxic fluid could escape!

▷ Comply with the operating data indicated in the data sheet.

▷ Never use the pump for handling fluids it is not designed for.

▷ Avoid prolonged operation against a closed shut-off element.

▷ Never operate the pump at temperatures, pressures or rotational speedsexceeding those specified in the data sheet or on the name plate unless thewritten consent of the manufacturer has been obtained.

6.2.1 Ambient temperature

Observe the following parameters and values during operation:

Table 7: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °CMinimum See data sheet.



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

▷ Observe the specified limits for permissible ambient temperatures.

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

6.2.2 Frequency of starts

DANGER

Excessive 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 8: Flow rate

Temperature range (t) Minimum flow rate Maximum flow rate-30 to +350 °C ≈ 25 % of QOpt 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 9: Key

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



Symbol Description UnitTo Temperature at the casing surface °C

Pump efficiency at duty point -Temperature difference K

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, plain bearing and shaft seal are to be expected. In this case, reducethe intervals commonly recommended for servicing and maintenance.

6.2.4 Permissible speed

Table 10: Permissible speed for pump control systems with continuously variablespeed adjustment

nmin

[rpm]nmax

[rpm]800 -

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains installed

✓ 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) is removed and stored

✓ The pump has been properly drained (⇨ Section 7.3 Page 42) and the safetyinstructions for dismantling the pump have been observed.(⇨ Section 7.4.1 Page42)

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).

3. Oil or grease all exposed machined parts and surfaces of the pump (withsilicone-free oil or grease, food-approved, if required) to protect them againstcorrosion.Observe the additional instructions.(⇨ Section 3.3 Page 13)

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



Observe any additional instructions and information provided.(⇨ Section 3 Page 12)

6.4 Returning to service

For returning the pump to service observe the sections on commissioning/start-up (⇨Section 6.1 Page 31) and the operating limits.(⇨ Section 6.2 Page 34)In addition, carry out all servicing/maintenance operations before returning thepump (set) to service.(⇨ Section 7 Page 38)

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

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

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



7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Sparks produced during servicing workExplosion hazard!

▷ Observe the safety regulations in force at the place of installation!

▷ Always perform maintenance work on explosion-proof pump sets outsidepotentially explosive atmospheres.

DANGER

Improperly serviced pump setExplosion hazard!Damage to the pump set!

▷ Service the pump set regularly.

▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft sealand coupling.

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 and supplies posing a health hazard and/or hot fluids or suppliesRisk of 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 orauthorised workshops. Find your contact in the attached "Addresses" booklet or onthe 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

7.2 Maintenance/inspection

7.2.1 Supervision of operation

DANGER

Risk of potentially 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.

DANGER

Excessive 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 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(heating up of the fluid).

▷ Observe the temperature limits in the data sheet and in the section onoperating 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.

▪ Check the shaft seal.

▪ Check the static seals for leakage.

▪ Check the rolling element bearings for running noises.Vibrations, noise and an increase in power 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.

▪ Check the quench liquid level.Make sure the quench pot always contains sufficient quench liquid.



NOTEIf the liquid level in the quench pot rises, fluid from the pump has mixed with thequench liquid, which indicates leakage at the pump-end mechanical seal. Duringstart-up it is normal for the liquid level in the quench pot to rise until the operatingtemperature has been reached.

NOTEIf the liquid level in the quench pot drops rapidly, this indicates leakage at thedrive-end mechanical seal. In this case, the quench liquid could mix with the greaseof rolling element bearing 321 and affect lubrication. Check the rolling elementbearing and replace it, if required.

▪ Monitor the rolling element bearing temperature.The bearing temperature must not exceed 90 °C (measured on the outside of thebearing bracket).

CAUTIONOperation outside the permissible bearing temperatureDamage to the pump!

▷ The rolling element bearing temperature of the pump (set) must never exceed90 °C (measured on the outside of the bearing bracket).

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

7.2.2 Inspection work

DANGER

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

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

7.2.2.1 Checking the coupling

Check the flexible elements of the coupling. Replace the relevant parts in due time ifthere is any sign of wear and check the alignment.

7.2.2.2 Checking the clearance gaps

Clearances between impeller and casing

For checking the clearance gaps remove the impeller, if required. (⇨ Section 7.4.5Page 44)If the clearance is larger than permitted (see the following table), fit new casing wearring 502.1 and/or 502.2.The clearances given refer to the diameter.



Table 11: Clearances between impeller and casing / between impeller and casingcover

Permissible clearance

[mm]New 0.3Maximum permissible enlargement 0.9

NOTEIf the clearances given are exceeded by more than 1 mm (referring to the diameter)replace the affected components or restore the original clearance by means of acasing wear ring. Contact KSB.

Plain bearing clearances

Table 12: Plain bearing clearances in mm

Shaft unit Permissible clearance

[mm]

New Maximum permissibleenlargement

25 0.08 - 0.13 0.3535 0.08 - 0.13 0.455 0.08 - 0.13 0.4

7.2.2.3 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 at appropriate intervals.

7.2.3 Lubricating the rolling element bearing

DANGER

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

▷ Regularly check the bearing seal.

The bearings are delivered packed for life with a special high-temperature grease.

7.2.3.1 Intervals

Under normal operating conditions the grease-packed rolling element bearing willrun for 15,000 operating hours. Under unfavourable operating conditions (e.g. highroom temperature, high atmospheric humidity, dust-laden air, aggressive industrialatmosphere etc.), check the rolling element bearing earlier and replace it, if required.

7.2.4 Lubricating the plain bearing

The pump-end plain bearing is lubricated by the fluid handled. It is maintenance-free.



7.3 Drainage/cleaning

WARNINGFluids, consumables and supplies which are hot or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ 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, hotor other hazardous fluids.Always flush and clean the pump before transporting it to the workshop.Provide a cleaning record for the pump.

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

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, lifting equipment and lifting tackle to moveheavy assemblies or components.

Always observe the safety instructions and safety information.(⇨ Section 7.1 Page 38)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.

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



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

DANGER

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

▷ Properly shut down the pump set.(⇨ Section 6.1.7 Page 34)▷ Close the shut-off elements in 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.

NOTEAfter a prolonged period of operation the individual components may be hard topull off the shaft. If this is the case, use a brand name penetrating agent and/or - ifpossible - an appropriate puller.

7.4.2 Preparing the pump set

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

2. Disconnect and remove all auxiliary pipework.

3. Remove the coupling guard.

4. Remove the coupling spacer, if any.

7.4.3 Dismantling the motor

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

WARNINGMotor tipping overRisk of crushing hands and feet!

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

1. Disconnect the motor from the power supply.

2. Unbolt the motor from the baseplate.

3. Shift the motor to separate it from the pump.

7.4.4 Removing the back pull-out unit

✓ The notes and steps stated in(⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.3 Page43) have been observed/carried out.

✓ On pump sets without spacer-type coupling, the motor has been removed.

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

▷ Suspend or support the bearing bracket at the pump end.

1. If required, suspend or support bearing bracket 330 to prevent it from tippingover.

2. Unbolt support foot 183 from the baseplate.

3. Undo nuts 920.1 at the volute casing.

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



5. Remove and dispose of joint ring 411.4.

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.

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

7.4.5 Removing the impeller

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 42) to (⇨ Section 7.4.4 Page43) have been observed/carried out.

✓ The back pull-out unit has been placed in a clean and level assembly area.

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

2. Remove impeller 230 with an impeller removal tool.

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

4. Remove keys 940.1 from shaft 210.

7.4.6 Removing the shaft seal

7.4.6.1 Removing the pump assembly from the bearing bracket — all shaft units

✓ The notes and steps stated in(⇨ Section 7.4.1 Page 42) to(⇨ Section 7.4.5 )have been observed/carried out.

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

1. Undo nuts 920.2.

2. Pull bearing bracket 330 out of discharge cover 163.

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.

3. Remove and dispose of joint ring 411.3.

4. Remove bearing cover 360.

5. Remove circlip 932.2.

6. Press shaft 210 out of bearing bracket 330.

7.4.6.1.1 Dismantling a single mechanical seal — shaft units 25 and 35

✓ The notes and steps stated in(⇨ Section 7.4.1 Page 42) to(⇨ Section 7.4.6.1 Page44) have been observed/carried out.

1. Remove circlip 932.1 and support disc 550.2.

2. Pull bearing 321 off shaft 210.

3. Remove support disc 550.1 and mating ring holder 476.

4. Press the mating ring of mechanical seal 433 out of mating ring holder 476.

5. Remove the rotating assembly of mechanical seal 433 (primary ring) from shaft210.



7.4.6.1.2 Dismantling a single mechanical seal — shaft unit 55



2. Remove the rotating assembly of mechanical seal 433 (primary ring) from theshaft.

3. Remove mating ring holder 476.

4. Press the mating ring of mechanical seal 433 out of mating ring holder 476.

7.4.6.1.3 Dismantling a double mechanical seal — shaft units 25 and 35



2. Pull bearing 321 off shaft 210.

3. Remove support disc 550.1 and mating ring holder 476.

4. Press the mating ring of mechanical seal 433.2 out of mating ring holder 476.

5. Remove spacer sleeve 525.

6. Remove the rotating part of mechanical seal 433.2 (primary ring) from theshaft.


8. Remove mating ring holder 476.1.

9. Press the mating ring of mechanical seal 433.1 out of mating ring holder 476.1.

10. Remove the rotating part of mechanical seal 433.1 (primary ring) from theshaft.

7.4.6.1.4 Dismantling a double mechanical seal — shaft unit 55



2. Remove the rotating assembly of mechanical seal 433.1 (primary ring) from theshaft.

3. Remove mating ring holder 476.1.

4. Press the mating ring of mechanical seal 433.1 out of mating ring holder 476.1.

5. Remove spacer sleeve 525.


7. Remove the rotating assembly of mechanical seal 433.2 (primary ring) from theshaft.

8. Remove mating ring holder 476.

9. Press the mating ring of mechanical seal 433.2 out of mating ring holder 476.

7.4.7 Removing the plain bearing

Removing the carbon bearing


1. Push plain bearing 310 out of bearing bracket 330 from the drive end.

Removing the SiC bearing





2. Pull bearing sleeve 529 off shaft 210.


4. Push bush 540.1 and bearing cartridge 381 out of bearing bracket 330 from thedrive end.

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, lifting 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.

Should an assembly adhesive be required after all, use a commercially availablecontact adhesive (e.g. "Pattex") or sealant (e.g. HYLOMAR or Epple 33).

Only apply adhesive at selected points and in thin layers.

Never use quick-setting adhesives (cyanoacrylate adhesives).

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

For reassembly, tighten all screws and bolts as specified in this manual. (⇨ Section 7.6Page 49)

7.5.2 Installing the plain bearing

Fitting the carbon bearing

✓ 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 plain bearing 310 carefully into bearing bracket 330 until it will not go anyfurther.

Fitting the SiC bearing

✓ The individual parts are kept in a clean and level assembly area.

Sequence

Dichtungen

Assembly adhesives

Tightening torques






1. Push bearing sleeve 529 onto shaft 210.

2. Fit circlip 932.7.

3. Fit O-rings 412.3 at both sides of bearing cartridge 381.

4. Carefully press bearing bush 381 into bearing bracket 330.

5. Fit bush 540.1.


7.5.3 Installing the shaft 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.

7.5.3.1 Installing a single mechanical seal — shaft units 25 and 35

1. Clean the mating ring location in mating ring holder 476.

2. Carefully insert the mating ring of mechanical seal 433 into mating ring holder476. Press it in evenly.

3. Slide the rotating assembly of the mechanical seal (primary ring) onto shaft 210.

4. Fit mating ring holder 476 with O-Ring 412.1.

5. Fit support disc 550.1.

6. Press radial ball bearing 321 onto the shaft and secure it with support disc 550.2and circlip 932.1.

7.5.3.2 Installing a single mechanical seal — shaft unit 55

1. Clean the mating ring location in mating ring holder 476.

2. Carefully insert the mating ring of mechanical seal 433 into mating ring holder476.Make sure to apply pressure evenly.


4. Slide the rotating assembly of the mechanical seal (primary ring) onto shaft 210.

5. Fit support disc 550.5 and circlip 932.4.

7.5.3.3 Installing a double mechanical seal — shaft units 25 and 35

1. Clean the mating ring location of mating ring holders 476 and 476.1.

2. Insert the mating rings of mechanical seals 433.1 and 433.2 into mating ringholders 476 and 476.1.Press them in evenly.

3. Slide the rotating assembly of the mechanical seal 433.1 (primary ring) ontoshaft 210.

4. Fit mating ring holder 476.1 with O-Ring 412.2.

5. Fit circlip 932.5 and support disc 550.6.

6. Slide the rotating assembly of mechanical seal 433.2 (primary ring) onto shaft210.

7. Fit spacer sleeve 525.

Fitting themechanical seal




9. Fit support disc 550.1.

10. Press radial ball bearing 321 onto the shaft and secure it with support disc 550.2and circlip 932.1.

7.5.3.4 Installing a double mechanical seal — shaft unit 55

1. Clean the mating ring location of mating ring holders 476 and 476.1.

2. Insert the mating rings of mechanical seals 433.1 and 433.2 into mating ringholders 476 and 476.1. Make sure to apply pressure evenly.

3. Fit mating ring holder 476 with O-ring 412.1.

4. Slide the rotating part of mechanical seal 433.2 (primary ring) onto shaft 210.


6. Fit spacer sleeve 525 with mating ring holder 476.1 and O-ring 412.2.

7. Slide the rotating part of mechanical seal 433.1 (primary ring) onto shaft 210.


7.5.3.5 Installing the shaft assembly in the bearing bracket — all shaft units

1. Carefully press the shaft assembly into bearing bracket 330.


3. Fit bearing cover 360.

7.5.4 Fitting the impeller

✓ The notes and steps stated in(⇨ Section 7.5.1 Page 46) 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 cleanand level assembly area.




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, if any (see table:Tightening torques for screwed connections at the pump(⇨ Section 7.6 Page49)).

7.5.5 Installing the back pull-out unit

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

▷ Suspend or support the bearing bracket at the pump end.

✓ The notes and steps stated in(⇨ Section 7.5.1 Page 46) to(⇨ Section 7.5.4 )have been observed/carried out.



✓ For back pull-out units supplied without coupling: Fit the coupling in accordancewith the manufacturer's instructions.

1. Insert new joint ring 411.4 into volute casing 102.



2. If required, prevent the back pull-out unit from tipping over, e.g. by suspendingor supporting it. Then push it into volute casing 102.

3. Tighten nut 920.1 at the volute casing. Observe the tightening torques.

4. Fasten support foot 183 to the baseplate with a foundation bolt.

7.5.6 Mounting the motor

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

1. Shift the motor to connect it to the pump via the coupling.

2. Fasten the motor to the baseplate.

3. Align pump and motor.(⇨ Section 5.7 Page 27)4. Connect the motor to the power supply (refer to manufacturer's product

literature).

7.6 Tightening torques

7.6.1 Tightening torques for the pump

Fig. 16: Tightening points at the pump

Table 13: Tightening torques for screwed connections at the pump

Position Thread size Rated torque4)

[Nm]901.2 M12 50902.1/920.1 M10 35

M12 50902.2/920.2 M8 20

M10 35920.3 M12 x1.5 55

M24 x 1.5 130M30 x 1.5 170

4) Valid for unlubricated threads



7.6.2 Tightening torques for the pump set

1215:5/2

1 2 3 466

5

Fig. 17: Tightening points at the pump set

Table 14: Tightening torques for the pump set

Position Thread size Ratedtorque

[Nm]

Description

1 M12

M16

M20

30

75

75

Pump on baseplate

2 M12 303 M24 x 1.5

M36 x 1.5

140

140

Levelling screws in baseplate

4 M6

M8

M10

M12

M16

M20

M24

10

10

15

30

75

140

140

Motor on baseplate or

motor on levelling screws or shims

5 M6

M8

M10

13

18

44

Coupling (only for spacer-typecoupling made by Flender)

6 M6 10 Coupling guard

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 variants

▪ Size

▪ Seal code

▪ KSB order number

▪ Order item number

▪ Consecutive number

▪ Year of construction

Refer to the name plate for all data. (⇨ Section 4.4 Page 15)Also specify 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 56)

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

Table 15: 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 andmore

210 Shaft 1 1 1 2 2 2 20 %230 Impeller5) 1 1 1 2 2 2 20 %310 Plain bearing 2 3 4 5 7 9 100 %321 Radial ball bearing 1 1 2 2 2 3 25 %330 Bearing bracket6) - - - - - 1 2433 Mechanical seal7) 1 1 2 2 3 3 25 %502.1/.2 Casing wear ring 1 1 1 2 2 2 20 %411.3/.4 Joint ring 4 6 8 8 9 12 150 %412 O-ring8) 4 6 8 8 9 10 100 %- Torque-transmitting

coupling elements (set)1 1 2 2 3 4 30 %

5) Including casing wear ring 502.26) Complete bearing bracket. Example of a pump set with single mechanical seal and carbon plain bearing: shaft 210, plain

bearing 310, radial ball bearing 321, bearing bracket 330, bearing cover 360, joint ring 411.1, O-ring 412.1, mechanical seal433, mating ring holder 476, disc 550.1/.2/.3/.5, stud 902.2, screw plug 903.1, pan head screw 914, hexagon nut 920.2/.3,spring washer 930, circlip 932.1/.2/.4, key 940.1/.2

7) For double mechanical seals double the quantity.8) For double mechanical seal: parts 412.1 and 412.2



7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

Table 16: Interchangeability of pump componentsEt

ano

rm S

YT

Shaf

t u

nit

Etab

loc

SYT

Etal

ine

SYT

Description

Dis

char

ge

cove

r

Sup

po

rt f

oo

t9)

Shaf

t 9)

Imp

elle

r

Plai

n b

eari

ng

Dee

p-g

roo

ve b

all b

eari

ng

9)

Bea

rin

g b

rack

et9)

Bea

rin

g h

ou

sin

g10

)

Bea

rin

g c

ove

r9)

Mec

han

ical

sea

l9)11

)

Mec

han

ical

sea

l10)

Seal

co

ver10

)

Mat

ing

rin

g c

arri

er9)

Cas

ing

wea

r ri

ng

, su

ctio

n s

ide

Cas

ing

wea

r ri

ng

, dis

char

ge

sid

e

Part No.

163

183

210

230

310

321

330

350

360

433

433

471

476

502.

1

502.

2

32-125.5 25 32-125.1/. - 1 1 1 O O 1 1 1 1 1 3 1 1 1 ✘32-160.1 25 32-160.1/. 40-160/.. 1 2 1 1 O 1 1 1 1 1 3 1 1 1 332-200.1 25 32-200.1/. 40-200/.. 2 3 1 2 O 1 1 1 1 1 3 1 1 1 332-160 25 32-160/.. 50-160/.. 1 2 1 1 O 1 1 1 1 1 3 1 1 1 332-200 25 32-200/.. 50-200/.. 2 3 1 2 O 1 1 1 1 1 3 1 1 1 332-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 1 1040-160 25 40-160/.. 65-160/.. 1 2 1 O O 1 1 1 1 1 3 1 1 2 340-200 25 40-200/.. 65-200/.. 2 3 1 O O 1 1 1 1 1 3 1 1 O 340-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 2 1040-315 35 - - O 7 2 O 3 2 2 - 2 2 - - 2 2 1350-160 25 50-160/.. 80-160/.. 1 3 1 O O 1 1 1 1 1 3 1 1 3 350-200 25 50-200/.. 80-200/.. 2 3 1 O O 1 1 1 1 1 3 1 1 3 350-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 3 1050-315 35 - - 7 7 2 O 3 2 2 - 2 2 - - 2 4 1165-160 25 65-160/.. 100-160/.. 4 3 1 O O 1 1 1 1 1 3 1 1 4 565-200 25 65-200/.. - O 4 1 O O 1 1 - 1 1 - - 1 4 565-250 35 - - O 5 2 O 3 2 2 - 2 2 - - 2 5 1365-315 35 - - 7 7 2 O 3 2 2 - 2 2 - - 2 5 1180-160 25 80-160/.. 100-170/.. 4 4 1 O O 1 1 - 1 1 - - 1 6 580-200 35 - - 5 O 2 O 3 2 2 - 2 2 - - 2 6 1180-250 35 - - 6 5 2 O 3 2 2 - 2 2 - - 2 6 1180-315 35 - - 7 6 2 O 3 2 2 - 2 2 - - 2 6 11100-160 35 - - 5 5 2 O 3 2 2 - 2 2 - - 2 7 11100-200 35 - - 5 5 2 O 3 2 2 - 2 2 - - 2 7 11100-250 35 - - 6 7 2 O 3 2 2 - 2 2 - - 2 7 11100-315 35 - - 7 6 2 O 3 2 2 - 2 2 - - 2 7 11125-200 35 - - O 6 2 O 3 2 2 - 2 2 - - 2 8 O125-250 35 - - O 6 2 O 3 2 2 - 2 2 - - 2 8 O125-315 55 - - 8 9 3 O 3 3 3 - 3 2 - - 3 8 12125-400 55 - - 9 8 3 O 3 3 3 - 3 2 - - 3 8 12150-315 55 - - 8 9 3 O 3 3 3 - 3 2 - - 3 9 12150-400.1 55 - - 10 8 3 O 3 3 3 - 3 2 - - 3 9 -

9) Etanorm SYT only10) Etabloc SYT/Etaline SYT only11) Single mechanical seal 433 not interchangeable with double mechanical seal 433.1/.2



Table 17: Key to the symbols

Symbol DescriptionO Components differ✘ Component not fitted



8 Trouble-shootingPump delivers insufficient flow rate

Motor is overloaded

Excessive pump discharge pressure

Increased bearing temperature

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Impermissible rise of temperature inside the pump

Table 18: Trouble-shooting

A B C D E F G H Possible cause Remedy12)

X Pump delivers against an excessivelyhigh pressure.

Re-adjust to duty point.

Check system for impurities.Fit a larger impeller.13)

Increase speed (turbine, I.C. engine).X X X Pump or piping are not completely

vented or primed.Vent and/or prime.

Clean vent hole.X Supply 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, NPSHavailable

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

X Wrong direction of rotation Interchange two of the phases of the powercable.

X Speed is too low

- Operation with frequency inverter

- Operation without frequency inverter

- Increase voltage/frequency at the frequencyinverter in the permissible range.- Check voltage.

X X Wear of internal pump parts Replace worn parts by new ones. X X Pump back pressure lower than specified

in purchase order.Adjust duty point accurately. In the case of persistent overloading, turndown impeller.13)

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

Contact KSB.

X X Speed is too high Reduce speed.13)

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

A

B

C

D

E

F

G

H

12) Release pump pressure before attempting to remedy faults on parts which are subjected to pressure.13) Contact KSB.

8 Trouble-shooting


A B C D E F G H Possible cause Remedy12)

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 and 920.2at the discharge cover.

4. Start up the pump set.(⇨ Section 6 Page31)

X Worn shaft seal Fit new shaft seal.Check flushing liquid/barrier fluid.

X Pump runs rough Correct suction conditions.Re-align the pump set.Re-balance the impeller.Increase pressure at the pump suction nozzle.

X X X Pump set misaligned Re-align the pump set. 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 Increased axial thrust13) Clean balancing holes in the impeller.Replace the casing wear rings.

X Non-compliance with specified couplingdistance

Correct distance according to generalarrangement drawing.

X X Motor 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 X Flow rate is too low Increase minimum flow rate.

12) Release pump pressure before attempting to remedy faults on parts which are subjected to pressure.

8 Trouble-shooting


9 Related Documents

9.1 Exploded views and lists of components

9.1.1 Etanorm SYT, SU 25

UG1278203:001/2

Fig. 18: Exploded view of Etanorm SYT, SU 25

Table 19: List of components

Part No. Description Part No. Description Part No. Description102 Volute casing 412.1 O-ring 930 Spring washer163 Discharge cover 433 Mechanical seal 932.1/.2 Circlip183 Support foot 476 Mating ring holder 940.1/.2 Key210 Shaft 502.1/.214) Casing wear ring 99-20 Repair kit230 Impeller 550.1/.2/.3 Disc 310 Plain bearing 901.2 Hexagon head bolt 321 Radial ball bearing 902.1/.2 Stud 1M Connection for

pressure gauge330 Bearing bracket 903.1/.2 Screw plug 6B Fluid drain360 Bearing cover 914 Pan head screw 6D Fluid vent411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 8B Leakage drain

14) 502.2 not for pump size 32-125.1

9 Related Documents


9.1.2 Etanorm SYT, SU 25 with double mechanical seal

UG1278452:001/2

Fig. 19: Exploded view of Etanorm SYT, SU 25 with double mechanical seal


Part No. Description Part No. Description Part No. Description102 Volute casing 433.1/.2 Mechanical seal 930 Spring washer163 Discharge cover 476/476.1 Mating ring holder 932.1/.2/.5 Circlip183 Support foot 940.1/.2 Key210 Shaft 502.1/.215) Casing wear ring 99-20 Repair kit230 Impeller 525 Spacer sleeve 310 Plain bearing 550.1/.2/.3/.6 Disc 24A Outlet of the quench

liquid321 Radial ball bearing 901.2 Hexagon head bolt 24E Inlet of the quench

liquid330 Bearing bracket 902.1/.2 Stud 1M Connection for

pressure gauge360 Bearing cover 903.1/.2 Screw plug 6B Fluid drain411.1/.3/.4/.5 Joint ring 914 Pan head screw 6D Fluid vent412.1/.2 O-ring 920.1/.2/.3 Nut 8B Leakage drain

15) 502.2 not for pump size 32-125.1

9 Related Documents



UG1278322:001/2



Part No. Description Part No. Description Part No. Description102 Volute casing 412.1 O-ring 930 Spring washer163 Discharge cover 433 Mechanical seal 932.1/.2/.4 Circlip183 Support foot 476 Mating ring holder 940.1/.2 Key210 Shaft 502.1/.2 Casing wear ring 99-20 Repair kit230 Impeller 550.1/.2/.5 Disc 310 Plain bearing 901.2 Hexagon head bolt 321 Radial ball bearing 902.1/.2 Stud 1M Connection for


9 Related Documents



UG1278474:001/2



Part No. Description Part No. Description Part No. Description102 Volute casing 433.1/.2 Mechanical seal 932.1/.2/.4/.5 Circlip163 Discharge cover 476/476.1 Mating ring holder 940.1/.2 Key183 Support foot 502.1/.2 Casing wear ring 99-20 Repair kit210 Shaft 525 Spacer sleeve 230 Impeller 550.1/.2/.5/.6 Disc 310 Plain bearing 901.2 Hexagon head bolt 24A Outlet of the quench

liquid321 Radial ball bearing 902.1/.2 Stud 24E Inlet of the quench

liquid330 Bearing bracket 903.1/.2 Screw plug 1M Connection for

pressure gauge360 Bearing cover 914 Pan head screw 6B Fluid drain411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 6D Fluid vent412.1/.2 O-ring 930 Spring washer 8B Leakage drain

9 Related Documents



UG1289004:001/2



Part No. Description Part No. Description Part No. Description102 Volute casing 412.1 O-ring 930 Spring washer163 Discharge cover 433 Mechanical seal 932.1/.2/.4 Circlip183 Support foot 476 Mating ring holder 940.1/.2 Key210 Shaft 502.1/.216) Casing wear ring 99-20 Repair kit230 Impeller 550.1/.2/.5 Disc 310 Plain bearing 901.2 Hexagon head bolt 321 Radial ball bearing 902.1/.2 Stud 1M Connection for


16) 502.2 not for pump size 150-400.1

9 Related Documents



UG1289009:001/2



Part No. Description Part No. Description Part No. Description102 Volute casing 433.1/.2 Mechanical seal 932.1/.2/.4/.5 Circlip163 Discharge cover 476/476.1 Mating ring holder 940.1/.2 Key183 Support foot 502.1/.217) Casing wear ring 99-20 Repair kit210 Shaft 525 Spacer sleeve 230 Impeller 550.1/.2/.5/.6 Disc 310 Plain bearing 901.2 Hexagon head bolt 24A Outlet of the quench

liquid321 Radial ball bearing 902.1/.2 Stud 24E Inlet of the quench

liquid330 Bearing bracket 903.1/.2 Screw plug 1M Connection for

pressure gauge360 Bearing cover 914 Pan head screw 6B Fluid drain411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 6D Fluid vent412.1/.2 O-ring 930 Spring washer 8B Leakage drain

17) Not for pump size 150-400.1

9 Related Documents


9.1.7 Etanorm SYT with SiC plain bearing

Fig. 24: Exploded view of Etanorm SYT with plain bearing


Part No. Description Part No. Description Part No. Description381 Bearing cartridge 412.3 O-ring 529 Bearing sleeve540.1 Bush 561 Half round head

grooved pin932.6/.7 Circlip

9.2 Wiring diagrams for double mechanical seal

Fig. 25: Wiring diagram for double mechanical seal

1M.1/.2 Connection for pressure gauge6B Fluid drain6D Fluid vent8B Leakage drain24A Outlet of the quench liquid24E Inlet of the quench liquid

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) (country)

The EC Declaration of Conformity was issued in/on:

Place, date

..............................18).............................

Name

FunctionCompanyAddress

Address

18) 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 number19) ................................................................................................................................

Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid pumped19): ................................................................................................................................

Please tick where applicable19):

⃞ ⃞ ⃞ ⃞Radioactive Explosive Corrosive Toxic

⃞ ⃞ ⃞ ⃞Harmful Bio-hazardous Highly flammable Safe

Reason for return19): ................................................................................................................................

Comments: ................................................................................................................................ ................................................................................................................................

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal.

We hereby declare that this product is free from hazardous chemicals, biological or radioactive substances.

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

19) Required fields

11 Certificate of Decontamination


Index

AAbrasive fluids 36Auxiliary connections 25

BBearing temperature 40Bearings 16

CCertificate of decontamination 64Clearances 40Commissioning/start-up 31Coupling 40Coupling alignment 27

DDesign 16, 17Designation 15Direction of rotation 30Dismantling 42Disposal 14

EExplosion protection 9, 19, 20, 26, 28, 29, 30, 31, 32,33, 34, 35, 38, 39, 40, 41

FFilter 22, 41Final check 32Frequency of starts 35Function 17

GGrease lubrication

Intervals 41

IImpeller type 16Installation

Installation on a foundation 20Installation without foundation 21

Installation at site 20Intended use 7Interchangeability of pump components 52

MMechanical seal 33Misuse 8Monitoring equipment 10

NName plate 15Noise characteristics 18

OOperating limits 7, 34Order number 6

PPartly completed machinery 6Permissible forces at the pump nozzles 24Piping 22Preservation 13, 37Priming and venting 31Pump casing 16

RReassembly 42, 46Return to supplier 13Returning to service 37

SSafety 7Safety awareness 8Scope of supply 18, 19Servicing/maintenance 38Shaft seal 16Shutdown 37Spare part

Ordering spare parts 50Spare parts stock 51Start-up 33Storage 13, 37

TTemperature limits 10Tightening torques 49, 50Transport 12Trouble-shooting 54

Index


1226

.8/0

3-EN

(01

3173

31)

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

thermoil heater etanorm, pump

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