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Omega V
Operating Manual
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KSB Omega, Omega V Operating Manual

Axially Split Volute Casing Pump
Omega / Omega V
Horizontal installation type 3E Vertical installation types DB, DK, DP, DJ
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual Omega / Omega V
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.
© KSB Aktiengesellschaft, Frankenthal 20.06.2016
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 ..................................................................................... 12
3.1 Checking the condition upon delivery ........................................................................................................12
3.2 Transport .......................................................................................................................................................12
3.3 Storage/preservation ....................................................................................................................................14
3.4 Return to supplier .........................................................................................................................................15
3.5 Disposal .........................................................................................................................................................15
4 Description of the Pump (Set) .................................................................................................... 17
4.1 General description ......................................................................................................................................17
4.2 Designation ...................................................................................................................................................18
4.3 Name plate ....................................................................................................................................................19
4.4 Design details ................................................................................................................................................19
4.5 Configuration and function .........................................................................................................................20
4.6 Noise characteristics .....................................................................................................................................20
4.7 Scope of supply .............................................................................................................................................22
4.8 Dimensions and weights ..............................................................................................................................22
5 Installation at Site ....................................................................................................................... 23
5.1 Safety regulations .........................................................................................................................................23
5.2 Checks to be carried out prior to installation .............................................................................................23
5.3 Installing the pump set ................................................................................................................................23
5.4 Connecting the piping .................................................................................................................................30
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5.5 Enclosure/insulation .....................................................................................................................................32
5.6 Aligning the pump and motor ....................................................................................................................32
5.7 Permissible forces and moments at the pump nozzles .............................................................................. 34
5.8 Auxiliary connections ...................................................................................................................................36
5.9 Connection to power supply ........................................................................................................................37
5.10 Checking the direction of rotation ..............................................................................................................38
5.11 Removing the transport lock .......................................................................................................................39
6 Commissioning/Start-up/Shutdown ........................................................................................... 40
6.1 Commissioning/start-up ...............................................................................................................................40
6.2 Operating limits ............................................................................................................................................43
6.3 Shutdown/storage/preservation ..................................................................................................................46
6.4 Returning to service .....................................................................................................................................46
7 Servicing/Maintenance ............................................................................................................... 47
7.1 Safety regulations .........................................................................................................................................47
7.2 Servicing/inspection ......................................................................................................................................48
7.3 Drainage/cleaning ........................................................................................................................................53
7.4 Dismantling the pump set ............................................................................................................................53
7.5 Reassembling the pump set .........................................................................................................................60
7.6 Tightening torques .......................................................................................................................................66
7.7 Spare parts stock ...........................................................................................................................................67
8 Trouble-shooting ........................................................................................................................ 69
8.1 Explanation of faults ....................................................................................................................................73
9 Related Documents .................................................................................................................... 74
9.1 Weights of individual components .............................................................................................................74
9.2 General assembly drawing with list of components .................................................................................. 75
10 EU Declaration of conformity .................................................................................................... 90
11 Certificate of Decontamination ................................................................................................. 91
Index ............................................................................................................................................ 92
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Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled.
Discharge line
The pipeline which is connected to the discharge nozzle
Drive end
The side of the pump which faces the motor
Hydraulic system
The part of the pump in which the kinetic energy is converted into pressure energy
Non-drive end
The side of the pump which faces away from the motor
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 see (⇨ Section 4.6 Page 20)
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
1)
Sectional drawing of the pump Sub-supplier product literature
1)
Operating manuals and other product literature
describing accessories and integrated machinery
components Spare parts lists
1)
Description of spare parts Piping layout
1)
Description of auxiliary piping List of components
1)
Description of all pump components Drawing for assembly
1)
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
1)
If agreed upon in scope of supply
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Symbol Description
1.
2.
Step-by-step instructions
Note Recommendations and important information on how to handle the product
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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
DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.
!
WARNING
WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.
CAUTION
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.
!
DANGER
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▪ 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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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 6.3 Page 46)
▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3
Page 53)
▪ 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 40)
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). The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. Never operate the pump set outside the limits stated in the data sheet and on the name plate.
!
DANGER
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Prevent impermissible modes of operation at all times. For information on application options of individual components (if any) in potentially explosive atmospheres, refer to the manufacturer's product literature.
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. (⇨ Section 2.10.2 Page 11)
An EC manufacturer's declaration is required for the shaft coupling; the shaft coupling must be marked accordingly.
The motor must be considered separately.
2.10.2 Temperature limits
In normal pump operation, the highest temperatures are to be expected at 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, 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 to EN 13463-1
Maximum permissible fluid
temperature
T1 Maximum 140 °C T2 Maximum 140 °C T3 Maximum 140 °C T4 80 °C T5 45 °C T6 Impermissible
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.
2.10.3 Repair
Special regulations apply to repair work on explosion-proof pumps. Modifications or alterations of the pump set can affect explosion protection and are only permitted after consultation with the manufacturer.
Repair work at the flameproof joints must only be performed in accordance with the manufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 is not permitted.
Pump
Shaft coupling
Motor
Temperature class T5
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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
Lifting lugs of pump/motor/base frame overloaded Danger to life from falling parts!
▷ Never transport the pump set components (pump/motor/base frame) in any way
other than as described in the Transport section.
▷ Refer to the weights of the individual components stated in the manufacturer's
product literature.
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.
For transporting the motor, observe the motor supplier's product literature! To transport the pump/pump set suspend it from the lifting tackle as shown.
Fig. 1: The angle of pull must not be greater than 90°!
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Table 5: Transport options
Transporting the pump horizontally
(figure 0)
Transporting the pump vertically
(figure 0 or installation type DJ)
Transporting the pump with base frame (figure 0)
▪ Motor size 315 and larger
▪ Total weight (of the pump set) more than 1500 kg
Transporting the pump vertically
(installation types DB and DK)
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Transporting the pump set on the base frame
(installation type 3E)
▪ Up to motor size 280 (IEC standard)
▪ Up to a total weight (of the pump set) of 1500 kg
Transporting the pump set on the base frame
(installation type 3E)
Use the hooks welded to the baseplate!
▪ Up to motor size 280 (IEC standard)
▪ Up to a total weight (of the pump set) of 1500 kg
Transporting the base frame (installation type DP)
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the following measures be taken:
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.
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CAUTION
Bearings in the same position for a prolonged period of time Damage to the rolling element bearings!
▷ Rotate the shaft by hand once a month with suitable tools.
▷ Store the pump in a vibration-free room.
CAUTION
Pump stored too long or incorrectly Damage to the pump!
▷ Check especially the rolling element bearings and the lubricant. If any damage
is suspected, replace the rolling element bearings.
▪ Store the pump and supplied components under dry, vibration-free conditions, if
possible in their original packaging.
▪ The ambient temperatures for transport and storage must not be below -20 °C or
above 60 °C.
1. Manually rotate the pump shaft once a month with a suitable tool.
2. Spray the preservative through the suction and discharge nozzles. It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).
NOTE
Observe the manufacturer's instructions for application/removal of the preservative.
3.4 Return to supplier
1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 53)
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.
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 91)
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.
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1. Dismantle the pump (set). Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another controlled manner.
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4 Description of the Pump (Set)
4.1 General description
▪ Volute casing pump installed in a horizontal or vertical position
▪ Volute casing pump with double-entry radial impeller
Pump for use in water works, irrigation and drainage pumping systems, power stations and industrial water supply.
Table 6: Installation types
Installation type
Illustration Description
Figure 0 Bare shaft pump
Figure 3E Pump and drive on a common base frame
Horizontal installation, direct coupling
Figure DJ Pump on its own base frame;
drive on a different construction level
Vertical installation
Figure DB Pump on base frame and drive on drive
lantern
Vertical installation
4 Description of the Pump (Set)
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Installation type
Illustration Description
Figure DK Pump on base frame and drive on drive
lantern with support
Vertical installation
Figure DP Pump on base frame, drive on support frame
4.2 Designation
Example: Omega V 150 - 460 A GB P M
Table 7: Designation key
Code Description
Omega Type series V Design
2)
Horizontal installation
V Vertical installation 150 Nominal discharge nozzle diameter [mm] 460 Nominal impeller diameter [mm] A Impeller type GB Material variant
GB Grey cast iron / bronze
GC Grey cast iron / chrome steel
SB Nodular cast iron / bronze
SC Nodular cast iron / chrome steel
DD35Duplex stainless steel / duplex stainless steel P Shaft seal
P Gland packing
G Mechanical seal M Bearing lubrication
F Grease
M Fluid handled
2)
Blank
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4.3 Name plate
Omega 250 - 600 A P-No. 9971423078 / 000100
Q 1050 m3/h H 120 m n 1475 1/min SNr. 24 15 26
Aktiengesellschaft Johann-Klein-Straße 9 D-67227 Frankenthal
Mat.-No. 01 111 383 ZN 3804 - D 74 x 105
2016
Gew. 1090 kg
1
2
5
4
3
9
8
7
6
Fig. 2: Name plate (example)
1
Designation of the pump set 2 Order number 3 Flow rate 4 Speed 5 Weight of Fig. 0 pump 6 Year of supply 7 Order item number 8 Head 9 Series number
4.4 Design details
Design
▪ Volute casing pump
▪ Horizontal/vertical installation
▪ Single-stage
▪ Nominal diameter of the discharge nozzles: 80 mm to 350 mm
Pump casing
▪ Axially split volute casing
▪ Volute casing with integrally cast pump feet
▪ Replaceable casing wear rings
▪ Mating dimensions to EN or ASME
Impeller type
▪ Double-entry radial impeller
Optionally with impeller wear rings
Pump shaft
▪ Completely dry shaft for design with rolling element bearings
▪ Shaft protecting sleeves in the seal area
Shaft seal
▪ Gland packing
▪ Mechanical seal
Bearings
For horizontal installation:
▪ Rolling element bearings, greased for life
For vertical installation:
▪ Product-lubricated plain bearing at the bottom / rolling element bearing,
greased for life, on top
4 Description of the Pump (Set)
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4.5 Configuration and function
6
7
2
3
4
8
9
10
5
1
Fig. 3: Sectional drawing
1
Suction nozzle 2 Bearing housing 3 Rolling element bearing 4 Volute casing 5 Impeller 6 Clearance gap 7 Shaft 8 Rolling element bearing 9 Shaft seal 10 Discharge nozzle
The pump is designed with a tangential fluid inlet and a tangential fluid outlet. The hydraulic system runs in its own bearings and is connected to the motor by a shaft coupling.
The fluid enters the pump tangentially via the suction nozzle (1) and is accelerated outward by the rotating impeller (5). 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 (10), where it leaves the pump. The clearance gap (6) prevents any fluid from flowing back from the casing to the suction nozzle. The shaft (7) enters the hydraulic system through the volute casing (4). The shaft passage through the sealing housing is sealed to atmosphere with a shaft seal (9). The shaft runs in rolling element bearings (3 and 8) located in a bearing housing (2) which is connected to the volute casing (4).
The pump is sealed by a shaft seal (standardised mechanical seal or gland packing).
4.6 Noise characteristics
Table 8: Surface sound pressure level L
pA
3)
depending on the rotational speed
Rated power PN [kW]
Surface sound pressure level L
pA
3)
Pump
3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 / 870
rpm
960 / 750
rpm
[dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)]
10 69,5 69,0 67,4 67,0 65,6 64,6 15 70,8 70,3 68,7 68,3 66,9 65,9 20 71,8 71,3 69,7 69,3 67,8 66,8
Design
Function
Sealing
Pump
3)
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. The values indicated do not apply to operation on a frequency inverter.
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Rated power PN [kW]
Surface sound pressure level L
pA
3)
Pump
3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 / 870
rpm
960 / 750
rpm
[dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)]
30 73,1 72,7 71,0 70,6 69,1 68,2 40 74,1 73,6 71,9 71,5 70,1 69,1 50 74,8 74,3 72,7 72,2 70,8 69,8 60 75,4 75,0 73,3 72,8 71,4 70,4 70 75,9 75,5 73,8 73,3 71,9 70,9 80 76,4 75,9 74,2 73,8 72,3 71,3 90 76,8 76,3 74,6 74,2 72,7 71,7 100 77,1 76,7 74,9 74,5 73,1 72,1 150 78,5 78,0 76,3 75,8 74,4 73,4 200 79,4 79,0 77,2 76,8 75,3 74,3 250 80,2 79,7 77,9 77,5 76,0 75,0 300 80,8 80,3 78,5 78,1 76,6 75,6 350 81,3 80,8 79,0 78,6 77,1 76,1 400 82,0 81,5 79,8 79,3 77,8 76,8 450 82,1 81,6 79,9 79,4 77,9 76,9 500 82,5 82,0 80,2 79,7 78,3 77,3 600 83,1 82,6 80,8 80,3 78,9 77,8 700 83,6 83,1 81,3 80,8 79,4 78,3 800 84,0 83,6 81,7 81,3 79,8 78,8 900 84,4 84,0 82,1 81,7 80,2 79,2 1000 84,8 84,3 82,5 82,0 80,5 79,5
Table 9: Surface sound pressure level L
pA
4)
depending on the rotational speed
Rated power PN [kW]
Surface sound pressure level L
pA
4)
Pump set
3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 / 870
rpm
960 / 750
rpm
[dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)]
10 74,5 74,0 70,0 69,0 66,4 64,6 15 75,7 75,2 71,4 70,5 67,9 66,2 20 76,6 76,1 72,4 71,5 69,0 67,4 30 77,8 77,3 73,8 72,9 70,6 69,0 40 78,7 78,2 74,8 74,0 71,7 70,1 50 79,4 78,9 75,6 74,8 72,6 71,0 60 79,9 79,4 76,3 75,4 73,3 71,8 70 80,4 79,9 76,8 76,0 73,8 72,4 80 80,8 80,3 77,3 76,5 74,4 72,9 90 81,2 80,7 77,7 76,9 74,8 73,4 100 81,5 81,0 78,0 77,2 75,2 73,8 150 82,7 82,2 79,4 78,7 76,8 75,4 200 83,6 83,1 80,4 79,7 77,9 76,6 250 84,3 83,8 81,2 80,5 78,7 77,5 300 84,8 84,3 81,8 81,2 79,4 78,2 350 85,3 84,8 82,4 81,7 80,0 78,8 400 85,7 85,2 82,8 82,2 80,5 79,3 450 86,0 85,6 83,2 82,6 81,0 79,8 500 86,4 85,9 83,6 83,0 81,4 80,2 600 86,9 86,4 84,2 83,7 82,1 81,0 700 87,4 86,9 84,8 84,2 82,7 81,6 800 87,8 87,3 85,2 84,7 83,2 82,1
Pump set
4)
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. The values indicated do not apply to operation on a frequency inverter.
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Rated power PN [kW]
Surface sound pressure level L
pA
4)
Pump set
3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 / 870
rpm
960 / 750
rpm
[dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)]
900 88,2 87,7 85,7 85,1 83,6 82,6 1000 88,5 88,0 86,0 85,5 84,0 83,0
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪ Pump
▪ Drive
▪ Baseplate
▪ Coupling, coupling guard
▪ Universal-joint shaft
▪ Fasteners for pump and base frame
Optional accessories:
▪ Vibration monitoring
▪ Pt100 temperature sensor
▪ Pressure gauge
▪ Measuring nipple for shock pulse measurement
▪ Cyclone
4.8 Dimensions and weights
For dimensions and weights please refer to the data sheet of the pump (set).
▪ Pump weight: See name plate of the pump.
▪ Motor weight: See motor product literature.
▪ Weight of the shipping unit base frame with pump: See weight indicated on the
base frame.
▪ Weight of the shipping unit base frame with pump and motor: See weight
indicated on the base frame.
NOTE
Some individual components weigh more than 25 kg. Observe the weights indicated.( (⇨ Section 9.1 Page 74) or other applicable documents)
4 Description of the Pump (Set)
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5 Installation at Site
5.1 Safety regulations
For all work involving assembly, reassembly and installation, observe the following safety information:
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.
DANGER
Improper transport Risk of injury from lifting heavy components!
▷ Select lifting accessories which are suitable for the component weight.
▷ Always use the attachment points provided for the lifting accessories.
▷ Comply with the applicable health and safety regulations.
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
WARNING
Hands or foreign objects inside the pump casing Risk of injuries, damage to the pump!
▷ Check that the inside of the pump is free from any foreign objects. Remove any
foreign objects.
▷ Never insert your hands or any other objects into the pump, if the pump set has
not been disconnected from the power supply and secured against unintentional start-up.
Depending on the type of installation, several instructions need to be carried out as applicable:
▪ Prepare and install the base frame/support frame.
▪ Install the pump and motor on the prepared base frame/support frame.
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▪ Check the alignment of pump and motor.
▪ Align the pump with the piping.
▪ Install and align the coupling.
▪ Connect the piping.
▪ Perform precision alignment of pump and motor.
▪ Remove any transport locks.
5.3.1 Type of installation 3E
DANGER
The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts!
▷ Always transport the pump or components in the specified position.
▷ Never attach the suspension arrangement to the free shaft end of the pump.
▷ Refer to the weights indicated for the individual components.
▷ Observe the applicable local health and safety regulations.
▷ Use suitable, permitted lifting accessories.
Fig. 4: 3E installation — pump and motor on a common base frame
✓ The relevant general arrangement drawing is available.
✓ The foundation has the required strength and characteristics.
✓ The foundation has been prepared in accordance with the dimensions given in
the outline drawing.
1
2
3
4
Fig. 5: Installation drawing
1
Base frame, part No. 891 2 Adjusting screw, part No. 901.05
3 Shim, part No. 89-4.03 4 Foundation bolt, part No. 900.01
1. Screw adjusting screws (2) into the threaded holes provided in the base frame (1).
2. Insert the foundation bolts (4) into the drilled holes of the base frame (1).
3. Place the shim (3) next to the holes for the foundation bolts (4) in accordance with the general arrangement drawing.
4. Align the pump with the piping.
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5. Place the base frame (1) with the inserted foundation bolts (4) and the screwed­in adjusting screws (2) on the shims (3). Use the adjusting screws to align the base frame.
6. Grout the holes for the foundation bolts with a quick-setting, low-shrinkage concrete mixture5).
7. When the concrete has set, tighten the foundation bolts evenly until no clearance remains between the nuts and the base frame.
8. Grout the base frame with a quick-setting, low-shrinkage concrete mixture5). Make sure that the base frame is completely grouted and that no cavities remain.
9. When the concrete has set, tighten the foundation bolts.
10. Lift the motor (if not already mounted) onto the base frame with suitable lifting equipment. Align the shafts with each other. Mount the motor as described in the motor manufacturer's operating manual.
11. Connect the piping to the pump without transmitting any stresses or strains. (⇨ Section 5.4 Page 30)
12. Align the coupling as described in the coupling manufacturer's operating manual.
5.3.2
Type of installation DJ
DANGER
The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts!
▷ Always transport the pump or components in the specified position.
▷ Never attach the suspension arrangement to the free shaft end of the pump.
▷ Refer to the weights indicated for the individual components.
▷ Observe the applicable local health and safety regulations.
▷ Use suitable, permitted lifting accessories.
Fig. 6: Pump on its own foot (baseplate), drive on a different construction level
✓ The relevant general arrangement drawing is available.
✓ The foundation has the required strength and characteristics.
✓ The foundation has been prepared in accordance with the dimensions given in
the general arrangement drawing.
✓ The motor is installed on a separate base frame which is arranged on a higher
level in the building in accordance with the motor manufacturer's operating instructions.
5)
Minimum strength class C2
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1
2
3
4
5
6
Fig. 7: Installation drawing
1
Foot, part No. 182 2 Hexagon head bolt, part No.
901-11 3 Disc, part No. 550.05 4 Foundation block, part No. 898.01 5 Adjusting screw, part No. 901.10 6 Shim, part No. 89-4.04
1. Screw the foundation blocks (4) with hexagon head bolts (2) and discs (3) to the foot (1).
2. Screw the adjusting screws (5) into the foundation blocks (4).
3. Place the shim (6) into the recesses for the foundation blocks (4) in accordance with the general arrangement drawing.
4. Align the pump with the piping.
5. Place the foot (4) including the foundation blocks (1) with the adjusting screws (5) on the shims (6). Use the adjusting screws to align the foot.
6. Grout the holes for the foundation blocks with a quick-setting, low-shrinkage concrete mixture.
6)
7. When the concrete has set, tighten the foundation bolts (2) evenly.
8. Connect the piping to the pump without transmitting any stresses or strains. (⇨ Section 5.4 Page 30)
5.3.3
Installation type DJ with cardan shaft
WARNING
Exposed rotating coupling or universal-joint shaft 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.
NOTE
If the customer specifically requests not to include a cardan shaft guard in our delivery, then the operator must supply one.
For installing and aligning the cardan shaft refer to the technical product literature of the cardan shaft manufacturer.
6)
Minimum strength class C25/30
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5.3.4 Type of installation DB and DK
DANGER
The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts!
▷ Always transport the pump or components in the specified position.
▷ Never attach the suspension arrangement to the free shaft end of the pump.
▷ Refer to the weights indicated for the individual components.
▷ Observe the applicable local health and safety regulations.
▷ Use suitable, permitted lifting accessories.
Fig. 8: DB and DK installation
✓ The relevant general arrangement drawing is available.
✓ The foundation has the required strength and characteristics.
✓ The foundation has been prepared in accordance with the dimensions given in
the general arrangement drawing.
1
2
3
4
5
6
Fig. 9: Installation drawing
1
Foot, part No. 182 2 Hexagon head bolt, part No.
901-11 3 Disc, part No. 550.05 4 Foundation block, part No. 898.01 5 Adjusting screw, part No. 901.10 6 Shim, part No. 89-4.04
1. Screw the foundation blocks (4) with hexagon head bolts (2) and discs (3) to the foot (1).
2. Screw the adjusting screws (5) into the foundation blocks (4).
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3. Place the shim (6) into the recesses for the foundation blocks (4) in accordance with the general arrangement drawing.
4. Align the pump with the piping.
5. Place the foot (4) including the foundation blocks (1) with the adjusting screws (5) on the shims (6). Use the adjusting screws to align the foot so that the machined motor flange of the drive lantern is horizontal in both dimensions.
6. Grout the holes for the foundation blocks with a quick-setting, low-shrinkage concrete mixture.
7)
7. When the concrete has set, tighten the foundation bolts (2) evenly.
8. Connect the piping to the pump without transmitting any stresses or strains. (⇨ Section 5.4 Page 30)
9. Mount the motor on the drive lantern as described in the motor manufacturer's operating instructions.
10. Align the coupling as described in the coupling manufacturer's operating instructions.
5.3.5
Type of installation DP
DANGER
The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts!
▷ Always transport the pump or components in the specified position.
▷ Never attach the suspension arrangement to the free shaft end of the pump.
▷ Refer to the weights indicated for the individual components.
▷ Observe the applicable local health and safety regulations.
▷ Use suitable, permitted lifting accessories.
Fig. 10: Pump on foot (baseplate), drive on support frame
✓ The relevant general arrangement drawing is available.
✓ The foundation has the required strength and characteristics.
✓ The foundation has been prepared in accordance with the dimensions given in
the outline drawing.
7)
Minimum strength class C25/30
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1
2
3
4
5
6
Fig. 11: Installation drawing
1
Foot, part No. 182 2 Hexagon head bolt, part No.
901-11 3 Disc, part No. 550.05 4 Foundation block, part No. 898.01 5 Adjusting screw, part No. 901.10 6 Shim, part No. 89-4.04
1. Screw the foundation blocks (4) with hexagon head bolts (2) and discs (3) to the foot (1).
2. Screw the adjusting screws (5) into the foundation blocks (4).
3. Place the shim (6) into the recesses for the foundation blocks (4) in accordance with the general arrangement drawing.
4. Align the pump with the piping.
5. Place the foot (4) including the foundation blocks (1) with the adjusting screws (5) on the shims (6). Use the adjusting screws to align the foot.
Installing the motor support frame
1
2
3
4
Fig. 12: Installation drawing
1. Screw adjusting screws (2) into the foundation rails (1) in accordance with the general arrangement drawing.
2. Insert the foundation bolts (4) into the drilled holes of the foundation rails (1).
3. Place shims (3) into the recesses for the foundation rails (1) in the foundation.
5 Installation at Site
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