KSB Etabloc Operating Instructions Manual
Operating Instructions
Close-coupled Pumps
Etabloc
Page
1 General 4
2 Safety 4
2.1 Marking of instructions in the manual 4
2.2 Personnel qualification and training 4
2.3 Non-compliance with safety instructions 4
2.4 Safety awareness 4
2.5 Safety instructions for the operator / user 4
2.6 Safety instructions for maintenance, inspection
and installation work 4
2.7 Unauthorized modification and manufacture of
spare parts 5
2.8 Unauthorized modes of operation 5
3 Transport and interim storage 5
3.1 Transport 5
3.2 Interim storage / Preservation 5
4 Description of the product and accessories 5
4.1 Technical specification 5
4.2 Designation 5
4.3 Design details 6
4.3.1 Pump 6
4.4 Noise characteristics 6
5 Installation at site 6
5.1 Safety regulations 6
5.2 Checks to be carried out prior to installation 6
5.3 Installation method 6
5.4 Installing the pump set 6
5.4.1 Place of installation 6
5.5 Connecting the piping 7
5.5.1 Auxiliary connections 7
5.5.2 Vacuum balance line 7
5.6 Final check 7
5.7 Connection to power supply 7
5.7.1 Motor connection 8
5.7.2 Setting the time relay 8
5.7.3 Checking the direction of rotation 8
6 Commissioning, start-up / shutdown 8
6.1 Commissioning 8
6.1.1 Shaft seal 8
6.1.2 Priming the pump and checks to be carried out 8
6.1.3 Final check 8
6.1.4 Contact guard 8
6.1.5 Start-up 8
6.1.6 Shutdown 8
6.2 Operating limits 9
6.2.1 Temperature of the medium handled 9
6.2.2 Switching frequency 9
6.2.3 Minimum flow 9
6.2.4 Density of medium handled 9
6.3 Shutdown / storage / preservation 9
6.3.1 Storage of new pumps 9
6.3.2 Measures to be taken for prolonged shutdown 9
6.4 Returning to service after storage 9
Page
7 Servicing / maintenance 9
7.1 General instructions 9
7.2 Servicing / inspection 9
7.2.1 Supervision of operation 9
7.2.2 Lubrication and lubricant change 9
7.3 Drainage / disposal 10
7.4 Dismantling 10
7.4.1 Fundamental instructions and recommendations 10
7.4.2 Preparations for dismantling 10
7.4.3 Pump 10
7.4.4 Mechanical seal 10
7.5 Reassembly 11
7.5.1 Pump 11
7.5.2 Mechanical seal 11
7.5.3 Motor for Etabloc N 11
7.5.4 Tightening torques 11
7.6 Spare parts 12
7.6.1 Ordering spare parts 12
7.6.2 Recommended spare parts stock 12
8 Trouble-shooting 13
9 Related documents 14
9.1 Typical Installation Positions 14
9.2 Exploded view and list of components
Etabloc G 15
9.3 Exploded view and list of component Etabloc G 16
9.4 Exploded view and list of components
Etabloc N 17
Etabloc
Contents
2
3
Etabloc
Section Page
Auxiliary connections 5.5.1 7
Checking the direction of rotation 5.7.3 8
Checks to be carried out prior to installation 5.2 6
Commissioning 6.1 8
Commissioning, start-up / shutdown 6 8
Connecting the piping 5.5 7
Connection to power supply 5.7 7
Contact guard 6.1.4 8
Density of medium handled 6.2.4 9
Description of the product and accessories 4 5
Design details 4.3 6
Designation 4.2 5
Dismantling 7.4 10
Drainage / disposal 7.3 10
Exploded view and list of components
Etabloc G 9.3 16
Exploded view and list of components
Etabloc G 9.2 15
Exploded view and list of components
Etabloc N 9.4 17
Final check 5.6/ 7/
6.1.3 8
Fundamental instructions and
recommendations 7.4.1 10
General 1 4
General instructions 7.1 9
Installation at site 5 6
Installing the pump set 5.4 6
Installation method 5.3 6
Interim storage / Preservation 3.2 5
Lubrication and lubricant change 7.2.2 9
Marking of instructions in the manual 2.1 4
Measures to be taken for prolonged shutdown 6.3.2 9
Mechanical seal 7.4.4/ 10/
7.5.2 11
Minimum flow 6.2.3 9
Motor connection 5.7.1 8
Motor for Etabloc N 7.5.3 11
Noise characteristics 4.4 6
Non-compliance with safety instructions 2.3 4
Operating limits 6.2 9
Ordering spare parts 7.6.1 12
Personnel qualification and training 2.2 4
Place of installation 5.4.1 6
Preparations for dismantling 7.4.2 10
Priming the pump and checks to be carried out 6.1.2 8
Pump 4.3.1/ 6/
7.4.3/ 10/
7.5.1 11
Reassembly 7.5 11
Recommended spare parts 7.6.2 13
Related documents 9 14
Returning to service after storage 6.4 8
Safety 2 4
Safety awareness 2.4 4
Section Page
Safety instructions for maintenance, inspection
and installation work 2.6 4
Safety instructions for the operator / user 2.5 4
Safety regulations 5.1 6
Servicing / inspection 7.2 9
Servicing / maintenance 7 9
Setting the time relay 5.7.2 8
Shaft seal 6.1.1 8
Shutdown 6.1.6 8
Shutdown / storage / preservation 6.3 9
Spare parts 7.6 12
Start-up 6.1.5 8
Storage of new pumps 6.3.1 9
Supervision of operation 7.2.1 9
Switching frequency 6.2.2 9
Technical specification 4.1 5
Temperature of the medium handled 6.2.1 9
Tightening torques 7.5.4 11
Transport 3.1 5
Transport and interim storage 3 5
Trouble-shooting 8 13
Typical installation positions 9.1 14
Unauthorized modes of operation 2.8 5
Unauthorized modification and manufacture of
spare parts 2.7 5
Vacuum balance line 5.5.2 7
Index
Etabloc
1 General
This KSB product has been developed in accor-
dance with state-of-the-art technology; it is manufactured with utmost care and subject to continuous quality
control.
These operating instructions are intended to facilitate familiarization with the unit and its designated use. The manual contains important information for reliable, proper and efficient
operation. Compliance with the operating instructions is of
vital importance to ensure reliability and a long service life of
the unit and to avoid any risks.
These operating instructions do not take into account local
regulations; the operator must ensure that such regulations
are strictly observed by all, including the personnel called in
for installation.
This pump / unit must not be operated beyond the limit
values for the medium handled, capacity, speed, densi-
ty,
pressure, temperature and motor rating specified in the technical documentation. Make sure that operation is in accordance with the instructions laid down in this manual or in the
contract documentation. Contact the manufacturer, if required.
The name plate indicates the type series / size, main operating data and identification number; please quote this information in all queries, repeat orders and particularly when ordering spare parts.If you need any additional information or
instructions exceeding the scope of this manual or in case of
damage please contact KSB’s nearest customer service centre. Noise characteristics see section 4.5.
2 Safety
These operating instructions contain fundamental information
which must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read
and understood both by the installing personnel and the
responsible trained personnel / operators prior to installation
and commissioning, and it must always be kept close to the
location of operation of the machine / unit for easy access. Not
only must the general safety instructions laid down in this
chapter on ”Safety” be complied with, but also the safety
instructions outlined under specific headings.
2.1 Marking of instructions in the manual
The safety instructions contained in this manual whose
non-observance might cause hazards to persons are specially marked with the symbol
general hazard sign to ISO 7000-0434
The electrical danger warning sign is
safety sign to IEC 417 - 5036,
The word
is used to introduce safety instructions whose non-observance may lead to damage to the machine and its functions.
Instructions attached directly to the machine, e.g.
- arrow indicating the direction of rotation
- markings for fluid connections
must always be complied with and be kept in a perfectly legible condition at all times.
2.2 Personnel qualification and training
All personnel involved in the operation, maintenance, inspection and installation of the unit must be fully qualified to carry
out the work involved.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question
is not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required,
the operator may commission the manufacturer / supplier to
take care of such training. In addition, the operator is responsible for ensuring that the contents of the operating instructions are fully understood by the responsible personnel.
2.3 Non-compliance with safety instructions
Non-compliance with safety instructions can jeopardize the
safety of personnel, the environment and the machine / unit
itself. Non-compliance with these safety instructions will also
lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
- failure of important unit/system functions,
- failure of prescribed maintenance and servicing practices,
- hazard to persons by electrical, mechanical and chemical
effects,
- hazard to the environment due to leakage of hazardous
substances.
2.4 Safety awareness
It is imperative to comply with the safety instructions contained
in this manual, the relevant national health and safety regulations and the operator’s own internal work, operation and
safety regulations.
2.5 Safety instructions for the operator / user
- Any hot or cold components that could pose a hazard
must be equipped with a guard by the operator.
- Guards which are fitted to prevent accidental contact with
moving parts (e.g. coupling)must not be removed whilst
the unit is operating.
- Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot)must be contained so as to
avoid any danger to persons or the environment. All relevant laws must be heeded.
- Electrical hazards must be eliminated. (In this respect
refer to the relevant safety regulations applicable to different countries and/or the local energy supply companies.)
2.6 Safety instructions for maintenance, inspection and
installation work
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the manual.
The pump must have cooled down to ambient temperature,
pump pressure must have been released and the pump must
have been drained.
Work on the machine / unit must be carried out only during
standstill. The shutdown procedure described in the manual
for
taking the unit out of service must be adhered to without fail.
Pumps or pump units handling media injurious to health must
be decontaminated.
Caution
!
!
Caution
4
5
Immediately following completion of the work, all safety-relevant and protective devices must be re-installed and / or reactivated.
Please observe all instructions set out in the chapter on
“Commissioning/Start-up” before returning the unit to service.
2.7 Unauthorized modification and manufacture of spare
parts
Modifications or alterations of the equipment supplied are only
permitted after consultation with the manufacturer. Original
spare parts and accessories authorized by the manufacturer
ensure safety. The use of other parts can invalidate any liability of the manufacturer for consequential damage.
2.8 Unauthorized modes of operation
The warranty relating to the operating reliability and safety of
the unit supplied is only valid if the equipment is used in accordance with its designated use as described in the following
sections of this manual. The limits stated in the data sheet
must not be exceeded under any circumstances.
3 Transport and interim storage
3.1 Transport
Transport of the unit requires proper preparation and handling.
Always make sure that the pump or the unit remains in horizontal position during transport and cannot slip out of the
transport suspension arrangement. Do not use a lifting sling
on the free shaft end of the pump or on the motor eyebolt.
If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage to
property!
Fig. 3.1-1 Transport of the unit with support foot
Fig. 3.1-2 Transport of the unit with motor/pump foot
During transport the shaft 210 of the pump without motor must
be locked in place.
1.Press cover plates 68-3 slightly together and remove from
drive lantern 341.
2.Insert lock washer 931 into the shaft groove.
Fig. 3.1-3 Transport of the pump
3.2 Interim storage (indoors) / Preservation
When the unit is temporarily put into storage, only the wetted
low alloy components (e.g. grey cast iron JL 10401), nodular
cast iron JS 1025 2)) must be preserved. Commercially available preservatives can be used for this purpose. Please
observe the manufacturer’s instructions for application/removal.
The relevant procedure is described in section 6.3.
The unit / pump should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.
Protect all stored goods against humidity, dirt,
vermin and unauthorized access! All openings of
the assembled unit components are closed and must only be
opened when required during installation.
All blank parts and surfaces of the pump are oiled or greased
(silicone-free oil and grease) to protect them against corrosion.
4 Description of the product and
accessories
4.1 Technical specification
Close-coupled pumps for handling clean or aggressive liquids.
4.2 Designation
Etab
loc G (N) 50-160 / 75 2
Type series
Casing material, e.g. JL 1040 1)
Stub shaft version with standardized motor
Pump size, e.g.
Motor rating: kW x 10 (example 7.5 kW)
Number of motor poles
1) to EN 1561 = GJL-250
2) to EN 1563 = GJS-400-18-LT
Etabloc
!
Caution
167:452
1
1167:453/2
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