KSB KWP-Bloc Operating Manual

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Dry-installed Close-Coupled Pump

KWP-Bloc

Installation/Operating Manual

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Legal information/Copyright

Installation/Operating Manual KWP-Bloc

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

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Contents

Glossary .................................................................................................................................................. 5

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

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

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

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

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

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

1.6 Key to safety symbols/markings.......................................................................................................................7

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

2.1 General..............................................................................................................................................................8

2.2 Intended use .....................................................................................................................................................8

2.3 Personnel qualification and training...............................................................................................................9

2.4 Consequences and risks caused by non-compliance with this manual .........................................................9

2.5 Safety awareness ..............................................................................................................................................9

2.6 Safety information for the operator/user.......................................................................................................9

2.7 Safety information for maintenance, inspection and installation ..............................................................10

2.8 Unauthorised modes of operation................................................................................................................10

2.9 Explosion protection ......................................................................................................................................10

2.9.1 Marking ..............................................................................................................................................10

2.9.2 Temperature limits.............................................................................................................................11

2.9.3 Monitoring equipment......................................................................................................................11

2.9.4 Operating limits .................................................................................................................................12

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

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

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

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

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

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

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

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

4.2 Designation.....................................................................................................................................................15

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

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

4.5 Materials .........................................................................................................................................................18

4.6 Configuration and function...........................................................................................................................19

4.7 Noise characteristics .......................................................................................................................................20

4.8 Scope of supply...............................................................................................................................................20

4.9 Dimensions and weights ................................................................................................................................20

5 Installation at Site................................................................................................................................ 21

5.1 Checks to be carried out prior to installation...............................................................................................21

5.2 Installing the pump set ..................................................................................................................................21

5.3 Piping ..............................................................................................................................................................22

5.3.1 Connecting the piping.......................................................................................................................22

5.3.2 Permissible forces and moments at the pump nozzles....................................................................24

5.4 Enclosure/insulation .......................................................................................................................................25

5.5 Electrical connection ......................................................................................................................................25

5.5.1 Setting the time relay........................................................................................................................26

5.5.2 Connecting the motor .......................................................................................................................26

5.5.3 Earthing..............................................................................................................................................26

5.6 Checking the direction of rotation................................................................................................................26

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Contents

6 Commissioning/Start-up/Shutdown................................................................................................... 28

6.1 Commissioning/Start-up.................................................................................................................................28

6.1.1 Prerequisites for commissioning/start-up .........................................................................................28

6.1.2 Filling in the lubricant .......................................................................................................................28

6.1.3 Shaft seal ............................................................................................................................................29

6.1.4 Priming and venting the pump.........................................................................................................30

6.1.5 Start-up...............................................................................................................................................31

6.1.6 Shutdown ...........................................................................................................................................32

6.2 Operating limits..............................................................................................................................................33

6.2.1 Ambient temperature........................................................................................................................33

6.2.2 Frequency of starts.............................................................................................................................33

6.2.3 Fluid handled .....................................................................................................................................34

6.3 Shutdown/storage/preservation ....................................................................................................................35

6.3.1 Measures to be taken for shutdown ................................................................................................35

6.4 Returning to service .......................................................................................................................................35

7 Servicing/Maintenance........................................................................................................................ 37

7.1 Safety regulations...........................................................................................................................................37

7.2 Servicing/Inspection........................................................................................................................................38

7.2.1 Supervision of operation...................................................................................................................38

7.2.2 Inspection work..................................................................................................................................40

7.2.3 Lubrication and lubricant change.....................................................................................................40

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

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

7.4.1 General information/Safety regulations...........................................................................................42

7.4.2 Preparing the pump set.....................................................................................................................43

7.4.3 Dismantling the motor ......................................................................................................................43

7.4.4 Removing the impeller ......................................................................................................................43

7.4.5 Removing mechanical seal MG1-G6..................................................................................................43

7.4.6 Removing the shaft and rolling element bearings ..........................................................................44

7.5 Reassembling the pump set...........................................................................................................................44

7.5.1 General information/Safety regulations...........................................................................................44

7.5.2 Installing the shaft and rolling element bearing.............................................................................45

7.5.3 Fitting the mechanical seal................................................................................................................45

7.5.4 Fitting the impeller............................................................................................................................46

7.5.5 Mounting the motor..........................................................................................................................47

7.6 Tightening torques.........................................................................................................................................47

7.6.1 Tightening torques for the pump.....................................................................................................47

7.7 Spare parts stock.............................................................................................................................................47

7.7.1 Ordering spare parts..........................................................................................................................47

7.7.2 Recommended spare parts stock for 2 years' operation to DIN24296 ..........................................48

7.7.3 Interchangeability of pump components.........................................................................................49

8 Trouble-shooting.................................................................................................................................. 50

9 Related Documents.............................................................................................................................. 52

9.1 General assembly drawing with list of components ....................................................................................52

9.1.1 Horizontal installation.......................................................................................................................52

9.1.2 Vertical installation............................................................................................................................54

9.1.3 Mechanical seal..................................................................................................................................56

9.1.4 List of components.............................................................................................................................57

10 EU Declaration of Conformity............................................................................................................. 60

11 Certificate of Decontamination........................................................................................................... 61

Index ..................................................................................................................................................... 62

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Glossary

Certificate of decontamination

A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled.

Close-coupled design

Motor directly fitted to the pump via a flange or a drive lantern

Oil reservoir

The oil reservoir prevents the mechanical seal from running dry, for example in the event of a short period of negative pressure on the suction side.

Pool of pumps

Customers/operators’ pumps which are purchased and stored regardless of their later use.

Pump

Machine without drive, additional components or accessories

Pump set

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

Suction lift line/suction head line

The pipeline which is connected to the suction nozzle

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1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variants indicated on the front cover.

The manual describes the proper and safe use of this equipment in all phases of operation.

The name plate indicates the type series and size, the main operating data, the order number and the order item number. The order number and order item number clearly identify the pump set and serve as identification for all further business processes.

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

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB refer to the sub-sections under Servicing/Maintenance.

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialist technical personnel. (ðSection2.3,Page9)

1.4 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Data sheet Description of the technical data of the pump (set) General arrangement drawing/

outline drawing

Description of mating and installation dimensions

for the pump (set), weights Drawing of auxiliary connections Description of auxiliary connections Hydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power input General assembly drawing

Sectional drawing of the pump Sub-supplier product literature1)Operating manuals and other product literature

describing accessories and integrated machinery

components Spare parts lists Piping layout List of components Drawing for assembly

Description of spare parts

Description of auxiliary piping

Description of all pump components

Sectional drawing of the installed shaft seal

For accessories and/or integrated machinery components observe the relevant manufacturer's product literature.

1.5 Symbols

Table2: Symbols used in this manual

Symbol Description

1) If agreed upon in scope of supply

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✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳ Safety instructions

⇨

Result of an action

⇨ Cross-references

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1 General

DANGER

WARNING

CAUTION

Symbol Description

Step-by-step instructions

2. Note

Recommendations and important information on how to handle the product

1.6 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

DANGER

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

WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.

CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions.

Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with EU Directive 2014/34/EU (ATEX).

General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury.

Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage.

Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions.

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2 Safety

DANGER

2 Safety

All the information contained in this section refers to hazardous situations. In addition to the present general safety information the action-related safety

information given in the other sections must be observed.

2.1 General

This operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property.

The safety information in all sections of this manual must be complied with. The operating manual must be read and understood by the responsible specialist

personnel/operators prior to installation and commissioning. The contents of this operating manual must be available to the specialist personnel

at the site at all times. Information attached directly to the product must always be complied with and kept

in a perfectly legible condition at all times. This applies to, for example:

▪ Arrow indicating the direction of rotation ▪ Markings for connections ▪ Name plate

The operator is responsible for ensuring compliance with all local regulations not taken into account in this operating manual.

2.2 Intended use

▪ The pump (set) must only be operated in the fields of application and within the

use limits specified in the other applicable documents. (ðSection1.4,Page6)

▪ 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 product

literature of the pump model or variant.

▪ Never operate the pump without the fluid to be handled. ▪ Observe the minimum flow rates indicated in the data sheet or product literature

(to prevent overheating, bearing damage, etc).

▪ Observe the minimum flow rate and maximum flow rate indicated in the data

sheet or product literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc).

▪ Do not throttle the flow rate on the suction side of the pump (to prevent

cavitation damage).

▪ Consult the manufacturer about any use or mode of operation not described in

the data sheet or product literature.

▪ Only use the respective impeller types in combination with the fluids described

below.

Closed multi-channel impeller (impeller type K)

Suitable for the following fluids:

Contaminated, solids-laden fluids not containing stringy material and containing no or very little entrapped gas

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2 Safety

Open multi-vane impeller (impeller type O)

Free-flow impeller (impeller typeF)

Suitable for the following fluids:

uncontaminated or slightly contaminated fluids with little entrapped gas as well as fluids liable to form deposits and bunch

Suitable for the following fluids:

fluids containing coarse solids and stringy material as well as fluids with entrapped gas and entrapped air

2.3 Personnel qualification and training

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

The responsibilities, competence and supervision of all personnel involved in transport, installation, operation, maintenance and inspection must be clearly defined by the operator.

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

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

2.4 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with these operating instructions will lead to forfeiture of

warranty cover and of any and all rights to claims for damages.

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

– Hazards to persons due to electrical, thermal, mechanical and chemical

effects and explosions – Failure of important product functions – Failure of prescribed maintenance and servicing practices – Hazard to the environment due to leakage of hazardous substances

2.5 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 regulations and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards, directives and laws

2.6 Safety information for the operator/user

▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪ Do not remove any protective equipment (e.g. contact guards) during operation. ▪ Provide the personnel with protective equipment and make sure it is used.

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2 Safety

DANGER

▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.

explosive, toxic, hot) so as to avoid any danger to persons and the environment. Adhere to all relevant laws.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply companies.)

▪ 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 set installation.

2.7 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the pump (set) are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts/components authorised by the

manufacturer. The use of other parts/components can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that maintenance, inspection and installation is performed

by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

▪ Only carry out work on the pump (set) during standstill of the pump. ▪ Only perform work on the pump set when it has been disconnected from the

power supply (de-energised).

▪ The pump (set) must have cooled down to ambient temperature. ▪ Pump pressure must have been released and the pump must have been drained. ▪ When taking the pump set out of service always adhere to the procedure

described in the manual. (ðSection6.3,Page35)

▪ Decontaminate pumps which handle fluids posing a health hazard.

(ðSection7.3,Page42)

▪ As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service, observe all instructions on commissioning. (ðSection6.1,Page28)

2.8 Unauthorised modes of operation

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

The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use.

2.9 Explosion protection

Always observe the information on explosion protection given in this section when operating the product in potentially explosive atmospheres.

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

Special conditions apply to the operation of explosion-proof pump sets to EU Directive 2014/34/EU (ATEX). Especially adhere to the sections in this manual marked with the symbol opposite and the following sections, (ðSection2.9.1,Page10) to (ðSection2.9.4,Page12) The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. Never operate the pump set outside the limits stated in the data sheet and on the name plate. Prevent impermissible modes of operation at all times.

2.9.1 Marking

Pump The marking on the pump refers to the pump part only.

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2 Safety

Example of such marking: II 2 G c TX (EN 13463-1) or II 2G Ex h IIC T5-T1 Gb (ISO 80079-36)

The pump complies with the requirements of type of protection constructional safety "c" to ISO80079-37.

Refer to the data sheet for the applicable temperature class.

Motor The motor has its own marking. The marking is maintained on the condition that the

temperatures the pump causes to develop at the motor flange and motor shaft are permitted by the motor manufacturer. The motors used by KSB on pumps with ATEX certification meet this condition.

2.9.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected in the area of the rolling element bearings. The surface temperature at the pump casing corresponds to the temperature of the fluid handled. If the pump is heated, the operator of the system is responsible for observing the specified temperature class. The surfaces in the bearing bracket area must be freely exposed to the atmosphere. The table below lists the temperature classes and the resulting theoretical temperature limits of the fluid handled.

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

Table4: Temperature limits

Temperature class to EN 13463-1 or ISO

80079-36

T1 100°C T2 100°C T3 100°C

Maximum permissible

fluid temperature

T4 100°C T5 Only after consultation

with the manufacturer

Temperature class T4 Based on an ambient temperature of 40°C and proper maintenance and operation,

compliance with temperature class T4 is warranted in the area of the rolling element bearings. If the ambient temperature exceeds 40°C, contact the manufacturer.

Temperature class T5 A special design is required for compliance with temperature class T5 in the bearing

area. Misuse, malfunctions or non-compliance with the instructions may result in

substantially higher temperatures. If the pump is to be operated at a higher temperature, if there is no data sheet or if

the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature.

2.9.3 Monitoring equipment

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

Contact KSB for further information about monitoring equipment.

2) Due to the maximum permissible fluid temperature

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2 Safety

2.9.4 Operating limits

The minimum flows indicated in (ðSection6.2.3.1,Page34) refer to water and water-like fluids handled. Longer operating periods with these fluids and at the flow rates indicated will 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, it is essential to check whether an additional heat build-up may occur and if the minimum flow rate must therefore be increased. The calculation formula in (ðSection6.2.3.1,Page34) can be used to check whether additional heat build-up may lead to a dangerous temperature increase at the pump surface.

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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 and notify KSB or the supplying dealer and the insurer about the damage in writing immediately.

3.2 Transport

DANGER

The pump (set) could slip out of the suspension arrangement

Danger 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 motor

eyebolt.

▷ Observe the information about weights, centre of gravity and fastening points. ▷ Observe the applicable local accident prevention regulations. ▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.

CAUTION

Incorrect transport of the pump

Damage to the shaft seal!

▷ For transport, lock the pump shaft with a suitable transport lock to prevent any

movement of the shaft.

When transporting the pump without motor, shaft 210 must be locked. To transport the pump/pump set suspend it from the lifting tackle as shown.

Transporting the pump Transporting the pump set

3.3 Storage/preservation

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

CAUTION

Damage during storage due to humidity, dirt or vermin

Corrosion/contamination of the pump (set)!

▷ For outdoor storage cover the pump (set) or the packaged pump (set) and

accessories with waterproof material.

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3 Transport/Temporary Storage/Disposal

CAUTION

Wet, contaminated or damaged openings and connections

Leakage or damage to the pump!

▷ Clean and cover pump openings and connections as required prior to putting

the pump into storage.

Store the pump (set) in a dry, protected room where the atmospheric humidity is as constant as possible.

Rotate the shaft by hand once a month, e.g. via the motor fan. If properly stored indoors, the pump set is protected for a maximum of 12 months.

New pumps/pump sets are supplied by our factory duly prepared for storage. For storing a pump (set) which has already been operated, the shutdown measures

must be adhered to. (ðSection6.3.1,Page35)

3.4 Return to supplier

1. Drain the pump as per operating instructions. (ðSection7.3,Page42)

2. Flush and clean the pump, particularly if it has been used for handling noxious, explosive, hot or other hazardous fluids.

3. If the pump has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen also neutralise the pump and blow through with anhydrous inert gas to ensure drying.

4. Always complete and enclose a certificate of decontamination when returning the pump. Indicate any safety measures and decontamination measures taken. (ðSection11,Page61)

NOTE

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

3.5 Disposal

WARNING

Fluids handled, consumables and supplies which are hot and/or pose a health hazard

Hazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any fluid residues. ▷ Wear safety clothing and a protective mask if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

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

2. Separate and sort the pump materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

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

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4 Description of the Pump (Set)

4.1 General description

Pump for handling uncontaminated and contaminated fluids.

▪ Close-coupled pump with shaft seal ▪ Directly flanged standardised motor

4.2 Designation

Table5: Designation example

Position

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

K W P F 1 2 5 - 1 0 0 - 0 2 5 0 G D N G 1 0 A B H 7 4

See name plate and data sheet See data sheet

Table6: Designation key

Position Code Description

1-3 Pump type

KWP KWP

4 Impeller

F Free-flow impeller K Channel impeller O Open impeller

5-17 Size, e.g.

125 Nominal suction nozzle diameter [mm] 100 Nominal discharge nozzle diameter [mm] 0250 Nominal impeller diameter [mm]

18 Pump casing material

D NORIDUR 1.4593 G Grey cast iron GJL-250

19 Impeller material

D NORIDUR 1.4593 N ERN -

20 Wear plate material/ wear ring material

D NORIDUR 1.4593 N ERN -

21 Discharge cover material

D NORIDUR 1.4593 G Grey cast iron GJL-250

22-23 Design version

10 Version

24-25 Shaft seal operating mode

A Single mechanical seal in A-type cover

26 Design

Standard

X Non-standard (BT3D, BT3)

27-29 Installation type

0 Pump only (Fig.0 bare-shaft pump)

3) Available on request only

4) Blank

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4 Description of the Pump (Set)

KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal

ZN 3804 - E 37 X 52

Q n

P-No.

Mat. No. 01220221

KWPK125-100-0250 GGGG10

2018

0520-5-P-10000-31

997125086300550001

21.0

m³/h

1420

1/min

13.0

3 4

Position Code Description

27-29 BH Close-coupled, horizontal

BV Close-coupled, vertical

30-32 Motor rating PN [kW]

7 7

33 Number of motor poles

4.3 Name plate

Fig.1: Name plate (example)

1 Type series, size, material, and

design version

3 KSB order number and KSB order

item number 5 Speed 6 Year of construction 7 Head 8 Pump input power (optional) 9 Further required information

(optional)

4.4 Design details

Design

▪ Volute casing pump ▪ Radially split volute casing ▪ Close-coupled design ▪ Pump casing fitted with a wear plate ▪ Single-stage ▪ Single-entry

2 Customer-specific information

(optional)

4 Flow rate

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4 Description of the Pump (Set)

0,5

D00472

D00473

D00474

Fig.2: Design with wear plate for: GNNG, GDNG, DDDD

▪ Pump casing fitted with a wear plate ▪ Clearances

Fig.3: Clearances

1 Impeller type K 2 Impeller type O 3 Impeller type F

Installation types

▪ Horizontal installation ▪ Vertical installation

Shaft seal

▪ Uncooled mechanical seal with/without oil reservoir

Pump sets for vertical installation are generally fitted with an oil reservoir. For horizontal installation, an oil reservoir can be fitted as an option.

Only single mechanical seals are fitted in the conical discharge chamber.

Table7: Mechanical seal makes

Material variant of pump

Design Supplier Type Material

combination to EN12756

GNNG GDNG DDDD

Single, unbalanced

Burgmann

John Crane 2100 Q5Q5VGG

MG1 - G6 Q1Q1VGG

Q1Q1EGG

Q5Q5EGG

Single, balanced KSB 4 KBL U1U1VGG

5) Pump sets for vertical installation are fitted with an oil reservoir. For horizontal installation, an oil reservoir can be fitted as an option.

6) Other mechanical seal makes to EN12756 (DIN24960), version I1k possible

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4 Description of the Pump (Set)

Impeller type

▪ Various application-oriented impeller types (ðSection2.2,Page8)

Bearings

▪ Grease-packed deep groove ball bearings

Table8: Deep-groove ball bearings

Motor size Deep groove ball bearing

from to

90 112 6012 2RS C

132 180 6312 2RS C

to DIN 625

Automation

Automation options:

▪ PumpDrive ▪ PumpMeter

Connections

▪ Suction flange with blind holes to DIN2501, PN10/16 with tapped blind holes of

1,25d for hexagon head bolts

▪ Discharge flange with clearance holes to EN1092-2, PN16/21/B

4.5 Materials

Table9: Materials depending on material variant

Part No. Description Material variant

DDDD GDNG GNNG

101 Pump casing Noridur 1.4593 EN-GJL-250 EN-GJL-250

135.01 Wear plate, suction side Noridur 1.4593 ERN ERN 146 Intermediate lantern EN-GJL-250 EN-GJL-250 EN-GJL-250 163 Discharge cover Noridur 1.4593 EN-GJL-250 EN-GJL-250 210 Shaft 1.4462 1.4021+QT700 1.4021+QT700 230 Impeller Noridur 1.4593 Noridur 1.4593 ERN 509 Intermediate ring EN-GJL-250 - -

524.01 Shaft protecting sleeve 1.4539 1.4539 1.4539 906 Impeller screw 1.4539 C35E+N C35E+N

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4 Description of the Pump (Set)

4.6 Configuration and function

Fig.4: Sectional drawing C2 design

1 Wear plate 2 Casing/discharge nozzle 3 Discharge cover 4 Intermediate lantern 5 Shaft 6 Casing/suction nozzle 7 Impeller 8 Shaft seal chamber 9 Bearing, pump end 10 Motor

Design The horizontal, non-self-priming, radially split volute casing pump in back pull-out

design is designed with an axial fluid inlet and a radial outlet. The hydraulic system and the motor are firmly connected and form a close-coupled

unit. Impeller (7) and motor (10) are arranged on a common shaft (5).

Function The steadily rotating impeller (7) of the centrifugal pump transfers mechanical

energy to the fluid passing through. The fluid enters the pump axially via a suction nozzle (6) and is accelerated outward

in a cylindrical flow by the rotating impeller (7). The flow profile of the pump casing converts the kinetic energy of the fluid into pressure energy. The fluid leaves the pump via the discharge nozzle (2).

The casing is fitted with a replaceable wear plate (1). The diagonal clearance gap prevents frequent deviation of the flow in the clearance gap heading in the direction of the suction nozzle. This ensures a longer service life if solids-laden fluids are handled.

The casing is closed by a discharge cover (3). The shaft (5) enters the casing via this discharge cover. A shaft seal (8) provides reliable sealing towards the atmosphere.

The shaft is supported by oil-lubricated rolling element bearings (9). The motor (10) is connected to the casing via an intermediate lantern (4).

Sealing The pump is sealed with a shaft seal.

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4 Description of the Pump (Set)

4.7 Noise characteristics

Table10: Surface sound pressure level L

Rated power input PN [kW]

1 67 60 2 69 62 3 71 64 4 72 66 6 74 68

8 76 70 11 78 73 15 80 75 19 81 77 22 83 78

7)8)

2900 rpm

[dB]

Pump set

1450 rpm

[dB]

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 current squirrel-cage motor ▪ Cover plates at drive lantern to EN294

4.9 Dimensions and weights

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

7) Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.80 - 1.1 range and for noncavitating operation. If noise levels are to be warranted, add +3dB for measuring and constructional tolerance.

8) Increase for 60Hz operation: 3500 rpm, +3dB; 1750 rpm + 1dB; 1160 rpm + 0 dB

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5 Installation at Site

5.1 Checks to be carried out prior to installation

Place of installation

WARNING

Installation on mounting surface which is unsecured and cannot support the load

Personal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets the

requirements of exposure class XC1 to EN206-1.

▷ The mounting surface must be set, flat, and level. ▷ Observe the weights indicated.

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

5.2 Installing the pump set

DANGER

Static charging due to insufficient potential equalisation

Explosion hazard!

▷ Make sure that the connection between pump and baseplate is electrically

conductive.

Installing the pump set in a horizontal position

No special foundation is required for installation. An even slab of concrete is sufficient as an installation surface.

On pumps supplied with a mounting plate, the mounting plate can be used as a template for drilling. The mounting plate and the foundation rails must not be set in concrete.

ü The installation surface has the required strength and characteristics.

1. Position the pump set on the anchoring holes and align it with the help of a spirit level (on the discharge nozzle).

2. Compensate any differences in height until the discharge nozzle is in a horizontal position.

3. Fasten the pump set. The screws/bolts are not included in the scope of supply.

Size Fasteners

Foundation bolts Expanding anchor bolts

065-040-0250 M16×200 MU 065-050-0200 M16×200 MU 065-050-0201 M16×200 MU 080-065-0200 M16×200 MU 080-065-0201 M16×200 MU 080-040-0315 M16×200 MU F1/18-60, Ø 18×160 080-065-0313 M16×200 MU F1/18-60, Ø 18×160 080-065-0315 M16×200 MU F1/18-60, Ø 18×160 100-080-0250 M16×200 MU F1/18-60, Ø 18×160 100-080-0251 M16×200 MU F1/18-60, Ø 18×160 100-080-0311 M16×200 MU F1/18-60, Ø 18×160

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5 Installation at Site

Size Fasteners

Foundation bolts Expanding anchor bolts

100-080-0315 M16×200 MU F1/18-60, Ø 18×160 125-100-0250 M16×200 MU F1/18-60, Ø 18×160 125-100-0251 M16×200 MU F1/18-60, Ø 18×160 125-100-0253 M16×200 MU F1/18-60, Ø 18×160 125-100-0315 M16×200 MU F1/18-60, Ø 18×160

Installing the pump set in a vertical position

CAUTION

Ingress of leakage into the motor

Damage to the pump!

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

CAUTION

Insufficient lubrication of the mechanical seal

Damage to the mechanical seal!

▷ Pump sets which are designed for horizontal installation must never be

installed in a vertical position.

1. Check whether the pipeline can carry the weight of the pump. Install suitable supports if necessary.

2. Install the pump in the pipeline in a vertical position, with the motor on top.

5.3 Piping

5.3.1 Connecting the piping

DANGER

Impermissible loads acting on the pump nozzles

Danger to life from escaping hot, toxic, corrosive or flammable fluids!

▷ Do not use the pump as an anchorage point for the piping. ▷ Anchor the pipes in close proximity to the pump and connect them properly

without transmitting any stresses or strains.

▷ Observe the permissible forces and moments at the pump nozzles. ▷ Take appropriate measures to compensate for thermal expansion of the piping.

CAUTION

Incorrect earthing during welding work at the piping

Destruction of rolling element bearings (pitting effect)!

▷ Never earth the electric welding equipment on the pump or baseplate. ▷ Prevent current flowing through the rolling element bearings.

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5 Installation at Site

NOTE

Installing check and shut-off elements in the system is recommended, depending on the type of plant and pump. However, such elements must not obstruct proper drainage or hinder disassembly of the pump.

ü The suction lift line has been laid with a rising slope, the suction head line with a

downward slope towards the pump.

ü A flow stabilisation section having a length equivalent to at least twice the

diameter of the suction flange has been provided upstream of the suction flange.

ü The nominal diameters of the pipelines are equal to or greater than the nominal

diameters of the pump nozzles.

ü The pipelines have been anchored in close proximity to the pump and connected

without transmitting any stresses or strains.

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

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

CAUTION

Welding beads, scale and other impurities in the piping

Damage to the pump!

▷ Remove any impurities from the piping. ▷ If necessary, install a filter. ▷ Observe the information in (ðSection7.2.2.1,Page40) .

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

Fig.5: Filter in the piping

1 Differential pressure gauge 2 Filter

NOTE

Use a filter 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.

CAUTION

Aggressive flushing liquid and pickling agent

Damage to the pump!

▷ Match the cleaning operation mode and duration of flushing and pickling to

the casing materials and seal materials used.

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5 Installation at Site

[+]

DDDD

GNNG, GDNG

0,4

0,5

0,6

0,7

0,8

0,9

0 20 40 60 80 100

k = f(T)

T [°C]

5.3.2 Permissible forces and moments at the pump nozzles

The resulting permissible forces have been determined according to:

Forces and moments at the pump nozzles

The data on forces and moments apply to static piping loads only. If the limits are exceeded, they must be checked and verified. If a computerised strength analysis is required, values are available on request only. The values are only applicable if the pump is installed on a completely grouted baseplate and bolted to a rigid and level foundation.

Correction coefficients depending on material and temperature (see diagram below).

Table11: Permissible forces (F) and moments (M) at the pump nozzles

Size Suction nozzle Discharge nozzle

065-040-0250 3145 2065 2515 3235 2065 1525 1080 1527 990 1975 1255 1975 990 810 540 080-040-0315 3860 2515 3055 3950 2605 1975 1345 1527 990 1975 1255 1975 990 810 540 065-050-0200 3145 2065 2515 3235 2065 1525 1080 1527 990 1975 1255 1975 1255 990 630

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[N] [N] [N] [N] [Nm] [Nm] [Nm] [N] [N] [N] [N] [N] [Nm] [Nm] [Nm]

Fig.6: Temperature correction diagram Calculation of forces and moments for T > 20°C

Reduction formula:

Permissible force/moment = k (T) x force/moment from table Example:

▪ Material = DDDD ▪ T = 100°C ▪ k = 0.98

res

FxF

yTens+FyCom

pr-

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FzF

MxMyM

res

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5 Installation at Site

Size Suction nozzle Discharge nozzle

res

FxF

yTens+FyCom

FzF

pr-

MxMyM

res

[N] [N] [N] [N] [Nm] [Nm] [Nm] [N] [N] [N] [N] [N] [Nm] [Nm] [Nm]

065-050-0201 3145 2065 2515 3235 2065 1525 1080 1527 990 1975 1255 1975 1255 990 630 080-065-0200 3860 2515 3055 3950 2605 1975 1345 2515 1615 3145 2065 3235 2065 1525 1080 080-065-0201 3860 2515 3055 3950 2605 1975 1345 2515 1615 3145 2065 3235 2065 1525 1080 080-065-0315 3860 2515 3055 3950 2605 1975 1345 2515 1615 3145 2065 3235 2065 1525 1080 080-065-0313 3860 2515 3055 3950 2605 1975 1345 2515 1615 3145 2065 3235 2065 1525 1080 100-080-0250 4850 3145 3860 4940 3595 2695 1795 3055 1975 3860 2515 3950 2605 1975 1345 100-080-0251 4850 3145 3860 4940 3595 2695 1795 3055 1975 3860 2515 3950 2605 1975 1345 100-080-0311 4850 3145 3860 4940 3595 2695 1795 3055 1975 3860 2515 3950 2605 1975 1345 100-080-0315 4850 3145 3860 4940 3595 2695 1795 3055 1975 3860 2515 3950 2605 1975 1345 125-100-0250 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795 125-100-0251 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795 125-100-0253 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795 125-100-0315 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795

5.4 Enclosure/insulation

WARNING

The volute casing and casing/discharge cover take on the same temperature as the fluid handled

Risk of burns!

▷ Insulate the volute casing. ▷ Fit protective equipment.

5.5 Electrical connection

DANGER

Electrical connection work by unqualified personnel

Risk of fatal injury due to electric shock!

▷ Always have the electrical connections installed by a trained and qualified

electrician.

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

WARNING

Incorrect connection to the mains

Damage 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 starting method.

NOTE

A motor protection device is recommended.

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5 Installation at Site

5.5.1 Setting the time relay

CAUTION

Switchover between star and delta on three-phase motors with star-delta starting takes too long.

Damage to the pump (set)!

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

Table12: Time relay settings for star-delta starting:

Motor rating Y time to be set

[kW] [s]

≤ 30 < 3 > 30 < 5

5.5.2 Connecting the motor

NOTE

In compliance with IEC 60034-8, three-phase motors are always wired for clockwise rotation (looking at the motor shaft stub).

The pump's direction of rotation is indicated by an arrow on the pump.

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

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

5.5.3 Earthing

DANGER

Electrostatic charging

Explosion hazard! Damage to the pump set!

▷ Connect the PE conductor to the earthing terminal provided. ▷ Provide for potential equalisation between the pump set and foundation.

5.6 Checking the direction of rotation

DANGER

Temperature increases resulting from contact between rotating and stationary components

Explosion hazard! Damage to the pump set!

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

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WARNING

Hands inside the pump casing

Risk of injuries, damage to the pump!

▷ Always disconnect the pump set from the power supply and secure it against

unintentional start-up before inserting your hands or other objects into the pump.

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5 Installation at Site

CAUTION

Drive and pump running in the wrong direction of rotation

Damage 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 and

correct the direction of rotation.

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

1. Start the motor and stop it again immediately to determine the motor's direction of rotation.

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

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

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

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

▪ The pump set has been mechanically connected as specified. ▪ The pump set has been properly connected to the power supply and is equipped

with all protection devices. (ðSection5.5,Page25)

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

vented.

▪ The direction of rotation has been checked. (ðSection5.6,Page26) ▪ All auxiliary connections required are connected and operational. ▪ The lubricants have been checked. (ðSection7.2.3,Page40) ▪ After prolonged shutdown of the pump (set), the activities required for returning

the equipment to service have been carried out. (ðSection6.4,Page35)

6.1.2 Filling in the lubricant

▪ Grease-lubricated bearings

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

▪ Lubricant reservoir for mechanical seals

The oil reservoir is not filled at the factory. For horizontal installation of the pump, an oil reservoir can be fitted as an option. For vertical installation of the pump, an oil reservoir must be fitted. If oil lubrication is to be implemented, fill the oil reservoir as follows, prior to

commissioning of the pump set. Oil quality see (ðSection7.2.3.2.2,Page41)

Oil quantity see (ðSection7.2.3.2.3,Page41)

DANGER

Risk of potentially explosive atmosphere by mixing of incompatible fluids in the auxiliary piping

Risk of burns! Explosion hazard!

▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid

handled.

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6 Commissioning/Start-up/Shutdown

2130

Horizontal installation

Fig.7: Filling / topping up the oil reservoir — horizontal installation

A Maximum fill level B Minimum fill level

1. Unscrew vent plug 913.

2. Fill in lubricant until the lubricant level indicator lies between the minimum and maximum markings.

3. Tighten vent plug 913.

Vertical installation

Fig.8: Filling / topping up the oil reservoir — vertical installation

A Maximum fill level B Minimum fill level

1. Unscrew vent plug 913.

2. Fill in lubricant until the lubricant level indicator lies between the minimum and maximum markings.

3. Tighten vent plug 913.

6.1.3 Shaft seal

Shaft seals are fitted prior to delivery. Observe the instructions on dismantling (ðSection7.4.5,Page43) or assembly (ðSection7.5.3,Page45) .

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6.1.4 Priming and venting the pump

DANGER

Risk of potentially explosive atmosphere inside the pump

Explosion hazard!

▷ The pump internals in contact with the fluid to be handled, including the seal

chamber and auxiliary systems must be filled with the fluid to be handled at all times.

▷ Provide sufficient inlet pressure. ▷ Provide an appropriate monitoring system.

DANGER

Risk of potentially explosive atmosphere by mixing of incompatible fluids in the auxiliary piping

Risk of burns! Explosion hazard!

▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid

handled.

DANGER

Shaft seal failure caused by insufficient lubrication

Hot or toxic fluid could escape! Damage to the pump!

▷ Before starting up the pump set, vent the pump and suction line and prime

both with the fluid to be handled.

CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill. ▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

1. Vent the pump and suction line and prime both with the fluid to be handled. Connection 6D can be used for venting (see drawing of auxiliary connections).

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

3. Fully open all auxiliary feed lines (barrier fluid, flushing liquid, etc.), if any.

4. Open the shut-off element, if any, in the vacuum balance line and close the vacuum-tight shut-off element, if any.

NOTE

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

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6 Commissioning/Start-up/Shutdown

6.1.5 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits if the pump is operated with the suction and/or discharge line closed.

Explosion hazard! Hot or toxic fluids escaping!

▷ Never operate the pump with the shut-off elements in the suction line and/or

discharge line closed.

▷ Only start up the pump set with the discharge-side shut-off element slightly or

fully open.

DANGER

Excessive temperatures due to dry running or excessive gas content in the fluid handled

Explosion hazard! Damage to the pump set!

▷ Never operate the pump set without liquid fill. ▷ Prime the pump as per operating instructions. (ðSection6.1.4,Page30) ▷ Always operate the pump within the permissible operating range.

WARNING

Unprotected rotating shaft

Risk of injury by rotating shaft!

▷ Always operate the pump set with a shaft guard in accordance with the

accident prevention regulations.

CAUTION

Abnormal noises, vibrations, temperatures or leakage

Damage to the pump!

▷ Switch off the pump (set) immediately. ▷ Eliminate the causes before returning the pump set to service.

ü The system piping has been cleaned. ü Pump, suction line and inlet tank, if any, have been vented and primed with the

fluid to be pumped.

ü The lines for priming and venting have been closed.

CAUTION

Start-up against open discharge line

Motor 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.

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6 Commissioning/Start-up/Shutdown

3. Start up the motor.

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

6.1.6 Shutdown

CAUTION

Heat build-up inside the pump

Damage to the shaft seal!

▷ Depending on the type of installation, the pump set requires sufficient after-

run time – with the heat source switched off – until the fluid handled has cooled down.

ü 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 a standstill.

NOTE

If the discharge line is equipped with a non-return or check valve, the shut-off element may remain open provided that the system conditions and system regulations are considered and observed.

NOTE

If shut-off is not possible, the pump will run in reverse direction. The reverse runaway speed must be lower than the rated speed.

For prolonged shutdown periods:

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

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

3. Drain the pump. (ðSection7.3,Page42)

CAUTION

Risk of freezing during prolonged pump shutdown periods

Damage to the pump!

▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect

them against freezing.

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6.2 Operating limits

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled and speed

Explosion 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 speeds

exceeding those specified in the data sheet or on the name plate unless the written consent of the manufacturer has been obtained.

DANGER

Formation of a potentially explosive atmosphere inside the pump

Explosion hazard!

▷ When draining tanks take suitable measures to prevent dry running of the

pump (e.g. fill level monitoring).

6.2.1 Ambient temperature

CAUTION

Operation outside the permissible ambient temperature

Damage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table13: Permissible ambient temperatures

Permissible ambient temperature Value

Maximum 40 °C; if the ambient temperature is any

higher, contact the manufacturer.

Minimum See data sheet.

6.2.2 Frequency of starts

DANGER

Excessive surface temperature of the motor

Explosion hazard! Damage to the motor!

▷ In case of explosion-proof motors, observe the frequency of starts specified in

the manufacturer's product literature.

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

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Table14: Frequency of starts

Motor rating Maximum frequency of starts

[kW] [Starts/hour]

≤ 12 15 13 - 22 10

CAUTION

Re-starting while motor is still running down

Damage 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

Unless specified otherwise in the characteristic curves or in the data sheets, the following applies:

▪ Short-time operation: Q

▪ Continuous operation: Q

▪ 2-pole operation: Q

▪ 4-pole operation: Q

min

12)

=1.1×Q

max

12)

=1.25×Q

max

10)

=0.1×Q

10)

=0.3×Q

min

The data refer to water and water-like fluids. Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface. However, if the physical properties of the fluids handled differ from those of water, the calculation formula below must be used to check if an additional heat build-up may lead to a dangerous temperature increase at the pump surface. If necessary, the minimum flow must be increased.

11)

opt

11)

opt

11)

opt

11)

opt

Table15: Key

Symbol Description Unit

c Specific heat capacity J/kg K g Gravitational constant m/s² H Pump discharge head m T

Fluid temperature °C Temperature at the casing surface °C Pump efficiency at duty point Temperature difference K

6.2.3.2 Density of the fluid handled

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

9) The values indicated must only be exceeded after consultation with the motor manufacturer or KSB.

10) Minimum permissible flow rate

11) Flow rate at best efficiency point

12) Maximum permissible flow rate

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CAUTION

Impermissibly high density of the fluid handled

Motor overload!

▷ Observe the information about fluid density 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 the hydraulic system and shaft seal are to be expected. In this case, reduce the commonly recommended inspection intervals.

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains installed

ü Sufficient fluid is supplied for the functional check run of the pump.

1. For prolonged shutdown periods, start up the pump (set) regularly between once a month and once every three months for approximately five minutes.

ð This will prevent the formation of deposits within the pump and the pump

intake area.

The pump (set) is removed from the pipe and stored

ü The pump has been properly drained. (ðSection7.3,Page42) ü The safety instructions for dismantling the pump have been observed.

(ðSection7.4.1,Page42)

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

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

3. Oil or grease all exposed machined parts and surfaces of the pump (with silicone-free oil or grease, food-approved if required) to protect them against corrosion. Observe the additional instructions on preservation. (ðSection3.3,Page13)

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

6.4 Returning to service

For returning the equipment to service observe the sections on commissioning/startup and the operating limits. (ðSection6.1,Page28) (ðSection6.2,Page33)

In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. (ðSection7,Page37)

WARNING

Failure to re-install or re-activate protective devices

Risk of injury from moving parts or escaping fluid!

▷ As soon as the work is completed, re-install and re-activate any safety-relevant

devices and protective devices.

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6 Commissioning/Start-up/Shutdown

NOTE

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

36 of 64

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7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Sparks produced during servicing work

Explosion hazard!

▷ Observe the safety regulations in force at the place of installation! ▷ Always perform maintenance work on explosion-proof pump sets outside

potentially explosive atmospheres.

DANGER

Improperly serviced pump set

Explosion hazard! Damage to the pump set!

▷ Service the pump set regularly. ▷ Prepare a maintenance schedule with special emphasis on lubricants and shaft

seal.

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

WARNING

Unintentional starting of the pump set

Risk of injury by moving components and shock currents!

▷ Ensure that the pump set cannot be started unintentionally. ▷ Always make sure the electrical connections are disconnected before carrying

out work on the pump set.

DANGER

Improper cleaning of coated pump surfaces

Explosion hazard by electrostatic discharge!

▷ When cleaning coated pump surfaces in atmospheres of Explosion groupIIC,

use suitable anti-static equipment.

WARNING

Fluids handled, consumables and supplies which are hot and/or pose a health hazard

Risk of injury!

▷ Observe all relevant laws. ▷ When draining the fluid take appropriate measures to protect persons and the

environment.

▷ Decontaminate pumps which handle fluids posing a health hazard.

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7 Servicing/Maintenance

WARNING

Insufficient stability

Risk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent

tilting or tipping over.

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

NOTE

All maintenance work, service work and installation work can be carried out by KSB Service or authorised workshops. For contact details please refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet.

Never use force when dismantling and reassembling the pump set.

7.2 Servicing/Inspection

7.2.1 Supervision of operation

DANGER

Risk of potentially explosive atmosphere inside the pump

Explosion hazard!

▷ The pump internals in contact with the fluid to be handled, including the seal

chamber and auxiliary systems must be filled with the fluid to be handled at all times.

▷ Provide sufficient inlet pressure. ▷ Provide an appropriate monitoring system.

DANGER

Incorrectly serviced shaft seal

Explosion hazard! Hot, toxic fluid escaping! Damage to the pump set! Risk of burns! Fire hazard!

▷ Regularly service the shaft seal.

38 of 64

DANGER

Excessive temperatures as a result of bearings running hot or defective bearing seals

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

▷ Regularly check the rolling element bearings for running noises.

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7 Servicing/Maintenance

CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill. ▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

CAUTION

Impermissibly high temperature of fluid handled

Damage 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 on

operating limits. (ðSection6.2,Page33)

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 sealing elements for leakage. ▪ Check the rolling element bearings for running noises.

Vibrations, noise and an increase in current input occurring during unchanged operating conditions indicate wear.

▪ Monitor the correct functioning of any auxiliary connections. ▪ Monitor the stand-by pump.

To make sure that stand-by pumps are ready for operation, start them up once a week.

▪ Monitor the bearing temperature.

The bearing temperature must not exceed 90 °C (measured on the motor housing).

CAUTION

Operation outside the permissible bearing temperature

Damage to the pump!

▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured

on the outside of the motor housing).

NOTE

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

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7 Servicing/Maintenance

7.2.2 Inspection work

DANGER

Excessive temperatures caused by friction, impact or frictional sparks

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

▷ Regularly check the coupling guard, plastic components and other guards of

rotating parts for deformation and sufficient distance from rotating parts.

DANGER

Static charging due to insufficient potential equalisation

Explosion hazard!

▷ Make sure that the connection between pump and baseplate is electrically

conductive.

7.2.2.1 Cleaning filters

CAUTION

Insufficient inlet pressure due to clogged filter in the suction line

Damage to the pump!

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

gauge).

▷ Clean filter at appropriate intervals.

7.2.2.2 Checking the bearing seals

DANGER

Excessive temperatures caused by mechanical contact

Risk of explosion! Damage to the pump set!

▷ Check correct seating of axial seal rings mounted on the shaft.

Only gentle contact of the sealing lip shall be established.

7.2.3 Lubrication and lubricant change

DANGER

Excessive temperatures as a result of bearings running hot or defective bearing seals

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

▷ Regularly check the condition of the lubricant.

40 of 64

7.2.3.1 Grease lubrication

Deep groove ball bearing 321.01 is packed with grease for life and does not require re-lubrication.

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7 Servicing/Maintenance

7.2.3.1.1 Intervals

▪ Under suitable operating conditions the grease-lubricated bearings will run for

15,000 operating hours.

▪ Under unfavourable operating conditions (e.g. high room temperature, high

atmospheric humidity, dust-laden air, aggressive industrial atmosphere) check the bearings earlier and replace them, if required.

▪ Replace the rolling element bearings after 15,000 operating hours or 2 years of

continuous operation.

7.2.3.2 Oil reservoir (if applicable)

7.2.3.2.1 Intervals

Change to oil every 4000 operating hours but at least once a year.

7.2.3.2.2 Oil quality

Table16: Oil quality

Type Specification

Motor oil SAE 10 W/20 W Lubricating oil CL 32...68 DN 51 517

7.2.3.2.3 Oil quantity

Table17: Oil quantity for oil reservoir

Size Oil quantity

[l]

Horizontal Vertical

125-100-0250 Approx. 0.3 Approx. 1 080-040-0315 Approx. 0.3 Approx. 1 080-065-0315 Approx. 0.3 Approx. 1 065-040-0250 Approx. 0.5 Approx. 1 100-080-0250 Approx. 0.5 Approx. 1 100-080-0315 Approx. 0.5 Approx. 1 125-100-0315 Approx. 0.5 Approx. 1

7.2.3.2.4 Changing the oil

WARNING

Lubricants posing a health hazard and/or hot lubricants

Hazard to persons and the environment!

▷ When draining the lubricant take appropriate measures to protect persons and

the environment.

▷ Wear safety clothing and a protective mask if required. ▷ Collect and dispose of any lubricants. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

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7 Servicing/Maintenance

7.3 Drainage/cleaning

WARNING

Fluids handled, consumables and supplies which are hot and/or pose a health hazard

Hazard to persons and the environment!

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

2. Always flush the system if it has been used for handling noxious, explosive, hot or other hazardous fluids. Always flush and clean the pump before transporting it to the workshop. Provide a certificate of decontamination for the pump. (ðSection11,Page61)

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

DANGER

Insufficient preparation of work on the pump (set)

Risk of injury!

▷ Properly shut down the pump set. ▷ Close the shut-off elements in the suction line and discharge line. ▷ Drain the pump and release the pump pressure. (ðSection7.3,Page42) ▷ Shut off any auxiliary feed lines. ▷ Allow the pump set to cool down to ambient temperature.

WARNING

Unqualified personnel performing work on the pump (set)

Risk of injury!

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

qualified personnel.

WARNING

Hot surface

Risk of injury!

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

42 of 64

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to move

heavy assemblies or components.

Always observe the safety instructions and information. (ðSection7.1,Page37) For any work on the motor, observe the instructions of the relevant motor

manufacturer.

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7 Servicing/Maintenance

For dismantling and reassembly observe the exploded views and the general assembly drawing. (ðSection9.1,Page52)

In case of damage you can always contact KSB Service.

NOTE

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 puller.

7.4.2 Preparing the pump set

1. De-energise the pump set and secure it against unintentional start-up.

2. Disconnect and remove all auxiliary pipework.

3. If an oil reservoir has been fitted, drain the oil.

7.4.3 Dismantling the motor

WARNING

Motor tipping over

Risk of squashing hands and feet!

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

ü The pump (set) is disconnected from the power supply.

1. Fasten a rope to motor 800 and intermediate lantern 146 and suspend it from a suitable hoisting tackle.

2. Undo hexagon nuts 920.01.

3. Pull motor 800 with intermediate lantern 146 and discharge cover 163 out of pump casing 101 in axial direction. If the discharge cover is stuck, use forcing screws 901.30.

4. Undo hexagon nut 920.04.

5. Pull motor 800 out of intermediate lantern 146 in axial direction.

7.4.4 Removing the impeller

ü The motor has been removed. (ðSection7.4.3,Page43)

1. Undo impeller screw 906.

2. Remove O-ring 412.03.

3. Pull impeller 230 off with an impeller removal tool.

4. Leave key 940.01 in the keyway.

5. Clean all components and inspect them for signs of wear.

7.4.5 Removing mechanical seal MG1-G6

ü The impeller has been removed. (ðSection7.4.4,Page43) ü The oil reservoir has been drained.

1. Remove key 940.01.

2. Pull O-ring 412.06 and shaft protecting sleeve 524.01 with the rotating assembly of mechanical seal 433.02 off the shaft.

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7 Servicing/Maintenance

3. Undo hexagon nuts 920.15 or socket head cap screws 914.22 (on pump sizes 50-200 and 65-200).

4. Take off discharge cover 163.

5. Remove the stationary assembly of the mechanical seal.

6. Remove O-ring 412.08.

7. Clean all components and inspect them for signs of wear.

7.4.6 Removing the shaft and rolling element bearings

ü The mechanical seal has been removed. (ðSection7.4.5,Page43)

1. Remove circlip 932.01.

2. Slide joint ring 411.77 off the shaft. Remove the oil ring, if any.

3. Remove shaft 210 with rolling element bearing 321.01 from intermediate lantern 146.

4. Remove circlip 932.20.

5. Pull off rolling element bearing 321.01.

6. Remove insert ring 513.11 from intermediate lantern 146.

7. Insert O-ring 412.11.

8. Clean all components and inspect them for signs of wear.

7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to move

heavy assemblies or components.

CAUTION

Improper reassembly

Damage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of sound

engineering practice.

▷ Use original spare parts only.

Sequence Always reassemble the pump in accordance with the corresponding general assembly

drawing.

Sealing elements ▪ Gaskets

– Always use new gaskets, making sure that they are of the same thickness and

material as the old ones.

– Always fit gaskets of asbestos-free materials or graphite without using

lubricants (e.g. copper grease, graphite paste).

▪ O-rings

– Always use new O-rings, making sure that they are of the same thickness and

material as the old ones.

– Never use O-rings that have been made by cutting an O-ring cord to size and

gluing the ends together.

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7 Servicing/Maintenance

CAUTION

Contact of O-ring with graphite or similar material

Fluid could escape!

▷ Do not coat O-ring with graphite or similar material. ▷ Use animal fats or lubricants based on silicone or PTFE.

▪ Assembly adhesives

– For gaskets, avoid the use of assembly adhesives if possible. – If assembly adhesives are required, use a commercially available contact

adhesive (e.g. "Pattex"). – 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 and screwed

connections with graphite or similar before reassembly.

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

(ðSection7.6,Page47)

7.5.2 Installing the shaft and rolling element bearing

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

1. Slide rolling element bearing 321.01 onto shaft 210.

2. Slide on circlip 932.20.

3. Insert O-ring 412.11.

4. Fit insert ring 513.11.

5. Half-fill the space between insert ring 513.11 and rolling element bearing

321.01 with a multi-purpose high-temperature resistant grease of NLGI grade2/ KP2P-20.

6. Apply a thin coat of oil to the outside diameter of rolling element bearing

321.01.

7. Insert shaft 210 into intermediate lantern 146.

8. Slip joint ring 411.77 onto the shaft.

9. Insert circlip 932.01.

7.5.3 Fitting the mechanical seal

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

▪ For installing the mechanical seal, refer to general assembly drawing. ▪ Work cleanly and accurately. ▪ Only remove the protective wrapping of the contact faces immediately before

installation takes place.

▪ Exclude any damage to the sealing surfaces or O-rings. ▪ After inserting the mating ring, check that it is plane-parallel in relation to the

casing part.

▪ The surface of the shaft protecting sleeve must be absolutely clean and smooth,

and the sleeve's mounting edge must be chamfered.

▪ When sliding the rotating unit onto the shaft protecting sleeve, take appropriate

steps to protect the surface of the shaft protecting sleeve from damage.

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7 Servicing/Maintenance

Installing mechanical seal MG1-G6

CAUTION

Contact of O-ring with lubricant made of mineral grease or oil

Damage to the O-ring!

▷ Make sure that O-rings made of ethylene propylene rubber cannot come into

contact with mineral oil or mineral grease.

▷ Make sure that O-rings made of silicone rubber cannot come into contact with

silicone oil or silicone grease.

CAUTION

Use of grease or other permanent lubricants

Hinders torque transmission! Overheating of and damage to the pump!

▷ If required, use soft soap to reduce friction.

Do not use grease or other permanent lubricants.

▷ Do not coat seal faces with grease or oil.

ü The bearing assembly and the individual parts of mechanical seal 433.02 are kept

in a clean and level assembly area.

ü All dismantled parts have been cleaned and checked for wear. ü Any damaged or worn parts have been replaced by original spare parts. ü The sealing surfaces have been cleaned.

1. Insert O-ring 412.08.

2. Fit the mating ring

3. Fit the oil ring, if any.

4. Fit discharge cover 163 on intermediate lantern 146.

5. Fasten hexagon nuts 920.15 (on pump sizes 50-200 and 65-200 socket head cap screws 914.22).

6. Slide the rotating assembly onto shaft protecting sleeve 524.01 and fasten it.

7. Slide O-ring 412.06 onto shaft protecting sleeve 524.01.

7.5.4 Fitting the impeller

ü The assembled bearing with shaft seal as well as the individual parts are kept in a

clean and level assembly area.

ü All disassembled parts have been cleaned and checked for wear. ü Any damaged or worn parts have been replaced by original spare parts. ü The seal faces have been cleaned. ü Impeller bore, shaft and keyways are clean and free from burrs.

1. Insert keys 940.01 into the shaft keyway.

2. Fit the impeller with an impeller fitting and removal tool.

3. Insert O-ring 412.03.

4. Insert and tighten impeller screw 906. Observe the tightening torque. (ðSection7.6.1,Page47)

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7 Servicing/Maintenance

7.5.5 Mounting the motor

WARNING

Motor tipping over

Risk of squashing hands and feet!

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

1. Generously grease the joining surfaces of the motor shaft/ pump shaft 210 connection.

2. Insert motor 800 into intermediate lantern 146.

3. Tighten hexagon nut 920.04.

4. Fasten a rope to motor 800 and intermediate lantern 146 and suspend it from a suitable hoisting tackle.

5. Push motor 800 with intermediate lantern 146 and discharge cover 163 into pump casing 101.

6. Tighten hexagon nuts 920.01.

7.6 Tightening torques

7.6.1 Tightening torques for the pump

Casing bolts

Table18: Tightening torques for bolted/screwed connections

Materials of bolt/hexagon nut C35E+QT A4-70

Stamp on bolt/hexagon nut YK/Y

Thread Torque [Nm]

M 6 5 7 M 10 25 35 M 12 40 60 M 16 100 150

Impeller nut

Tightening torques for the impeller nut of all pump sizes: 50Nm

13)

A4-70

7.7 Spare parts stock

7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:

▪ Order number ▪ Order item number ▪ Consecutive number ▪ Type series ▪ Size ▪ Material variant ▪ Seal code ▪ Year of construction

Refer to the name plate for all data.

13) Unstamped bolted/screwed connections shall be treated as material combination C35E+QT.

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7 Servicing/Maintenance

Also specify the following data:

▪ Part number and description (ðSection9.1,Page52) ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight)

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

Table19: Quantity of spare parts for recommended spare parts stock

Part No. Description Number of pumps (including stand-by pumps)

1 2 3 4 5 6 and 7 8 and 9 10 and

135.01 Wear plate 1 2 2 2 3 3 4 50% 210 Shaft with hardware 1 1 1 1 2 2 2 20% 230 Impeller 1 1 1 1 2 2 2 20%

321.01 Deep groove ball

1 1 1 2 2 2 3 25%

bearing

411.77 Joint ring 1 2 2 2 3 3 4 50%

433.02 Complete mechanical seal

Set of sealing

14)

1 1 1 2 2 2 3 25%

2 4 6 8 8 9 12 150%

elements

14) Includes shaft protecting sleeve 524.01

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KWP-bloc Description

7 Servicing/Maintenance

7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

15)

Pump casing

Intermediate

lantern

cover

Discharge

Shaft

Impeller

15)

ball

V-ring

bearing

Deep groove

16)

Shaft

seal

Mechanical

sleeve

Spring

protecting

Part No.

101 146 163 210 230 321.01 411.77 433.02 524.01 950.10

065-040-0250 1 1/2 1 1/2/3/4/5 1 1/2 1 1 1 1 065-050-0200 3 1/2 3 1/2/3/4/5 3 1/2 1 1 1 1 080-065-0200 4 1/2 3 1/2/3/4/5 4 1/2 1 1 1 1 080-040-0315 5 1/2 4 10/11/12/13/14 5 1/2 2 1 3 1 080-065-0315 6 1/2 4 10/11/12/13/14 6 1/2 2 1 3 1 100-080-0250 7 1/2 1 1/2/3/4/5 7 1/2 1 1 1 1 100-080-0315 8 1/2 4 10/11/12/13/14 8 1/2 2 1 3 1 125-100-0250 9 1/2 5 10/11/12/13/14 9 1/2 2 1 3 1 125-100-0315 10 1/2 4 10/11/12/13/14 10 1/2 2 1 3 1

Table20: *Shaft 210: combination of motor size and shaft number

Motor size Shaft number

90 1,6, 10 110, 112 2, 7, 11 132 3, 8, 12 160 4, 9, 13 180 5, 14

15) Intermediate lantern / deep groove ball bearing: 1 = up to motor size 112; 2 = from motor size 132 to motor size 180

16) For the interchangeability of KSB mechanical seal 4KBL refer to the shaft protecting sleeve as the shaft protecting sleeve is part of the mechanical seal.

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8 Trouble-shooting

WARNING

Improper work to remedy faults

Risk of injury!

▷ For any work performed to remedy faults, observe the relevant information

given in this operating manual and/or in the product literature provided by the accessories manufacturer.

If problems occur that are not described in the following table, consultation with the KSB customer service is required.

A Pump delivers insufficient flow rate

B Motor is overloaded C Excessive discharge pressure

D Increased bearing temperature

E Leakage at the pump

F Excessive leakage at the shaft seal G Vibrations during pump operation H Impermissible temperature increase in the pump

Table21: Trouble-shooting

A B C D E F G H Possible cause Remedy

✘ - - - - - - - Pump delivers against an excessively

Re-adjust to duty point.

17)

high pressure.

✘ - - - - - - - Excessively high back pressure Check system for impurities.

Fit a larger impeller.

18)

Increase the speed.

✘ - - - - - ✘ ✘ Pump or piping are not completely

Vent and/or prime.

vented or primed.

✘ - - - - - - - Supply line or impeller clogged Remove deposits in the pump and/or piping. ✘ - - - - - - - Formation of air pockets in the piping Alter piping layout.

Fit vent valve.

- - - ✘ - ✘ ✘ - Pump is warped or sympathetic vibrations in the piping.

Check the piping connections and secure fixing of pump; if required, reduce distances between the pipe clamps. Fix the pipelines using anti-vibration material.

✘ - - - -

✘ ✘ Suction lift is too high/

NPSH

available

low.

(positive suction head) is too

Check/alter fluid level. Fully open the shut-off element in the supply line. Change suction line, if the friction losses in the suction line are too high. Check any strainers installed/suction opening. Observe permissible speed of pressure fall.

- - - ✘ - - - - Increased axial thrust

18)

Correct the rotor adjustment.

✘ - - - - - - - Air intake at the shaft seal Fit new shaft seal. ✘ - - - - - - - Wrong direction of rotation Interchange two of the phases of the power

cable.

✘ ✘ - - - - - - Motor is running on two phases only. Replace the defective fuse.

Check the electric cable connections.

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

18) Contact the manufacturer.

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8 Trouble-shooting

A B C D E F G H Possible cause Remedy

17)

✘ - - - - - - - Speed too low

- Operation with frequency inverter

- Operation without frequency inverter

- Increase voltage/frequency at the frequency inverter in the permissible range.

- Check voltage.

- - - ✘ - ✘ ✘ - Defective bearing(s) Replace.

- - - ✘ - - ✘ ✘ Flow rate is too low. Increase the minimum flow rate.

✘ - - - - - ✘ - Wear of internal components Replace worn components by new ones.

- - - - - - ✘ - Pump back pressure lower than specified

Re-adjust to duty point.

in the purchase order

- ✘ - - - - - - Density or viscosity of fluid handled

Contact the manufacturer.

higher than stated in purchase order

- - - - - ✘ - - Use of unsuitable materials Change the material combination.

- ✘ ✘ - - - - - Speed too high Reduce speed.

18)

- - - - ✘ - - - Tie bolts/sealing element defective Fit new sealing element between volute

casing and discharge cover. Re-tighten the bolts.

- - - - - ✘ - - Worn shaft seal Fit new shaft seal.

✘ - - - - ✘ - - Score marks or roughness on shaft

protecting sleeve / shaft sleeve

Replace shaft protecting sleeve/shaft sleeve. Replace shaft seal. Check balancing line. Check throttling bush/throttling sleeve clearances.

- - - - - ✘ - - Lack of cooling liquid or dirty cooling chamber

Increase cooling liquid quantity. Clean out cooling chamber. Purify/clean cooling liquid.

- ✘ - - - - ✘ - Pump back pressure lower than specified

Re-adjust to duty point.

in the purchase order

- - - - - ✘ - - Vibrations during pump operation Correct the suction conditions.

Re-align the pump set. Re-balance the impeller. Increase pressure at the pump suction nozzle.

- - - ✘ - ✘ ✘ - The pump set is misaligned. Re-align the pump set.

- - - ✘ - - - - Insufficient or excessive quantity of

Top up, reduce or change lubricant.

lubricant or unsuitable lubricant.

- ✘ - - - - - - Operating voltage too low Increase the voltage.

Check voltage drop in the power cable.

- - - - - - ✘ - Rotor out of balance Clean rotor.

Re-balance rotor.

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Page 52

9 Related Documents

800

680.01

901.57

920.04

550.57

932.01

321.01

411.77

412.11

513.11

950.10

146

904.30

932.20

230

411.10

412.08

902.01

920.01

550.44

903.25

411.25

412.75

135

914.05

411.13

412.05

412.03

940.01

906

210

412.06

901.01

524.01

903.01

411.01

903.03

411.03

101 163

903.02

411.02

902.15

920.15

550.45

901.30

639.N1

720.N1

731.N2

731.N3

731.N1

411.27

731.N4

731.N5

710.N1

710.N2

913

903.17

644

901.30

550.22

163

914.22

9 Related Documents

9.1 General assembly drawing with list of components

9.1.1 Horizontal installation

Fig.9: General assembly drawing of variants GNNG, GDNG

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9 Related Documents

800

901.57

920.04

550.57

932.01

321.01

411.77

412.11

513.11

950.10

146

904.30

932.20

230

412.12

914.03

411.10 509

412.75

135

914.05

411.13

412.05

412.03

940.01

906

210

412.06

901.01

524.01

903.01

411.01

903.03

411.03 101

163

903.02

411.02

902.15

920.15

550.45

901.30

639.N1

720.N1

731.N2

731.N3

731.N1

411.27

731.N4

731.N5

710.N1

710.N2

913

903.17 644

412.08

902.01

920.01

550.44

903.25

411.25

680.01

500.14

163

901.30

509

914.03 550.22

914.02

Fig.10: General assembly drawing of variant DDDD

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9 Related Documents

412.75 135

914.05

411.13

412.05

412.03

940.01 906

210

412.06

901.01

524.01

800

680.01

901.57

920.04

550.57

932.01

321.01

411.77

412.11

513.11

903.03

411.03

101

163

903.02

411.02

902.15

920.15

550.45

901.30

913.N1

731.N3

731.N4

731.N5

720.N1

950.10

146

904.30

932.20

230

411.10

412.08

902.01

920.01

550.44

903.01

411.01

639.N1

731.N1

731.N2

731.N6

901.30

550.22

163

914.22

9.1.2 Vertical installation

Fig.11: General assembly drawing of variants GNNG, GDNG

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800

680.01

901.57

920.04

550.57

932.01

321.01

411.77

412.11

513.11

903.03

411.03

101

163

903.02

411.02

902.15

920.15

550.45

901.30

913.N1

731.N3

731.N4

731.N5

720.N1

412.75 135

914.05

411.13

412.05

412.03

940.01

210

412.06

901.01

524.01

903.01

411.01

906

950.10

146

904.30

932.20

230

411.10

412.08

902.01

920.01

550.44

639.N1

731.N1

731.N2

731.N6

509

412.12

914.03

163

901.30

509

914.03 550.22

914.02

9 Related Documents

Fig.12: General assembly drawing of variant DDDD

KWP-Bloc

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Mechanical seal KSB 4KBL

412.06

412.53

412.52

523

487

477

473

472.53

472.52

500.54

412.06

477.54

481.54

500.55

472.54

475.55 412.55

504.54

9 Related Documents

9.1.3 Mechanical seal

Mechanical seal, Burgmann

MG1-G6

Fig.13: Mechanical seal KSB 4KBL

Fig.14: Mechanical seal, Burgmann MG1-G6

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Mechanical seal, John Crane

524.01

433.02

504.54

2100

9 Related Documents

Fig.15: Mechanical seal, John Crane 2100

9.1.4 List of components

Table22: List of components

19)

Part No. Comprising Scope of supply

101 101 Pump casing

20)

411.01

/.02

20)

/.03

/.10 Joint ring

550.44 Disc

901.01 Hexagon head bolt

902.01 Stud

20)

903.01

/.02

/.03

20)

Screw plug

920.01 Hexagon nut

135 135 Wear plate

411.13 Joint ring

412.05/.75 O-ring

914.05 Hexagon socket head cap screw

146 146 Intermediate lantern

550.57 Disc 913 Vent plug

901.57 Hexagon head bolt

903.17/.25/.26 Screw plug

920.04 Hexagon nut

932.01 Circlip

163 163 Discharge cover

412.08 O-ring

550.45/.22 Disc

901.30 Hexagon head bolt

902.15 Stud

920.15 Hexagon nut

914.22 Hexagon socket head cap screw

500.14 Ring

19) Depending on the design

20) If any

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9 Related Documents

Part No. Comprising Scope of supply

210 210 Shaft

904.30 Grub screw

932.20 Circlip

940.01 Key

950.10 Spring

230 230 Impeller

321.01 321.01 Deep groove ball bearing

411.77 411.77 Joint ring

21)

504.54

504.54 Spacer ring

509 509 Intermediate ring

412.12 O-ring

914.02/.03 Hexagon socket head cap screw

513.11 513.11 Insert ring

412.11 O-ring

524.01 524.01

22)

Shaft protecting sleeve

412.06 O-ring

23)

639

411.25/.27 Joint ring

639.N1 Oil level gauge, complete 644 Lubricating ring

710.N1/.N2 Pipe 720/731.N1 Barrel nipple

731.N6 Pipe union

731.N2/.N3/.N4/.N5 Angle

903.25 Screw plug

680.01 680.01 Guard 800 800 Motor, complete 906 906 Impeller screw

412.03 O-ring

99-9 99-9 Set of sealing elements

411.01/.02/.03/.10/.12/.13/.

Joint ring

16/.17/.77

412.03/.05/.06/.08/.11/.75 O-ring

Table23: List of components for mechanical seal 4KBL

Part No. Comprising Scope of supply

433 412.52/.53 O-ring

472.53 Primary ring

472.52 Primary ring 473 Primary ring carrier 477 Spring 487 Mating ring carrier 523 Shaft protecting sleeve

Table24: List of components for mechanical seal MG1-G6

Part No. Comprising Scope of supply

433 412.55 O-ring

472.54 Primary ring

21) On pumps with standardised mechanical seal only

22) This is part of mechanical seal 4KBL

23) On pumps with oil reservoir only

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9 Related Documents

Part No. Comprising Scope of supply

433 475.55 Mating ring

477.54 Spring

481.54 Bellows

500.54 Ring

500.55 Ring

KWP-Bloc

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10 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

KWP, KWPR, KWP-Bloc

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

Person authorised to compile the technical file:

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

The EU Declaration of Conformity was issued in/on:

Place, date

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

24)

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

Name

Function

Company

Address

24) A signed, legally binding EU Declaration of Conformity is supplied with the product.

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11 Certificate of Decontamination

Type: ................................................................................................................................

Order number/ Order item number

Delivery date: ................................................................................................................................

Field of application: ................................................................................................................................

Fluid handled

25)

: ................................................................................................................................

25)

: ................................................................................................................................

Please tick where applicable

25)

   

Radioactive Explosive Corrosive Toxic

   

Harmful Bio-hazardous Highly flammable Safe

Reason for return

25)

: ................................................................................................................................

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

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

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

We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.

For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has been removed from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern, leakage barrier and bearing bracket or adapter have also been cleaned.

For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage at the stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it has been removed.

 No special safety precautions are required for further handling.  The following safety precautions are required for flushing fluids, fluid residues and disposal:

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

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the relevant legal provisions.

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

Place, date and signature Address Company stamp

25) Required fields

KWP-Bloc

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Index

Abrasive fluids35 Automation18

Bearing temperature39 Bearings18

Certificate of decontamination61 Commissioning28 Configuration and function19 Connections18

Design16 Direction of rotation27 Dismantling43 Disposal14

Event of damage6

Ordering spare parts47

Explosion protection10, 26, 30, 31, 33, 37, 38, 40

Fields of application8 Filter23, 40 Flow rate34

Fluid handled

Density34

Frequency of starts33, 34

Grease lubrication

Intervals41

Horizontal installation29

Impeller type18 Installation

without foundation21 Installation at site21 Installation types17 Intended use8 Interchangeability of pump components49

Key to safety symbols/markings7

List of components57

Maintenance38 Materials18 Monitoring equipment11

Name plate16 Noise characteristics20

Oil lubrication

Oil quality41 Oil reservoir28 Operating limits33 Order number6 Other applicable documents6

Partly completed machinery6 Permissible forces and moments at the pump

nozzles24 Piping23 Preservation14, 35 Priming and venting30 Product description15

Reassembly43 Return to supplier14 Returning to service35

Safety8 Safety awareness9 Scope of supply20 Shaft seal17 Shutdown35

Spare part

Ordering spare parts47 Start-up31 Storage14, 35

Temperature limits11 Tightening torques47 Transport13

Trouble-shooting

Causes and remedies50

62 of 64

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Vertical installation29

Warnings7 Warranty claims6

Index

KWP-Bloc

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Page 64

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com

2362.8/05-EN (01317103)

KSB KWP-Bloc Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Glossary

1 General

1.1 Principles

1.2 Installation of partly completed machinery

1.3 Target group

1.4 Other applicable documents

1.5 Symbols

1.6 Key to safety symbols/markings

2 Safety

2.1 General

2.2 Intended use

2.3 Personnel qualification and training

2.4 Consequences and risks caused by non-compliance with this manual

2.5 Safety awareness

2.6 Safety information for the operator/user

2.7 Safety information for maintenance, inspection and installation

2.8 Unauthorised modes of operation

2.9 Explosion protection

2.9.1 Marking

2.9.2 Temperature limits

2.9.3 Monitoring equipment

2.9.4 Operating limits

3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

3.2 Transport

3.3 Storage/preservation

3.4 Return to supplier

3.5 Disposal

4 Description of the Pump (Set)

4.1 General description

4.2 Designation

4.3 Name plate

4.4 Design details

4.5 Materials

4.6 Configuration and function

4.7 Noise characteristics

4.8 Scope of supply

4.9 Dimensions and weights

5 Installation at Site

5.1 Checks to be carried out prior to installation

5.2 Installing the pump set

5.3 Piping

5.3.1 Connecting the piping

5.3.2 Permissible forces and moments at the pump nozzles

5.4 Enclosure/insulation

5.5 Electrical connection

5.5.1 Setting the time relay

5.5.2 Connecting the motor

5.5.3 Earthing

5.6 Checking the direction of rotation

6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

6.1.2 Filling in the lubricant

6.1.3 Shaft seal

6.1.4 Priming and venting the pump

6.1.5 Start-up

6.1.6 Shutdown

6.2 Operating limits

6.2.1 Ambient temperature

6.2.2 Frequency of starts

6.2.3 Fluid handled

6.2.3.1 Flow rate

6.2.3.2 Density of the fluid handled

6.2.3.3 Abrasive fluids

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

6.4 Returning to service

7 Servicing/Maintenance

7.1 Safety regulations

7.2 Servicing/Inspection

7.2.1 Supervision of operation

7.2.2 Inspection work

7.2.2.1 Cleaning filters

7.2.2.2 Checking the bearing seals