KSB MegaCPK Operating Manual

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Standardised Chemical Pump

MegaCPK

Installation/Operating Manual

Page 2

Legal information/Copyright

Installation/Operating Manual MegaCPK

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4.5 Configuration and function .........................................................................................................................18

4.6 Noise characteristics .....................................................................................................................................19

4.7 Scope of supply .............................................................................................................................................19

4.8 Dimensions and weights ..............................................................................................................................19

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

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

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

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

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

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Contents

5.5 Enclosure/insulation .....................................................................................................................................27

5.6 Checking the coupling alignment ...............................................................................................................27

5.7 Aligning the pump and motor ....................................................................................................................28

5.8 Electrical connection ....................................................................................................................................30

5.9 Checking the direction of rotation ..............................................................................................................32

6 Commissioning/Start-up/Shutdown ........................................................................................... 33

6.1 Commissioning/start-up ...............................................................................................................................33

6.2 Operating limits ............................................................................................................................................39

6.3 Shutdown/storage/preservation ..................................................................................................................41

6.4 Returning to service .....................................................................................................................................42

7 Servicing/Maintenance ............................................................................................................... 43

7.1 Safety regulations .........................................................................................................................................43

7.2 Servicing/inspection ......................................................................................................................................44

7.3 Drainage/cleaning ........................................................................................................................................48

7.4 Dismantling the pump set ............................................................................................................................48

7.5 Reassembling the pump set .........................................................................................................................52

7.6 Tightening torques .......................................................................................................................................58

7.7 Spare parts stock ...........................................................................................................................................60

8 Trouble-shooting ........................................................................................................................ 64

9 Related Documents .................................................................................................................... 66

9.1 General assembly drawing with list of components .................................................................................. 66

10 EU Declaration of Conformity ................................................................................................... 70

11 Certificate of Decontamination ................................................................................................. 71

Index ............................................................................................................................................ 72

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Glossary

Back pull-out design

The complete back pull-out unit can be pulled out without having to remove the pump casing from the piping.

Back pull-out unit

Pump without pump casing; partly completed machinery

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.

Discharge line

The pipeline which is connected to the discharge nozzle

Hydraulic system

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

Pool of pumps

Pumps which are purchased and stored independently 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 uniquely 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.

Noise characteristics (⇨ Section 4.6 Page 19)

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. (⇨ Section 2.4 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

Sub-supplier product literature

Sectional drawing of the pump

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

✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

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

If agreed upon in scope of supply

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1 General

Symbol Description

Step-by-step instructions

Note Recommendations and important information on how to handle the product

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DANGER

WARNING

CAUTION

DANGER

2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

DANGER 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 EC 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.

2.2 General

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

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the specialist personnel/ operators responsible prior to installation and commissioning.

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

Information attached directly to the pump must always be complied with and be 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 manual.

2.3 Intended use

▪ The pump (set) must only be operated within the operating limits described in

the other applicable documents. (⇨ 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.

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2 Safety

▪ 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 maximum flow rates 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.

Prevention of foreseeable misuse

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

– The maximum flow rates specified in the product literature or data sheet

would be exceeded.

– Risk of cavitation damage

▪ Never exceed the permissible operating limits specified in the data sheet or

product literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, 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.

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

▪ Non-compliance with this operating manual 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

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use, the following safety regulations shall be complied with:

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

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DANGER

2 Safety

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and check

that the guards function properly.

▪ Do not remove any contact guards during operation.

▪ Provide the personnel with protective equipment and make sure it is used.

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

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

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

2.8 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the pump are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use of

other parts 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.

▪ The pump casing must have cooled down to ambient temperature.

▪ Pump pressure must have been released and the pump must have been drained.

▪ When taking the pump set out of service always adhere to the procedure

described in the manual. (⇨ Section 6.1.12 Page 39) (⇨ Section 6.3 Page 41)

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

Page 48)

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

relevant and protective devices. Before returning the product to service, observe all instructions on commissioning. (⇨ Section 6.1 Page 33)

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2.9 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. (⇨ Section 2.3 Page 8)

2.10 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 (⇨ Section 2.10.1 Page 11) to (⇨ Section 2.10.4 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.

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2 Safety

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.

Pump

2.10.1 Marking

The marking on the pump refers to the pump part only. Example of such marking: II 2 G c TX Refer to the Temperature Limits table for the temperatures permitted for the individual pump variants.

Shaft coupling

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

Motor

The motor must be considered separately.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on the surface of the pump casing, at the shaft seal and in the bearing areas. The surface temperature at the pump casing corresponds to the temperature of the fluid handled. If the pump is heated in addition, the operator of the system is responsible for observing the specified temperature class and fluid temperature (operating temperature). The table below lists the temperature classes and the resulting theoretical temperature limits of the fluid handled (a possible temperature rise in the shaft seal area has already been taken into account).

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 T5

Temperature class T6

Temperature class to EN 13463-1

Maximum permissible fluid

temperature

Maximum 400 ℃

T2 280 °C T3 185 °C T4 120 °C T5 85 °C T6 Only after consultation

with the manufacturer

Based on an ambient temperature of 40 °C and proper maintenance and operation, compliance with temperature class T5 is warranted in the area of the rolling element bearings. If the ambient temperature exceeds 40 °C, contact the manufacturer.

If grease lubrication is used, compliance with temperature class T5 is not possible.

A special design is required to comply with the requirements of temperature class T6 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.

2.10.3 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,

Depending on the material variant

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2 Safety

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 on monitoring equipment.

2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.2.3.1 Page 40) refer to water and waterlike 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 (⇨ Section 6.2.3.1 Page 40) 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 (as applicable) 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.

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

▷ Observe the applicable local health and safety regulations.

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

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

Fig. 1: Transporting the back pull-out unit

Fig. 2: Transporting the pump

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≤ 90 °

3 Transport/Temporary Storage/Disposal

Fig. 3: Transporting the pump set

Fig. 4: Transporting the pump on the baseplate

3.3 Storage/preservation

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

CAUTION

Damage during storage by humidity, dirt, or vermin Corrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessories

with waterproof material.

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. (⇨ Section 6.3.1 Page 41)

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3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 48)

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

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

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3 Transport/Temporary Storage/Disposal

4. Always complete and enclose a certificate of decontamination when returning the pump (set). Always indicate any safety and decontamination measures taken. (⇨ Section 11 Page 71)

NOTE

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

3.5 Disposal

WARNING

Fluids, 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 residues of the fluid

handled.

▷ 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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MCPK 50-32-160 CD

P-No. 997125086300550001

Q 20 m

/h H 25 m

n 2955 1/min

KSB Aktiengesellschaft 67227 Frankenthal

Mat-No. 01 109 223 ZN 3804 - D 52 x 74

2011

0520-5-P-10000-31

4 Description of the Pump (Set)

4.1 General description

▪ Standardised chemical pump with shaft seal

Pump for handling aggressive liquids in the chemical and petrochemical industries.

4.2 Designation

Example: MCPK 50-32-160 CDhix

Table 5: Key to the designation

Code Description

MCPK Type series (full name: MegaCPK) 50 Nominal suction nozzle diameter [mm] 32 Nominal discharge nozzle diameter [mm] 160 Nominal impeller diameter [mm] C Casing material, e.g. C = stainless steel D Impeller material if different from casing material, e.g. D =

duplex

hix Additional description, e.g. h = heatable, i = inducer, x =

special version

4.3 Name plate

Fig. 5: Name plate (example)

Type series, size, material 2 Customer-specific information

(optional) 3 KSB order and order item number 4 Flow rate 5 Speed 6 Manufacturer's name and address 7 Year of construction 8 Head

4.4 Design details

Design

▪ Volute casing pump

▪ Horizontal installation

▪ Back pull-out design

▪ Single-stage

▪ Meets the technical requirements to ISO 5199

▪ Dimensions and ratings to ISO 2858

complemented by pumps of nominal diameters DN 25, DN 200 and above

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▪ Single or double volute, depending on the pump size

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Pump casing

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Bearing bracket

designation

4 Description of the Pump (Set)

▪ Radially split volute casing

▪ Volute casing with integrally cast pump feet

▪ Replaceable casing wear rings (as required)

Impeller type

▪ Closed radial impeller with multiply curved vanes

Shaft seal

▪ Gland packing

▪ Commercial single and double mechanical seals

▪ Commercial cartridge seals

▪ Shaft fitted with a replaceable shaft protecting sleeve in the shaft seal area

Alternative:

▪ Version without shaft protecting sleeve with "wet shaft" (in Europe and

Northern Asia only)

Bearings

Bearings:

▪ Medium-duty

– Radial bearing: cylindrical roller bearing

– Fixed bearing: paired angular contact ball bearings / double-row angular

contact ball bearing

▪ Economy

– Floating bearing assembly: deep groove ball bearings

Lubrication:

▪ Oil lubrication

▪ Grease lubrication

Example: CS50E

Table 6: Bearing bracket designation

Code Description

CS Bearing bracket 50 Size code (based on dimensions of seal chamber and shaft

E Bearing design

Bearings used

Table 7: Standard bearing assembly

Design Bearing

Medium-duty (oil and grease lubrication)

Economy (oil lubrication) CS40E 6208 C3 6208 C3

Blank

FAG designation: B-TVP-UA; SKF designation: BECBP

end)

E = Economy

= Medium-duty

bracket

CS40 NU208-E 3208 CS50 NU310-E CS60 NU312-E CS80 NU216-E

CS50E 6310 C3 6310 C3 CS60E 6312 C3 6312 C3 CS80E 6216 C3 6216 C3

Rolling element bearings

Pump end Drive end

2 x 7310 2 x 7312 2 x 7216

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6 7

4 Description of the Pump (Set)

Design Bearing

bracket

Economy (grease lubrication) CS40E 6208-2Z C3 6208-2Z C3

CS50E 6310-2Z C3 6310-2Z C3 CS60E 6312-2Z C3 6312-2Z C3 CS80E 6216-2Z C3 6216-2Z C3

Rolling element bearings

Pump end Drive end

4.5 Configuration and function

Fig. 6: Sectional drawing

Clearance gap 2 Discharge nozzle

1 3 Casing cover 4 Shaft 5 Bearing bracket 6 Suction nozzle 7 Impeller 8 Shaft seal 9 Rolling element bearing, pump

end

Design

Function

Sealing

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

The fluid enters the pump axially via the suction nozzle (6) and is accelerated outward by the rotating impeller (7). In the flow passage of the pump casing the kinetic energy of the fluid is converted into pressure energy. The fluid is pumped to the discharge nozzle (2), where it leaves the pump. The clearance gap (1) prevents any fluid from flowing back from the casing to the suction nozzle. At the rear side of the impeller, the shaft (4) enters the casing via the casing cover (3). The shaft passage through the cover is sealed to atmosphere with a shaft seal (8). The shaft runs in rolling element bearings (9 and 10), which are supported by a bearing bracket (5) linked with the pump casing and/or casing cover.

The pump is sealed by a shaft seal (standardised mechanical seal or gland packing).

10 Rolling element bearing, drive end

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4 Description of the Pump (Set)

4.6 Noise characteristics

Table 8: Surface sound pressure level L

960 rpm,

760 rpm

[kW] [dB] [dB] [dB] [dB] [dB] [dB]

1,5 52 53 54 56 58 63 2,2 53 55 56 58 60 66 3 55 56 57 60 62 68 4 56 58 59 61 63 69 5,5 58 59 61 62 65 71 7,5 59 61 62 64 66 72 11 61 63 64 65 68 74 15 63 65 66 67 69 75 18,5 64 66 67 68 70 76 22 65 67 68 68 71 77 30 66 68 70 70 72 78 37 67 70 71 70 73 79 45 68 71 72 71 74 80 55 69 72 73 72 74 80 75 71 73 75 73 76 81 90 71 74 76 73 76 82 110 72 75 77 74 77 82 132 73 76 78 75 77 83 160 74 77 79 75 78 84 200 75 78 80 76 79 84 250 - 79 81 - 80 85

5)6)

Pump Pump set

1450 rpm 2900 rpm 960 rpm,

1450 rpm 2900 rpm

760 rpm

4.7 Scope of supply

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

▪ Pump

Drive

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

Coupling

▪ Flexible coupling with or without spacer

Contact guard

▪ Coupling guard

Baseplate

▪ Cast or welded baseplate for the complete unit (pump and motor), in torsion-

resistant design

▪ Channel section steel or folded steel plate

Special accessories

▪ As required

4.8 Dimensions and weights

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

Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.8 - 1.1 range and for noncavitating operation. If noise levels are to be guaranteed: add +3 dB for measuring and constructional tolerance.

Increase for 60 Hz operation: 3500 rpm +3 dB, 1750 rpm +1 dB, 1160 rpm ±0 dB

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5 Installation at Site

5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations.

▷ Observe the information in the data sheet and on the name plates of pump and

motor.

5.2 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 have set and must be completely horizontal and

even.

▷ 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.

5.3 Installing the pump set

Always install the pump set in a horizontal position.

DANGER

Excessive temperatures due to improper installation Explosion hazard!

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

5.3.1 Installation on the foundation

Fig. 7: Fitting the shims

Bolt-to-bolt distance 1 Shim

L 2 Shim if (L) > 800 mm 3 Foundation bolt

The foundation has the required strength and characteristics.

✓

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5 Installation at Site

✓ The foundation has been prepared in accordance with the dimensions given in

the outline drawing/general arrangement drawing.

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

2. Use shims (1) for height compensation, if necessary. Always fit shims, if any, immediately to the left and right of the foundation bolts (3) between the baseplate/foundation frame and the foundation. For a bolt-to-bolt distance (L) > 800 mm fit additional shims (2) halfway between the bolt holes. All shims must lie perfectly flush.

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

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

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

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

7. Grout the baseplate using low-shrinkage concrete with a standard particle size and a water/cement ratio of ≤ 0.5. Produce flowability with the help of a solvent. Perform secondary treatment of the concrete to DIN 1045.

NOTE

For low-noise operation contact the manufacturer to check whether the pump set can be installed on anti-vibration mounts.

NOTE

Expansion joints can be fitted between the pump and the suction/discharge line.

5.3.2 Installation without foundation (European version)

Adjusting the levelling elements

Fig. 8:

1, 3

Locknut 2 Adjusting nut

4 Levelling element

✓ The installation surface has the required strength and characteristics.

1. Position the pump set on the machine mounts (4) and align it with the help of a spirit level (on the shaft/discharge nozzle).

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

3. Turn the adjusting nut (2) until any differences in height have been compensated.

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5 Installation at Site

4. Re-tighten the locknuts (1, 3) at the machine mounts (4).

5.4 Piping

5.4.1 Connecting the piping

DANGER

Impermissible loads acting on the pump nozzles Danger to life from leakage of hot, toxic, corrosive or flammable fluids!

▷ Do not use the pump as an anchorage point for the piping.

▷ Anchor the pipes in close proximity to the pump and connect them 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.

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.

✓ Suction lift lines have been laid with a rising slope, suction head lines with a

downward slope towards the pump.

✓ 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.

✓ The nominal diameters of the pipelines are at least equal to the nominal

diameters of the pump nozzles.

✓ Adapters to larger diameters have a diffuser angle of approximately 8° to

prevent excessive pressure losses.

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

connected without transmitting any stresses or strains.

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CAUTION

Welding beads, scale and other impurities in the piping Damage to the pump!

▷ Free the piping from any impurities.

▷ If necessary, install a filter.

▷ Comply with the instructions set out in (⇨ Section 7.2.2.3 Page 46) .

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.

3. Check that the inside of the pump is free from any foreign objects. Remove any foreign objects.

4. If required, install a filter in the piping (see figure: Filter in the piping).

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5 Installation at Site

Fig. 9: Filter in the piping

Differential pressure gauge 2 Filter

NOTE

Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter) made of corrosion-resistant material. Use a filter with a filter area three times the cross-section of the piping. Conical filters have proved suitable.

5. Connect the pump nozzles to the piping.

CAUTION

Aggressive flushing and pickling agents Damage to the pump!

▷ Match the cleaning operation mode and duration for flushing and pickling

service to the casing and seal materials used.

Fig. 10: Forces and moments at the pump nozzles Table 9: Forces and moments at the pump nozzles for material variant C (1.4408/A743 GR CF8M) at 20° C.

Size Suction nozzle Discharge nozzle

DN F

040-025-160 40 970 780 650 1404 845 585 683 25 490 455 600 898 370 390 455 040-025-200 40 970 780 650 1404 845 585 683 25 460 455 600 898 370 390 455 050-032-125 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050-032-125.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050-032-160 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050-032-160.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050-032-200 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050-032-200.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050-032-250 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050-032-250.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 065-040-125 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 065-040-160 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685

[N]

5.4.2 Permissible 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.

∑F

[N]

MegaCPK

[N]

[Nm]

DN F

[N]

∑F

[N]

[Nm]

[N]

[Nm]

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[Nm]

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5 Installation at Site

Size Suction nozzle Discharge nozzle

DN F

[N]

065-040-160.1 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 065-040-200 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 065-040-200.1 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 065-040-250 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 065-040-250.1 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 065-040-315 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 065-040-315.1 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685 080-050-125 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-160 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-160.1 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-200 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-200.1 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-250 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-250.1 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-315 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 080-050-315.1 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750 100-065-125 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790 100-065-160 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790 100-065-200 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790 100-065-250 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790 100-065-315 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790 125-080-160 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000 125-080-200 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000 125-080-200.1 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000 125-080-250 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000 125-080-315 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000 125-080-400 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000 125-100-160 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400 125-100-200 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400 125-100-250 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400 125-100-315 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400 125-100-400 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400 150-125-200 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900 150-125-250 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900 150-125-315 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900 150-125-400 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900 200-150-200 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450 200-150-250 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450 200-150-315 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450 200-150-400 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450 200-150-500 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450 200-200-250 200 6750 5250 4300 9572 4850 2450 3550 200 5250 4300 6750 9572 4850 2450 3550 250-200-315 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550 250-200-400 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550 250-200-500 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550 300-250-315 300 11000 9200 7350 16114 8400 4150 6350 250 7350 6150 9150 13250 6900 3350 5250

∑F

[N]

[Nm]

DN F

[N]

∑F

[N]

[Nm]

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

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C, V

0,6

0,7

0,8

0,9

1,2

50 100 150 200 250 300 400

°C

350

1,1

Correction coefficient

Table 10: Forces and moments at the pump nozzles for "G" variant (JL1040/ A48CL35B) at 20 °C

Size Suction nozzle Discharge nozzle

040-025-160 40 450 400 350 696 450 320 370 25 265 250 300 472 315 210 245 040-025-200 40 450 400 350 696 450 320 370 25 265 250 300 472 315 210 245 050-032-125 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 050-032-125.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 050-032-160 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 050-032-160.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 050-032-200 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 050-032-200.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 050-032-250 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 050-032-250.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300 065-040-125 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-160 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-160.1 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-200 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-200.1 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-250 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-250.1 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-315 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 065-040-315.1 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370 080-050-125 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-160 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-160.1 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-200 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-200.1 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-250 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-250.1 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-315 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 080-050-315.1 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400 100-065-125 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420 100-065-160 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420 100-065-200 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420 100-065-250 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420 100-065-315 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420 125-080-160 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460 125-080-200 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460 125-080-200.1 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460 125-080-250 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460 125-080-315 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460 125-080-400 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460 125-100-160 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510 125-100-200 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510 125-100-250 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510 125-100-315 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510

DN F

[N]

5 Installation at Site

Fig. 11: Temperature correction diagram for "E, D, C, V" variant (1.4408/ A743 GR CF8M)

∑F

[N]

[Nm]

DN F

[N]

∑F

[N]

[Nm]

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0,9

0,92

0,94

0,96

0,98

20 40 60 80 100 120 140

160

°C

Correction coefficient

5 Installation at Site

Size Suction nozzle Discharge nozzle

DN F

[N]

125-100-400 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510 150-125-200 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670 150-125-250 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670 150-125-315 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670 150-125-400 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670 200-150-200 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720 200-150-250 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720 200-150-315 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720 200-150-400 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720 200-150-500 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720 200-200-250 200 2350 2100 1900 3680 1150 800 930 200 2100 1900 2350 3680 1150 800 930 250-200-315 250 3340 2980 2700 5227 1780 1260 1460 200 2100 1900 2350 3680 1150 800 930 250-200-400 250 3340 2890 2700 5227 1780 1260 1460 200 2100 1900 2350 3680 1150 800 930 250-200-500 250 3340 2890 2700 5227 1780 1260 1460 200 2100 1900 2350 3680 1150 800 930 300-250-315 300 4000 3580 3220 6260 2420 1720 1980 250 2980 2700 3340 5227 1780 1260 1460

∑F

[N]

[Nm]

DN F

[N]

∑F

[N]

[Nm]

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

Fig. 12:

5.4.3

Temperature correction diagram for "G" variant (JL1040/ A48CL35B)

Auxiliary connections

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 and quench liquid are compatible with the

fluid pumped.

WARNING

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

▷ Refer to the general arrangement drawing, the piping layout and pump

markings (if any) for the quantity, dimensions and locations of auxiliary connections.

▷ Use the auxiliary connections provided.

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5 Installation at Site

5.5 Enclosure/insulation

DANGER

Risk of potentially explosive atmosphere due to insufficient venting Explosion hazard!

▷ Make sure the space between the casing cover/discharge cover and the bearing

cover is sufficiently vented.

▷ Never close or cover the perforation of the bearing bracket guards (e.g. by

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.

CAUTION

Heat build-up in the bearing bracket Damage to the bearing!

▷ Never insulate the casing cover and the bearing bracket.

5.6 Checking the coupling alignment

DANGER

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

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

CAUTION

Misalignment of pump and motor shafts Damage to pump, motor and coupling!

▷ Always check the coupling after the pump has been installed and connected to

the piping.

▷ Also check the coupling of pump sets supplied with pump and motor mounted

on the same baseplate.

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a) b)

5 Installation at Site

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

1 Straight-edge 2 Gauge

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

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

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

3. Leave the straight-edge in this position and turn the coupling by hand. The coupling is aligned correctly if the distances A and B to the respective shafts are the same at all points around the circumference. The radial and axial deviation between the two coupling halves must not exceed 0.1 mm, during standstill as well as at operating temperature and under inlet pressure.

4. Check the distance (dimension see general arrangement drawing) between the two coupling halves around the circumference. The coupling is correctly aligned if the distance between the two coupling halves is the same at all points around the circumference. The radial and axial deviation between the two coupling halves must not exceed 0.1 mm, during standstill as well as at operating temperature and under inlet pressure.

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

5.7 Aligning the pump and motor

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

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5 Installation at Site

5.7.1 Motors with adjusting screw

Fig. 14:

Motor with adjusting screw

Hexagon head bolt 2 Adjusting screw

3 Locknut

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

1. Check the coupling alignment.

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

3. Turn the adjusting screws (2) by hand or by means of an open-end wrench until the coupling alignment is correct and all motor feet rest squarely on the baseplate.

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

5. Check proper functioning of coupling/shaft. Check that coupling/shaft can easily be rotated by hand.

WARNING

Unprotected rotating coupling Risk of injury by rotating shafts!

▷ Always operate the pump set with a coupling guard.

If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one!

▷ Observe all relevant regulations for selecting a coupling guard.

DANGER

Risk of ignition by frictional sparks Explosion hazard!

▷ Choose a coupling guard material that is non-sparking in the event of

mechanical contact (see DIN EN 13463-1).

6. Fit the coupling guard and its footboard, if any.

7. Check the distance between coupling and coupling guard. The coupling guard must not touch the coupling.

5.7.2 Motors without adjusting screw

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

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5 Installation at Site

Fig. 15: Pump set with shim

1 Shim

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

1. Check the coupling alignment.

2. Loosen the hexagon head bolts at the motor.

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

4. Re-tighten the hexagon head bolts.

5. Check proper functioning of coupling/shaft. Check that coupling/shaft can easily be rotated by hand.

WARNING

Unprotected rotating coupling Risk of injury by rotating shafts!

▷ Always operate the pump set with a coupling guard.

If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one!

▷ Observe all relevant regulations for selecting a coupling guard.

DANGER

Risk of ignition by frictional sparks Explosion hazard!

▷ Choose a coupling guard material that is non-sparking in the event of

mechanical contact (see DIN EN 13463-1).

6. Fit the coupling guard and its footboard, if any.

7. Check the distance between coupling and coupling guard. The coupling guard must not touch the coupling.

5.8 Electrical connection

DANGER

Incorrect electrical installation Explosion hazard!

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

▷ Always use a motor protection switch for explosion-proof motors.

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DANGER

Electrical connection work by unqualified personnel Danger of death from 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.

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5 Installation at Site

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 start-up method.

NOTE

A motor protection device is recommended.

5.8.1 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 11: Time relay settings for star-delta starting:

Motor rating Y time to be set [kW] [s]

≤ 30 < 3 > 30 < 5

5.8.2 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.

5.8.3 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.

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5 Installation at Site

5.9 Checking the direction of rotation

DANGER

Temperature increase 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 set.

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

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.

CAUTION

Incorrect direction of rotation with non-reversible mechanical seal Damage to the mechanical seal and leakage!

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

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 is running in the wrong direction of rotation, check the electrical connection of the motor and switchgear, if any.

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6 Commissioning/Start-up/Shutdown

Grease-lubricated bearings

Oil-lubricated bearings

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. (⇨ Section 5.8 Page 30)

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

vented.

▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 32)

▪ All auxiliary connections required are connected and operational.

▪ The lubricants have been checked.

▪ After prolonged shutdown of the pump (set), the activities required for returning

the pump (set) to service have been carried out. (⇨ Section 6.4 Page 42)

6.1.2

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

Fill the bearing bracket with lubricating oil. Oil quality see (⇨ Section 7.2.3.1.2 Page 46) Oil quantity see - (⇨ Section 7.2.3.1.3 Page 46)

Filling the constant level oiler with lubricating oil (oil-lubricated bearings only)

✓ The constant level oiler is screwed into the upper tapping hole of the bearing

Filling in lubricants

bracket.

NOTE

If no constant level oiler is provided on the bearing bracket, the oil level can be read in the middle of the oil level sight glass arranged at the side of the bearing bracket.

CAUTION

Insufficient quantity of lubricating oil in the reservoir of the constant level oiler Damage to the bearings!

▷ Regularly check the oil level.

▷ Always fill the oil reservoir completely.

▷ Keep the oil reservoir properly filled at all times.

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6 Commissioning/Start-up/Shutdown

Fig. 16: Bearing bracket with constant level oiler

Constant level oiler 2 Vent plug

1 3 Connection elbow of the constant

4 Screw plug

level oiler

5 Bearing bracket

1. Pull out the vent plug (2).

2. Hinge down the reservoir of the constant level oiler (1) from the bearing bracket (5) and hold it in this position.

3. Fill in oil through the hole for the vent plug until the oil reaches the connection elbow of the constant level oiler (3).

4. Completely fill the reservoir of the constant level oiler (1).

5. Snap the constant level oiler (1) back into its operating position.

6. Fit the vent plug (2) again.

7. After approximately 5 minutes, check the oil level in the glass reservoir of the constant level oiler (1). The oil reservoir must be properly filled at all times to provide a constant oil level. Repeat steps 1 - 6, if necessary.

8. To check the function of the constant level oiler (1), slowly drain some oil via the screw plug (4) until air bubbles can be seen in the oil reservoir.

Reservoir of non-

pressurised external fluid

Double mechanical seal

External liquid feed

NOTE

An excessively high oil level can lead to a temperature rise and to leakage of the fluid handled or oil.

6.1.3 Shaft seal

Shaft seals are fitted prior to delivery. Observe the instructions on dismantling (⇨ Section 7.4.6 Page 50) or assembly (⇨ Section 7.5.3 Page 55) .

If applicable, fill the reservoir of non-pressurised external fluid in accordance with the general arrangement drawing.

Prior to starting up the pump, apply barrier pressure as specified in the general arrangement drawing.

Apply the quantities and pressures specified in the data sheet and the general arrangement drawing.

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6.1.4 Priming and venting the pump

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 and quench liquid are compatible with the

fluid pumped.

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

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.

1. Vent the pump and suction line and prime both with the fluid to be handled.

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

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

6.1.5 Final check

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

2. Check the coupling alignment; re-align the coupling, if required. (⇨ Section 5.6 Page 27)

3. Check proper functioning of coupling/shaft. Check that coupling/shaft can be easily rotated by hand.

4. Fit the coupling guard and its footboard, if any.

5. Check the distance between coupling and coupling guard. The coupling guard must not touch the coupling.

6.1.6 Water cooling

CAUTION

Deposit-forming, aggressive cooling water Damage to the pump!

▷ Observe the cooling water quality.

Observe the following quality data of the cooling water:

▪ Not deposit-forming

▪ Not aggressive

▪ Free from suspended solids

▪ Hardness on average 5 °dH (~1 mmol/l)

▪ pH > 8

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▪ Conditioned and neutral with regard to mechanical corrosion

▪ Inlet temperature t

Outlet temperature t

=10 to 30 °C

inl

= 45 °C max.

outl

6.1.7 Cooling of the bearing bracket (special design)

If the pump is permanently heated during standstill (above 185 °C) the bearing bracket has to be cooled.

Observe the following values for cooling the bearing bracket:

▪ Cooling liquid pressure: 6 bar max.

▪ Cooling liquid quantities: see table below.

Table 12: Cooling liquid quantities for cooling the bearing bracket

Bearing bracket Cooling liquid quantity [l/min]

CS40 5 CS50 6 CS60 8 CS80 10

6.1.8 Heating (version "h")

The pump can also be heated, if necessary. The volute casing and the casing cover have heating chambers. The heating chambers can be heated with hot water, steam or thermal oil.

The following limits must be observed:

▪ Maximum temperature: 300 °C

▪ Maximum pressure: 20 bar

DANGER

Excessive surface temperature Explosion hazard! Risk of burns!

▷ Observe the permissible temperature classes.

CAUTION

Lack of heating medium Damage to the pump!

▷ Provide sufficient quantities of a suitable heating medium.

CAUTION

Time for warming up the pump too short Damage to the pump!

▷ Check that the pump is sufficiently warmed up throughout.

CAUTION

Impermissibly high temperature of the heating medium Fluid or heating medium could escape!

▷ Observe the application limits of the heating media.

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Fluid temperatures above

150 °C

Temperature difference

6.1.9 Heating up/keeping warm the pump (set)

CAUTION

Pump blockage Damage to the pump!

▷ Prior to pump start-up, heat up the pump as described in the manual.

Observe the following when heating up the pump (set) and keeping it warm:

▪ Make sure that the temperature is increased continuously.

▪ Max. heating speed: 10 °C/min (10 K/min)

When the pump is used for handling fluids at temperatures above 150 °C make sure that the pump has been heated throughout before starting it up.

The temperature difference between the pump's surface and the fluid handled must not exceed 100 °C (100 K) when the pump is started up.

6.1.10 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! Leakage of hot or toxic fluids!

▷ 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. (⇨ Section 6.1.4 Page 35)

▷ Always operate the pump within the permissible operating range.

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.

✓ The system piping has been cleaned.

✓ The pump, suction line and, if applicable, inlet tank have been vented and

primed with the fluid to be handled.

✓ 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.

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

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

3. Start up the motor.

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

CAUTION

Misalignment of pump and coupling Damage to pump, motor and coupling!

▷ When the operating temperature has been reached, switch off the pump set

and check the coupling alignment.

Mechanical seal

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

6.1.11 Checking the shaft seal

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

Gland packing

The gland packing must drip slightly during operation.

DANGER

Impermissibly high temperatures at gland packings Explosion hazard!

▷ Always use suitable temperature monitoring for gland packings.

▷ Gland packing must be tightened correctly.

Pure graphite packing

Prior to commissioning

After five minutes of

If a pure graphite packing is used, there must always be some leakage.

Table 13: Leakage rate of the pure graphite packing

Quantity Values

Minimum 10 cm³/min Maximum 20 cm³/min

Adjusting the leakage

1. Only lightly tighten the nuts of the gland follower by hand.

2. Use a feeler gauge to verify that the gland follower is mounted centred and at a right angle to the shaft.

⇨ The gland must leak after the pump has been primed.

operation

WARNING

Unprotected rotating parts Risk of personal injury!

▷ Do not touch rotating parts.

▷ When the pump is running, perform any work with utmost caution.

The leakage can be reduced.

1. Tighten the nuts on the gland follower by 1/6 turn.

2. Monitor the leakage for another five minutes.

Excessive leakage: Repeat steps 1 and 2 until the minimum value has been reached.

Not enough leakage: Slightly loosen the nuts at the gland follower.

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No leakage: Immediately switch off pump set! Loosen the gland follower and repeat commissioning.

Checking the leakage

After the leakage has been adjusted, monitor the leakage for about two hours at maximum fluid temperature. Check that enough leakage occurs at the gland packing at minimum fluid pressure.

6.1.12 Shutdown

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

✓ On pump sets with double mechanical seal, apply the required pressure

specified in the general arrangement drawing to the mechanical seal chamber also during standstill.

✓ Also ensure quench liquid supply is ON during pump standstill.

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 check valve, the shut-off element in the discharge line may remain open, provided the site's requirements and regulations are taken into account 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 the auxiliary connections. If the fluid to be handled is fed in under vacuum, also supply the shaft seal with barrier fluid during standstill. Only turn off the cooling liquid supply after the pump has cooled down.

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.

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.

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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 14: Permissible ambient temperatures

Permissible ambient temperature Value

Maximum 50 °C

40 °C

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 start-ups are evenly spaced over the period indicated, the following limits serve as orientation for start-up with the discharge-side gate valve slightly open:

Table 15: Frequency of starts

Motor rating Maximum frequency of starts [kW] [Start-ups/hour]

≤ 12 15 ≤ 100 10 > 100 5

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

= 0.15 × Q

min

= 0.3 × Q

min

opt

For compliance with 2014/34/EU (ATEX Equipment Directive). Higher ambient temperature possible in individual cases, see data sheet and name plate.

Minimum permissible flow rate

Flow rate at best efficiency point

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▪ 2-pole operation: Q

▪ 4-pole operation: Q

▪ 6-pole operation: Q

max

10)

= 1.1 × Q

= 1.25 × Q

opt

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.

Table 16: Key

Symbol

Description Unit

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

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.

CAUTION

Impermissibly high density of the fluid handled Motor overload!

▷ Observe the information on 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

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

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

10)

Maximum permissible flow rate

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

✓ The pump has been properly drained (⇨ Section 7.3 Page 48) and the safety

instructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page 48)

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 and discharge nozzles. It is advisable to close the pump nozzles (e.g. with plastic caps or similar).

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

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

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

6.4 Returning to service

For returning the pump to service, observe the sections on commissioning/start-up (⇨ Section 6.1 Page 33) and the operating limits (⇨ Section 6.2 Page 39) .

In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. (⇨ Section 7 Page 43)

WARNING

Failure to re-install or re-activate protective devices Risk of personal injury from moving parts or escaping fluid!

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

and protective devices.

NOTE

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

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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 at an explosion-proof pump (set) outside of

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, shaft seal

and coupling.

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 pump set Risk of injury by moving parts!

▷ Ensure that the pump set cannot be started up unintentionally.

▷ Always make sure the electrical connections are disconnected before carrying

out work on the pump set.

WARNING

Fluids, 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.

WARNING

Insufficient stability Risk of crushing hands and feet!

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

tipping or falling 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, service 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.

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7.2 Servicing/inspection

7.2.1 Supervision of operation

DANGER

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

▷ Regularly check the lubricant level.

▷ Regularly check the rolling element bearings for running noises.

DANGER

Incorrectly serviced shaft seal Explosion hazard! Leakage of hot, toxic fluids! Damage to the pump set! Risk of burns! Fire hazard!

▷ Regularly service the shaft seal.

DANGER

Incorrectly serviced barrier fluid system Explosion hazard! Fire hazard! Damage to the pump set! Leakage of hot and/or toxic fluids!

▷ Regularly service the barrier fluid system.

▷ Monitor the barrier fluid pressure.

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. (⇨ Section 6.2 Page 39)

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

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

▪ In case of oil lubrication, ensure the oil level is correct. (⇨ Section 6.1.2 Page 33)

▪ Check the shaft seal. (⇨ Section 6.1.11 Page 38)

▪ Check the static sealing elements for leakage.

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7 Servicing/Maintenance

▪ 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.

▪ Cooling system

Take the pump out of service at least once a year to thoroughly clean the cooling system.

▪ 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 outside of the bearing bracket).

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 bearing bracket).

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).

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.

7.2.2.1 Checking the coupling

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

7.2.2.2 Checking the clearances

The back pull-out unit must be removed to check the clearances. If the clearance is larger than permitted (see the following table), fit a new casing wear ring 502.01 and/or 502.02. The clearances given refer to the diameter.

Table 17: Clearances between impeller and casing (cover)/between impeller and casing wear ring

Impeller material

New Maximum

Clearances

G, B 0,3 mm 0,9 mm C, D, E 0,5 mm 1,5 mm

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7.2.2.3 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.

7.2.3 Lubrication and lubricant change of rolling element bearings

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.

7.2.3.1 Oil lubrication

The rolling element bearings are usually lubricated with mineral oil.

7.2.3.1.1 Intervals

Table 18: Oil change intervals

Temperature at the

bearing

First oil change All subsequent oil

changes

11)

up to 70 ℃ After 300 operating hours Every 8500 operating hours 70 °C - 80 °C After 300 operating hours Every 4200 operating hours 80 °C - 90 °C After 300 operating hours Every 2000 operating hours

7.2.3.1.2 Oil quality

Table 19: Oil quality

Description Properties

Lubricating oil CL46 or

CLP46 to DIN 51517

Kinematic viscosity at 40 °C 46±4 mm²/s

Flash point (to Cleveland) +175 °C

Solidification point (pour point) -15 °C

12)

Application temperature

Higher than permissible

bearing temperature

7.2.3.1.3 Oil quantity

Table 20: Oil quantity

Bearing bracket Oil quantity [l]

CS40 0.2 CS50 0.4 CS60 0.4 CS80 0.7

11)

At least once a year

12)

For ambient temperatures below -10 °C use a suitable different type of lubricating oil. Contact KSB.

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7 Servicing/Maintenance

7.2.3.1.4 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.

Fig. 17: Bearing bracket with constant level oiler

Constant level oiler 2 Screw plug

3 Bearing bracket

✓ A suitable container for the used oil is on hand.

1. Place the container underneath the screw plug.

2. Undo the screw plug (2) at the bearing bracket (3) and drain the oil.

3. Once the bearing bracket (3) has been drained, re-insert and re-tighten the screw plug (2).

4. Re-fill with oil. (⇨ Section 6.1.2 Page 33)

7.2.3.2

Grease lubrication

The bearings are supplied packed with high-quality lithium-soap grease.

7.2.3.2.1 Intervals

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

25,000 operating hours.

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

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

▪ Replace the rolling element bearings after 25,000 operating hours or 2 years of

continuous operation.

7.2.3.2.2 Grease quality

Table 21: Grease quality to DIN 51825

Soap basis NLGI grade Worked penetration

at 25 °C in mm/10

Lithium 2 to 3 220-295 ≥ 175 °C -30 °C to 120 °C

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Medium-duty

7.2.3.2.3 Grease quantities

Table 22: Grease quantities for new grease fill

Bearings Bearing + cover,

pump-end

[g]

Bearing + cover,

drive-end

[g]

CS40 15 40 CS50 30 100 CS60 50 150 CS80 50 80

Economy

Economy bearings are greased for life; the grease fill cannot be renewed. If necessary, replace the complete bearing.

7.2.3.2.4 Changing the grease

CAUTION

Mixing greases of differing soap bases Changed lubricating qualities!

▷ Thoroughly clean the bearings.

▷ Adjust the re-lubrication intervals to the grease used.

✓ The pump has been dismantled for changing the grease. (⇨ Section 7.4 Page 48)

1. Only half-fill the bearing cavities with grease.

2. Fill the cavities in the bearing cover until they are about 1/3 full.

7.3 Drainage/cleaning

WARNING

Fluids, 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 residues of the fluid

handled.

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

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

If the pump set has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen, the pump set must be neutralised, and anhydrous inert gas must be blown through the pump to ensure drying.

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

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

WARNING

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

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

qualified personnel.

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WARNING

Hot surface Risk of injury!

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

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.

Observe the general safety instructions and information. (⇨ Section 7 Page 43)

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

For dismantling and reassembly refer to the general assembly drawing.

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

DANGER

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

▷ Properly shut down the pump set. (⇨ Section 6.1.12 Page 39)

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

▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 48)

▷ Close any auxiliary connections.

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

7.4.2 Preparing the pump set

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

2. Disconnect and remove all auxiliary pipework.

3. Remove the coupling guard.

4. Remove the coupling spacer, if any.

5. Drain the oil fill of oil-lubricated bearings. (⇨ Section 7.2.3.1.4 Page 47)

7.4.3 Removing the motor

NOTE

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

WARNING

Motor tipping over Risk of crushing hands and feet!

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

1. Disconnect the motor from the power supply.

2. Unbolt the motor from the baseplate.

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

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7.4.4 Removing the back pull-out unit

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.3 Page

49) have been observed/carried out.

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

WARNING

Back pull-out unit tipping over Risk of crushing hands and feet!

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

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

2. Unbolt support foot 183 from the baseplate.

3. Only for heated version: Undo pipe union 731.01/.02.

4. Only for heated version: Remove by-pass pipe 710.02.

5. Undo hexagon nut 920.01 at the volute casing.

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

7. Remove and dispose of joint ring 411.10.

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

7.4.5 Removing the impeller

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.4 Page

50) have been observed/carried out.

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

1. Undo impeller nut 922 (right-hand thread).

2. Remove impeller 230 with an impeller removal tool.

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

4. Remove keys 940.01 from shaft 210.

5. Remove and dispose of joint rings 411.31/411.32.

7.4.6 Removing the shaft seal

7.4.6.1 Removing the mechanical seal - cylindrical casing cover

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.5 Page

50) have been observed/carried out.

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

1. Unscrew hexagon nuts 920.02 and slide back seal cover 471 (if fitted).

2. Undo hexagon head bolts 901.22, if any.

3. Remove casing cover 161 from bearing bracket 330.

4. Pull complete mechanical seal 433 with shaft protecting sleeve 524.01, seal cover 471 and thrower 507.01 off shaft 210.

7.4.6.2 Removing the mechanical seal - conical casing cover

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.5 Page

50) have been observed/carried out.

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

1. Pull shaft sleeve 524.01 with the rotating assembly of mechanical seal 433 off the shaft.

2. Undo hexagon head bolts 901.22, if any.

3. Dismantle casing cover 161 with the stationary ring of mechanical seal 433.

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4. Remove thrower 507.01.

5. Press the stationary ring of mechanical seal 433 out of casing cover 161.

7.4.6.3 Removing the gland packing

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.5 Page

50) have been observed/carried out.

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

1. Undo hexagon nuts 920.02 at gland follower 452 and remove the gland follower.

2. Undo hexagon head bolt 901.22, if any.

3. Remove casing cover 161 from bearing bracket 330.

4. Remove stuffing box ring 454.01 and drip plate 463.01.

5. Remove packing rings 461.01 and lantern ring 458.01, if any, from the packing chamber.

6. Pull shaft protecting sleeve 524.01 and thrower 507.01 off shaft 210.

7.4.7

Dismantling the bearings

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.6 Page

50) have been observed/carried out.

✓ The bearing bracket is kept in a clean and level assembly area.

1. Unscrew the hexagon socket head cap screw in the coupling hub.

2. Pull the coupling half off the pump shaft with a puller.

3. Remove key 940.02.

4. Undo screws 914.02 and remove drive-end bearing cover 360.02 and joint ring

400.02.

5. Undo screws 914.01 and remove pump-end bearing cover 360.01 and joint ring

400.01.

7.4.7.1

Dismantling the medium-duty bearing assembly

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.7 Page

51) have been observed/carried out.

1. Carefully drive shaft 210 together with angular contact ball bearing 320.02 and the inner ring of cylindrical roller bearing 322.01 out of the bearing bracket towards the drive end.

2. Remove support disc 550.23 of angular contact ball bearing 320.02 from bearing bracket 330.

3. In case of grease lubrication, remove disc 550.25.

4. Remove cylindrical roller bearing 322.01 (roller cage) from bearing bracket 330.

5. In case of grease lubrication, remove disc 550.24.

6. Bend open lock washer 931.01 behind keywayed nut 920.21 on shaft 210.

7. Unscrew keywayed nut 920.21 (right-hand thread) and remove lock washer

931.01.

WARNING

Hot surfaces due to heating of components for assembly/dismantling Risk of burns!

▷ Wear heat-resistant protective gloves.

▷ Remove flammable substances from the danger zone.

8. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical roller bearing 322.01 to 80 °C, and pull them off shaft 210.

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9. Dispose of joint rings 400.01/.02.

7.4.7.2 Dismantling the economy bearing assembly

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.7 Page

51) have been observed/carried out.

1. Carefully press shaft 210 with deep groove ball bearing 321.01/.02 out of the bearing bracket.

2. Heat up the deep groove ball bearing to 80°C and pull it off shaft 210. On grease-lubricated models, pull deep groove ball bearing 321.01/.02 off the shaft in cold condition.

3. Dispose of joint rings 400.01/.02.

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 have the same thickness as

the old ones.

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

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

▪ O-rings

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

gluing the ends together.

▪ Packing rings

– Always use pre-compressed packing rings

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.

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– Never use quick-setting adhesives (cyanoacrylate adhesives).

– Coat the locating surfaces of the individual components and screwed

connections with graphite or similar before reassembly.

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

7.5.2 Reassambling the bearing assembly

7.5.2.1 Reassembling the medium-duty bearing assembly

✓ The individual parts have been placed in a clean and level assembly area.

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

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

WARNING

Hot surfaces due to heating of components for assembly/dismantling Risk of burns!

▷ Wear heat-resistant protective gloves.

▷ Remove flammable substances from the danger zone.

1. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical roller bearing 322.01 to approx. 80 °C in an oil bath.

2. Slide angular contact ball bearing 320.02 and the inner ring of cylindrical roller bearing 322.01 onto shaft 210 until they will not go any further.

NOTE

Angular contact ball bearings must be installed in back-to-back arrangement. Angular contact ball bearings installed in pairs must always be from the same manufacturer.

3. Use a C-spanner to tighten slotted round nut 920.21 without lock washer

931.01.

4. Let angular contact ball bearing 320.01 cool down to approximately 5 °C above ambient temperature.

5. Re-tighten slotted round nut 920.21 to torque M1. (⇨ Section 7.6.2 Page 59) Then unscrew it again.

6. Apply a few spots of a suitable lubricant (e.g. Molykote) to the contact faces of lock washer 931.01 and slotted round nut 920.21.

7. Fit lock washer 931.01.

8. Tighten slotted round nut 920.21 (⇨ Section 7.6.2 Page 59) to torque M2.

9. Bend back lock washer 931.01.

10. Insert circlip 932.01/932.02 into the bearing bracket.

11. On grease-lubricated models, insert disc 550.24.

12. Fit cylindrical roller bearing 322.01 (roller cage) in the bearing bracket.

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Fig. 18: Reassembling the medium-duty bearing assembly

13. On grease-lubricated models, insert disc 550.25.

14. Insert support disc 550.23 of angular contact ball bearing 320.02 into bearing bracket 330.

15. Carefully insert pre-assembled shaft 210 with angular contact ball bearing

320.02 and the inner ring of cylindrical roller bearing 322.01 into bearing bracket 330 from the drive end.

16. On grease-lubricated models, fill the bearing and bearing cover with grease. Grease lubrication see (⇨ Section 7.2.3.2 Page 47)

17. Fit pump-end bearing cover 360.01 with joint ring 400.01; take care not to damage lip seal 421.01.

18. Fit drive-end bearing cover 360.02 with joint ring 400.02; take care not to damage lip seal 421.02.

19. Fit thrower 507.01 and 507.02, if applicable, and align flush with the shaft shoulder.

20. Fit keys 940.02.

21. Slide the coupling hub onto the shaft end.

22. Secure the coupling hub with an adjusting screw.

7.5.2.2

Reassembling the economy bearing assembly

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

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

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

WARNING

Hot surfaces due to heating of components for assembly/dismantling Risk of burns!

▷ Wear heat-resistant protective gloves.

▷ Remove flammable substances from the danger zone.

1. Oil-lubricated models: Heat up deep groove ball bearing 321.01/.02 in an oil bath to approx. 80°C and slide it onto shaft 210 until it will not go any further. Grease-lubricated models: Press deep groove ball bearing 321.01/.02 onto shaft 210 in cold condition until it will not go any further. Only apply force via the inner ring of the deep groove ball bearings.

2. Carefully slide pre-assembled shaft 210 with deep groove ball bearing

321.01/.02 into bearing bracket 330.

3. Fit pump-end bearing cover 360.01 with joint ring 400.01; take care not to damage lip seal 421.02.

4. Fit drive-end bearing cover 360.02 with joint ring 400.02; take care not to damage lip seal 421.02.

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5. Fit throwers 507.01 and 507.02, if any, and align flush with the shaft shoulder.

6. Fit keys 940.02.

7. Pull the coupling hub onto the shaft end.

8. Secure the coupling hub with a set screw.

7.5.3 Fitting the shaft seal

7.5.3.1 Fitting the mechanical seal

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

▪ For installing the mechanical seal, proceed as shown in the seal installation

drawing.

▪ Work cleanly and accurately.

▪ Only remove the protective wrapping of the contact faces immediately before

installation takes place.

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

▪ After inserting the stationary ring of the mechanical seal, 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 assembly onto the shaft protecting sleeve, take

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

7.5.3.1.1

Fitting the single mechanical seal – cylindrical casing cover

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 52) to (⇨ Section 7.5.2 Page

53) have been observed/carried out.

✓ The bearing assembly and the individual parts of mechanical seal 433 are kept

in a clean and level assembly area.

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

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

1. Fit thrower 507.01, if applicable, and align flush with the shaft shoulder.

2. Fasten seal cover 471 with inserted O-ring, the stationary ring of the mechanical seal and gasket 411.05 to casing cover 161 with hexagon nut 920.02.

3. Place casing cover 161 into the locating fit of bearing bracket 330.

4. Fit and tighten hexagon head bolt 901.22, if any.

5. Fit the rotating assembly of mechanical seal 433 on shaft protecting sleeve

524.01 (observe distance B - see Supplementary Sheet of the mechanical seal).

6. Slide pre-assembled mechanical seal 433 and shaft protecting sleeve 524.01 onto shaft 210.

7.5.3.1.2

Fitting the double mechanical seal – cylindrical casing cover

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 52) to (⇨ Section 7.5.2 Page

53) have been observed/carried out.

✓ The bearing assembly and the individual parts of mechanical seal 433 are kept

in a clean and level assembly area.

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

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

1. Fit thrower 507.01, if any, and align flush with the shaft shoulder.

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2. Fit the rotating assembly of mechanical seals 433.01 and 433.02 on shaft protecting sleeve 524.01 (observe distance B - see Supplementary Sheet for the mechanical seal).

3. Position the stationary ring of mechanical seal 433.01 with the O-ring in casing cover 161. Fit ring and circlip, if any.

4. Position the stationary ring of mechanical seal 433.02 with the O-ring in casing cover 471.01.

5. Insert pre-assembled mechanical seals 433.01 and 433.02 and shaft protecting sleeve 524.01 in the casing cover.

6. Fit seal cover 471.01 with gasket 411.15 on the casing cover. Make sure the connection bores are positioned correctly.

7.5.3.1.3 Fitting the mechanical seal – conical casing cover

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 52) to (⇨ Section 7.5.2 Page

53) have been observed/carried out.

✓ The bearing assembly and the individual parts of mechanical seal 433 are kept

in a clean and level assembly area.

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

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

1. Fit thrower 507.01, if applicable, and align flush with the shaft shoulder.

2. Carefully press the stationary ring of mechanical seal 433 with O-ring into casing cover 161.

3. Fit casing cover 161 with the inserted stationary ring of the mechanical seal into bearing bracket 330.

4. Fit and tighten hexagon head bolt 901.22, if any.

5. Fit the rotating assembly of mechanical seal 433 and spacer ring, if any, on shaft protecting sleeve 524.01 (observe distance B - see Supplementary Sheet for the mechanical seal).

6. Slide pre-assembled mechanical seal 433 and shaft protecting sleeve 524.01 onto shaft 210.

7.5.3.2

Fitting the gland packing

Fig. 19: Gland packing chamber a) with lantern ring and b) without lantern ring

Table 23: Gland packing chamber (dimensions in mm)

Bearing bracket Gland packing chamber Packing cross-section Packing rings

Ø d

CS40 35 51 53 8×8 4 rings and CS50 45 65 64 10×10 CS60 55 75 64 10×10 CS80 70 95 79 12,5×12,5

Pure graphite packings see supplementary operating instructions.

1 lantern ring

6 rings

Always use pre-compressed packing rings.

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✓ The notes and steps stated in (⇨ Section 7.5.1 Page 52) to (⇨ Section 7.5.2 Page

53) have been observed/carried out.

✓ The bearing assembly as well as the individual parts are kept in a clean and level

assembly area.

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

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

1. Clamp casing cover 161 into a vice.

2. Insert the first packing ring, ensuring that its cut edge is in a horizontal position.

3. Hold the packing ring in place and slide shaft protecting sleeve 524.01 (chamfered side first) into the gland packing chamber from the pump end.

4. Slightly expand the inside diameter of the packing ring by moving shaft protecting sleeve 524.01 back and forth. Then pull out shaft protecting sleeve

524.01. Insert lantern ring 458, if any (see drawing above). Insert subsequent packing rings one at a time, with their joints staggered at approximately 90°. When the last packing ring has been inserted, shaft protecting sleeve 524.01 remains in the packing chamber.

5. Insert stuffing box ring 454.01 with the drilled hole down.

6. Fit gland follower 452 and lightly fasten it by hand with the two hexagon nuts

920.02; watch discs 550.01.

7. Place the entire casing cover 161 with shaft protecting sleeve 524.01 into the locating fit of bearing bracket 330.

8. Fit and tighten hexagon head bolts 901.22, if any.

7.5.4

Fitting the impeller

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 52) to (⇨ Section 7.5.3 Page

55) have been observed/carried out.

✓ The bearing assembly/mechanical seal as well as the individual parts are kept in

a clean and level assembly area.

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

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

✓ Impeller bore, shaft and keyways are clean and free from burrs.

1. Insert keys 940.01 into the shaft keyway.

2. Insert joint ring 411.08 into shaft protecting sleeve 524.01.

3. Coat the impeller seat with a suitable lubricant.

4. Slide impeller 230 onto shaft 210.

5. Thread impeller nut 922 with inserted joint ring 411.31 onto shaft 210 and tighten. (⇨ Section 7.6.3 Page 60)

7.5.5

Installing the back pull-out unit

WARNING

Back pull-out unit tipping over Risk of crushing hands and feet!

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

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 52) to (⇨ Section 7.5.4 Page

57) have been observed/carried out.

✓ Any damaged or worn parts have been replaced by original spare parts.

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7 Servicing/Maintenance

✓ The sealing surfaces have been cleaned.

✓ For back pull-out units without coupling, fit the coupling in accordance with

the manufacturer's instructions.

1. If required, suspend or support the back pull-out unit to prevent it from tipping over. Then slide it into volute casing 102 with a new gasket 411.10.

2. Tighten nut 920.01 at the volute casing.

3. Bolt support foot 183 to the baseplate.

4. Only for heated version: Fit by-pass pipe 710.02 with pipe union 731.01/.02.

7.5.6 Mounting the motor

NOTE

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

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

2. Fasten the motor to the baseplate.

3. Align pump and motor. (⇨ Section 5.7 Page 28)

4. Connect the motor to the power supply (refer to manufacturer's product literature).

7.6 Tightening torques

7.6.1 Tightening torques for the pump

Fig. 20:

a) Tightening points at the pump, b) Model with clamped casing cover

Use a torque wrench to tighten the bolted connections (902.01/920.01) between the volute casing and the bearing bracket.

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Table 24: Tightening torques

Position Thread size Nominal value [Nm]

13)

125

200

300

A M12

M16

B M14x1,5 SW21 (CS40)

M16x1,5 SW24 (CS50)

M20x1,5 SW30 (CS60)

M24x1,5 SW36 (CS80)

C M8

M10

M12

PN16 (G, C, V)

125

D M12 90

M16 210

X 1/8

1/4

3/8

1/2

3/4

130

220

PN25 (E, D)

165

13)

7.6.2 Tightening torques for the shaft nut

Fig. 21:

Tightening point at the shaft nut

Table 25: Shaft nut tightening torques

Position Bearing bracket Slotted round

E CS 40 KM 8 M 40x1.5 100 65

CS 50 KM 10 M 50x1.5 150 90 CS 60 KM 12 M 60x2 200 120 CS 80 KM 16 M 80x2 200 120

nut

Thread Tightening torques [Nm]

14)

15)

13)

Casing material: G = cast iron; C,V = stainless steel; E = unalloyed steel; D = duplex stainless steel

14)

Loosen the screwed connection again after first tightening.

15)

Final tightening torque

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7.6.3 Tightening torques for the pump set

Fig. 22: Tightening points at the pump set

Table 26: Tightening torques

Position

Thread Tightening

Comment

torque

[Nm]

1 M12 30 Pump on baseplate

M16 75 M20 75

M24 140 2 M12 30 3 M24 × 1.5 140 Adjusting screws in

M36 × 1.5 140

baseplate

4 M6 10 Motor on adjusting screws or

M8 10

bases M10 15 M12 30 M16 75 M20 140 M24 140

5 M6 13 Coupling (only for spacer-

type coupling made by

Flender) M8 18

M10 44

6 M6 10 Coupling guard

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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

▪ Type series

▪ Size

▪ Material variant

▪ Year of construction

Refer to the name plate for all data.

Also specify the following data:

▪ Part number and description

▪ Quantity of spare parts

▪ Shipping address

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

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

Table 27: Quantity of spare parts for recommended spare parts stock

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

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

210 Shaft 1 1 1 2 2 2 20 % 230 Impeller 1 1 1 2 2 2 20 %

320.02 Rolling element bearing (set) 1 1 2 2 2 3 25 %

321.01 Radial ball bearing 1 1 2 2 2 3 25 %

321.02 Radial ball bearing 1 1 2 2 2 3 25 %

322.01 Radial roller bearing 1 1 2 2 2 3 25 %

502.01/.02 Casing wear ring 2 2 2 3 3 4 50 %

503.01/.02 Impeller wear ring 2 2 2 3 3 4 50 %

524.01 Shaft protecting sleeve 2 2 2 3 3 4 50 %

- Sealing elements for pump

4 6 8 8 9 12 150 %

casing (set)

- Torque-transmitting coupling

1 1 2 2 3 4 30 %

elements (set) Versions with mechanical seal: 433 Mechanical seal, complete 1 1 2 2 2 3 25 % Versions with gland packing:

461.01 Gland packing (set) 4 4 6 6 6 8 100 %

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7.7.3 Interchangeability of pump components Components featuring the same number in a column are interchangeable.

Table 28: Interchangeability of pump components

Description

18)

17)

16)

Casing wear ring

Casing cover

Support foot

Shaft, medium-duty

Shaft, economy

Rolling element bearing

Radial ball bearing

Radial roller bearing

Radial ball bearing

16)

Bearing bracket

Part No.

161

183

210

320.01

321.01

321.02

322.01

330

502.01

502.02

Size

Bearing bracket

502.01 040-025-160 CS40 1 1 1 1 1 1 1 1 1 1 - 1 1 - - 1 1 1 1 1 1 1 1 1 1 040-025-200 CS40 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 050-032-125 CS40 1 3 1 1 1 1 1 1 1 3 - 3 3 - - 1 1 1 1 1 1 1 1 1 1 050-032-125.1 CS40 1 3 1 1 1 1 1 1 1 2 - 2 2 - - 1 1 1 1 1 1 1 1 1 1 050-032-160 CS40 1 1 1 1 1 1 1 1 1 3 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 050-032-160.1 CS40 1 1 1 1 1 1 1 1 1 2 1 2 2 - - 1 1 1 1 1 1 1 1 1 1 050-032-200 CS40 2 2 1 1 1 1 1 1 1 3 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 050-032-200.1 CS40 2 2 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 065-040-125 CS40 1 3 1 1 1 1 1 1 1 5 - 4 4 - - 1 1 1 1 1 1 1 1 1 1 065-040-160 CS40 1 1 1 1 1 1 1 1 1 5 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 065-040-160.1 CS40 1 1 1 1 1 1 1 1 1 4 1 5 5 1 1 1 1 1 1 1 1 1 1 1 1 065-040-200 CS40 2 2 1 1 1 1 1 1 1 5 1 6 6 1 1 1 1 1 1 1 1 1 1 1 1 065-040-200.1 CS40 2 2 1 1 1 1 1 1 1 4 1 5 5 1 1 1 1 1 1 1 1 1 1 1 1 080-050-125 CS40 1 1 1 1 1 1 1 1 1 6 1 7 7 1 1 1 1 1 1 1 1 1 1 1 1 080-050-160 CS40 1 2 1 1 1 1 1 1 1 6 1 8 8 1 1 1 1 1 1 1 1 1 1 1 1 080-050-160.1 CS40 1 2 1 1 1 1 1 1 1 22 1 27 27 1 1 1 1 1 1 1 1 1 1 1 1 080-050-200 CS40 2 2 1 1 1 1 1 1 1 6 1 7 7 1 1 1 1 1 1 1 1 1 1 1 1 080-050-200.1 CS40 2 2 1 1 1 1 1 1 1 22 1 27 27 1 1 1 1 1 1 1 1 1 1 1 1 100-065-125 CS40 1 2 1 1 1 1 1 1 1 7 1 9 9 1 1 1 1 1 1 1 1 1 1 1 1 050-032-250 CS50 3 4 2 2 2 2 2 2 2 3 2 4 4 2 2 2 2 2 2 2 2 2 2 2 2 050-032-250.1 CS50 3 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 065-040-250 CS50 3 4 2 2 2 2 2 2 2 9 2 11 11 2 2 2 2 2 2 2 2 2 2 2 2 065-040-250.1 CS50 3 4 2 2 2 2 2 2 2 8 2 10 10 2 2 2 2 2 2 2 2 2 2 2 2 065-040-315 CS50 4 5 2 2 2 2 2 2 2 9 3 11 11 3 3 2 2 2 2 2 2 2 2 2 2 065-040-315.1 CS50 4 5 2 2 2 2 2 2 2 8 3 10 10 3 3 2 2 2 2 2 2 2 2 2 2 080-050-250 CS50 3 4 2 2 2 2 2 2 2 6 2 7 7 2 2 2 2 2 2 2 2 2 2 2 2 080-050-250.1 CS50 3 4 2 2 2 2 2 2 2 23 2 28 28 2 2 2 2 2 2 2 2 2 2 2 2 080-050-315 CS50 4 6 2 2 2 2 2 2 2 11 3 13 13 3 3 2 2 2 2 2 2 2 2 2 2 080-050-315.1 CS50 4 6 2 2 2 2 2 2 2 10 3 12 12 3 3 2 2 2 2 2 2 2 2 2 2 100-065-160 CS50 5 7 2 2 2 2 2 2 2 11 4 13 13 4 4 2 2 2 2 2 2 2 2 2 2 100-065-200 CS50 6 4 2 2 2 2 2 2 2 11 4 14 14 4 4 2 2 2 2 2 2 2 2 2 2 100-065-250 CS50 7 5 2 2 2 2 2 2 2 7 3 9 9 3 3 2 2 2 2 2 2 2 2 2 2 125-080-160 CS50 5 4 2 2 2 2 2 2 2 12 4 15 15 4 4 2 2 2 2 2 2 2 2 2 2 125-080-200 CS50 8 4 2 2 2 2 2 2 2 12 3 16 16 3 3 2 2 2 2 2 2 2 2 2 2 125-080-200.1 CS50 8 4 2 2 2 2 2 2 2 24 3 29 29 3 3 2 2 2 2 2 2 2 2 2 2 125-080-250 CS50 7 6 2 2 2 2 2 2 2 12 3 16 16 3 3 2 2 2 2 2 2 2 2 2 2 125-100-160 CS50 8 5 2 2 2 2 2 2 2 13 3 17 17 3 3 2 2 2 2 2 2 2 2 2 2 125-100-200 CS50 8 5 2 2 2 2 2 2 2 13 3 17 17 3 3 2 2 2 2 2 2 2 2 2 2 100-065-315 CS60 9 6 3 3 3 3 3 3 3 12 3 16 16 3 3 3 3 3 3 3 3 3 3 3 3 125-080-315 CS60 9 8 3 3 3 3 3 3 3 12 3 16 16 3 3 3 3 3 3 3 3 3 3 3 3 125-080-400 CS60 10 9 3 3 3 3 3 3 3 13 5 17 17 5 5 3 3 3 3 3 3 3 3 3 3 125-100-250 CS60 11 6 3 3 3 3 3 3 3 13 3 17 17 3 3 3 3 3 3 3 3 3 3 3 3 125-100-315 CS60 9 8 3 3 3 3 3 3 3 13 3 17 17 3 3 3 3 3 3 3 3 3 3 3 3

17)

Impeller wear ring

Casing wear ring

503.01

502.02

Thrower

Impeller wear ring

503.02

507.01

Thrower

Shaft protecting sleeve

507.02

524.01

Mechanical seal

433

Seal cover

471.07

Impeller nut

922

Stuffing box ring

Lantern ring

Gland follower

452.01

454.01

458.01

Gland packing

461.01

16)

On pumps with casing wear ring only

17)

On pumps with casing wear ring and impeller wear ring only

18)

Depending on mechanical seal type

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Description

18)

17)

16)

Casing wear ring

Casing cover

Support foot

Shaft, medium-duty

Shaft, economy

Rolling element bearing

Radial ball bearing

Radial roller bearing

16)

Bearing bracket

Part No.

161

183

210

320.01

321.01

321.02

322.01

330

502.01

502.02

Size

Bearing bracket

502.01 125-100-400 CS60 10 9 3 3 3 3 3 3 3 14 5 18 18 5 5 3 3 3 3 3 3 3 3 3 3 150-125-200 CS60 12 8 3 3 3 3 3 3 3 14 6 18 18 6 6 3 3 3 3 3 3 3 3 3 3 150-125-250 CS60 13 8 3 3 3 3 3 3 3 14 6 18 18 6 6 3 3 3 3 3 3 3 3 3 3 150-125-315 CS60 14 9 3 3 3 3 3 3 3 14 5 18 18 5 5 3 3 3 3 3 3 3 3 3 3 150-125-400 CS60 10 10 3 3 3 3 3 3 3 14 5 18 18 5 5 3 3 3 3 3 3 3 3 3 3 200-150-200 CS60 12 9 3 3 3 3 3 3 3 15 6 19 19 6 6 3 3 3 3 3 3 3 3 3 3 200-150-250 CS60 13 9 3 3 3 3 3 3 3 16 6 20 20 6 6 3 3 3 3 3 3 3 3 3 3 200-150-315 CS80 15 11 4 4 4 4 4 4 4 16 5 20 20 5 5 4 4 4 4 4 4 4 4 4 4 200-150-400 CS80 16 11 4 4 4 4 4 4 4 16 5 20 20 5 5 4 4 4 4 4 4 4 4 4 4 200-150-500 CS80 17 12 4 4 4 4 4 4 4 17 7 21 21 7 7 4 4 4 4 4 4 4 4 4 4 200-200-250 CS80 18 13 4 4 4 4 4 4 4 16 8 22 22 8 8 4 4 4 4 4 4 4 4 4 4 250-200-315 CS80 19 13 4 4 4 4 4 4 4 18 9 23 23 9 9 4 4 4 4 4 4 4 4 4 4 250-200-400 CS80 20 13 4 4 4 4 4 4 4 19 9 24 24 9 9 4 4 4 4 4 4 4 4 4 4 250-200-500 CS80 17 14 4 4 4 4 4 4 4 20 7 25 25 7 7 4 4 4 4 4 4 4 4 4 4 300-250-315 CS80 19 15 5 5 4 4 4 4 4 21 9 26 26 9 9 4 4 4 4 4 4 4 4 4 4

17)

Impeller wear ring

Casing wear ring

503.01

502.02

Thrower

Impeller wear ring

503.02

507.01

Thrower

Shaft protecting sleeve

507.02

524.01

Mechanical seal

433

Seal cover

471.07

Impeller nut

922

Gland follower

Stuffing box ring

Lantern ring

452.01

454.01

458.01

Gland packing

461.01

16)

On pumps with casing wear ring only

17)

On pumps with casing wear ring and impeller wear ring only

18)

Depending on mechanical seal type

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Page 64

8 Trouble-shooting

WARNING

Improper work to remedy faults Risk of injury!

▷ For any work to remedy faults observe the relevant information in this manual

or in the relevant accessory manufacturer's product literature.

Table 29: Trouble-shooting

A B C D E F G H Possible cause

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

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

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

✘ - - - - - ✘ ✘ Suction lift is too high/NPSH

✘ - - - - - - - Air intake at the shaft seal Clean barrier fluid duct, supply external

✘ - - - - - - - Wrong direction of rotation Check the electrical connection of the motor

✘ - - - - - - -

✘ - - - - - ✘ - Impeller Replace worn components by new ones.

- ✘ - - - - ✘ - Pump back pressure is lower than

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

- ✘ - - - ✘ - - Gland follower over-tightened or cocked Correct.

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

Pump delivers insufficient flow rate

Motor is overloaded

Excessive discharge pressure

Increased bearing temperature

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Impermissible temperature increase in the pump

Remedy

19)

Re-adjust to duty point.

high pressure.

Check system for impurities. Fit a larger impeller.

20)

Increase the speed (turbine, I.C. engine). Vent and/or prime.

vented or primed.

Fit vent valve.

(positive suction head) is too low.

available

Check/alter fluid level. Install pump at a lower level. Fully open the shut-off element in the suction 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.

barrier fluid, if necessary, or increase barrier fluid pressure. Replace shaft seal.

and the control system, if any.

Speed is too low.

20)

- Operation with frequency inverter

- Operation without frequency inverter

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

- Check voltage.

Re-adjust to duty point.

specified in the purchase order.

In the case of persistent overloading, turn down impeller.

20)

Contact KSB.

higher than stated in purchase order

19)

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

20)

Contact KSB.

64 of 74

MegaCPK

Page 65

8 Trouble-shooting

A B C D E F G H Possible cause

- ✘ ✘ - - - - - Speed is too high.

Remedy

Reduce speed.

19)

20)

- - - - ✘ - - - Defective gasket Fit new gasket between volute casing and casing cover.

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

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

protecting sleeve / shaft sleeve

Replace shaft protecting sleeve/shaft sleeve. Fit new shaft seal.

- - - - - ✘ - - Vibrations during pump operation Correct suction conditions. Re-align the pump. Re-balance the impeller. Increase pressure at the pump suction nozzle.

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

- - - ✘ - ✘ ✘ - 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.

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

Top up, reduce or change lubricant.

lubricant or unsuitable lubricant.

- - - ✘ - - - - Non-compliance with specified coupling

distance

Correct the distance according to general arrangement drawing.

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

Check the electric cable connections.

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

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

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

- - - - - ✘ - - Incorrect inflow of circulation liquid Increase the free cross-section.

19)

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

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Page 66

901.22

9 Related Documents

9.1 General assembly drawing with list of components

Fig. 23: General assembly drawing of standard version (oil-lubricated)

Version with bearing bracket CS40 Model with clamped casing cover Version with labyrinth seal

66 of 74

MegaCPK

Page 67

9 Related Documents

Version with gland packing

Mechanical seal with cylindrical casing cover

Mechanical seal with conical casing cover

Mechanical seal with cylindrical casing cover (heatable version "h")

Grease-lubricated version (medium-duty bearings) Oil-lubricated version (economy bearings)

MegaCPK

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Page 68

9 Related Documents

Version with coolable bearing bracket Heatable version ("h" version)

Table 30: List of components

Part No. Comprising Description

102 102 Volute casing

411.01/.02

21)

502.01

/03

/.04

/.10

22)

Joint ring Casing wear ring

21)

902.01 Stud

903.01/.02

/.03

/.04

21)

Screw plug

21)

920.01 Hexagon nut

161 161 Casing cover

502.02

901.22

21)

23)

/31

Casing wear ring Hexagon head bolt

902.02 Stud

920.02 Hexagon nut 183 183 Support foot 210 210 Shaft

24)

920.21

24)

931.01

940.01/.02/.09

25)

Slotted round nut Lock washer Key

230 230 Impeller

320.02

321.01

321.02

322.01

24)

26)

24)

503.01/.02

21)

320.02 Angular contact ball bearing (double-row in CS40)

321.01 Deep groove ball bearing

321.02 Deep groove ball bearing

322.01 Cylindrical roller bearing

Impeller wear ring

330 330 Bearing bracket

360.01 360.01 Bearing cover

360.02 360.02 Bearing cover

400.01 400.01 Gasket

400.02 400.02 Gasket

411.15

22)

411.15 Joint ring

411.31 411.31 Joint ring

411.32 411.32 Joint ring

421.01 421.01 Lip seal

421.02 421.02 Lip seal

21)

Not on all versions

22)

Joint rings 411.10 and 411.15 (411.15 for versions with mechanical seal with seal cover only) depending on the operating temperature. Order separately in spare parts order.

23)

Only for clamped cover

24)

Not fitted on versions with economy bearings

25)

From CS 60

26)

On versions with economy bearings only

68 of 74

MegaCPK

Page 69

9 Related Documents

Part No. Comprising Description

433.02 433.02 Mechanical seal, complete

452.01 452.01 Gland follower

454.01 454.01 Stuffing box ring

458.01 458.01 Lantern ring

461.01 461.01 Gland packing

463.01 463.01 Drip plate

471.01 471.01 Seal cover

502.01

502.02

503.01

503.02

21)

502.01 Casing wear ring

502.02 Casing wear ring

503.01 Impeller wear ring

503.02 Impeller wear ring

507.01 507.01 Thrower

507.02

27)

507.02 Thrower

524.01 524.01 Shaft protecting sleeve

550.01 550.01 Disc

550.23 550.23 Disc

550.24

550.25

28)

550.24 Disc

550.25 Disc

550.74 550.74 Disc

554.98 554.98 Washer

561.03 561.03 Grooved pin

636.02

636.03

29)29)

638

29)

642

29)

672

28)

636.02 Lubricating nipple

636.03 Lubricating nipple

638 Constant level oiler 642 Oil level sight glass

672 Vent plug 81-92 81-92 Cover plate 99-9 411.01/.02/.03/.04/.10/.15/31/.32/.46 Joint ring

400.01/02 Gasket

901.04 901.04 Hexagon head bolt

901.30 901.30 Hexagon head bolt

901.31 901.31 Hexagon head bolt

901.32 901.32 Hexagon head bolt

901.98 901.98 Hexagon head bolt

902.15 902.15 Stud

903.46 903.46 Screw plug

914.01 914.01 Hexagon socket head cap screw

914.02 914.02 Hexagon socket head cap screw

920.15 920.15 Hexagon nut 922 922 Impeller nut

932.01 932.01 Circlip

932.02 932.02 Circlip

The relevant version is indicated in the product literature supplied.

27)

On versions with labyrinth seal only

28)

On grease-lubricated versions only

29)

Not applicable for grease-lubricated versions

MegaCPK

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Page 70

10 EU Declaration of Conformity

Manufacturer: KSB Aktiengesellschaft

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

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

▪ Applied national technical standards and specifications, in particular:

– DIN EN ISO 5199

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

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

30)

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

Name

Function

Company

Address

MegaCPK (MCPK)

30)

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

70 of 74

MegaCPK

Page 71

11 Certificate of Decontamination

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

Order number/ Order item number

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

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

Fluid handled

Please tick where applicable

Radioactive Explosive Corrosive Toxic

Reason for return

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 intermediate piece 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

31)

   

Harmful Bio-hazardous Highly flammable Safe

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

31)

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

31)

Required fields

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Page 72

Index

Abrasive fluids 41 Applications 8 Auxiliary connections 26

Bearing assembly 17 Bearing temperature 45

Certificate of decontamination 71 Clearances 45 Commissioning 33 Constant level oiler 33 Contact guard 19 Coupling 19, 45 Coupling alignment 28

Design 16, 18 Designation 16 Direction of rotation 32 Disassembly 49 Disposal 15 Drive 19

Event of damage

Ordering spare parts 60 Explosion protection 10, 20, 27, 29, 30, 31, 32, 35, 36, 37, 38, 39, 40, 43, 44, 45, 46

Faults

Causes and remedies 64 Filter 22, 46 Final check 35 Flow rate 40 Fluid handled

Density 41 Frequency of starts 40 Function 18

General assembly drawing 66 Gland packing 38 Grease lubrication

Grease quality 47 Grease quantities 48

Heating 36 Heating speed 37 Heating up 37

Impeller type 17 Installation

Installation on a foundation 20

Installation without foundation 21 Installation at site 20 Intended use 8 Interchangeability of pump components 62

Keeping warm 37

Leakage rate 38 Lubrication 17

Maintenance 43 Mechanical seal 38 Misuse 9 Monitoring equipment 12

Name plate 16 Noise characteristics 19

Oil lubrication

Intervals 46

Oil quality 46

Oil quantity 46 Operating limits 39 Order number 6 Other applicable documents 6

Partly completed machinery 6 Permissible forces and moments at the pump nozzles 23 Piping 22 Preservation 14, 42 Priming and venting 35 Product description 16 Pump casing 16 Pure graphite packing 38

Return to supplier 14 Returning to service 42 Running noises 44, 45

72 of 74

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Page 73

Index

Safety 8 Safety awareness 9 Scope of supply 19 Shaft seal 17 Shutdown 39, 42 Spare part

Ordering spare parts 60 Spare parts stock 61 Special accessories 19 Start-up 37 Storage 14, 42

Temperature difference 37 Temperature limits 11 Tightening torques 58, 60

Shaft nut 59

Transport 13

Water cooling 35

MegaCPK

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Page 74

KSB Aktiengesellschaft

67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com

KSB Bombas Hidráulicas SA

Rua José Rabello Portella, 638 13220-540 - Várzea Paulista - SP - Brasil Tel.: +55 11 4596 8500 • Fax: +55 11 4596 8580 www.ksb.com.br

KSB Pumps Limited

Plot no. E3 & E4, MIDC, Sinnar, (Malegaon) • Nashik 422 113 Tel. +91 2551 230252 Tel. +91 2551 230253 Tel. +91 2551 229700 Fax +91 2551 230254 • www.ksbindia.co.in

2731.8/11-EN (01362313)

KSB MegaCPK Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Glossary

1 General

2 Safety

2.10.1 Marking

2.10.2 Temperature limits

2.10.3 Monitoring equipment

2.10.4 Operating limits

3 Transport/Temporary Storage/Disposal

4 Description of the Pump (Set)

5 Installation at Site

5.3.1 Installation on the foundation

5.3.2 Installation without foundation (European version)

5.4.1 Connecting the piping

5.4.2 Permissible forces and moments at the pump nozzles

Auxiliary connections

5.7.1 Motors with adjusting screw

5.7.2 Motors without adjusting screw

5.8.1 Setting the time relay

5.8.2 Earthing

5.8.3 Connecting the motor

6 Commissioning/Start-up/Shutdown

6.1.1 Prerequisites for commissioning/start-up

Filling in lubricants

6.1.3 Shaft seal

6.1.4 Priming and venting the pump

6.1.5 Final check

6.1.6 Water cooling

6.1.7 Cooling of the bearing bracket (special design)

6.1.8 Heating (version "h")

6.1.9 Heating up/keeping warm the pump (set)

6.1.10 Start-up

6.1.11 Checking the shaft seal

6.1.12 Shutdown

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

7 Servicing/Maintenance

7.2.1 Supervision of operation

7.2.2 Inspection work

7.2.2.1 Checking the coupling

7.2.2.2 Checking the clearances

7.2.2.3 Cleaning filters

7.2.3 Lubrication and lubricant change of rolling element bearings

7.2.3.1 Oil lubrication

Grease lubrication

7.4.1 General information/Safety regulations

7.4.2 Preparing the pump set

7.4.3 Removing the motor

7.4.4 Removing the back pull-out unit

7.4.5 Removing the impeller

7.4.6 Removing the shaft seal

7.4.6.1 Removing the mechanical seal - cylindrical casing cover

7.4.6.2 Removing the mechanical seal - conical casing cover

7.4.6.3 Removing the gland packing

Dismantling the bearings

Dismantling the medium-duty bearing assembly

7.4.7.2 Dismantling the economy bearing assembly

7.5.1 General information/Safety regulations

7.5.2 Reassambling the bearing assembly

7.5.2.1 Reassembling the medium-duty bearing assembly

Reassembling the economy bearing assembly

7.5.3 Fitting the shaft seal

7.5.3.1 Fitting the mechanical seal

Fitting the single mechanical seal – cylindrical casing cover

Fitting the double mechanical seal – cylindrical casing cover

Fitting the gland packing

Fitting the impeller

Installing the back pull-out unit

7.5.6 Mounting the motor

7.6.1 Tightening torques for the pump

7.6.2 Tightening torques for the shaft nut

7.6.3 Tightening torques for the pump set

7.7.1 Ordering spare parts