KSB RPH Installation & Operating Manual

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Process Pump

RPH

Installation/Operating Manual

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Legal information/Copyright

Installation/Operating Manual RPH

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.

Page 3

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 these operating instructions

2.6

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

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

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

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

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

........................................................................................................ 9

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 .............................................................................................................. 21

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Contents

5.5 Enclosure/insulation .......................................................................................24

5.6 Checking the coupling alignment ................................................................. 25

5.7 Aligning the pump and motor ...................................................................... 26

5.8 Electrical connection ...................................................................................... 27

5.9 Checking the direction of rotation ................................................................ 27

6 Commissioning/Start-up/Shutdown ...................................................29

6.1 Commissioning/start-up ................................................................................. 29

6.2 Operating limits .............................................................................................. 36

6.3 Shutdown/storage/preservation .................................................................... 38

6.4 Returning to service .......................................................................................38

7 Servicing/Maintenance .......................................................................40

7.1 Safety regulations ........................................................................................... 40

7.2 Maintenance/inspection ................................................................................. 41

7.3 Drainage/cleaning ..........................................................................................46

7.4 Dismantling the pump set .............................................................................. 46

7.5 Reassembling the pump set ........................................................................... 49

7.6 Tightening torques ......................................................................................... 53

7.7 Spare parts stock ............................................................................................. 57

8 Trouble-shooting ................................................................................60

9 Related Documents ............................................................................62

9.1 General assembly drawing with list of components .................................... 62

10 EC Declaration of Conformity ............................................................71

11 Certificate of Decontamination .........................................................72

Index ....................................................................................................73

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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 line 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 line 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. (⇨ Section 7.5.5 Page 52

Target group

1.3

This operating manual is aimed at the target group of trained and qualified specialist technical personnel. (⇨ Section 2.4 Page

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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Page 14

max. 90 °

3 Transport/Temporary Storage/Disposal

Fig. 3: Transporting the complete 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 set!

▷ Only remove caps/covers from the openings of the pump set at the time of

installation.

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, observe the instructions in. (⇨ Section 6.3.1 Page 38

)

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Return to supplier

3.4

1. Drain the pump as per operating instructions.

(⇨ Section 7.3 Page

46)

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 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 72)

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 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

Dispose of materials in accordance with local regulations or in another

3. controlled manner.

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Page 16

Aktiengesellschaft 67225 Frankenthal

Ord.-No.

Ser.-No. Item-No.

Q n

Shaft seal Bearings Impeller∅ mm standard / 1st stage

2nd stage

Type

Test pressure

Year

m3/h

1/min

kg/dm

t MAWP

kPa

°C

kPa@°C

max. min.

rated

Ident-No 00380 249

ZN 3823 - E 13

997186942100630001

2008

107-P-102B

110 2950

0,51

H75VK/85-PTA80

NU 213C3/2 * 7311BMUA

295 230

243

RPH 100-280

7200 70,00 60

4800/85

16 15 14

13 12 11

789

4 Description of the Pump (Set)

4.1 General description

▪ Process pump to API 610

Pump for handling the large variety of crude oil products in refineries as well as in the chemical and petrochemical industry.

4.2 Designation

Example: RPH-H-I S1 80-280B

Table 5: Key to the designation

Code Description

RPH Type series H Heatable model I Version with auxiliary impeller (inducer) S1 Material variant to API 610 80 Nominal discharge nozzle diameter [mm] 280 Nominal impeller diameter [mm] B Special hydraulic system (type B)

4.3 Name plate

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Fig. 5: Name plate (example)

1 Year of construction 2 Type series, size 3 Test pressure 4 Head 5 Application temperature 6 Maximum application

7 Impeller diameter when installed 8 Minimum impeller diameter

9 Maximum impeller diameter 10 Bearings 11 Shaft seal 12 Density of the fluid handled 13 Rated speed 14 Flow rate 15 Item number 16 KSB order number

4.4 Design details

Design

▪ Volute casing pump

▪ Horizontal installation

▪ Back pull-out design

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pressure@temperature

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4 Description of the Pump (Set)

▪ Single-stage

▪ Meets technical requirements to API 610, 11th edition / ISO 13709

Pump casing

▪ Volute casing with integrally cast pump feet

▪ Centreline pump feet

▪ Single or double volute, depending on the pump size

▪ Radially split volute casing

▪ Axial inlet nozzle, tangential discharge nozzle pointing vertically upwards.

(From DN 250 / from impeller diameter 500 / pump size 200-401: radial discharge nozzle pointing vertically upwards)

▪ Volute casing with casing wear ring

▪ Casing cover (with casing wear ring, as required)

Optional:

▪ Casing and casing cover heatable/coolable, depending on size

Impeller type

▪ Closed radial impeller

▪ Impeller with impeller wear ring on the suction side

(if required also on the discharge side)

▪ Sealing gap and balancing holes balance axial forces.

Optional:

▪ Inducer to improve the NPSH value

Bearing bracket

designation

Shaft seal

▪ Cartridge seal to API 682

Bearings

▪ Uncooled

Optional:

▪ Cooled bearing bracket

Drive-end bearing:

▪ Fixed bearing

▪ Paired angular contact ball bearings

▪ Oil bath lubrication

▪ Optional: oil mist lubrication

Pump-end bearing:

▪ Radial bearing

▪ Cylindrical roller bearing

▪ Absorbs radial loads only

▪ Oil bath lubrication

▪ Optional: oil mist lubrication

Example: B03

Table 6: Bearing bracket designation

Designation Description

B Back pull-out bearing bracket 03 Size code (based on dimensions of seal chamber, shaft end

and bearings)

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8 9

4 Description of the Pump (Set)

Bearings used

Table 7: Bearing design

KSB designation FAG designation SKF designation

B.MUA B-MP-UA BECBM

Table 8: Standard bearing assembly

Bearing bracket Rolling element bearings

Pump end Motor end

B02 NU211C3 2 x 7309B-MUA B03 NU213C3 2 x 7311B-MUA B05 NU316C3 2 x 7315B-MUA B06 NU324C3 2 x 7224B-MUA B07 NU324C3 2 x 7324B-MUA

Table 9: Reinforced bearing assembly (triple bearing assembly)

Bearing bracket Rolling element bearings

Pump end Motor end

B02 NU211C3 3 x 7309B-MUA B03 NU213C3 3 x 7311B-MUA B05 NU316C3 3 x 7315B-MUA B06 NU324C3 3 x 7224B-MUA B07 NU324C3 3 x 7324B-MUA

4.5 Configuration and function

Design

1 Clearance gap 2 Discharge nozzle 3 Casing cover 4 Shaft 5 Bearing bracket 6 Suction nozzle 7 Impeller 8 Shaft seal 9 Rolling element bearing, pump

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.

end

10 Rolling element bearing, motor

end

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4 Description of the Pump (Set)

Function

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 pump casing into the suction nozzle. At the rear side of the impeller, the shaft (4) enters the hydraulic system 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) connected to the casing cover.

Sealing

The pump is sealed by a standardised mechanical seal.

4.6 Noise characteristics

Table 10: Surface sound pressure level L

Rated

power

input

PN [kW]

960 rpm

760 rpm

[dB]

Pump Pump set

1450 rpm

[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

3)4)

2900 rpm

[dB]

960 rpm 760 rpm

[dB]

1450 rpm

[dB]

2900 rpm

[dB]

4.7 Scope of supply

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

▪ Pump

Coupling

Contact guard

Baseplate

▪ Torsion-resistant flexible disc coupling

▪ Coupling guard

▪ Welded baseplate for the complete unit (pump and motor), in torsion-resistant

design

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 horizontal position.

DANGER

Excessive temperatures due to improper installation Explosion hazard!

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

5.3.1 Installation on a foundation

Fig. 6: Fitting the shims

L Bolt-to-bolt distance 1 Shim

2 Shim if (1) > 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.

Use shims (1) for height compensation, if necessary.

2. 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 the pump set can be mounted on vibration dampers upon confirmation by the manufacturer. In this case, only fasten the flexible elements at the baseplate after the piping has been connected.

NOTE

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

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.

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

connected without transmitting any stresses or strains.

▷ Observe permissible forces and moments at the pump nozzles. (⇨ Section 5.4.2

Page 23)

▷ Take appropriate measures to compensate thermal expansion of the piping.

CAUTION

Incorrect earthing during welding work at the piping Destruction of rolling element bearings (pitting effect)!

▷ Never earth the electric welding equipment on the pump or baseplate.

▷ Prevent current flowing through the rolling element bearings.

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5 Installation at Site

NOTE

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

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

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 44) .

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.

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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Fig. 7: Filter in the piping

1 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.

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5 Installation at Site

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.

5.4.2 Permissible forces and moments at the pump nozzles

Fig. 8: Coordinate system of forces and moments

1 Discharge nozzle 2 Suction nozzle 3 Shaft centreline

The pumps are designed to withstand twice the piping forces and moments required by API 610.

Table 11: Forces and moments at the pump nozzles

Suction nozzle Discharge nozzle

Size

Forces

[N]

res

Moments

[Nm]

MxMyMzM

Forces

[N]

res

Moments

[Nm]

MxMyMzM

25-180 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 25-230 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 40-180 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 40-230 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 40-280 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 40-181 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 40-231 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 40-281 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 40-361 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240 50-180 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240 50-230 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240 50-280 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240 50-360 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240 50-450 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240 80-180 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560 80-230 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560 80-280 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560 80-360 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560 80-450 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560 100-180 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600 100-230 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600 100-280 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600 100-360 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600 100-450 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600 150-230 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260 150-280 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260 150-360 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260 150-450 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260 150-501 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260

res

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5 Installation at Site

Suction nozzle Discharge nozzle

Forces

[N]

Size

res

150-630 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260 200-280 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420 200-360 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420 200-401 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420 200-450 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420 200-501 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420 200-670 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420 250-401 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500 250-501 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500 250-630 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500 250-710 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500 300-400 17800 14240 11560 25560 12740 6240 9500 17080 13340 10680 16000 23400 12200 5960 9220 16420 300-500 17800 14240 11560 25560 12740 6240 9500 17080 13340 10680 16000 23400 12200 5960 9220 16420 300-630 17800 14240 11560 25560 12740 6240 9500 17080 13340 10680 16000 23400 12200 5960 9220 16420 350-400 17800 14240 11560 25560 12740 6240 9500 17080 14240 11560 17800 25560 12740 6240 9500 17080 350-500 17800 14240 11560 25560 12740 6240 9500 17080 14240 11560 17800 25560 12740 6240 9500 17080 350-650 20460 16900 13340 29700 14640 7340 10840 19640 14240 11560 17800 25560 12740 6240 9500 17080 350-710 20460 16900 13340 29700 14640 7340 10840 19640 14240 11560 17800 25560 12740 6240 9500 17080 400-504 20460 16900 13340 29700 14640 7340 10840 19640 16900 13340 20460 29700 14640 7340 10840 19640 400-506 20460 16900 13340 29700 14640 7340 10840 19640 16900 13340 20460 29700 14640 7340 10840 19640 400-710 20460 16900 13340 29700 14640 7340 10840 19640 16900 13340 20460 29700 14640 7340 10840 19640

Moments

[Nm]

MxMyMzM

Forces

[N]

res

Moments

[Nm]

MxMyMzM

res

5.4.3 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.

5.5 Enclosure/insulation

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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).

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5 Installation at Site

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.

Checking the coupling alignment with a dial gauge

Fig. 9: Checking the spacer-type coupling with a dial gauge

1. Mark the installation position of the coupling by dotting marks (balancing condition).

Remove the coupling spacer.

NOTE

While the pump's coupling is disengaged, also check the direction of rotation.

(⇨ Section 5.9 Page 27)

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5 Installation at Site

3. Check the alignment of the coupling halves with a dial gauge (see drawing "Checking the spacer-type coupling with a dial gauge"). Admissible run-out of coupling face (axial) maximum 0.1 mm. Admissible radial deviation, measured over the complete circumference, maximum 0.2 mm.

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 (with the motor).

Any differences in shaft centre height between the pump and the motor are compensated by means of shims.

Fig. 10: Pump set with shim

1 Shim

✓ The coupling guard and the footboard for the coupling guard, if any, have been

removed.

1. Check the coupling alignment.

Unscrew 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 that the coupling and 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.

6. Re-install the coupling guard and the footboard for the coupling guard, if any.

7. Check the distance between coupling and coupling guard. The coupling and coupling guard must not come into contact.

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).

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5 Installation at Site

5.8 Electrical connection

DANGER

Incorrect electrical installation Explosion hazard!

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

▷ Always connect explosion-proof motors via a motor protection switch.

DANGER

Work on the pump set 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.

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 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.

Checking the direction of rotation

5.9

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.

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5 Installation at Site

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 of model with auxiliary impeller (inducer) Damage to the pump!

▷ 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 motor and pump is in clock-wise direction (seen from the motor end).

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

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 direction of rotation is incorrect, check the connection of the motor and the switchgear, if any.

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6 Commissioning/Start-up/Shutdown

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 properly connected to the electric power supply and is

equipped with all protection devices.

▪ The pump has been primed with the fluid to be handled. (⇨ Section 6.1.4 Page

31)

▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 27)

▪ All auxiliary connections required are connected and operational.

▪ The lubricants have been checked.

▪ After prolonged shutdown of the pump (set), the activities described in

(⇨ Section 6.4 Page 38) have been carried out.

6.1.2

Filling in the lubricant

Fill the bearing bracket with lubricating oil.

▪ Oil quality (⇨ Section 7.2.3.1.2 Page 44)

▪ Oil quantity (⇨ Section 7.2.3.1.3 Page 45)

NOTE

On uncooled bearing brackets, first remove the reservoir of the constant level oiler. Then screw in the connection elbow separately.

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

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

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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1 2

6 Commissioning/Start-up/Shutdown

Fig. 11: Bearing bracket with constant level oiler

1 Constant level oiler 2 Vent plug 3 Connection elbow of the constant

level oiler

5 Bearing bracket 6 Oil level sight glass

1. Remove the protective cage.

2. Unscrew the vent plug (2).

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

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

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

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

7. Screw the vent plug (2) back in.

8. Fit the protective cage.

9. 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 - 8, if necessary.

10. 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.

4 Screw plug

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NOTE

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

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6 Commissioning/Start-up/Shutdown

Bearings with oil mist

lubrication

Connecting the oil mist lubrication system (for oil mist lubrication only)

Fig. 12: Oil mist lubrication

✓ Always observe the instructions of the lubricating system manufacturer

(especially on dosing and oil quantity).

1. Remove plugs 916.N3.

Connect the lines of the oil mist lubrication system.

3. Remove drain plug 916.46.

4. Connect the drain line (returning the oil back into the oil mist system).

5. Screw in plug 916.N1.

Reservoir of non-

pressurised external fluid

Double mechanical seal

External liquid feed

NOTE

Plug 916.N1 replaces vent plug 913.03.

6.1.3 Shaft seal

Shaft seals are fitted prior to delivery. Observe the instructions on dismantling (⇨ Section 7.4.6 Page 48) or assembly

(⇨ Section 7.5.3 Page 51

) .

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.

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.

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6 Commissioning/Start-up/Shutdown

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.

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

6.1.5 Final check

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

Check the coupling alignment; re-align the coupling if required.

Check that the coupling and shaft can easily be rotated by hand.

4. Re-install the coupling guard and the footboard for the coupling guard, if any.

5. Check the distance between the coupling and coupling guard. The coupling and coupling guard must not come into contact.

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

▪ Conditioned and neutral with regard to mechanical corrosion

▪ Inlet temperature tE=10 to 30 °C

Outlet temperature tA= 45 °C max.

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6.1.7 Cooling of the pump

The casing cover, the bearing bracket and the casing support on the baseplate can be cooled.

Observe the following quality data of the cooling water:

▪ Maximum permissible cooling liquid pressure: 10 bar

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6 Commissioning/Start-up/Shutdown

▪ Maximum permissible cooling liquid test pressure: 15 bar

▪ Observe the specified cooling liquid quantity.

6.1.8 Cooling of the shaft seal

CAUTION

Vaporisation pressure of fluid handled higher than atmospheric pressure Damage to the shaft seal/pump!

▷ Cool the shaft seal.

▷ Provide sufficient quantities of cooling liquid (see table).

NOTE

The vaporisation pressure varies depending on the fluid handled, the system pressure and the material of the shaft seal (e.g. hot water).

Table 12: Cooling liquid quantities:

Fluid temperature

[°C]

Cooling liquid quantities

[m3/h]

Casing cover < 250 0,3

< 400 0,6

Bearing bracket

2006)/250 to 315 > 315

0.2

Support on baseplate > 250 0.2

6.1.8.1 Cooling of the heat exchanger

For mechanical seals with product circulation observe the following for the heat exchanger:

Table 13: Cooling liquid quantity depending on the bearing bracket

At speed n

[rpm]

Cooling liquid

[m3/h]

Bearing bracket

B02 B03 B05 B06 B07

1750/1450 0.35 0.5 0.6 0.8 0.8 3500/2900 1.2 1.2 1.8 - -

6.1.9 Heating

DANGER

Excessive surface temperature Explosion hazard! Risk of burns!

▷ Observe the permissible temperature classes. (⇨ Section 2.10.2 Page 11)

The cooling liquid quantities indicated are based on Δt = max. 15 °C.

For n = 3500 rpm and n = 2900 rpm in conjunction with triple bearing assembly. In all other cases from 250 °C!

Water cooling or fan wheel

Water cooling (and fan wheel optional)

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CAUTION

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

▷ Check that the pump is sufficiently warmed up throughout.

The casing cover can be heated with hot water or steam. Observe the following data for the heating medium:

▪ Maximum permissible temperature t = 150 °C

▪ Maximum permissible pressure p = 10 bar

▪ Seal casing cover with O-rings made of EP.

CAUTION

Lack of heating medium Damage to the pump!

▷ Provide sufficient quantities of a suitable heating medium.

Fluid temperatures above

150 °C

Temperature difference

6.1.10 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.

6.1.11 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.

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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 specified. (⇨ Section 6.1.4 Page 31)

▷ Always operate the pump within the permissible operating range.

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6 Commissioning/Start-up/Shutdown

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.

✓ Pump, suction line and inlet tank, if any, have been vented and primed with the

fluid to be pumped.

✓ The lines for priming and venting have been closed.

CAUTION

Start-up against open discharge line Motor overload!

▷ Make sure the motor has sufficient power reserves.

▷ Use a soft starter.

▷ Use speed control.

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

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

Start up the motor.

4. Immediately after the pump has reached rated 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.

6.1.12 Checking the shaft seal

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

6.1.13 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.

Close the shut-off element in the discharge line.

Switch off the motor and make sure the pump set runs down smoothly to a

2. standstill.

NOTE

If the discharge line is equipped with a non-return or 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.

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6 Commissioning/Start-up/Shutdown

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.

Close the auxiliary connections.

2. 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.

6.2.1 Ambient temperature

Observe the following parameters and values during operation:

Table 14: Permissible ambient temperatures

Permissible ambient temperature Temperature

Maximum 43 °C Minimum See data sheet

CAUTION

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Operation outside the permissible ambient temperature Damage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.

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6 Commissioning/Start-up/Shutdown

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

[kW]

Maximum number of start-ups

[Start-ups/hour]

up to 12 15

up to 100 10

more than 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:

See characteristic curves.

max

min

10)

= 0.3 × Q

opt

11)

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

Maximum permissible flow rate

10)

Minimum permissible flow rate

11)

Best efficiency point

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6 Commissioning/Start-up/Shutdown

Symbol Description Unit

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 indicated 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.

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

✓ The pump has been properly drained

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

46)

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)

(⇨ Section 7.3 Page 46) and the safety

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6.4 Returning to service

For returning the pump to service observe the sections on commissioning/start-up

(⇨ Section 6.1 Page

and the operating limits. (⇨ Section 6.2 Page 36)

29)

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6 Commissioning/Start-up/Shutdown

In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. (⇨ Section 7 Page 40)

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 Servicing/Maintenance

7.1 Safety regulations

DANGER

Sparks produced during servicing work Explosion hazard!

▷ Observe the safety regulations in force at the place of installation!

▷ Always perform maintenance work 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 all maintenance, inspection and installation work 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!

▷ Make sure 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 and supplies posing a health hazard and/or hot fluids or supplies 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. Find your contact in the attached "Addresses" booklet or on the Internet at "www.ksb.com/contact".

Never use force when dismantling and reassembling the pump set.

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7 Servicing/Maintenance

7.2 Maintenance/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 36)

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.

▪ Check the shaft seal.

▪ Check the static seals 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 the stand-by pumps are ready for operation, start them up once a week.

▪ Keep the stand-by pump warm.

Observe the following conditions to make sure stand-by pumps are operational and kept warm:

– All cooling points are in operation.

The permissible nozzle forces and moments are not exceeded.

–

– In extreme cases, contact the manufacturer.

▪ 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).

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 gaps

For checking the clearances gaps remove impeller 230, if required. (⇨ Section 7.4.5

Page 47

)

If the clearance is larger than permitted (see the following table), replace casing wear ring 502.01/502.02 and/or impeller wear ring 503.01/503.02. The clearances given refer to the diameter.

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7 Servicing/Maintenance

Table 17: Clearances between impeller and casing and/or between impeller and casing cover

Size Suction-side casing wear ring Discharge-side casing wear ring

Inner nominal

diameter

(rounded)

Clearance

(standard)

Minimum

clearance to

API 610

Inner nominal

diameter

(rounded)

Clearance

(standard)

Minimum

clearance to

API 610

[mm] [mm] [mm] [mm] [mm] [mm] 25-180 70 0,5 25-230 70 0,5 40-180 80 0,5 40-230 80 0,5 40-280 85 0,6 40-181 95 0,6 40-231 95 0,6 40-281 95 0,6 40-361 95 0,6 50-180 120 0,6 50-230 120 0,6 50-280 120 0,6 50-360 120 0,6 50-450 120 0,6 80-180 135 0,6 80-230 135 0,6 80-280 135 0,6 80-360 135 0,6 80-450 135 0,6 100-180 165 0,4 100-230 165 0,6 100-280 165 0,6 100-360 165 0,6 100-450 175 0,6 150-230 195 0,7 150-280 195 0,7 150-360 195 0,7 150-450 200 0,7 150-501 225 0,6 150-630 240 0,7 200-280 225 0,7 200-360 235 0,7 200-450 235 0,7 200-401 250 0,6 200-501 255 0,6 200-670 290 0,6 250-401 330 0,75 250-501 310 0,6 250-630 330 0,75 250-710 310 0,7 300-400 330 0,75 300-500 350 0,75 300-630 360 0,85 250-400A 380 0,85 350-400B 350 0,85 350-500 380 0,85 350-630 400 0,85 350-710 400 0,85 400-504 410 0,85

-0,05

-0,050

-0,05

-0,08

-0,05

-0,08

-0,05

-0,08

-0,100

-0,08

-0,1

0,30 70 0,5 0,30 70 0,5 0,33 80 0,5 0,33 80 0,5 0,33 120 0,6 0,35 95 0,6 0,35 95 0,6 0,35 120 0,6 0,35 165 0,6 0,40 120 0,6 0,40 120 0,6 0,40 120 0,6 0,40 165 0,6 0,40 195 0,6 0,43 135 0,6 0,43 135 0,6 0,43 135 0,6 0,43 165 0,6 0,43 195 0,6 0,45 165 0,4 0,45 165 0,6 0,45 165 0,6 0,45 165 0,6 0,45 195 0,7 0,48 195 0,7 0,48 195 0,7 0,48 195 0,7 0,48 235 0,7 0,50 225 0,6 0,53 290 0,7 0,50 225 0,7 0,53 280 0,7 0,53 280 0,7 0,53 250 0,6 0,55 255 0,6 0,58 290 0,6 0,63 330 075 0,60 310 0,6 0,63 340 0,75 0,60 340 0,85 0,63 330 0,75 0,65 350 0,75 0,65 340 0,75 0,68 340 0,85 0,65 340 0,85 0,68 380 0,85

0,7 400 0,85 0,7 400 0,85 0,7 410 0,85

-0,05

-0,08

-0,05

-0,08

-0,05

-0,08

-0,05

-0,08

-0,05

-0,08

-0,1

-0,08

-0,1

0,30 0,30 0,33 0,33 0,40 0,35 0,35 0,40 0,45 0,40 0,40 0,40 0,45 0,48 0,43 0,43 0,43 0,45 0,48 0,45 0,45 0,45 0,45 0,48 0,48 0,48 0,48 0,53 0,50 0,58 0,50 0,58 0,58 0,53 0,55 0,58 0,63 0,60 0,63 0,63 0,63 0,65 0,63 0,63 0,63 0,68

0,7 0,7 0,7

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7 Servicing/Maintenance

Size Suction-side casing wear ring Discharge-side casing wear ring

Inner nominal

diameter

(rounded)

Clearance

(standard)

Minimum

clearance to

API 610

Inner nominal

diameter

(rounded)

Clearance

(standard)

Minimum

clearance to

API 610

[mm] [mm] [mm] [mm] [mm] [mm] 400-506 440 0,85 400-710 440 0,85

-0,1

0,73 440 0,85 0,73 500 0,85

-0,1

0,73 0,80

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.

12)

At least once a year

7.2.3.1.1 Intervals

Table 18: Oil change intervals

Temperature at the

bearing

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

Designation Symbol to DIN

51502

CLP46 lubricating oil

to DIN 51517

HD 20W/20 SAE

First oil change All subsequent oil

changes

Properties

□ Kinematic viscosity

at 40 °C

Flash point (to

Cleveland)

12)

46±4 mm²/s

+175 ℃

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7 Servicing/Maintenance

Designation Symbol to DIN

Properties

51502

Solidification point

-15 ℃

(pour point)

Application

temperature

13)

Higher than

permissible bearing

temperature

7.2.3.1.3 Oil quantity

Bearing bracket Oil quantity bearing bracket

[l]

B02 0.9 B03 1.8 B05 2.5 B06 5.7 B07 4.7

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. 13: Bearing bracket with constant level oiler

1 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.

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.

13)

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

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7 Servicing/Maintenance

7.3 Drainage/cleaning

WARNING

Fluids, consumables and supplies which are hot 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 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.

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 40)

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 6.1.13 Page 35)

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

▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 46)

▷ Close any auxiliary connections.

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

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7 Servicing/Maintenance

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.

Remove the coupling guard.

4. Remove the coupling spacer, if any.

5. Drain the oil fill of oil-lubricated bearings.

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.

Shift the motor to separate it from the pump.

7.4.4 Removing the back pull-out unit

✓ At 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.

Remove hexagon nut 920.01 at volute casing 102.

Use forcing screws 901.30 to pull the back pull-out unit out of volute casing 102.

4. Remove and dispose of joint ring 411.10.

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

7.4.5 Removing the impeller

7.4.5.1 Loosening the impeller — for bearing brackets B02 to B05

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to (⇨ Section 7.4.4 Page

47) have been observed/carried out.

✓ The back pull-out unit has been placed in a clean and level assembly area.

Unscrew impeller nut 922.01 with threaded insert (right-hand thread).

1. For versions with auxiliary impeller:

Unscrew auxiliary impeller 23-2 with the

threaded insert (right-hand thread).

2. Remove and dispose of joint ring 411.31, if any

3. Remove lock washer 931.02.

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7 Servicing/Maintenance

7.4.5.2 Loosening the impeller — for bearing brackets B06 and B07

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to (⇨ Section 7.4.4 Page

47) have been observed/carried out.

✓ The back pull-out unit has been placed in a clean and level assembly area.

1. Unscrew and remove impeller hub cap 260 (right-hand thread). For versions with auxiliary impeller:

Unscrew and remove impeller hub cap

260.01 (right-hand thread).

2. Remove and dispose of joint ring 411.31. For versions with auxiliary impeller: Remove and dispose of joint ring 411.59.

3. Bend open lock washer 931.02.

4. Remove impeller screw 906 with lock washer 931.02 and disc 550.87. For versions with auxiliary impeller: Pull auxiliary impeller 23-2 off the shaft. Remove keys 940.03 from shaft 210. Remove and dispose of joint ring 411.31.

7.4.5.3 Removing the impeller — for all bearing bracket sizes

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to and (⇨ Section 7.4.5.2

Page 48) have been observed/carried out.

1. Remove impeller 230 with an impeller removal tool.

Place impeller 230 on a clean and level surface.

3. Remove keys 940.01 from shaft 210.

4. If throttling bush 542.02 is fitted, undo grub screws 904.38.

5. Remove throttling bush 542.02, if any.

7.4.6 Removing the cartridge seal

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to (⇨ Section 7.4.5.3 Page

48) have been observed/carried out.

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

1. If assembling jigs are provided, loosen the hexagon head bolts for fitting the assembling jigs.

Engage assembling jigs, if any, in the groove of shaft protecting sleeve 524.01

2. and re-tighten the hexagon head bolts.

3. Loosen hexagon head bolts 920.15 at casing cover 161.

4. Use forcing screws 901.31 to remove bearing bracket 330. At the same time, pull shaft protecting sleeve 524.01 (if any) with complete cartridge seal 433 off shaft 210.

5. Take care not to damage O-rings 412.01/.31, if any.

6. Undo hexagon nut 920.02 and remove seal cover 471.01 and/or the seal cartridge. Observe the seal installation drawing of the mechanical seal.

7.4.7 Dismantling the bearings

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to (⇨ Section 7.4.6 Page

48) have been observed/carried out.

✓ The bearing bracket has been placed in a clean and level assembly area.

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

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

3. Remove key 940.02.

4. Remove fan hood 882, fan hub 485.02 and fan wheel 831.02, if any.

5. Undo hexagon nut 920.02 and remove seal cover 471.01 and/or the seal cartridge.

6. Undo grub screws 904.41/.42 and remove throwers 507.01/.02.

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7 Servicing/Maintenance

7. Undo hexagon socket head cap screws 914.01 and remove pump-end bearing cover 360.01 as well as joint ring 400.01.

8. Undo hexagon head bolts 901.37 and remove motor-end bearing cover 360.02 as well as O-ring 412.22, if required.

Carefully drive shaft 210 together with angular contact ball bearing 320.02 and

9. the inner ring of cylindrical roller bearing 322.01, including oil thrower 508.01, if any, out of the bearing bracket towards the drive end.

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

11. If oil thrower 508.01 is fitted, remove grub screw 904.20 and pull the oil thrower off the shaft.

12. Bend open lock washer 931.01 behind slotted round nut 920.21 on shaft 210.

13. Unscrew slotted round 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.

14. 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.

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

Sealing elements

Always reassemble the pump in accordance with the corresponding general assembly drawing.

▪ 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 glued together from material sold by the

metre.

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7 Servicing/Maintenance

CAUTION

Contact of O-ring with graphite or similar material Fluid could escape!

▷ Do not coat O-ring with graphite or similar material.

▷ Use animal fats or lubricants based on silicone or PTFE.

Tightening torques

▪ Assembly adhesives

– For gaskets, avoid the use of assembly adhesives, if possible.

If assembly adhesives are required, use a commercially available contact

–

adhesive (e.g. "Pattex").

– Only apply adhesive at selected points and in thin layers.

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

– Coat the locating surfaces of the individual components and screwed

connections with graphite or similar before reassembly.

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

7.5.2 Fitting the bearings

✓ 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 rolling element bearing 322.01 to approximately 80 ℃ in an oil bath or by means of an induction heater.

2. Guide angular contact ball bearing 320.02 onto shaft 210 as far as it will go.

Slide the inner ring of cylindrical roller bearing 322.01 onto shaft 210 as far as it

3. will go.

4. For bearing brackets B03 and B05 make sure that disc 550 is positioned correctly.

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.

5. Use a C-spanner to tighten slotted round nut 920.21 (right-hand thread) without lock washer 931.01.

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

Re-tighten slotted round nut 920.21, then unscrew it again.

8. 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.

9. Fit lock washer 931.01.

10. Tighten slotted round nut 920.21.

11. Bend back lock washer 931.01.

12. If provided, slide oil thrower 508.01 on shaft 210.

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7 Servicing/Maintenance

13. Screw grub screw 904.20 into oil thrower 508.01.

14. Guide cylindrical roller bearing 322.01 (roller cage) into bearing bracket 330.

Carefully insert shaft 210 together with angular contact ball bearing 320.02 and

15. the inner ring of cylindrical roller bearing 322.01, including oil thrower 508.01 (if any) into bearing bracket 330 towards the pump end.

16. Insert O-ring 412.22 into the groove of motor-end bearing cover 360.02.

17. Insert motor-end bearing cover 360.02 with O-ring 412.22 into bearing bracket 330 from the motor end.

18. Screw hexagon head bolts 901.37 with bearing cover 360.02 into bearing bracket 330 from the motor end.

19. Fit pump-end bearing cover 360.01 with joint ring 400.01.

20. Screw socket head cap screws 914.01 into bearing bracket 330.

21. Slide thrower 507.01 onto shaft 210 from the pump end, leaving a 2 mm gap between the thrower and pump-end bearing cover 360.01.

22. Screw grub screw 904.41 into pump-end thrower 507.01.

23. Slide thrower 507.02 onto shaft 210 from the motor end, leaving a 2 mm gap between the thrower and motor-end bearing cover 360.02.

24. Screw grub screw 904.41 into motor-end thrower 507.02.

25. Fit fan hood 882, fan hub 485.02 and fan wheel 831.02, if any.

26. From the motor end, insert key 940.02 into the keyway at the shaft end.

27. Pull the coupling half onto the shaft end.

28. Screw the socket head cap screw into the coupling hub.

7.5.3 Fitting the shaft seal

7.5.3.1 Installing the cartridge seal

Always observe the following points when installing the cartridge seal:

▪ Install the cartridge seal as described in the seal installation drawing.

▪ Work cleanly and accurately.

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

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 49) to (⇨ Section 7.5.2 Page

50) have been observed/carried out.

Fit seal cover 471 and/or seal cartridge and tighten hexagon head bolts 920.02.

Guide casing cover 161 with cartridge seal 433 onto the shaft from the pump

2. end.

3. Carefully guide complete pre-assembled bearing bracket 330 over the studs

902.15 which have been screwed into casing cover 161.

4. On cooled versions, make sure not not damage O-rings 412.01/.31 at casing cover 161.

5. Screw casing cover 161 to the complete bearing cover 330 with hexagon nuts

920.15.

7.5.4 Fitting the impeller

7.5.4.1 Fitting the impeller — for all bearing bracket sizes

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 49) to (⇨ Section 7.5.3.1 Page

51) have been observed/carried out.

✓ The back pull-out unit has been placed in a clean and level assembly area.

✓ The pre-assembly (motor, shaft, bearing bracket, casing cover) has been placed in

a clean and level assembly area.

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7 Servicing/Maintenance

✓ 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. If applicable, guide throttling bush 542.02 onto impeller 230.

Screw grub screws 904.38 into throttling bush 542.02.

3. Slide joint ring 411.32, if any, onto shaft 210.

4. Place key 940.01 into the keyway of shaft 210.

5. Slide impeller 230 onto shaft 210.

7.5.4.2 Fastening the impeller — for bearing brackets B02 to B05

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 49) to (⇨ Section 7.5.4.1 Page

51) have been observed/carried out.

✓ The sealing surfaces have been cleaned.

Insert lock washer 931.02.

Insert new joint ring 411.31, if applicable.

3. Screw impeller nut 922.01 with threaded insert (right-hand thread) onto shaft

210. For versions with auxiliary impeller: Screw auxiliary impeller 23-2 with threaded insert (right-hand thread) onto shaft 210. Observe the tightening torques. (⇨ Section 7.6.1 Page 53)

4. Bend back the lock washer.

7.5.4.3 Fastening the impeller — for bearing brackets B06 and B07

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 49) to (⇨ Section 7.5.4.1 Page

51) have been observed/carried out.

✓ The sealing surfaces have been cleaned.

1. Only for versions with auxiliary impeller: Insert keys 940.03 into shaft 210. Insert a new joint ring 411.31 into impeller 210. Guide auxiliary impeller 23-2 onto the shaft.

2. Insert disc 550.87 and lock washer 931.02.

Screw impeller screw 906 into shaft 210.

4. Observe the tightening torques. (⇨ Section 7.6.1 Page 53)

5. Bend back lock washer 931.02.

6. Insert new joint ring 411.31 into impeller 230. For versions with auxiliary impeller: Place a new joint ring 411.59 on auxiliary impeller 23-2. Screw impeller hub cap 260.01 onto auxiliary impeller 23-2.

7. Screw impeller hub cap 260 into impeller 230 (right-hand thread).

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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 49) to (⇨ Section 7.5.4 Page

51) have been observed/carried out.

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

✓ The sealing surfaces have been cleaned.

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

manufacturer's instructions.

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7 Servicing/Maintenance

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 volute casing 102. Observe the tightening torques.

(⇨ Section 7.6.1 Page 53)

7.5.6

Mounting the motor

NOTE

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

Table 20: Tightening torques of screwed connections

Material

(Asia and

Americas)

Material

(Europe)

A 193 Grade B7/

B16 /

A 540 Grade B24

1.7709/1.6772 (Monix 3K)

Stud

902.01

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

2. Fasten the motor to the baseplate.

Align pump and motor.

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

7.6 Tightening torques

7.6.1 Tightening torques of the pump

Use a torque wrench to tighten the screwed connections (902.01/920.01) between the volute casing and the casing cover.

A 193 Grade

B7/B16

C35E+QT 8.8 A4-70 1.4571/1.4021

14)

Stud

14)

902.15

10.9 -- CF6M/Type 316

Hexagon head

bolt 901.37

Stud

14)

902.02

Impeller nut 922.01

or impeller screw 906

15)16)

Tightening torque

Bearing bracket

B02S 25-180 12 M 16

25-230 16 M 16

14)

Stud to DIN 938/DIN 939 with hexagon nuts to ISO 4032.

15)

These values are determined on the basis of a friction coefficient of μ = 0.1

16)

After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.

17)

Re-tighten impeller nut 922.01 or impeller screw 906 some 20 to 30 minutes after assembly. Bend back lock washer 931.02.

18)

Values for 1.7709 / A 193 Grade B7/B16 /

19)

Values for 1.6772 (Monix 3K) / A 540 Grade B24

20)

Values for 1.4571 / A 276 Type 316Ti

Size

Quantity

Thread

163

280

163

280

Quantity

[Nm]

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5

19)

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5

19)

15)16)

Tightening torque

Thread

[Nm]

Quantity

Thread

15)

Tightening torque

[Nm]

Quantity

Thread

15)16)

Tightening torque

Quantity

[Nm]

Thread

15)17)

Tightening torque

[Nm]

20)

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7 Servicing/Maintenance

Material

(Asia and

Americas)

Material

(Europe)

A 193 Grade B7/

B16 /

A 540 Grade B24

1.7709/1.6772 (Monix 3K)

Stud

902.01

Bearing bracket

Size

Quantity

40-180 12 M 16

40-230 16 M 16

B02L 40-181 12 M 16

40-231 16 M 16

40-280 16 M 20

40-281 16 M 20

40-361 20 M 20

50-180 12 M 16

B03 50-230 12 M 20

50-280 16 M 20

50-360 20 M 20

50-450 20 M 24

80-180 12 M 16

80-230 12 M 20

80-280 16 M 20

80-360 20 M 20

100-180 12 M 16

14)

Thread

163

280

163

280

163

280

163

280

330

565

330

565

330

565

163

280

330

565

330

565

330

565

970

163

280

330

565

330

565

330

565

163

280

A 193 Grade

10.9 -- CF6M/Type 316

B7/B16

C35E+QT 8.8 A4-70 1.4571/1.4021

Stud

14)

902.15

Hexagon head

bolt 901.37

15)16)

Tightening torque

Quantity

[Nm]

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5

19)

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5

19)

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5

19)

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5

19)

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5

19)

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 16x1.5

19)

18)

4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

15)16)

Tightening torque

Thread

[Nm]

Quantity

Thread

15)

Tightening torque

[Nm]

14)

Stud

Quantity

902.02

Thread

or impeller screw 906

15)16)

Tightening torque

[Nm]

Impeller nut 922.01

Quantity

Thread

130

250

15)17)

Tightening torque

[Nm]

20)

14)

Stud to DIN 938/DIN 939 with hexagon nuts to ISO 4032.

15)

These values are determined on the basis of a friction coefficient of μ = 0.1

16)

After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.

17)

Re-tighten impeller nut 922.01 or impeller screw 906 some 20 to 30 minutes after assembly. Bend back lock washer 931.02.

54 of 76

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Page 55

7 Servicing/Maintenance

Material

(Asia and

Americas)

Material

(Europe)

A 193 Grade B7/

B16 /

A 540 Grade B24

1.7709/1.6772 (Monix 3K)

Stud

902.01

Bearing bracket

Size

Quantity

100-230 12 M 20

100-280 16 M 20

150-230 12 M 20

B05S 80-450 20 M 24

150-280 12 M 24

100-360 16 M 24

100-450 20 M 24

150-360 16 M 24

200-280 12 M 24

B05L 150-450 20 M 24

150-501 30 M 16

200-360 16 M 24

200-450 20 M 24

200-401 24 M 16

200-501 24 M 20

250-401 24 M 16

250-501 24 M 20

14)

Thread

330

565

330

565

330

565

970

565

970

565

970

565

970

565

970

565

970

565

970

163

280

565

970

565

970

163

280

330

565

163

280

330

565

A 193 Grade

10.9 -- CF6M/Type 316

B7/B16

C35E+QT 8.8 A4-70 1.4571/1.4021

Stud

14)

902.15

Hexagon head

bolt 901.37

15)16)

Tightening torque

Quantity

[Nm]

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

15)16)

Tightening torque

Thread

[Nm]

Quantity

Thread

15)

Tightening torque

[Nm]

14)

Stud

Quantity

902.02

Thread

or impeller screw 906

15)16)

Tightening torque

[Nm]

Impeller nut 922.01

Quantity

Thread

250

350

600

15)17)

Tightening torque

[Nm]

20)

14)

Stud to DIN 938/DIN 939 with hexagon nuts to ISO 4032.

15)

These values are determined on the basis of a friction coefficient of μ = 0.1

16)

After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.

17)

Re-tighten impeller nut 922.01 or impeller screw 906 some 20 to 30 minutes after assembly. Bend back lock washer 931.02.

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55 of 76

Page 56

7 Servicing/Maintenance

Material

(Asia and

Americas)

Material

(Europe)

A 193 Grade B7/

B16 /

A 540 Grade B24

1.7709/1.6772 (Monix 3K)

Stud

902.01

Bearing bracket

Size

Quantity

300-400 24 M 20

300-500 24 M 20

B06 150-630 20 M 24

200-670 24 M 24

250-630 20 M 24

250-710 24 M 24

300-630 20 M 24

350-400 16 M 24

350-500 20 M 24

350-630 20 M 24

B07 350-710 24 M 24

400-504 20 M 24

400-506 20 M 24

400-710 24 M 24

14)

Thread

330

565

330

565

970

565

970

565

970

565

970

565

970

565

970

565

970

565

970

565

970

565

970

565

970

565

970

A 193 Grade

10.9 -- CF6M/Type 316

B7/B16

C35E+QT 8.8 A4-70 1.4571/1.4021

Stud

14)

902.15

Hexagon head

bolt 901.37

15)16)

Tightening torque

Quantity

[Nm]

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5

19)

18)

4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5

19)

15)16)

Tightening torque

Thread

[Nm]

Quantity

Thread

15)

Tightening torque

[Nm]

14)

Stud

Quantity

902.02

Thread

or impeller screw 906

15)16)

Tightening torque

[Nm]

Impeller nut 922.01

Quantity

Thread

600

300

400

300

400

300

400

300

400

300

400

300

400

300

400

300

400

300

400

300

400

300

400

300

400

15)17)

Tightening torque

[Nm]

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

20)

21)

14)

Stud to DIN 938/DIN 939 with hexagon nuts to ISO 4032.

15)

These values are determined on the basis of a friction coefficient of μ = 0.12.

16)

After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.

17)

Re-tighten impeller nut 922.01 or impeller screw 906 some 20 to 30 minutes after assembly. Bend back lock washer 931.02.

21)

Values for 1.4021 / A 276 Type 420

56 of 76

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Page 57

7 Servicing/Maintenance

7.7 Spare parts stock

Table 21: Quantity of spare parts for recommended spare parts stock

7.7.1 Ordering spare parts

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

▪ Type series

▪ Size

▪ KSB order number

▪ Material variant

▪ Year of construction

Refer to the name plate for all data. (⇨ Section 4.3 Page 16)

Also specify the following data:

▪ Description

▪ Part No.

▪ Quantity of spare parts

▪ Shipping address

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

Refer to the general assembly drawing for part numbers and descriptions.

9.1 Page 62)

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

(⇨ Section

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 % 23-2 Auxiliary impeller 1 1 1 2 2 2 20 %

320.02 Angular contact ball bearing

1 1 2 2 2 3 25 %

(set)

322.01 Cylindrical roller bearing 1 1 2 2 2 3 25 % 330 Bearing bracket - - - - - 1 2

22)

502.01/.02

503.01/.02

Casing wear ring 2 2 2 3 3 4 50 %

22)

Impeller wear ring 2 2 2 3 3 4 50 %

542.02 Throttling bush 1 1 2 2 2 3 30 %

- Sealing elements 4 6 8 8 9 10 100 % 433 Mechanical seal, complete 1 1 2 2 2 3 25 %

22)

If any

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57 of 76

Page 58

7 Servicing/Maintenance

7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

Table 22: Interchangeability of pump components

Part description

Volute casing

Casing cover, uncooled

Casing cover, cooled

Shaft

Impeller

Impeller hub cap

Angular contact ball bearing

Cylindrical roller bearing

Bearing bracket

Bearing cover, pump end

Bearing cover, motor end

Joint ring

Mechanical seal

Seal cover

Casing wear ring, suction side

Casing wear ring, discharge side

Impeller wear ring, suction side

Impeller, discharge side

Thrower, pump end

Thrower, motor end

Oil thrower

Throttling bush

Impeller screw

Part No.

Bearing bracket

102

161

210

230

260

320.02

322.01

330

360.01

360.02

433

411.10

471.01

502.01

502.02

503.01

503.02

507.01

507.02

508.01

906

542.01

Pump size

B02S 25-180 1 1 1 1 1 - 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 - 1

25-230 2 2 2 1 2 - 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 - 1 40-180 3 1 1 1 3 - 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 - 1 40-230 4 2 2 1 4 - 1 1 1 1 1 2 1 1 2 2 2 2 1 1 1 1 - 1

B02L 40-181 6 3 3 2 6 - 1 1 1 1 1 1 1 1 4 4 4 4 1 1 1 2 - 2

40-280 5 5 5 2 5 - 1 1 1 1 1 3 1 1 3 5 3 5 1 1 1 2 - 2 40-231 7 4 4 2 7 - 2 2 2 2 2 2 1 1 4 4 4 4 1 1 1 2 - 2 40-281 8 5 5 2 8 - 2 2 2 2 2 3 1 1 4 5 5 5 1 1 1 2 - 2 40-361 9 6 6 2 9 - 2 2 2 2 2 4 1 1 4 7 4 7 1 1 1 2 - 2 50-180 10 7 7 2 10 - 2 2 2 2 2 1 1 1 5 5 5 5 1 1 1 2 - 2

B03 50-230 11 8 8 3 11 - 2 2 2 2 2 2 2 2 5 5 5 5 2 2 2 3 - 3

50-280 12 9 9 3 12 - 2 2 2 2 2 3 2 2 5 5 5 5 2 2 2 3 - 3 50-360 13 10 10 3 13 - 2 2 2 2 2 4 2 2 5 7 5 7 2 2 2 3 - 3 50-450 14 11 11 3 14 - 2 2 2 2 2 5 2 2 5 9 5 9 2 2 2 3 - 3 80-180 15 12 12 3 15 - 2 2 2 2 2 2 2 2 6 6 6 6 2 2 2 3 - 3 80-230 16 12 12 3 16 - 2 2 2 2 2 2 2 2 6 6 6 6 2 2 2 3 - 3 80-280 17 9 9 3 17 - 2 2 2 2 2 3 2 2 6 6 6 6 2 2 2 3 - 3 80-360 18 13 13 3 18 - 2 2 2 2 2 4 2 2 6 7 6 7 2 2 2 3 - 3 100-180 19 15 15 3 19 - 2 2 2 2 2 5 2 2 7 7 7 7 2 2 2 3 - 3 100-230 20 16 16 3 20 - 2 2 2 2 2 5 2 2 7 7 7 7 2 2 2 3 - 3 100-280 21 17 17 3 21 - 2 2 2 2 2 3 2 2 7 7 7 7 2 2 2 3 - 3 150-230 22 20 20 3 22 - 2 2 2 2 2 2 2 2 9 9 9 9 2 2 2 3 - 3

B05S 80-450 23 14 14 4 23 - 3 3 3 3 3 5 3 3 6 6 6 6 3 3 3 4 - 4

100-360 24 18 18 4 24 - 3 3 3 3 3 4 3 3 7 7 7 7 3 3 3 4 - 4 100-450 25 19 19 4 25 - 3 3 3 3 3 5 3 3 8 8 8 8 3 3 3 4 - 4 150-280 26 21 21 4 26 - 3 3 3 3 3 3 3 3 9 9 9 9 3 3 3 4 - 4 150-360 27 22 22 4 27 - 3 3 3 3 3 4 3 3 9 9 9 9 3 3 3 4 - 4 200-280 28 24 24 4 28 - 3 3 3 3 3 5 3 3 11 11 11 11 3 3 3 4 - 4

B05L 150-450 29 23 23 5 29 - 3 3 3 4 3 5 3 3 10 12 10 12 3 3 3 5 - 5

150-501 32 27 27 5 32 - 3 3 3 3 3 6 3 3 11 11 11 11 3 3 3 5 - 5 200-360 30 25 25 5 30 - 3 3 3 4 3 4 3 3 12 13 12 13 3 3 3 5 - 5 200-401 33 28 28 5 33 - 3 3 3 3 3 7 3 3 14 14 14 14 3 3 3 5 - 5 200-450 31 26 26 5 31 - 3 3 3 4 3 5 3 3 12 13 12 13 3 3 3 5 - 5 200-501 34 29 29 5 34 - 3 3 3 3 3 6 3 3 15 15 15 15 3 3 3 5 - 5 250-401 35 30 30 5 35 - 3 3 3 3 3 7 3 3 16 16 16 16 3 3 3 5 - 5 250-501 36 31 31 5 36 - 3 3 3 3 3 6 3 3 17 17 17 17 3 3 3 5 - 5 300-400 41 36 36 5 41 - 3 3 3 3 3 7 3 3 21 22 21 22 3 3 3 5 - 5 300-500 42 37 37 5 42 - 3 3 3 3 3 8 3 3 25 26 25 26 3 3 3 5 - 5

B06 150-630 37 32 32 6 37 1 4 4 4 4 4 8 4 4 18 19 18 19 4 4 4 6 1 -

200-670 38 33 33 6 38 1 4 4 4 4 4 9 4 4 20 20 20 20 4 4 4 6 1 -

Impeller nut

922.01

58 of 76

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Page 59

7 Servicing/Maintenance

Part description

Volute casing

Casing cover, uncooled

Casing cover, cooled

Part No.

Shaft

Impeller

Impeller hub cap

Angular contact ball bearing

Cylindrical roller bearing

Bearing bracket

Bearing cover, pump end

Bearing cover, motor end

Joint ring

Mechanical seal

Seal cover

Casing wear ring, suction side

Casing wear ring, discharge side

Impeller wear ring, suction side

Impeller, discharge side

Thrower, pump end

Thrower, motor end

Oil thrower

Throttling bush

Impeller screw

Impeller nut

Bearing bracket

250-630 39 34 34 6 39 1 4 4 4 4 4 8 4 4 21 22 21 22 4 4 4 6 1 250-710 40 35 35 6 40 1 4 4 4 4 4 9 4 4 23 24 23 24 4 4 4 6 1 300-630 43 36 36 6 43 1 4 4 4 4 4 9 4 4 27 28 27 28 4 4 4 6 1 350-400 44 37 37 7 44 1 4 4 4 4 4 7 4 4 29 30 27 31 4 4 4 6 1 350-500 45 38 38 6 45 1 4 4 4 4 4 9 4 4 29 29 27 27 4 4 4 6 1 350-630 46 36 36 6 46 1 4 4 4 4 4 8 4 4 32 32 33 33 4 4 4 6 1 -

B07 350-710 47 37 37 8 47 1 5 5 5 5 5 10 5 5 34 34 35 35 5 5 5 7 1 -

400-504 48 38 38 8 48 1 5 5 5 5 5 11 5 5 34 34 35 35 5 5 5 7 1 400-506 49 38 38 8 49 1 5 5 5 5 5 11 5 5 36 36 37 37 5 5 5 7 1 400-710 50 37 37 8 50 1 5 5 5 5 5 10 5 5 38 39 37 40 5 5 5 7 1 -

Pump size

102

161

210

230

260

320.02

322.01

330

360.01

360.02

411.10

433

471.01

502.01

502.02

503.01

503.02

507.01

507.02

508.01

542.01

906

922.01

RPH

59 of 76

Page 60

8 Trouble-shooting

WARNING

Improper remedial work on the pump (set) Risk of injury!

▷ For any work performed in order to remedy faults on the pump (set) observe

the relevant information given in this operating manual or the product literature provided by the accessories manufacturers.

Table 23: Trouble-shooting

A B C D E F G H Possible cause

✘

✘ ✘

✘

✘ ✘ Pump or piping are not completely

✘ ✘ Suction lift is too high/NPSH

✘ ✘

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

Pump delivers insufficient flow rate

Motor is overloaded

Excessive pump discharge pressure

Increased bearing temperature

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Impermissible rise of temperature inside the pump

Pump delivers against an excessively high pressure.

vented or primed. Supply line or impeller clogged Remove deposits in the pump and/or piping.

Formation of air pockets in the piping Alter piping layout.

(positive suction head) is too low.

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

Wrong direction of rotation Check the electrical connection of the motor

Speed is too low.

- Operation with frequency inverter

- Operation without frequency inverter

Impeller Replace worn components by new ones. Pump back pressure is lower than

specified in the purchase order.

Density or viscosity of fluid handled higher than stated in purchase order

24)

available

Remedy

23)

Re-adjust to duty point. Check system for impurities. Fit a larger impeller.

24)

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

Fit vent valve. 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.

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

- Check voltage.

Re-adjust to duty point. In the case of persistent overloading, turn down impeller.

24)

Contact KSB.

23)

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

24)

Contact KSB.

60 of 76

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Page 61

8 Trouble-shooting

A B C D E F G H Possible cause

✘ ✘

✘

✘ ✘

✘

✘ ✘ ✘ ✘

✘

Speed is too high. Defective gasket Fit new gasket between volute casing and

Worn shaft seal Fit new shaft seal.

Vibrations during pump operation Correct suction conditions.

The pump set is misaligned. Re-align. Pump is warped or sympathetic

vibrations in the piping.

✘

Insufficient or excessive quantity of lubricant or unsuitable lubricant. Non-compliance with specified coupling distance Motor is running on two phases only. Replace the defective fuse.

✘

Rotor out of balance Clean the impeller.

✘

Defective bearing(s) Fit new bearing(s).

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

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

Remedy

Reduce speed.

discharge cover.

Check flushing liquid/barrier fluid.

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

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

Correct distance according to general arrangement drawing.

Check the electric cable connections.

Re-balance the impeller.

23)

24)

23)

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

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61 of 76

Page 62

D01040/3

411.67

931.02

922.01

503.01

502.01

904.38

940.01

102

411.31

904.04

904.07

330

914.01

904.41

400.01

902.01

931.01

920.01

916.16

920.21

411.32

904.42

485.02

901.37

904.37

412.22

360.01

913.03 720-12

638

69-10

831.02

642

940.02

210

832

901.80

901.84

550.74

904.43

744.07

525.09

507.02

360.02

916.46

507.01

322.01

902.15

920.15

320.02 550

412.31

920.02

412.01

901.30

902.02

901.31

916.19

916.18

904.06

710.21

901.20

904.03

920.20

550.20

724.01

411.41

723.21

723.23

502.02

902.42

920.42

550.42

542.02

411.10

411.01

503.02

230

9 Related Documents

9.1 General assembly drawing with list of components

Fig. 14: Bearing brackets B02 to B05, a) uncooled and b) cooled

62 of 76

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Page 63

D01042/3

931.02

260

550.87 906

411.31

503.01

502.01 102

904.07

904.04

940.01

904.38

916.16

902.01

920.01

161

904.41 330

914.01

400.01

360.01

913.03

411.32

642

169-10 638

931.01

920.21

901.37

831.02

904.42

412.22

904.37

210

485.02

940.02

901.20

920.20

710.21

904.03

724.01

723.21

411.41

744.07

550.20

230

904.06

723.23

902.42

550.42

920.42

411.01

503.02

502.02

542.02

411.10

916.18

916.19

412.01

901.30

412.31

902.15

920.02

901.31

920.15

902.02

320.02

322.01

916.46

525.09

507.01

832

550.74

904.43

901.80

360.02

507.02

901.84

9 Related Documents

Fig. 15: Bearing brackets B06 and B07, a) uncooled and b) cooled

Table 24: List of components

Part No. Comprising Description

102 102 Volute casing

411.10 Joint ring

502.01 Casing wear ring

902.01 Stud

904.03 Grub screw

25)

916.01

920.01 Hexagon nut

Plug

161 161 Casing cover

411.10 Joint ring

412.01/.31

33)

502.02

26)

O-ring Casing wear ring

901.30 Hexagon head bolt

902.15 Stud

904.04

33)

Grub screw

916.16 Plug

920.15 Hexagon nut

210 210 Shaft

920.21 Slotted round nut

931.01 Lock washer

940.01/.02 Key

230 230 Impeller

931.02 Lock washer

25)

Not shown in drawing

26)

For cooled design only

RPH

63 of 76

Page 64

9 Related Documents

Part No. Comprising Description

503.01/.02 Impeller wear ring

904.06/.07 Grub screw

27)

260

29)

411.31

/.32

/.67

27)28)

260 Impeller hub cap

Joint ring

550.87 Disc 906 Impeller screw

320.02/550

30)

320.02

32)

550

31)

Angular contact ball bearing Adjusting washer

322.01 322.01 Cylindrical roller bearing 330 330 Bearing bracket

69.10 Protective cage

360.01/.02 Bearing cover

400.01 Gasket

412.22 O-ring 638 Constant level oiler 642 Oil level sight glass

710.21 Pipe

901.31/.37 Hexagon head bolt

913.03 Vent plug

916.46 Plug

914.01 Hexagon socket head cap screw

360.01/.02 360.01/.02 Bearing cover

400.01 Gasket

412.22 O-ring

914.01 Hexagon socket head cap screw

33)

502.01/.02

503.01/.02

502.01/.02 Casing wear ring

904.03/.04

33)

503.01/.02 Impeller wear ring

904.06/.07

33)

Grub screw

507.01/.02 507.01/.02 Thrower

904.41/.42 Grub screw

542.02 542.02 Throttling bush

904.38 Grub screw 638 638 Constant level oiler 70-3

28)

70-3 Drain line

411.01 Joint ring

902.42 Stud

920.42 Hexagon nut

550.42 Disc

723.23 Flange

744.07 Gate valve

710.21 Pipe

723.21 Flange

411.41 Joint ring

724.01 Blind flange

901.20 Hexagon head bolt

920.20 Hexagon nut

550.20 Disc

831.02

28)

831.02 Fan impeller

832 Fan hood

485.02 Fan hub

27)

For bearing brackets B02 to B05 only

28)

Optional

29)

For bearing brackets B06 and B07 only

30)

For bearing brackets B03 and B05 only

31)

For bearing brackets B03 and B05 only

32)

For bearing brackets B03 and B05 only

33)

For impellers with balancing of axial thrust only

64 of 76

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Page 65

D01040/3

411.67

931.02

922.01

503.01

502.01

904.38

940.01

102

411.31

904.04

904.07 330

914.01

904.41

400.01

902.01

931.01

920.01

916.16

920.21

411.32

904.42

485.02

901.37

904.37

412.22

360.01

913.03 720-12

638

69-10

831.02

642

940.02

210

832

901.80

901.84

550.74

904.43

744.07

525.09

507.02

360.02

916.46

507.01

322.01

902.15

920.15

320.02 550

412.31

920.02

412.01

901.30

902.02

901.31

916.19

916.18

904.06

710.21

901.20

904.03

920.20

550.20

724.01

411.41

723.21

723.23

502.02

902.42

920.42

550.42

542.02

411.10

411.01

503.02

230

9 Related Documents

Part No. Comprising Description

904.37 Grub screw

922.01

27)

922.01 Impeller nut

931.02 Lock washer

99-9

25)

99-9

25)

Set of sealing elements, complete

9.1.1 Bearing brackets B02 to B05

Fig. 16: Bearing brackets B02 to B05, a) uncooled and b) cooled

Table 25: List of components, bearing brackets B02 to B05

Part No. Comprising Description

102 102 Volute casing

411.10 Joint ring

502.01 Casing wear ring

902.01 Stud

904.03 Grub screw

916.01

34)

Screw plug

920.01 Hexagon nut

161 161 Casing cover

411.10 Joint ring

412.01/.31

33)

502.02

35)

O-ring Casing wear ring

901.30 Hexagon head bolt

902.15 Stud

34)

Not shown in drawing

35)

For cooled design only

904.04

33)

Grub screw

RPH

65 of 76

Page 66

9 Related Documents

Part No. Comprising Description

916.16 Screw plug

920.15 Hexagon nut

210 210 Shaft

920.21 Slotted round nut

931.01 Lock washer

940.01/.02 Key

230 230 Impeller

931.02 Lock washer

503.01/.02 Impeller wear ring

904.06/.07 Grub screw

320.02/550

411.31/.32/.67

37)

Angular contact ball bearing with disc 550 (adjusting washer)

36)

Joint ring

322.01 322.01 Cylindrical roller bearing 330 330 Bearing bracket

69.10 Protective cage

360.01/.02 Bearing cover

400.01 Gasket

412.22 O-ring 638 Constant level oiler 642 Oil level sight glass

710.21 Pipe

901.31/.37 Hexagon head bolt

913.03 Vent plug

916.46 Screw plug

914.01 Hexagon socket head cap screw

360.01/.02 360.01/.02 Bearing cover

400.01 Gasket

412.22 O-ring

914.01 Hexagon socket head cap screw

38)

502.01/.02

503.01/.02

502.01/.02 Casing wear ring

904.03/.04

33)

503.01/.02 Impeller wear ring

904.06/.07

33)

Grub screw

507.01/.02 507.01/.02 Thrower

904.41/.42 Grub screw

542.02 542.02 Throttling bush

904.38 Grub screw 638 638 Constant level oiler 70-3

28)

70-3 Drain line

411.01 Joint ring

902.42 Stud

920.42 Hexagon nut

550.42 Disc

723.23 Flange

744.07 Gate valve

710.21 Pipe

723.21 Flange

411.41 Joint ring

724.01 Blind flange

901.20 Hexagon head bolt

920.20 Hexagon nut

550.20 Disc

831.02

28)

831.02 Fan impeller

832 Fan hood

485.02 Fan hub

904.37 Grub screw

36)

Optional

37)

For bearing brackets B03 and B05 only

38)

For impellers with balancing of axial thrust only

66 of 76

RPH

Page 67

D01042/3

931.02

260

550.87 906

411.31

503.01

502.01 102

904.07

904.04

940.01

904.38

916.16

902.01

920.01

161

904.41 330

914.01

400.01

360.01

913.03

411.32

642

169-10 638

931.01

920.21

901.37

831.02

904.42

412.22

904.37

210

485.02

940.02

901.20

920.20

710.21

904.03

724.01

723.21

411.41

744.07

550.20

230

904.06

723.23

902.42

550.42

920.42

411.01

503.02

502.02

542.02

411.10

916.18

916.19

412.01

901.30

412.31

902.15

920.02

901.31

920.15

902.02

320.02

322.01

916.46

525.09

507.01

832

550.74

904.43

901.80

360.02

507.02

901.84

9 Related Documents

Part No. Comprising Description

922.01 922.01 Impeller nut 99-9

25)

99-9

25)

Set of sealing elements, complete

9.1.2 Bearing brackets B06 and B07

Fig. 17: Bearing brackets B06 and B07, a) uncooled and b) cooled

Table 26: List of components for pumps sets with bearing brackets B06 and B07

Part No. Comprising Description

102 102 Volute casing

411.10 Joint ring

502.01 Casing wear ring

902.01 Stud

904.03 Grub screw

916.01

39)

Screw plug

920.01 Hexagon nut

161 161 Casing cover

411.10 Joint ring

412.01/.31

41)

502.02

40)

O-ring Casing wear ring

901.30 Hexagon head bolt

902.15 Stud

904.04

41)

Grub screw

916.16 Screw plug

39)

Not shown in drawing

40)

For cooled design only

41)

For impellers with balancing of axial thrust only

RPH

67 of 76

Page 68

9 Related Documents

Part No. Comprising Description

920.15 Hexagon nut

210 210 Shaft

920.21 Slotted round nut

931.01 Lock washer

940.01/.02 Key

230 230 Impeller

503.01/.02 Impeller wear ring

904.06/.07 Grub screw

411.31/.32

42)

Joint ring

260 260 Impeller hub cap

320.02 320.02 Angular contact ball bearing

322.01 322.01 Cylindrical roller bearing 330 330 Bearing bracket

69.10 Protective cage

360.01/.02 Bearing cover

400.01 Gasket

412.22 O-ring 638 Constant level oiler 642 Oil level sight glass

710.21 Pipe

901.31/.37 Hexagon head bolt

913.03 Vent plug

916.46 Screw plug

914.01 Hexagon socket head cap screw

360.01/.02

33)

360.01/.02

33)

Bearing cover

400.01 Gasket

412.22 O-ring

914.01 Hexagon socket head cap screw

502.01/.02

33)

502.01/.02

904.03/.04

33)

41)

Casing wear ring Grub screw

503.01/.02 503.01/.02 Impeller wear ring

904.06/.07

41)

Grub screw

507.01/.02 507.01/.02 Thrower

904.41/.42 Grub screw

542.02 542.02 Throttling bush

904.38 Grub screw

550.87 550.87 Disc 638 638 Constant level oiler 70-3

42)

70-3

42)

Drain line

411.01 Joint ring

902.42 Stud

920.42 Hexagon nut

550.42 Disc

723.23 Flange

744.07 Gate valve

710.21 Pipe

723.21 Flange

411.41 Joint ring

24.01 Blind flange

901.20 Hexagon head bolt

920.20 Hexagon nut

550.20 Disc

831.02

42)

831.02

42)

Fan impeller

832 Fan hood

485.02 Fan hub

904.37 Grub screw

906 906 Impeller screw

42)

Optional

68 of 76

RPH

Page 69

D01044

D01047

904.20

508.01

916.01

D01044

9 Related Documents

Part No. Comprising Description

931.02 931.02 Lock washer 99-9

39)

99-9

39)

Set of sealing elements, complete

9.1.3 Design variants

Table 27: Design variants

Design Detailed view

Design with coolable bearing bracket

Design with thrower

Design with plug

Design with welded drain

69 of 76

RPH

Page 70

D01043

320.02

D01126

23-2

9 Related Documents

Design Detailed view

Design with bearings in tandem arrangement

Design with heatable casing

Design with auxiliary impeller

70 of 76

RPH

Page 71

10 EC 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 13709

Person authorised to compile the technical file:

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

The EC Declaration of Conformity was issued in/on:

Place, date

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

43)

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

Name

Function

Company

Address

RPH

43)

A signed, legally binding declaration of conformity is supplied with the product.

RPH

71 of 76

Page 72

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.

On seal-less pumps, the rotor has been removed from the pump for cleaning.

 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

44)

   

Harmful Bio-hazardous Highly flammable Safe

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

44)

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

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

44)

Required fields

72 of 76

RPH

Page 73

Index

Abrasive fluids 38 Auxiliary connections 24

Back pull-out unit 47 Bearing temperature 42 Bearings 17

Certificate of decontamination 72 Clearances 43 Commissioning/start-up 29 Constant level oiler 29 Coupling 42

Design 16, 18 Designation 16 Direction of rotation 28 Disassembly 46 Disposal 15

Explosion protection 10, 20, 24, 25, 26, 27, 32, 33, 34, 36, 37, 40, 41, 42, 44

Filter 22, 44 Final check 32 Flow rate 37 Fluid handled

Density 38 Frequency of starts 37 Function 18

List of components 63, 65, 67

Maintenance 40 Mechanical seal 35 Misuse 9 Monitoring equipment 11

Name plate 16 Noise characteristics 19

Oil lubrication

Intervals 44

Oil quality 44 Operating limits 8, 36 Order number 6 Ordering spare parts 57 Other applicable documents 6

Partly completed machinery 6 Piping 22 Preservation 14, 38 Priming and venting 32 Product description 16 Pump casing 17

Return to supplier 14 Returning to service 39 Running noises 41, 42

Heating 34 Heating speed 34 Heating up 34

Impeller type 17 Installation

Installation on a foundation 20 Installation at site 20 Intended use 8 Interchangeability of pump components 58

Keeping warm 34

RPH

Safety 8 Safety awareness 9 Scope of supply 19 Shaft seal 17 Shutdown 35, 38 Start-up 35 Storage 14, 38

Temperature difference 34 Temperature limits 11 Tightening torques 53 Transport 13 Trouble-shooting 60

73 of 76

Page 74

Water cooling 32

Index

74 of 76

RPH

Page 75

Page 76

KSB Aktiengesellschaft

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

1316.8014/06-EN (01316772)

KSB RPH Installation & Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Glossary

1 General

Target group

Other applicable documents

2 Safety

2.10.1 Marking

Temperature limits

2.10.3 Monitoring equipment

2.10.4 Operating limits

3 Transport/Temporary Storage/Disposal

Transport

Return to supplier

4 Description of the Pump (Set)

5 Installation at Site

5.3.1 Installation on a foundation

5.4.1 Connecting the piping

5.4.2 Permissible forces and moments at the pump nozzles

5.4.3 Auxiliary connections

5.8.1 Connecting the motor

Checking the direction of rotation

6 Commissioning/Start-up/Shutdown

6.1.1 Prerequisites for commissioning/start-up

Filling in the lubricant

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 pump

6.1.8 Cooling of the shaft seal

6.1.8.1 Cooling of the heat exchanger

6.1.9 Heating

6.1.10 Heating up/keeping warm the pump (set)

6.1.11 Start-up

6.1.12 Checking the shaft seal

6.1.13 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 gaps

7.2.2.3 Cleaning filters

7.2.3 Lubrication and lubricant change of rolling element bearings

7.2.3.1 Oil 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

7.4.5.1 Loosening the impeller — for bearing brackets B02 to B05

7.4.5.2 Loosening the impeller — for bearing brackets B06 and B07

7.4.5.3 Removing the impeller — for all bearing bracket sizes

7.4.6 Removing the cartridge seal

7.4.7 Dismantling the bearings

7.5.1 General information/Safety regulations

7.5.2 Fitting the bearings

7.5.3 Fitting the shaft seal

7.5.3.1 Installing the cartridge seal

7.5.4 Fitting the impeller

7.5.4.1 Fitting the impeller — for all bearing bracket sizes

7.5.4.2 Fastening the impeller — for bearing brackets B02 to B05

7.5.4.3 Fastening the impeller — for bearing brackets B06 and B07

7.5.5 Installing the back pull-out unit

Mounting the motor

7.6.1 Tightening torques of the pump

7.7.1 Ordering spare parts

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

7.7.3 Interchangeability of pump components

8 Trouble-shooting

9 Related Documents

9.1.1 Bearing brackets B02 to B05