Page 1
Operating Instructions
Close-coupled Pumps
Etabloc
Page 2
Page 3
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
Page 4
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
Page 5
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
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Caution
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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
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4.3 Design details
4.3.1 Pump
Design: Volute casing pumps, single-stage with rat-
ings to EN 733. [The shaft is fitted with a
replaceable shaft sleeve in the shaft seal
area. Volute casing and impeller with
replaceable casing / impeller wear rings
1)
]
1) Etabloc G only.
Etabloc N
Pump and motor flanged together to form a
close-coupled unit; with standardised motor.
Pump shaft and motor shaft are rigidly connected.
Etabloc G
Pump and motor flanged together to form a
close-coupled unit with common
pump/motor shaft.
Shaft seal: Mechanical seal to EN 12 756.
4.4 Noise characteristics
Rated power A-weighted surface sound pressure level pA
input PN Pump with motor
(kW) 1450 1/min 2900 1/min
dB 3) dB 3)
0.25 53.0 -
0.37 54.0 -
0.55 55.0 -
0.75 56.0 66.0
1.1 57.0 66.0
1.5 58.0 67.0
2.2 59.0 67.0
3.0 60.0 68.0
4.0 61.0 68.0
5.5 62.0 70.0
7.5 64.0 71.0
11.0 65.0 73.0
15.0 67.0 74.0
18.5 68.0 75.0
22.0 69.0 76.0
30.0 70.0 77.0
37.0 71.0 78.0
45.0 73.0 78.0
3) measured at a distance of 1 m from the pump outline (as per ISO 3744)
The above noise characteristics apply to non-cavitating pump
operation in the Qopt range.
5 Installation at site
5.1 Safety regulations
Electrical equipment operated in hazardous locations
must comply with the relevant explosion protection regulations. This is indicated on the motor rating plate.
If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and
the regulations of the test certificate supplied with the
equipment and issued by the responsible approval
authorities must be observed and complied with. The
test certificate supplied must be kept close to the location of operation for easy access (e.g. foreman’s
office).
5.2 Checks to be carried out prior to installation
All structural work required must have been prepared in accordance with the dimensions stated in the dimension table / general arrangement drawing.
The concrete foundations shall have sufficient strength (min.
class X0) to ensure safe and functional installation in accordance with DIN 1045.
Make sure that the concrete foundation has set firmly before
placing the unit on it. Its surface shall be truly horizontal and
even.
5.3 Installation method
For safety reasons the arrangement of “motor
below” is not permitted.
Etabloc pumps up to 4 kW, or explosion-proof units up to
3.3 kW, can either be flanged into the piping (remove support
foot 183) or mounted with the support foot. Installation examples see 9.1.
Etabloc pumps from 5.5 kW or explosion-proof units from
4.6 kW are fixed by means of the motor foot.
Etabloc 4 pole, 30 kW and above are fixed by means of the
pump foot and a motor support.
5.4 Installing the pump set
After placing the unit on the foundation, align it with the help
of a spirit level placed on the discharge nozzle.
If the volute casing is turned, a drain hole must be drilled in the
volute casing.
On Etabloc G, the position of the condensation water drain
holes on the motor must be observed meticulously (see 9.1).
The screwed plug needs to be changed depending on the
installation position.
5.4.1 Place of installation
The volute casing and discharge cover take on rough-
ly the same temperature as the medium handled. The
discharge cover and the drive lantern must not be insulated.
Take the necessary precautions to avoid burns!
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5.5 Connecting the piping
Never use the pump itself as an anchorage point
for the piping.
The pump must not be subjected to any pipeline forces and
moments (for example by torsion, thermal expansion).
Suction lift lines shall be laid with a rising slope towards the
pump and suction head lines with a downward slope towards
the pump. The pipelines shall be anchored in close proximity
to the pump and connected without transmitting any stresses
or strains.
With short pipelines, the nominal diameters should be at least
equal to the nominal diameters of the pump nozzles. For long
pipelines, the most economical nominal diameter has to be
determined from case to case.
Adapters to larger diameters should have a diffuser angle of
approx. 8 in order to avoid any increase in pressure losses.
It is recommended to install check and shut-off elements in
the system, depending on the type of plant and pump.
Thermal expansions of the pipelines must be compensated by
appropriate measures so as not to impose any extra loads on
the pump exceeding the permissible pipeline forces and
moments.
An excessive, impermissible increase in the pipeline
forces may cause leaks on the pump where the medium
handled can escape into the atmosphere.
Danger of life when hot media are handled!
The flange covers on the pump suction and discharge nozzles
must be removed prior to installation in the piping.
Before commissioning new installations thoroughly clean,
flush and blow through all vessels, pipelines and connections.Often welding beads, scale and other impurities only
come off after a certain period of operation. Fit a strainer in the
suction line to prevent them from entering the pump.The total
cross-section of the holes in the strainer shall be three times
the cross-section of the pipeline in order to avoid excessive
pressure loss across the strainer due to clogging. Conical
strainers with laid-in wire mesh having a mesh width of 0.5
mm and a wire diameter of 0.25 mm, of corrosion-resistant
material, shall be used.
1 Strainer housing
2 Fine screen
3 Perforated plate
4 Pump suction nozzle
5 Differential pressure gauge
Fig. 5.5-1 Conical strainer for the suction line
5.5.1 Auxiliary connections
The dimensions and location of the auxiliary connection (drain
line) are indicated on the general arrangement drawing or piping layout.
5.5.2 Vacuum balance line
Where liquid has to be pumped out of a vessel under vacuum,
it is advisable to install a vacuum balance line. This line shall
have a nominal diameter of at least 25 mm and must be
arranged to lead into the vessel at a point above the highest
permissible liquid level.
An additional pipeline fitted with a shut-off valve – from the
pump discharge nozzle to the balance line – facilitates venting
of the pump before start-up.
A Main shut-off valve
B Vacuum balance line
C Shut-off valve
E Vacuum-tight shut-off valve
R Swing check valve
V Vessel under vacuum
Z Intermediate flange
Fig. 5.5-2 Suction line and vacuum balance line
5.6 Final check
Check the integrity and proper functioning of all
connections.
5.7 Connection to power supply
Connection to the power supply must be effected by a trained
electrician only.
The applicable DIN VDE regulations 0100 and, for explosionproof units, 0165 must be complied with.
Check available mains voltage against the data on the motor
rating plate and select appropriate start-up method.
All connections shall be effected in accordance with the
technical specifications issued by the local energy supply company.
We strongly recommend to use a motor protection device.DIN
VDE 0170/0171 stipulates that explosion-proof motors, type of
protection IP 54, increased safety Ex EEx, temperature class
T3, must always be connected via a motor protection switch.
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5.7.1 Motor connection
In compliance with DIN VDE 0530 – Part 8, the three-phase
motors are always wired for clockwise rotation (looking at the
motor shaft stub).
The pump’s direction of rotation is anti-clockwise (looking at
the suction flange).
For the motor’s direction of rotation to match the pump’s direction of rotation, the motor must be connected as shown in fig.
5.7-1 or 5.7-2, as applicable.
n configuration (low voltage)
Fig. 5.7-1 Connection diagram for three-phase motors,
n configuration
Y configuration (high voltage)
Fig. 5.7-2 Connection diagram for three-phase motors,
Y configuration
If required, connect the PTC resistors as per DIN
44081/44082 with the tripping unit in accordance with fig. 5.7-
3.
Fig. 5.7-3 Connection diagram for PTC resistors
5.7.2 Setting the time relay
Make sure that in the case of three-phase motors with stardelta starting method switching over from star to delta will be
effected at very short intervals. Prolonged switch-over intervals will result in pump damage.
Time relay setting for star-delta starting: <3 s.
5.7.3 Checking the direction of rotation
The motor’s direction of rotation must correspond to the direction indicated by the arrow on the pump’s volute casing (clockwise seen from the motor end). Verify by switching the motor
on and then off again immediately.
If the pump runs in the wrong direction of rotation, interchange
any two phases L1, L2 or L3 of the power cable in the motor
terminal box.
6 Commissioning, start-up / shutdown
6.1 Commissioning
Before starting up the pump make sure that
- the pump unit has been properly connected to the electric
power supply and is equipped with all protection devices;
- the pump has been primed with the liquid to be pumped;
- the direction of rotation has been checked;
- all auxiliary connections have been properly connected.
6.1.1 Shaft seal
Shaft seal (see sections 7.4.4 and 7.5.2)
6.1.2 Priming the pump and checks to be carried out
Before start-up, the pump and the suction line must be vented
and primed with the liquid to be pumped.
The shut-off valve in the suction line must be fully open.
Open the shut-off valve in the vacuum balance line (if any),
and close the vacuum-tight shut-off valve E (fig. 5.5-2).
Dry-running will result in increased wear and
must be avoided.
6.1.3 Final check
It must be easy to rotate the shaft by hand.
Check the integrity and proper functioning of all connections.
6.1.4 Contact guard
In compliance with the accident prevention regulations
the pump must not be operated without a contact guard.
6.1.5 Start-up
Always make sure that the shut-off valve in the discharge line
is closed before the pump is started up! Only after the pump
has reached full rotational speed shall the shut-off valve in the
discharge line be opened slowly and adjusted to comply with
the duty point.
After the operating temperature has been reached and/or in
the event of leakage, switch off the unit and retighten hex. nuts 920.2 or .3 or .4.
6.1.6 Shutdown
Close the shut-off valve in the discharge line.
If the discharge line is equipped with a non-return or check
valve, the shut-off element may remain open if there is back
pressure.
The shut-off valve in the suction line must not be closed
when switching off the pump.
Switch off the motor, making sure that the unit runs down
smoothly to a standstill.
Depending on the type of installation, the pump should have a
sufficient after-run time – with the heat source shut off – until
the medium handled has cooled down sufficiently to avoid a
heat build-up in the pump.
For prolonged shutdown, close the shut-off valve in the suction line. Close the auxiliary connections.
In the event of frost and/or prolonged shutdowns, the pump
must be drained or otherwise protected against freezing.
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6.2 Operating limits
6.2.1 Temperature of the medium handled
Do not operate the pump at product temperatures exceeding those specified on the data
sheet or the name plate.
6.2.2 Switching frequency
To prevent high temperature increases in the motor and
excessive loads on the pump, motor, seals and bearings, the
switching frequency shall not exceed the following number of
start-ups per hour (h).
Etabloc G, M: 15 start-ups/h
Etabloc GN, MN, SN: 15 start-ups/h
Etabloc BN, CN: 6 start-ups/h
6.2.3 Minimum flow
If the plant configuration is such that the pump might be
operated against a closed discharge side valve, a minimum
flow of
t -30to+ 70C ≈ 15 % of Qopt.
t >70 to +140 C ≈ 25 % of Qopt.
must be ensured during this period.
6.2.4 Density of medium handled
The power input of the pump will increase in proportion to
the density of the medium handled. To avoid overloading of
the motor and pump, the density of the medium must comply
with the data specified on the purchase order.
6.3 Shutdown / storage / preservation
Each KSB pump leaves the factory carefully assembled. If
commissioning is to take place some time after delivery, we
recommend that the following measures be taken for pump
storage.
6.3.1 Storage of new pumps
- New pumps are supplied by our factory duly prepared for
storage.
Maximum protection for up to 12 months, if the pump is
properly stored indoors.
- Store the pump in a dry location.
6.3.2 Measures to be taken for prolonged shutdown
1.The pump remains installed; periodic check of operation
In order to make sure that the pump is always ready for
instant start-up and to prevent the formation of deposits
within the pump and the pump intake area, start up the
pump set regularly once a month or once every 3 months
for a short time (approx. 5minutes) during prolonged shutdown periods.
Prior to an operation check run ensure that there is sufficient liquid available for operating the pump.
2.The pump is removed from the pipe and stored
Before putting the pump into storage, carry out all checks
specified in sections 7.1 to 7.4. Then apply appropriate
preservatives:
Spray-coat the inside wall of the pump casing, and in particular the impeller clearance areas,with a preservative.
Spray the preservative through the suction and discharge
nozzles. It is advisable to close the pump nozzles (e.g.with
plastic caps or similar).
6.4 Returning to service after storage
Before returning the pump to service, carry out all checks
and maintenance work specified in sections 7.1 and 7.2.
In addition, the instructions laid down in the sections
on “Commissioning” (6.1) and ”Operating limits” (6.2)
must be observed.
Immediately following completion of the work, all safety-relevant and protective devices must be re-installed
and/or re-activated.
7 Servicing / maintenance
7.1 General instructions
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.
A regular maintenance schedule will help avoid expensive
repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure and
work.
Work on the unit must only be carried out with the
electrical connections disconnected. Make sure
that the pump set cannot be switched on accidentally
(danger to life!).
Pumps handling liquids posing health hazards
must be decontaminated. When draining the medi
um see to it that there is no risk to persons or the environment. All relevant laws must be adhered to (danger to
life)!
7.2 Servicing / inspection
7.2.1 Supervision of operation
The pump must run quietly and free from vibrations at all times.
The pump must never be allowed to run dry.
Do not run the pump against a closed shut-off valve for
prolonged periods of time so as to avoid heating up of
the fluid pumped.
Max. permissible room temperature 40 ºC.
Bearing temperature may exceed room temperature by up to
50 ºC but must never rise above +90 ºC (measured external-
ly on the motor housing).
For required minimum flows please refer to section 6.2.3.
During pump operation the shut-off valve in the suction
line must not be closed.
The mechanical seal shows only slight or invisible (vapour)
leakage during operation. It is maintenance-free.
Any stand-by pumps installed shall be switched on and then
immediately off again once a week to keep them operational.
Attention shall be paid to the correct functioning of the auxil-
iary connections.
7.2.2 Lubrication and lubricant change
7.2.2.1 Lubrication
The rolling element bearings in the KSB IEC motor are
grease-lubricated. The lubricant change intervals as well as
the required quantity and quality are specified below.
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Etabloc
Caution
Caution
Page 11
7.2.2.2 Grease quality / grease change
The bearings are packed with high-quality lithium-soap
grease. Under normal conditions the grease-lubricated bearings will run for 15,000 operating hours or 2 years. Under
unfavourable operating conditions, e.g. high room temperature, high atmospheric humidity, dust-laden air, aggressive
industrial atmosphere etc., the bearings shall be checked
earlier and cleaned and re-lubricated, if required.
Use a high-quality lithium-soap grease, free of resin and acid,
not liable to crumble and with good rust-preventive characteristics. The grease should have a penetration number
between 2 and 3, corresponding to a worked penetration
between 220 and 295 mm/10. Its drop point must not be
below 175ºC. The bearing cavities must only be half-filled
with grease.
If required, the bearings may be lubricated with greases of
other soap bases. Since greases of differing soap bases must
not be mixed, the bearings must be thoroughly cleaned
beforehand. The re-lubrication intervals required must then
be adjusted to the greases used.
Please observe the local laws applicable to the
disposal of such substances!
7.2.2.3 Deep-groove ball bearings/ Lubricant quantity for
KSB IEC motor
Deep-groove ball bearings to DIN 625
Code Grease g
6004 C3 2
6205 C3 3
6206 C3 4
6208 C3 6
6209 C3 7
6210 C3 7
6212 C3 7
6213 C3 11
- for KSB motor with extended shaft
Deep-groove ball bearings to DIN 625
Code
6305 C3
6306 C3
6308 C3
6309 C3
Closed bearings greased for life (2 Z or 2 RS bearings) cannot be washed out and refilled. They will have to be replaced
by new ones.
7.3 Drainage / disposal
If the pump was used for handling liquids posing health
hazards, see to it that there is no risk to persons or the
environment when draining the medium. All relevant laws
must be heeded. If required, wear safety clothing and a protective mask!
The flushing liquid used and any liquid residues in the pump
must be properly collected and disposed of without posing
any risk to persons or the environment.
7.4 Dismantling
Before dismantling the pump, secure it so as to make
sure it cannot be switched on accidentally . The shut-of f
valves in the suction and discharge lines must be closed.
The pump must have cooled down to ambient temperature,
pump pressure must have been released and the pump must
have been drained.
Dismantling and reassembly must always be carried out in
accordance with the relevant exploded view.
7.4.1 Fundamental instructions and recommendations
Repair and maintenance work to the pump must only be carried out by specially trained personnel, using original spare
parts
(see 2.7).
Observe the safety regulations laid down in section 7.1.
Any work on the motor shall be governed by the specifications and regulations of the respective motor supplier.
Dismantling and reassembly must always be carried out
in the sequence shown in the relevant exploded views on
pages 16 to 23.
In the case of damage or pump failure please contact our
nearest customer service centre.
For customer service centres please refer to the attached list
of addresses.
7.4.2 Preparations for dismantling
1 Interrupt power supply.
2 Dismantling the complete unit:
2.1 Disconnect the motor from the power supply.
2.2 Unbolt the discharge and suction nozzle from the piping.
2.3 Depending on the pump /motor size, unscrew the bolts
that fix the support foot and/or motor foot to the foundation.
2.4 Remove the complete unit from the piping.
3 The pump casing remains in the piping during disman-
tling.
3.1 Disconnect the motor from the power supply.
3.2 Unscrew hex. nuts 920.2/.3/.4.
3.3 Depending on the pump /motor size, unscrew the bolts
that fix the support foot and/or motor foot to the foundation.
3.4 Withdraw the complete rotating assembly with the motor
from the pump casing.
4 Pump (Etabloc-N only) remains in the piping,motor is
removed
4.1 Disconnect the motor from the power supply.
4.2 Press cover plates 68-3 slightly together and remove
from drive lantern 341.
4.3 Undo hex. nuts 920.5.
4.4 Undo hex. head bolts 901.3.
4.5 Insert both lock washers 931 into the groove in shaft 210.
4.6 Tighten hex. head bolts 901.
4.7 Remove the motor.
After a prolonged period of operation the individual components may be hard to pull off the shaft. If this is the case, use
a brand name penetrating agent and/or - if possible - an
appropriate pull-off device.
Under no circumstances use force.
7.4.3 Pump
Dismantle the pump in the sequence shown in the exploded
views on pages 16 to 23.
7.4.4 Mechanical seal
In order to replace the mechanical seal the pump must be
dismantled.
After removing impeller 230 pull mechanical seal 433 off the
shaft by hand.
Prior to reassembly, clean the shaft sleeve 523 and touch up
score marks or scratches, if any, with a polishing cloth. If the
score marks are still visible, fit a new shaft sleeve. Clean the
seat ring location.
Etabloc
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Caution
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Page 12
11
7.5 Reassembly
7.5.1 Pump
The pump shall be reassembled in accordance with the rules
of sound engineering practice.
The locating surfaces of the individual components must be
coated with graphite or similar before reassembly. The same
applies to bolted connections.
O-rings shall be examined for signs of damage and replaced
by new ones, if necessary.
Gaskets shall always be replaced by new ones.Make sure that
new gaskets have the same thickness as the old ones.
Gaskets of asbestos-free materials or graphite must always
be fitted without using lubricants.
Avoid the use of mounting aids as far as possible. Should a
mounting aid be required after all, use a commercially available contact adhesive (e.g. Pattex) or sealing agent (HYLOMAR or Epple 33).The adhesive shall only be applied at
selected points and in thin layers. Do not use cyanoacrylate
adhesives (quick-setting adhesives).
If the seal area between the impeller neck and the casing
wear ring is worn, the casing wear rings 502.1 and 502.2 (if fitted) must be replaced by new ones.
Clearances:
new 0.3 mm in diameter
max. permissible enlargement to 0.9 mm in diameter
Reassembly is effected in reverse order to dismantling. Make
sure to assemble the components in their correct sequence.
7.5.2 Mechanical seal
Reassembly is effected in reverse order to dismantling.
The following rules must be observed when fitting a mechan-
ical seal:
Extreme care and cleanliness.
The protective wrapping of the contact faces shall only be
removed immediately before assembly takes place.
Take care not to damage the seal faces and O-rings.
Clean the shaft and the seat ring location in the discharge
cover and gently remove any deposits.
When fitting the seal, shaft sleeve 523 may be wetted with
water to reduce the friction forces.
Ethylene propylene rubber elastomers must
never come into contact with oil or grease. Water
shall be used as a lubricant during fitting.
Press the seat ring into discharge cover 163 by hand or fin-
gers only. Make sure that the pressure is applied evenly.
7.5.3 Motor for Etabloc N
Reassembly is effected in reverse order to dismantling.
When mounting shaft 210 onto the motor shaft
stub, make sure that the keyway of the motor
shaft end aligns with the slot in shaft 210.
7.5.4 Tightening torques
Fig. 7.5-2 Tightening points, pump set
Position Thread size Tightening torque
1)
mm MA [Nm]
M 10 40
A
M 12 55
M 12 x 1.5 25
B
M 20 x 1.5 85
M 30 x 1.5 140
M 8 15
C
M 10 30
M 12 45
M 16 80
D
M 6 10
M 8 25
1) for unlubricated threads
A = bolted connections at the casing components
B = impeller nut
C = bolts between drive lantern and motor
D = screw between taper lock ring and stub shaft
Etabloc
Caution
Caution
Page 13
7.6 Spare parts
7.6.1 Ordering spare parts
When ordering spare parts please always quote the following
data stated on the name plate, e.g.
Type
Serial No
7.6.2 Recommended spare parts stock for 2 years’ continuous operation in accordance with DIN 24 296
Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 10 and more
Part No. Description Quantity of spare parts
210 Shaft
1)
1 1 1 2 2 2 20 %
230 Impeller (including casing wear ring 502.2)2)1 1 1 2 2 2 20 %
400.1/.2 Gaskets (set) 4 6 8 8 9 12 150 %
433 Mechanical seal: 1 1 2 2 2 3 25 %
502.1 Casing wear ring
2)
2 2 2 3 3 4 50 %
523 Shaft sleeve
2)
2 2 2 3 3 4 50 %
1) not for Etabloc G
2) Casing wear rings and shaft sleeve applicable only to Etabloc G
Etabloc
12
Page 14
13
Cause Remedy
1)
D Pump delivers against an excessively high discharge Re-adjust to duty point.
pressure
.
D Excessively high back pressure. Check plant for impurities.
D D D Pump or piping are not completely vented or primed. Vent and/or prime.
D Suction line or impeller clogged Remove deposits in the pump and/or piping.
D Formation of air pockets in the piping. Alter piping layout.
Fit a vent valve.
D D D Suction head is too high/NPSH- available Check/alter liquid level.
(positive suction head) is too low. Fully open shut-off valve in the suction line.
Change suction line, if the friction losses in the suction line
are too high.
Check any strainers installed/suction opening.
D Wrong direction of rotation. Interchange two of the phases of the power supply cable.
D D Wear of internal pump parts. Replace worn components by new ones.
D D D Pump back pressure is lower than specified in the purchase Adjust to duty point.
order.
D The density or viscosity of the fluid pumped is higher than
2)
specified in the order.
D Defective gasket Fit new gasket between volute casing and discharge cover.
D Worn shaft seal. Fit new shaft seal.
D D Score marks or roughness on shaft sleeve. Fit new shaft sleeve.
Fit new shaft seal.
D Vibrations during pump operation Improve suction conditions.
Increase pressure at the pump suction nozzle.
D D D Pump is warped Check pipeline connections and secure fixing of pump; if required,
reduce the distances between the pipe clamps.
Fix the pipelines using anti-vibration material.
D Increased axial thrust.
2)
Clean balancing holes in the impeller.
Fit new wear rings.
D Insufficient or excessive quantity of lubricant or unsuitable Top up, reduce or change lubricant.
lubricant.
D D Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
D Rotor is out of balance. Clean the impeller.
Re-balance the impeller.
D Defective bearing(s). Fit new bearings.
D D Insufficient rate of flow. Increase the minimum rate of flow.
D Incorrect setting of motor protection switch Check setting.
Fit new motor protection switch
D D Transport lock has not been removed from the shaft groove. Remove.
1) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
2) Request particulars.
8 Trouble-shooting
Etabloc
Pump delivers insufficient flow rate
Motor is overloaded
Motor protection switch trips the pump
Excessive bearing temperature
Leakage at the pump
Excessive leakage at the shaft seal
Vibrations during pump operation
Excessive rise of temperature inside the pump
Page 15
9 Related documents
9.1 Typical installation positions
Etabloc G
up to motor size 112 = 4 kW up to motor size 132 = 5.5 kW to
180 = 22 kW
As-delivered condition
Horizontal installation, attachment below
up to motor size 112 = 4 kW
For vertical installation with motor on top please contact KSB
Position of condensate holes o = open
x = closed
Horizontal installation, attachment above
Motor has to be turned through 180º
Etabloc N
up to motor size 180 = 22 kW
Etabloc
to180=22 kW
For vertical installation a vent valve must be fitted
to prevent dry running of the mechanical seal
14
1165:21/4
1167:22/5
1167:72
1167:68
1167:69
For vertical installation a vent valve must be fitted
to prevent dry running of the mechanical seal.
Page 16
15
9.2 Exploded view and list of components Etabloc G
Version with bolted-on discharge cover
Etabloc
Supplied in packaging units only
Part No. Description
102 Volute casing
163 Discharge cover
183
2)
Support foot
230 Impeller
400.1/.2 Gasket
412.1 O-ring
423.1/.2 Labyrinth seal
433 Mechanical seal
502.1/.2 Casing wear ring
Part No. Description
523 Shaft sleeve
550.1 1)Disc
802 Motor for close coupling
902.1/.2/.4
2)
Stud
903.1 Screwed plug
920.1-.3 Hex. nut
920.4
2)
Hex. nut
930 Spring washer
940 Key
Auxiliary connections
1M Pressure gauge
6B Casing drain
6 D Priming and venting
1) for Etabloc with shaft unit 25 only.
2) up to motor size 112 = 4 kW only, (from motor size 132 = 5.5 kW upwards with motor foot, not shown in exploded view)
Page 17
Etabloc
Supplied in packaging units only
Part No. Description
102 Volute casing
163 Discharge cover
183
2)
Support foot
230 Impeller
400.1/2 Gasket
412.1 O-ring
423.1/2 Labyrinth seal
433 Mechanical seal
502.1/.2 Casing wear ring
Part No. Description
523 Shaft sleeve
550.1
1)
Disc
802 Motor for close coupling
902.3/.4
2)
Stud
903.1 Screwed plug
920.1/.4 Hex. nut
930 Spring washer
940 Key
Auxiliary connections
1M Pressure gauge
6B Casing drain
6D Priming and venting
9.3 Exploded view and list of components Etabloc G
Version with clamped discharge cover
1) for Etabloc with shaft unit 25 only.
2) up to motor size 112 = 4 kW only
(from motor size 132 = 5.5 kW upwards with motor foot, not shown in exploded view)
16
Page 18
9.4 Exploded view and list of components Etabloc N
Supplied in packaging units only
Part No. Description
102 Volute casing
163 Discharge cover
210 Shaft
230 Impeller
341 Drive lantern
400.1 Gasket
411.5 Joint ring
433 Mechanical seal
Part No. Description
801 Flanged motor
902.1/.3.4.5 Stud
903.1/.2 Screwed plug
920.1/.4/.5 Hex. nut
930 Spring washer
940 Key
Auxiliary connections
1M Pressure gauge
6B Casing drain
6D Priming and venting
Etabloc
17
Page 19
Page 20
Etabloc
Gartone Press: Tel: (011) 440-6126 29.6.2004 Subject to technical modification without prior notice
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