KSB Sewatec Operating Manual

Dry-installed Volute Casing Pump

Sewatec (60 Hz)

60 Hz
ASME / NEMA Motors
Bearing Brackets S01, S02, S03, S04

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual Sewatec (60 Hz)

Original operating manual

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

Subject to technical modification without prior notice.

© KSB SE & Co. KGaA, Frankenthal 4/4/2018

Contents

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Contents

Glossary .................................................................................................................................................. 5

1 General.................................................................................................................................................... 6

1.1 Principles ...........................................................................................................................................................6

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

1.3 Target group.....................................................................................................................................................6

1.4 Other applicable documents............................................................................................................................6

1.5 Symbols .............................................................................................................................................................6

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

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

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

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

2.4 Personnel qualification and personnel training.............................................................................................9

2.5 Consequences and risks caused by non-compliance with these operating instructions ............................10

2.6 Safety awareness ............................................................................................................................................10

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

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

2.9 Unauthorized modes of operation................................................................................................................11

2.10 Explosion protection ......................................................................................................................................11

3 Transport/Temporary Storage/Disposal............................................................................................. 12

3.1 Checking the condition upon delivery..........................................................................................................12

3.2 Transport.........................................................................................................................................................12

3.3 Storage/Preservation ......................................................................................................................................13

3.4 Return to supplier...........................................................................................................................................13

3.5 Disposal ...........................................................................................................................................................14

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

4.1 General description ........................................................................................................................................15

4.2 Designation.....................................................................................................................................................15

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

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

4.5 Configuration and function...........................................................................................................................17

4.6 Noise characteristics .......................................................................................................................................17

4.7 Scope of supply...............................................................................................................................................18

4.8 Dimensions and weights ................................................................................................................................18

5 Installation at Site................................................................................................................................ 19

5.1 Safety regulations...........................................................................................................................................19

5.2 Checks prior to installation............................................................................................................................19

5.3 Installing the pump set in a horizontal position ..........................................................................................19

5.4 Piping ..............................................................................................................................................................21

5.4.1 Connecting the piping.......................................................................................................................21

5.4.2 Permissible forces and moments at the pump nozzles....................................................................22

5.4.3 Vacuum balance line..........................................................................................................................25

5.5 Auxiliary connections .....................................................................................................................................25

5.6 Checking the coupling alignment .................................................................................................................26

5.7 Aligning the pump and motor ......................................................................................................................27

5.7.1 Motors with adjusting screw.............................................................................................................28

5.8 Checking the lubricant level ..........................................................................................................................28

5.9 Electrical connection ......................................................................................................................................29

5.10 Checking the direction of rotation................................................................................................................30

5.11 Priming and venting the pump .....................................................................................................................30

5.12 Protective equipment.....................................................................................................................................31

5.13 Connecting the vibration sensor ...................................................................................................................31

5.14 Connecting temperature measuring devices................................................................................................31

Contents

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5.15 Warning values and cut-out values...............................................................................................................31

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

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

6.1.1 Prerequisites for commissioning/start-up ......................................................................................... 33

6.1.2 Start-up............................................................................................................................................... 33

6.1.3 Shutdown ...........................................................................................................................................34

6.2 Operating limits..............................................................................................................................................34

6.2.1 Maximum operating pressure ........................................................................................................... 35

6.2.2 Frequency of starts.............................................................................................................................36

6.2.3 Fluid handled .....................................................................................................................................36

6.3 Shutdown/storage/preservation ....................................................................................................................37

6.4 Returning to service after storage.................................................................................................................37

7 Servicing/Maintenance........................................................................................................................ 38

7.1 Safety regulations...........................................................................................................................................38

7.2 Maintenance/inspection.................................................................................................................................39

7.2.1 Supervision of operation ................................................................................................................... 39

7.2.2 Visual inspection through the inspection hole ................................................................................39

7.2.3 Lubrication and lubricant change.....................................................................................................41

7.3 Drainage/disposal ...........................................................................................................................................43

7.4 Dismantling the pump set..............................................................................................................................44

7.4.1 General information/Safety regulations...........................................................................................44

7.4.2 Preparations for dismantling ............................................................................................................44

7.4.3 Separating the pump from the piping .............................................................................................45

7.4.4 Removing the back pull-out unit ...................................................................................................... 45

7.4.5 Removing the impeller ......................................................................................................................46

7.4.6 Removing the mechanical seals ........................................................................................................48

7.4.7 Removing the shaft and rolling element bearings .......................................................................... 49

7.4.8 Removing the wear plate (for D impellers only)..............................................................................50

7.5 Reassembling the pump set...........................................................................................................................50

7.5.1 General information/Safety regulations...........................................................................................50

7.5.2 Re-installing shaft and rolling element bearings.............................................................................51

7.5.3 Installing the mechanical seal ...........................................................................................................51

7.5.4 Fitting the impeller ............................................................................................................................55

7.5.5 Installing the back pull-out unit .......................................................................................................57

7.5.6 Leak test .............................................................................................................................................58

7.5.7 Mounting the motor..........................................................................................................................58

7.6 Tightening torques.........................................................................................................................................59

7.7 Spare parts stock.............................................................................................................................................59

7.7.1 Ordering spare parts.......................................................................................................................... 59

7.7.2 Recommended spare parts stock for 2 years' operation to DIN24296...........................................59

8 Trouble-shooting.................................................................................................................................. 61

9 Related Documents.............................................................................................................................. 63

9.1 General assembly drawing: Sewatec with bearing brackets S01, S02, S03, S04 .........................................63

9.2 Detailed views.................................................................................................................................................64

9.2.1 Impeller types..................................................................................................................................... 64

9.2.2 Inspection hole, bearing brackets S01 to S04...................................................................................65

9.3 Exploded view: Sewatec with bearing brackets S01, S02, S03, S04.............................................................66

10 EU Declaration of Conformity............................................................................................................. 67

11 Certificate of Decontamination........................................................................................................... 68

Index ..................................................................................................................................................... 69

Glossary

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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.

Certificate of decontamination

If a product is to be returned to the manufacturer,
the customer declares in a certificate of
decontamination that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.

Discharge line

The pipeline which is connected to the discharge
nozzle

Hydraulic system

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

Pump

Machine without drive, additional components or
accessories

Pump set

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

Suction lift line/suction head line

The pipeline which is connected to the suction
nozzle

1 General

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1 General

1.1 Principles

This operating manual is valid for the type series and variants indicated on the front
cover.

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

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

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

1.2 Installation of partly completed machinery

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

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.4,Page9)

1.4 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Data sheet Description of the technical data of the pump (set)

General arrangement drawing/
outline drawing

Description of mating and installation dimensions
for the pump (set), weights

Drawing of auxiliary connections Description of auxiliary connections

Hydraulic characteristic curve Characteristic curves showing head, NPSH req,

efficiency and power input

General assembly drawing

1)

Sectional drawing of the pump (set)

Sub-supplier product literature1)Operating manuals and other product literature

of accessories and integrated machinery
components

Spare parts lists

1)

Description of spare parts

Piping layout

1)

Description of auxiliary piping

List of components

1)

Description of all pump components

Assembly drawing

1)

Sectional drawing of the shaft seal

For accessories and/or integrated machinery components observe the product
literature of the corresponding manufacturer.

1.5 Symbols

Table2: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳ Safety instructions

⇨ Result of an action

⇨ Cross-references

1) If agreed to be included in the scope of supply

1 General

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Symbol Description

1.

2.

Step-by-step instructions

Note
Recommendations and important information on how to handle
the product

2 Safety

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2 Safety

!

DANGER

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

In addition to the present general safety information the action-related safety
information given in the other sections must be observed.

2.1 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

!

DANGER

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

!

WARNING

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

CAUTION

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

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

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

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

2.2 General

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

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

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

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

Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:

▪ Arrow indicating the direction of rotation

▪ Markings for connections

▪ Name plate

The operator is responsible for ensuring compliance with all local regulations which
are not taken into account.

2.3 Intended use

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

other applicable documents.

▪ Only operate pump sets which are in perfect technical condition.

▪ Do not operate partially assembled pump sets.

▪ Only use the pump set to handle the fluids described in the data sheet or product

literature of the pump variant.

▪ Never operate the pump set without the fluid to be handled.

2 Safety

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▪ Observe the limits for continuous duty specified in the data sheet or product

literature (Q

min

and Q

max

) (to prevent damage such as shaft fracture, bearing

failure, mechanical seal damage, etc).

▪ When untreated waste water is handled, the duty points in continuous operation

lie within 0.7 to 1.2×Q

opt

to minimize the risk of clogging/hardening.

▪ Avoid duty points for continuous operation at very low speeds and small flow

rates (<0.7xQ

opt

).

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

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

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

cavitation damage).

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

the data sheet or product literature.

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

below.

Free-flow impeller
(impeller type F/F-max)

Closed single-channel impeller
(impeller type E/E-max)

Open, diagonal single-vane impeller
(impeller type D)

Closed multi-channel impeller
(impeller type K/K-max)

Prevention of foreseeable misuse

▪ Observe the minimum flow velocities required to fully open the swing check

valves to prevent the reduction of pressure and risk of clogging.
(Contact the manufacturer for the required minimum flow velocities/loss
coefficients.)

▪ Never exceed the permissible operating limits and use limits specified in the data

sheet or product literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and personnel training

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

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

Deficits in knowledge must be rectified by sufficiently trained specialist personnel
training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.

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

2 Safety

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2.5 Consequences and risks caused by non-compliance with these operating
instructions

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

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

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

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

effects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

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

▪ Accident prevention, health regulations and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the operator/user

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

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

▪ Do not remove any protective equipment (e.g. contact guards) while the pump is

in operation. The only exception is the guard of the gland packing chamber.

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

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

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

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

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

▪ If shutting down the pump does not increase potential risk, fit an emergency

stop control device in the immediate vicinity of the pump (set) during pump set
installation.

2.8 Safety information for maintenance, inspection and installation

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

manufacturer's prior consent.

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

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

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

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

▪ Only carry out work on the pump (set) during standstill of the pump.

▪ Only perform work on the pump set when it has been disconnected from the

power supply (de-energized).

▪ The pump (set) must have cooled down to ambient temperature.

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

2 Safety

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

described in the manual.

▪ Decontaminate pumps which handle fluids posing a health hazard.

(ðSection7.3,Page43)

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

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

2.9 Unauthorized modes of operation

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

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

2.10 Explosion protection

Special conditions apply to the operation of explosion‑proof pumps.

▪ The explosion-proof status of the pump set is only assured if the pump set is used

in accordance with its intended use.

▪ The limits stated in the data sheet and on the name plate must not be exceeded

under any circumstances.

▪ Correct monitoring of the motor temperature is imperative to ensure explosion

protection.

▪ Observe the wiring diagrams.

▪ Never operate an explosion-proof pump set without temperature monitoring.

▪ Modifications or alteration of the pump set could affect explosion protection and

are only permitted after consultation with the manufacturer.

▪ Only original spare parts and accessories authorized by the manufacturer must be

used for explosion-proof pumps.

3 Transport/Temporary Storage/Disposal

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3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and

notify KSB or the distributor and the insurance company about the damage in
writing immediately.

3.2 Transport

DANGER

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

Danger to life from falling parts!

▷ Only transport the pump (set) in the position indicated.

▷ Never attach the suspension arrangement to the free shaft end or the motor

eyebolt.

▷ Pay attention to the weight data, center of gravity and fastening points.

▷ Comply with the applicable local accident prevention regulations.

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

WARNING

Uncontrolled lifting of pump/drive/pump set

Risk of personal injury!

▷ Maintain sufficient safety distance when lifting the pump set (which may swing

when pulled upright).

WARNING

Placing the pump set down on unsecured and uneven surfaces

Personal injury and damage to property!

▷ Only place the pump set on a surface of sufficient load-carrying capacity.

▷ Use appropriate means to secure the pump set against tilting or tipping over.

To transport the pump/pump set suspend it as illustrated.

Table4: Transport options

Transporting a bare-shaft pump Transporting the pump set in a vertical

position

3 Transport/Temporary Storage/Disposal

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Transporting the pump set on the

baseplate

Transporting a bare-shaft 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 due to humidity, dirt or vermin

Corrosion/contamination of the pump (set)!

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

accessories with waterproof material.

CAUTION

Wet, contaminated or damaged openings and connections

Leakage or damage to the pump!

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

the pump into storage.

Table5: Ambient conditions for storage

Ambient condition Value

Relative humidity 5% to 85%

(non-condensing)

Ambient temperature -4°F to 158°F [- 20°C to +70°C]

▪ Store the pump set under dry and vibration-free conditions, if possible in its

original packaging. (ðSection6.3,Page37)

1. Spray-coat the inside wall of the pump casing and, in particular, the impeller

clearance areas with a preservative.

2. Spray preservative through the suction nozzle and discharge nozzle.

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

NOTE

Observe the manufacturer's instructions for application/removal of the preservative.

3.4 Return to supplier

1. Drain the pump as per operating instructions. (ðSection7.3,Page43)

2. Flush and clean the pump, particularly if it has been used for handling noxious,

explosive, hot or other hazardous fluids.

3. If the pump has handled fluids whose residues could lead to corrosion damage

in the presence of atmospheric humidity or could ignite upon contact with
oxygen, the pump must also be neutralized, and anhydrous inert gas must be
blown through the pump to ensure drying.

4. Always complete and enclose a certificate of decontamination when returning

the pump.
Always indicate any safety measures and decontamination measures taken.

(ðSection11,Page68)

3 Transport/Temporary Storage/Disposal

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

Hazard to persons and the environment!

▷ Collect and properly dispose of the flushing fluid and of any residues of the

fluid handled.

▷ Wear safety clothing and a protective mask if required.

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

1. Dismantle the pump (set).

Collect greases and other lubricants during dismantling.

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

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

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

controlled manner.

4 Description of the Pump (Set)

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4 Description of the Pump (Set)

4.1 General description

Pump for handling untreated sewage and all types of waste water.

▪ Volute casing pump with single-vane, multi-channel, free flow or open diagonal

single-vane impeller

▪ Electric motor connected to the pump via a coupling or universal-joint shaft

Table6: Types of installation

Type of
installation

Illustration Description

Figure 0 Bare-shaft pump

Figure 3EN
Figure 3ENH

Pump set with directly coupled motor,
baseplate, coupling (also with coupling
spacer), coupling guard and height
adjustment of the motor

Figure V Pump with bare-shaft at the drive end,

soleplate and suction elbow

4.2 Designation

Example: Sewatec F100-250GV

Table7: Designation key

Code Description

Sewatec Type series

F Impeller type

100 Nominal discharge nozzle diameter [mm]

250 Nominal impeller diameter [mm]

G Material variant

V Installation type

4 Description of the Pump (Set)

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4.3 Name plate

Johann-Klein-Straße 9

Deutschland

67227 Frankenthal

KSB SE & Co. KGaA

2008

Sewatec D 300 - 400
P-No. 9971423078 / 000100

Q 306,44 GPM H 5,29 ft
n 983 rpm SNr. 24 15 26

Mat.-No. 00 117 385

ZN3804 - C37x52

1

2

3

4

5

6

7

8

Fig.1: Name plate (example)

1 Designation of the pump set 2 Order number

3 Flow rate 4 Speed

5 Year of supply 6 Order item number

7 Head 8 Serial number

4.4 Design details

Design

▪ Volute casing pump

▪ Back pull-out design

▪ Single-stage

▪ Various, application-oriented installation types

Shaft seal

▪ Two bi-directional mechanical seals in tandem arrangement, with liquid reservoir

Impeller type

▪ Various application-oriented impeller types

Bearings

▪ Maintenance-free deep groove ball bearings greased for life, pump end and

drive end

4 Description of the Pump (Set)

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4.5 Configuration and function

1

2 3 4 5

6

7 8 9 10

Fig.2: Sectional drawing with K impeller

1 Clearance gap 2 Discharge nozzle

3 Discharge cover 4 Shaft

5 Bearing bracket 6 Suction nozzle

7 Impeller 8 Shaft seal

9 Rolling element bearing 10 Rolling element bearing

Design

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 or belt drive.

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 casing into the suction nozzle. At the rear side
of the impeller, the shaft (4) enters the casing via the casing cover (3). The shaft
passage through the cover is sealed to atmosphere by a shaft seal (8). The shaft runs
in rolling element bearings (9 and 10) which are supported by a bearing bracket (5)
linked with the pump casing and/or casing cover.

Sealing

The pump is sealed by two bi-directional mechanical seals in tandem arrangement.
A lubricant chamber in-between the seals ensures cooling and lubrication of the
mechanical seals.

4.6 Noise characteristics

Table8: Surface sound pressure level L

pA

2)

Rated power input

P

N

Pump Pump set

1750 rpm 1160 / 875 rpm 1750 rpm 1160 / 875 rpm

[dB] [dB] [dB] [dB]

2 hp (1,5 kW) 52,0 51,0 56,5 55,0

3 hp (2,2 kW) 53,0 52,0 58,5 57,5

2) Measured at a distance of 3.28ft (1m) from the pump outline

4 Description of the Pump (Set)

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Rated power input

P

N

Pump Pump set

1750 rpm 1160 / 875 rpm 1750 rpm 1160 / 875 rpm

[dB] [dB] [dB] [dB]

4 hp (3,0 kW) 55,0 53,5 60,5 59,0

5 hp (4,0 kW) 57,0 55,0 62,0 60,0

7,5 hp (5,5 kW) 57,5 57,0 63,5 63,0

10 hp (7,5 kW) 58,5 57,5 65,0 63,5

15 hp (11,0 kW) 60,5 59,5 67,0 65,5

20 hp (15,0 kW) 61,5 60,5 68,0 66,5

25 hp (18,5 kW) 62,5 61,5 68,5 67,5

30 hp (22,0 kW) 63,5 62,5 69,0 68,0

40 hp (30,0 kW) 65,0 63,5 70,5 69,0

50 hp (37,0 kW) 65,5 64,5 71,0 69,5

4.7 Scope of supply

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

▪ Pump

▪ Drive

▪ Baseplate or soleplate

▪ Coupling

▪ Coupling guard

▪ Suction-side flanged spacer or suction elbow with inspection hole

▪ Universal-joint shaft

4.8 Dimensions and weights

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

▪ Pump weight: see pump name plate.

▪ Motor weight: see motor documentation.

▪ Weight of the shipping unit base frame with pump: see weight indicated on the

base frame.

▪ Weight of the shipping unit base frame with pump and motor: see weight

indicated on the base frame.

NOTE

Some individual components weigh more than 55 lbs (25 kg). Refer to the weights
indicated.

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Sewatec (60 Hz)

5 Installation at Site

5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheres

Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations.

▷ Observe the information given in the data sheet and on the pump/motor name

plates.

5.2 Checks prior to installation

Place of installation

WARNING

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

Personal injury and damage to property!

▷ Observe the required compressive strength class C12/15 of the concrete in

exposure class XC1 as per EN206-1.

▷ The mounting surface must be set, flat, and level.

▷ Observe the weights indicated.

1. Check the structural requirements.

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

5.3 Installing the pump set in a horizontal position

L

1

32

Fig.3: Installation on a foundation with chemical anchors

L Anchor-to-anchor distance 1 Shim

2 Shim for anchor-to-anchor distance

≥31.5inches(800mm)

3 Chemical

anchor

ü The foundation has the required strength and characteristics.

ü 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 align it with the help of a spirit

level placed on the shaft and discharge nozzle.
Permissible deviation: 0.0079 inch/m (0.2mm/m).

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

Always fit shims immediately to the left and right of the chemical anchors (3)
between the baseplate/foundation frame and the foundation itself.
For a bolt-to-bolt clearance (L) ≥ 31.5 inches (800 mm) fit additional shims (2)
halfway between the adjoining holes.
All shims must lie perfectly flush.

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Sewatec (60 Hz)

3. Drill the holes as specified in the table "Chemical anchor dimensions". Then

clean the holes.

WARNING

Improper handling of mortar cartridge

Skin sensitization and/or irritation!

▷ Wear suitable protective clothing.

4. Insert the mortar cartridges into the drilled holes.

Observe the curing times of the mortar cartridges!

5. Insert threaded rods into the corresponding drilled holes with an electric tool

(e.g. impact drill, hammer drill).

6. After the curing time (see table), tighten the chemical anchors (3) evenly and

tightly.

7. Grout the baseplate using low-shrinkage concrete.

Chemical anchor

dimensions

t

2

t

1

S

W

1

d

1

SW

2

d

2

l

1

Fig.4: Dimensions

Table9: Chemical anchor dimensions [″]

Size

(d1×l1)

d

2

t

1

t2SW

1

3)

SW

2

3)

M

d1

[″] [″] [″] [″] [″] [ft lb]

3

/8×5 1/8″

7

/

16

7

/83 9/

16

11

/

16

1

/414,75

7

/16×6 5/16″

9

/

16

1 4 5/

16

3

/

4

5

/1629,50

5

/8×71/2″

11

/161 3/84 15/

16

15

/

16

7

/1644,25

13

/16×101/4″ 1 2 9/166 11/161 3/

16

9

/1688,50

15

/16×1113/16″

4)

11/82 9/1681/41 7/

16

11

/16132,76

1 3/16×14 15/16″

4)

1 3/82 9/1611 1 13/

16

- 295,02

Table10: Chemical anchor dimensions [mm]

Size

(d1×l1)

d

2

t

1

t2SW

1

3)

SW

2

3)

M

d1

[mm] [mm] [mm] [mm] [mm] [Nm]

M10×130 12 22 90 17 6 20

M12×160 14 25 110 19 8 40

M16×190 18 35 125 24 12 60

M20×260 25 65 170 30 14 120

M24×300

4)

28 65 210 36 17 180

M30×380

4)

35 65 280 46 - 400

3) SW = Width across flats

4) Mounting accessories of the respective manufacturer are required.

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Sewatec (60 Hz)

Table11: Curing times of mortar cartridge

Floor temperature Curing time

[°F] [°C] [min]

23 to 32 -5 to 0 240

32 to 50 0 to +10 45

50 to 68 +10 to +20 20

> 68 > +20 10

5.4 Piping

NOTE

When installing pumps in a piping system prevent any resonances at the usual
excitation frequencies (1x and 2x rotational frequency, rotational noise) in the
foundation and in the connected piping. See DINISO10816-3.

5.4.1 Connecting the piping

DANGER

Impermissible loads acting on the pump nozzles

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

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

▷ Anchor the pipelines in close proximity to the pump and connect them properly

without transmitting any stresses or strains.

▷ Observe the permissible forces and moments at the pump nozzles.

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

NOTE

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

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

downward slope towards the pump.

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

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

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

diameters of the pump nozzles.

ü Adapters to larger nominal diameters are designed with a diffuser angle of

approx. 8° to avoid excessive pressure losses.

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

without transmitting any stresses or strains.

1. Before installing the pump in the piping, remove the flange covers on the

suction and discharge nozzles of the pump.

2. Connect the pump nozzles to the piping.

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5.4.2 Permissible forces and moments at the pump nozzles

[+]

F

z

F

y

F

x

F

x

F

y

F

z

F

x

F

y

F

z

M

z

M

y

M

x

Forces and moments at the pump nozzles

The values correspond with those
specified in EN ISO 5199 for horizontal
installation of pump family 1A, for cast
iron and 68°F (20°C). The values also
apply to Sewabloc pumps installed
vertically.

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

Horizontal installation

Table12: Forces and moments at the pump nozzles, Sewatec S01 to S04, horizontal installation

Sizes

Impeller type

Bearing bracket

Flanges Forces at suction nozzle Moments at suction

nozzle

Forces at discharge

nozzle

Moments at discharge

nozzle

DN1 DN2 Fy Fz Fx∑F My Mz Mx∑M Fy Fz Fx∑F My Mz Mx∑M

[lbs] [ft lbs] [lbs] [ft lbs]

050 - 215 F S01 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

050 - 216 F S01 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

050 - 250 K S01 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

050 - 251 K S02 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

065 - 215 F S01 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 216 E S02 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 217 F S01 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 250 K S01 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 252 K S02 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

080 - 215 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 216 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 216 E S02 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 217 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 250 K S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 252 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 253 F S02 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 253 E S02 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 315 F S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 315 K S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 315 D S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 316 D S03 125 80 283 249 317 486 403 477 550 770 158 203 181 317 293 330 440 587

080 - 317 D S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

100 - 215 F S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 250 E S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 251 F S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 252 F S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 253 F S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 253 E S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 253 K S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

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Sewatec (60 Hz)

Sizes

Impeller type

Bearing bracket

Flanges Forces at suction nozzle Moments at suction

nozzle

Forces at discharge

nozzle

Moments at discharge

nozzle

DN1 DN2 Fy Fz Fx∑F My Mz Mx∑M Fy Fz Fx∑F My Mz Mx∑M

[lbs] [ft lbs] [lbs] [ft lbs]

100 - 253 D S02 150 100 362 317 396 622 440 513 660 953 215 271 237 418 330 367 440 660

100 - 254 F S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 254 K S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 255 E S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 316 D S03 150 100 362 317 396 622 440 513 660 953 215 271 237 418 330 367 440 660

100 - 317 E S03 125 100 283 249 317 486 403 477 550 770 215 271 237 418 330 367 440 660

100 - 400 K S04 150 100 362 317 396 622 440 513 660 953 215 271 237 418 330 367 440 660

100 - 401 E S04 125 100 283 249 317 486 403 477 550 770 215 271 237 418 330 367 440 660

100 - 401 F S04 125 100 283 249 317 486 403 477 550 770 215 271 237 418 330 367 440 660

100 - 401 K S04 125 100 283 249 317 486 403 477 550 770 215 271 237 418 330 367 440 660

125 - 315 F S03 125 125 283 249 317 486 403 477 550 770 249 317 283 486 403 477 550 770

125 - 315 K S03 125 125 283 249 317 486 403 477 550 770 249 317 283 486 403 477 550 770

125 - 317 E S03 125 125 283 249 317 486 403 477 550 770 249 317 283 486 403 477 550 770

150 - 253 D S02 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 315 F S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 315 K S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 315 D S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 317 E S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 317 K S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 400 K S04 200 150 475 430 531 825 587 697 843 1247 317 396 362 622 440 513 660 953

150 - 401 E S04 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 401 F S04 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 401 K S04 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 403 K S04 200 150 475 430 531 825 587 697 843 1247 317 396 362 622 440 513 660 953

151 - 403 K S04 200 150 475 430 531 825 587 697 843 1247 317 396 362 622 440 513 660 953

200 - 315 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 315 D S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 316 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 317 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 318 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 330 K S04 250 200 588 543 667 1029 807 953 1137 1687 430 531 475 825 587 697 843 1247

200 - 401 E S04 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 401 K S04 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 402 K S04 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 403 K S04 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

250 - 400 K S04 250 250 588 543 667 1029 807 953 1137 1687 543 667 588 1029 807 953 1137 1687

250 - 401 K S04 250 250 588 543 667 1029 807 953 1137 1687 543 667 588 1029 807 953 1137 1687

250 - 403 K S04 250 250 588 543 667 1029 807 953 1137 1687 543 667 588 1029 807 953 1137 1687

300 - 400 K S04 300 300 712 633 791 1243 1100 1283 1540 2273 633 791 712 1243 1100 1283 1540 2273

300 - 401 K S04 300 300 712 633 791 1243 1100 1283 1540 2273 633 791 712 1243 1100 1283 1540 2273

Vertical installation

NOTE

For installation on the suction elbow the DN1 values shall be tripled for DN0.

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Sewatec (60 Hz)

Table13: Forces and moments at the pump nozzles, Sewatec S01 to S03, vertical installation

Sizes

Impeller type

Bearing bracket

Flanges Forces at suction nozzle Moments at suction

nozzle

Forces at discharge

nozzle

Moments at discharge

nozzle

DN1 DN2 Fy Fz Fx∑F My Mz Mx∑M Fy Fz Fx∑F My Mz Mx∑M

[lbs] [ft lbs] [lbs] [ft lbs]

050 - 215 F S01 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

050 - 216 F S01 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

050 - 250 K S01 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

050 - 251 K S02 65 50 147 136 170 260 293 293 403 550 113 136 124 203 257 293 367 513

065 - 215 F S01 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 216 E S02 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 217 F S01 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 250 K S01 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

065 - 252 K S02 80 65 181 158 203 317 293 330 440 587 136 170 147 260 293 293 403 550

080 - 215 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 216 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 216 E S02 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 217 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 250 K S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 252 F S01 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 253 F S02 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 253 E S02 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 315 F S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 315 K S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 315 D S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

080 - 316 D S03 125 80 283 249 317 486 403 477 550 770 158 203 181 317 293 330 440 587

080 - 317 D S03 100 80 237 215 271 418 330 367 440 660 158 203 181 317 293 330 440 587

100 - 215 F S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 250 E S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 251 F S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 252 F S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 253 F S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 253 E S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 253 K S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 253 D S02 150 100 362 317 396 622 440 513 660 953 215 271 237 418 330 367 440 660

100 - 254 F S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 254 K S01 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 255 E S02 100 100 237 215 271 418 330 367 440 660 215 271 237 418 330 367 440 660

100 - 316 D S03 150 100 362 317 396 622 440 513 660 953 215 271 237 418 330 367 440 660

100 - 317 E S03 125 100 283 249 317 486 403 477 550 770 215 271 237 418 330 367 440 660

125 - 315 F S03 125 125 283 249 317 486 403 477 550 770 249 317 283 486 403 477 550 770

125 - 315 K S03 125 125 283 249 317 486 403 477 550 770 249 317 283 486 403 477 550 770

125 - 317 E S03 125 125 283 249 317 486 403 477 550 770 249 317 283 486 403 477 550 770

150 - 253 D S02 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 315 F S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 315 K S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 315 D S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 317 E S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

150 - 317 K S03 150 150 362 317 396 622 440 513 660 953 317 396 362 622 440 513 660 953

200 - 315 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 315 D S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 316 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 317 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

200 - 318 K S03 200 200 475 430 531 825 587 697 843 1247 430 531 475 825 587 697 843 1247

5 Installation at Site

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Sewatec (60 Hz)

5.4.3 Vacuum balance line

NOTE

Where fluid has to be pumped out of a vessel under vacuum, installing a vacuum
balance line is recommended.

The following rules apply to vacuum balance lines:

▪ Minimum nominal line diameter: 0.98 inch [25 mm].

▪ The line extends above the highest permissible fluid level in the tank.

1 2

5

43

6

Fig.5: Vacuum balance line

1 Vessel under vacuum 2 Vacuum balance line

3 Shut-off element 4 Swing check valve

5 Main shut-off element 6 Vacuum-tight shut-off element

NOTE

An additional line fitted with a shut-off valve (from the pump discharge nozzle to
the balance line) facilitates venting of the pump before start-up.

5.5 Auxiliary connections

WARNING

Screw plugs subjected to pressure

Risk of injuries by parts flying off and escaping fluid!

▷ Never use screw plugs for releasing pressure from the pump casing.

▷ Always use a suitable venting device (e.g. vent valve).

The following auxiliary connections are available:

5 Installation at Site

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Sewatec (60 Hz)

8B

1M.1

1M.2/6D

13B

13D

1M.1

6B

6B

3M

Fig.6: Auxiliary connections

Table14: Sizes of auxiliary connections

Connection

Description

Size

050 - 215
050 - 216
050 - 250
050 - 251

065 - 215
065 - 216
065 - 217
065 - 250

K 065 - 252

065 - 253

080 - 215
080 - 216
080 - 217
080 - 250
080 - 252
080 - 253
080 - 315
080 - 316
080 - 317
100 - 250

100 - 251
F 100 - 252
F 100 - 253

100 - 254

100 - 255

100 - 315

100 - 316

100 - 317

150 - 251

125 - 315
125 - 317
150 - 315
150 - 317
200 - 315
200 - 316
200 - 317
200 - 318

100 - 401

K 100 - 400

K 150 - 400

150 - 401
150 - 403
151 - 403
200 - 401

K 200 - 402

200 - 403

200 - 330
250 - 400
250 - 401
250 - 403
300 - 400
300 - 401

1M.1 Pressure gage G 1/2

1M.2

5)

Pressure gage - G 1/2

6D Vent G 1/2 G 3/4 G 1 G 1 1/4

3M Pressure/vacuum gage G 1/2

6B Casing drain G 1/2 G 1

8B Leakage check G 3/8

13D Lubricant filler

opening

G 1/2

13B Lubricant

drain

G 3/8

5.6 Checking the coupling alignment

DANGER

Inadmissible temperatures at the coupling or bearings due to misalignment

Explosion hazard!

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

5) For vertical installation only

5 Installation at Site

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Sewatec (60 Hz)

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 if pump sets are supplied with pump and motor

mounted on the same baseplate.

B

A

A

B

a) b)

B

B

A

A

1

1

2

21

1

Fig.7: Checking the coupling alignment: a) coupling b) coupling with spacer

1 Straightedge 2 Feeler gage

ü The coupling guard and footboard for coupling guard, if any, have been

removed.

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

strains.

2. Place the straightedge axially on both coupling halves.

3. Leave the straightedge in this position and turn the coupling by hand.

The coupling is correctly aligned if the distances A) and B) to the respective
shafts are the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed

0.0039inch (0.1 mm), during standstill as well as at operating temperature and
under inlet pressure.

4. Check the distance between the two coupling halves around the circumference;

refer to the general arrangement drawing for the dimensions.
The coupling is correctly aligned if the distance between the two coupling
halves is the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed

0.0039inch (0.1 mm), during standstill as well as at operating temperature and
under inlet pressure.

5. If the coupling has been correctly aligned, re-install the coupling guard and

footboard for coupling guard, if any.

Checking the coupling alignment with a laser tool

Coupling alignment may also be checked with a laser tool. Observe the
documentation provided by the manufacturer of the measuring instrument.

5.7 Aligning the pump and motor

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

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Sewatec (60 Hz)

5.7.1 Motors with adjusting screw

1

3

2

Fig.8: Motor with adjusting screw

1 Hexagon head bolt 2 Adjusting screw

3 Locknut

ü The coupling guard and its footboard, if fitted, have been removed.

1. Check the coupling alignment.

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

baseplate.

3. Turn the adjusting screws (2) by hand or by means of an open-end wrench until

the coupling alignment is correct and all motor feet rest squarely on the
baseplate.

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

baseplate.

5. Check proper functioning of coupling/shaft.

Check that coupling/shaft can easily be rotated by hand.

WARNING

Unprotected rotating coupling

Risk of injury by rotating shafts!

▷ Always operate the pump set with a coupling guard.

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

▷ Observe all relevant regulations for selecting a coupling guard.

DANGER

Risk of ignition by frictional sparks

Explosion hazard!

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

mechanical contact (see DIN EN 13463-1).

6. Fit the coupling guard and its footboard if applicable.

7. Check the distance between coupling and coupling guard.

The coupling guard must not touch the coupling.

5.8 Checking the lubricant level

Grease-packed bearings

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

Lubricant supply for mechanical seals

The lubricant chambers have been filled at the factory.
Before commissioning the pump set, check the lubricant level.

5 Installation at Site

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Sewatec (60 Hz)

0.39 inch

1

1

2

2

10 mm

Fig.9: Checking the lubricant level

ü The pump set has been installed as described in this manual.

1. Unscrew and remove screw plug (1) with joint ring (2).

2. If the lubricant level is within the tolerance range of 0.39inch (10mm) below

the opening, re-insert and fasten screw plug (1) with joint ring (2).

3. If the lubricant level is below the tolerance range, refill the chamber with

lubricant.

5.9 Electrical connection

DANGER

Electrical connection work by unqualified personnel

Danger of death from electric shock!

▷ Always have the electrical connections installed by a trained electrician.

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

DANGER

Incorrect electrical installation

Danger of death from electric shock!

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

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

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

Fitting a motor protection device is recommended.

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Sewatec (60 Hz)

5.10 Checking the direction of rotation

DANGER

Temperature increase resulting from contact between rotating and stationary
components

Damage to the pump set!

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

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

WARNING

Hands inside the pump casing

Risk of injuries, damage to the pump!

▷ Never insert your hands or any other objects into the pump if the pump has not

been de-energized and secured against unintentional start-up.

CAUTION

Incorrect direction of rotation of pump with non-reversible mechanical seal

Damage to the mechanical seal and leakage!

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

CAUTION

Drive and pump running in the wrong direction of rotation

Damage to the pump!

▷ Refer to the arrow indicating the direction of rotation on the pump.

▷ Check the direction of rotation. If required, check the electrical connection and

correct the direction of rotation.

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

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

direction of rotation.

2. Check the direction of rotation.

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

3. If the impeller rotates in the wrong direction of rotation, check and correct the

electrical connection of the motor and the control system, if applicable.

5.11 Priming and venting the pump

DANGER

Shaft seal failure caused by insufficient lubrication

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

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

both with the fluid to be handled.

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

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

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

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5.12 Protective equipment

WARNING

Failure to re-install or re-activate protective equipment/devices

Risk of personal injury from moving parts or escaping fluid!

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

relevant devices and protective devices.

5.13 Connecting the vibration sensor

The pump is supplied prepared for the connection of a vibration sensor as an option.
Fasten the vibration sensor at the point indicated at the bearing bracket. For
fastening the sensor and connecting it to the power supply observe the sensor
product literature.

82-5
81-99

82-5
81-99

Fig.10: Position of vibration sensor

82-5 Adapter 81-99 Electrical part

5.14 Connecting temperature measuring devices

The pump is supplied prepared for the connection of resistance thermometers as an
option. Fasten the resistance thermometers at the points indicated at the bearing
bracket. For fastening the sensors and connecting them to the power supply observe
the sensor product literature.

692-02
(G 1/4)

692-01
(G 1/4)

692-02
(G 1/4)

692-01
(G 1/4)

Fig.11: Positions of resistance thermometers

692-01 Temperature measuring device

No.1

692-02 Temperature measuring device

No.2

5.15 Warning values and cut-out values

As an option, the pump can be fitted with various sensors. If such sensors are fitted,
observe the following warning values and cut-out values:

6) To DINISO10816-7, categoryII, zoneA

7) Within the preferred operating range of 0.7≤Q/Qopt≤1.2 the vibration values of newly commissioned pumps with good

system conditions (piping layout, approach flow at the pump, etc.) are below the boundary of zoneA to DINISO10816-7,
i.e. below 3.5mm/s rms.

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Table15: Warning values and cut-out values

Sensors Warning value Cut-out value

Vibrations

6)

in/s 0,248 0,374

mm/s 6,3

7)

9,5

Bearing temperature at the outer bearing ring °F 185 194

°C 85 90

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

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

▪ The pump set has been 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. The pump has been

vented.

▪ The direction of rotation has been checked.

▪ All auxiliary connections required are connected and operational.

▪ The lubricant has been checked.

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

the pump (set) to service have been carried out.

6.1.2 Start-up

DANGER

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

Hot or toxic fluid could escape!

▷ 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 gate valve slightly or fully

open.

DANGER

Excessive temperatures due to insufficient lubrication of shaft seal or excessive
gas content in the fluid handled

Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Prime the pump as per operating instructions.

▷ Always operate the pump within the permissible operating range.

WARNING

Pump sets with high noise characteristics

Damage to hearing!

▷ Persons must only enter the vicinity of the running pump set if they are

wearing protective clothing/ear protection.

▷ See noise characteristics.

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WARNING

Abnormal noises, vibrations, temperatures or leakage

Damage to the pump!
Risk of personal injury!

▷ Switch off the pump (set) immediately.

▷ Eliminate the causes before returning the pump set to service.

ü The pump, suction line and discharge line have been vented and primed with the

fluid to be handled.

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

2. Close/slightly open the shut-off element in the discharge line; fully open the

shut-off element if a check valve is installed.

3. Start up the motor.

4. Immediately after the pump has reached full rotational speed, swiftly open the

shut-off element in the discharge line and adjust it to comply with the duty
point.

Frequency inverter

When the pump is started up via frequency inverter, ensure short start ramps
(approximately 3-5 seconds).

NOTE

Only start speed-controlled operation after at least 3-5 minutes at the earliest.
Pump start-up with long start ramps and low frequency may cause clogging.

6.1.3 Shutdown

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

If the discharge line is equipped with a non-return or check valve, the shut-off
element may remain open if there is back pressure.

2. Switch off the motor.

Make sure that the pump set runs down smoothly to a standstill.

Prolonged shutdown

periods

For prolonged shutdown, close the shut-off element in the suction line.

Danger of frost/freezing

If there is any danger of frost/freezing, drain the pump and protect it against
freezing.

6.2 Operating limits

DANGER

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

Hot or toxic fluid could escape!
Explosion hazard!

▷ Comply with the operating data indicated in the data sheet.

▷ Avoid prolonged operation against a closed shut-off element.

▷ Never operate the pump at temperatures exceeding those specified in the data

sheet or on the name plate unless the written consent of the manufacturer has
been obtained.

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6.2.1 Maximum operating pressure

CAUTION

Non-compliance with permissible operating pressure

Damage to connections and seals!

▷ Never exceed the operating pressure specified in the data sheet.

Table16: Maximum operating pressure, maximum test pressure

Size Maximum operating pressure Maximum test pressure

[psi] [bar] [psi] [bar]

F 050 - 215 145 10 217 15

F 050 - 216 145 10 217 15

050 - 250 145 10 217 15

050 - 251 145 10 217 15

F 065 - 215 87 6 130 9

065 - 216 87 6 130 9

065 - 217 101 7 152 10,5

065 - 250 87 6 130 9

K 065 - 252 87 6 130 9

065 - 253 87 6 130 9

080 - 215 87 6 123 8,5

080 - 216 101 7 152 10,5

080 - 217 87 6 130 9

080 - 250 87 6 130 9

080 - 252 87 6 130 9

080 - 253 87 6 130 9

080 - 315 145 10 217 15

080 - 316 145 10 217 15

080 - 317 145 10 217 15

100 - 215 87 6 130 9

100 - 250 87 6 130 9

100 - 251 87 6 130 9

D 100 - 251 87 6 130 9

100 - 252 87 6 130 9

100 - 253 87 6 130 9

D 100 - 253 87 6 130 9

100 - 254 87 6 130 9

100 - 255 87 6 130 9

100 - 315 145 10 217 15

100 - 316 145 10 217 15

D 100 - 316 145 10 217 15

100 - 317 101 7 152 10,5

K 100 - 400 145 10 217 13

100 - 401 145 10 217 15

125 - 315 87 6 130 9

125 - 317 87 6 130 9

150 - 251 87 6 130 9

150 - 253 87 6 130 9

150 - 315 87 6 130 9

150 - 317 87 6 130 9

K 150 - 400 145 10 217 15

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Sewatec (60 Hz)

Size Maximum operating pressure Maximum test pressure

[psi] [bar] [psi] [bar]

150 - 401 145 10 217 15

150 - 403 145 10 217 15

151 - 403 145 10 217 15

200 - 315 87 6 130 9

200 - 316 87 6 130 9

200 - 317 58 4 87 6

200 - 318 58 4 87 6

200 - 330 145 10 217 15

300 - 401 145 10 217 15

K 200 - 402 145 10 217 15

200 - 403 145 10 217 15

250 - 400 145 10 217 15

250 - 401 145 10 217 15

250 - 403 145 10 217 15

300 - 400 145 10 217 15

300 - 401 145 10 217 15

6.2.2 Frequency of starts

To prevent high temperature increases in the motor and excessive loads on the
pump, motor, seal elements and bearings, the following number of starts per hour
shall not be exceeded.

Table17: Frequency of starts

Motor rating Maximum number of starts

[hp] [kW] [Starts per hour]

≤ 15 ≤ 11 25

≤ 50 ≤ 37 20

6.2.3 Fluid handled

6.2.3.1 Temperature of the fluid handled

CAUTION

Impermissibly high temperature of fluid handled

Damage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted

(heating up of the fluid).

▷ Observe the temperature limits in the data sheet and in the section on

operating limits. (ðSection6.2,Page34)

6.2.3.2 Density of the fluid handled

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

CAUTION

Impermissibly high density of fluid handled

Motor overload!

▷ Observe the information on fluid density in the data sheet.

▷ Make sure the motor has sufficient power reserves.

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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 the shaft seal is to be expected. In this case, halve the intervals
commonly recommended for servicing and maintenance.

6.3 Shutdown/storage/preservation

Storing a new pump set

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

▪ Store the pump (set) in a dry and protected location.

▪ 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.

▪ Rotate the pump shaft by hand once a month.

The pump (set) remains installed

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

1. For prolonged shutdown periods, start up the pump set regularly between once

a month and once every three months for approximately five minutes.

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

intake area.

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

ü The pump has been properly drained (ðSection7.3,Page43)

ü The safety instructions for dismantling the pump have been observed.

(ðSection7.4.1,Page44)

1. Spray-coat the inside wall of the pump casing, and in particular the impeller

clearance areas, with a preservative.

2. Spray the preservative through the suction nozzle and discharge nozzle.

It is advisable to then close the pump nozzles (e.g. with plastic caps).

3. Oil or grease all exposed machined parts and surfaces of the pump (with

silicone-free oil and grease, food-approved if required) to protect them against
corrosion.
Observe the additional instructions on preservation.

6.4 Returning to service after storage

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

In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (ðSection7,Page38)

WARNING

Failure to re-install or re-activate protective equipment/devices

Risk of personal injury from moving parts or escaping fluid!

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

relevant devices and protective devices.

NOTE

On pumps/pump sets older than 5 years we recommend replacing all elastomer
seals.

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7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Sparks produced during maintenance work

Explosion hazard!

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

▷ Never open a pump set that is connected to the power supply.

▷ Always perform maintenance work on pump sets outside potentially explosive

atmospheres.

DANGER

Improperly serviced pump set

Explosion hazard!
Damage to the pump set!

▷ Service the pump set regularly.

▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal

and coupling.

The operator ensures that all maintenance, all inspections and all installation work is
performed by authorized, qualified specialist personnel who are thoroughly familiar
with the manual.

WARNING

Unintentional starting of pump set

Risk of injury by moving components and shock currents!

▷ 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 handled, consumables and operating supplies which are hot or pose a
health hazard

Risk of personal 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 against tilting

or tipping over.

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

7 Servicing/Maintenance

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NOTE

All maintenance work, service work and installation work can be carried out by KSB
Service or authorized 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.

7.2 Maintenance/inspection

7.2.1 Supervision of operation

DANGER

Formation of a 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.

CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

CAUTION

Impermissibly high temperature of fluid handled

Damage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted

(heating up of the fluid).

▷ Observe the temperature limits in the data sheet and in the section on

operating limits. (ðSection6.2,Page34)

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

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

▪ Monitor the correct functioning of any auxiliary connections.

▪ Monitor the stand-by pump.

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

▪ Check the flexible elements of the coupling or belts. Replace them if required.

▪ For bearing temperature monitoring, set the temperatures as follows: alert at

185°F (85°C), pump cut-out at 194°F (90°C).

▪ In the case of vibration monitoring, set the values as follows: alert at 0.248in/s

(6.3mm/s) , pump cut-out at 0.374in/s (9.5mm/s).

7.2.2 Visual inspection through the inspection hole

If there are problems with clogging, the inside of the casing and/or the impeller can
be checked via the inspection hole.

7 Servicing/Maintenance

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Sewatec (60 Hz)

WARNING

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

Hazard to persons and the environment!

▷ Collect and properly dispose of the flushing fluid and of 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.

WARNING

Hands and/or foreign objects in the pump casing

Risk of injuries, damage to the pump!

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

foreign objects.

▷ Never insert your hands or any other objects into the pump, if the pump set has

not been disconnected from the power supply and secured against
unintentional start-up.

If a problem has occurred which requires visual inspection, observe the following
instructions:

900.02

920.17

550.04

164.02

412.05

Fig.12: Inspection hole in the casing

Opening the inspection hole

▪ Close the shut-off element on the suction side.

▪ Switch off the drive and make sure it cannot be re-started unintentionally.

▪ Close the shut-off element on the discharge side.

▪ Open the drain plug (auxiliary connection 6B). (ðSection5.5,Page25)

▪ Collect and dispose of any liquid residues.

▪ Loosen nuts 920.17 at the inspection hole and remove inspection cover 164.02.

▪ Perform a visual inspection with a lamp or similar.

Closing the inspection hole

▪ Fit new O-ring 412.05.

▪ Fit inspection cover 164.02.

▪ Place discs 550.04 and nuts 920.17 on screws 900.02 and tighten.

▪ Observe the instructions on commissioning/start-up. (ðSection6.1.1,Page33)

7 Servicing/Maintenance

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Sewatec (60 Hz)

7.2.3 Lubrication and lubricant change

DANGER

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

Fire hazard!
Damage to the pump set!

▷ Regularly check the rolling element bearings for running noises.

7.2.3.1 Lubricating the rolling element bearings

The rolling element bearings of the pump sets are grease-packed and maintenance­free.

7.2.3.2 Changing the lubricant of the shaft seal

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.

WARNING

Screw plugs subjected to pressure

When opening screw plugs, fluid might spurt out!

▷ Wear safety goggles and protective clothing, if required.

▷ Open the screw plug slowly.

The lubricant chamber of the pump set is filled with an environmentally friendly,
non-toxic lubricant of medical quality.

Replace the lubricant every 10,000 operating hours but at least every three years.

Draining the lubricant

903.90 903.46

411.46

903.22

411.22

411.90

Fig.13: Draining the
lubricant

ü A suitable container for the old lubricant is on hand.

1. Place the container underneath screw plug 903.46.

2. Remove screw plug 903.46 and joint ring 411.46 at the bottom of the bearing

bracket and drain off the lubricant.

3. Fit screw plug 903.46 with new joint ring 411.46.

NOTE

Paraffin oil is bright and transparent in appearance. If the oil fill is severely
contaminated, this will suggest a defect on the mechanical seal.

▷ Replace the mechanical seal.

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Sewatec (60 Hz)

Filling in the lubricant

903.90 903.46

411.46

903.22

411.22

411.90

Fig.14: Filling in the
lubricant

1. Unscrew and remove screw plug 903.90 with joint ring 411.90.

2. Fill the lubricant chamber up to the filler opening.

3. Re-insert and tighten screw plug 903.90 with joint ring 411.90.

7.2.3.3 Lubricant quantity

Table18: Lubricant quantity

Size Bearing bracket Lubricant quantity

[quart] [l]

050 - 215 S01 2,6 2,5

050 - 216 S01 2,6 2,5

050 - 250 S01 3,4 3,2

050 - 251 S02 4,2 4,0

065 - 215 S01 2,6 2,5

065 - 216 S01 2,6 2,5

065 - 217 S01 2,6 2,5

065 - 250 S01 3,4 3,2

065 - 252 S01 3,4 3,2

065 - 252 S02 4,2 4,0

065 - 253 S01 3,4 3,2

065 - 253 S02 4,2 4,0

080 - 215 S01 2,6 2,5

080 - 216 S01 2,6 2,5

080 - 217 S01 2,6 2,5

080 - 250 S01 3,4 3,2

080 - 252 S01 3,4 3,2

080 - 253 S02 4,2 4,0

080 - 315 S03 6,3 6,0

080 - 316 S03 6,3 6,0

080 - 317 S03 6,3 6,0

100 - 215 S01 2,6 2,5

100 - 250 S01 3,4 3,2

100 - 251 S02 4,2 4,0

100 - 252 S01 3,4 3,2

100 - 253 S02 4,2 4,0

100 - 254 S01 3,4 3,2

100 - 255 S02 4,2 4,0

100 - 315 S03 6,3 6,0

100 - 316 S03 6,3 6,0

100 - 317 S03 6,3 6,0

100 - 400 S04 8,5 8,0

100 - 401 S04 8,5 8,0

125 - 315 S03 6,3 6,0

125 - 317 S03 6,3 6,0

150 - 251 S02 4,2 4,0

150 - 253 S02 4,2 4,0

150 - 315 S03 6,3 6,0

150 - 317 S03 6,3 6,0

150 - 400 S04 8,5 8,0

150 - 401 S04 8,5 8,0

7 Servicing/Maintenance

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Sewatec (60 Hz)

Size Bearing bracket Lubricant quantity

[quart] [l]

150 - 403 S04 8,5 8,0

151 - 403 S04 8,5 8,0

200 - 315 S03 6,3 6,0

200 - 316 S03 6,3 6,0

200 - 317 S03 6,3 6,0

200 - 318 S03 6,3 6,0

200 - 330 S04 8,5 8,0

200 - 401 S04 8,5 8,0

200 - 402 S04 8,5 8,0

200 - 403 S04 8,5 8,0

250 - 400 S04 8,5 8,0

250 - 401 S04 8,5 8,0

250 - 403 S04 8,5 8,0

300 - 400 S04 8,5 8,0

300 - 401 S04 8,5 8,0

7.2.3.4 Lubricant quality

The lubricant chamber is filled with an environmentally friendly, non-toxic lubricant
of medical quality.
The following oils can be used for lubrication:

Recommended quality of

lubricant

▪ Merkur white oil Pharma 70; made by DEA

▪ Thin-bodied paraffin oil; made by Merck, No.: 7174

▪ or equivalent make of medical quality, non-toxic

Alternative

▪ All non-doped and doped motor oils of classes SAE 10W to SAE 20W

NOTE

Only use motor oil if there is no risk of the lubricant contaminating the fluid
handled and if the motor oil can be disposed of properly.

7.3 Drainage/disposal

WARNING

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

Hazard to persons and the environment!

▷ Collect and properly dispose of the flushing fluid and of any residues of the

fluid handled.

▷ Wear safety clothing and a protective mask if required.

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

If the pump set has handled fluids whose residues could lead to corrosion damage in
the presence of atmospheric humidity or could ignite upon contact with oxygen, the
pump set must be neutralized, 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 Servicing/Maintenance

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Sewatec (60 Hz)

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

WARNING

Unqualified personnel performing work on the pump (set)

Risk of personal injury!

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

qualified personnel.

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 in section.

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

For dismantling and reassembly observe the general assembly drawing.

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

DANGER

Insufficient preparation of work on the pump (set)

Risk of personal injury!

▷ Properly shut down the pump set.

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

▷ Drain the pump and release the pump pressure. (ðSection7.3,Page43)

▷ Shut off any auxiliary feed lines.

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

NOTE

An impeller removal tool is required to remove the impeller.

7.4.2 Preparations for dismantling

DANGER

Insufficient preparation of work on the pump (set)

Risk of personal injury!

▷ Properly shut down the pump set.

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

▷ Drain the pump and release the pump pressure. (ðSection7.3,Page43)

▷ Shut off any auxiliary feed lines.

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

7 Servicing/Maintenance

45 of 72

Sewatec (60 Hz)

WARNING

Components with sharp edges

Risk of cutting or shearing injuries!

▷ Always use appropriate caution for installation and dismantling work.

▷ Wear work gloves.

NOTE

For further dismantling the pump casing may remain installed in the piping.

1. Disconnect the power supply (e.g. at the motor).

2. Disconnect and remove all auxiliary pipework.

3. Remove coupling guard 681.

4. Remove the coupling spacer of coupling 848, if any.

5. Drain the oil .

7.4.3 Separating the pump from the piping

The pump can be dismantled without removing the pump casing from the pipeline.
Exception: When removing or re-fitting a casing wear ring or wear plate.

DANGER

Insufficient preparation of work on the pump (set)

Risk of personal injury!

▷ Properly shut down the pump set.

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

▷ Drain the pump and release the pump pressure. (ðSection7.3,Page43)

▷ Shut off any auxiliary feed lines.

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

NOTE

After the pump set has been removed from the piping, the suction casing should be
cleaned with water. Suitable protective clothing is recommended.

7.4.4 Removing the back pull-out unit

902.01

920.01
330

210

230

901.61

550.61

101

Fig.15: Removing the back
pull-out unit

ü The lubricant chamber has been drained of all lubricant.

ü Transport and lifting equipment are available.

ü An area for the back pull-out unit has been prepared.

1. Remove the coupling guard.

2. Remove the coupling spacer, if any.

3. Remove the drive, if required.

4. Loop a rope tightly around the bearing bracket.

5. Undo bolts 901.61 and discs 550.61 fastening the support foot.

6. Undo screwed connections 902.01 and 920.01 and pull the complete back pull-

out unit consisting of bearing bracket 330, shaft 210 and impeller 230 out of
pump casing 101.

7. Place the back pull-out unit in a safe and dry assembly area and secure it against

tipping over or rolling off.

7 Servicing/Maintenance

46 of 72

Sewatec (60 Hz)

7.4.5 Removing the impeller

7.4.5.1 Removing an impeller with tapered interference fit

914.10

550.23

230

Fig.16: Removing the
impeller

1. Unscrew socket head cap screw 914.10 with disc 550.23.

2. Screw the grub screw fully into the shaft thread.

3. Pull off impeller 230 with a forcing screw.

NOTE

The forcing screw is not included in the scope of supply. It can be ordered
separately from KSB.

Table19: Forcing screws for pulling off the impeller

Size Impeller type Forcing screw (ADS)

Thread Code

050 - 215 F M 10 ADS 0

050 - 216 F M 10 ADS 0

050 - 250 F, K M 16 ADS 1

050 - 251 F, K M 20 ADS 2

065 - 215 F M 10 ADS 6

065 - 216 E M 12 ADS 7

065 - 217 F M 10 ADS 6

065 - 250 F, K M 16 ADS 1

065 - 253 F M 20 ADS 2

080 - 215 F M 10 ADS 6

080 - 216 F M 10 ADS 6

080 - 216 E M 12 ADS 7

080 - 217 F M 10 ADS 6

080 - 250 F, K M 16 ADS 1

080 - 252 F M 16 ADS 1

080 - 253 F, E M 20 ADS 2

080 - 315 F, K M 20 ADS 2

080 - 315 D M 20 ADS 4

080 - 316 D M 20 ADS 4

080 - 317 D M 20 ADS 4

100 - 215 F M 10 ADS 6

100 - 250 E, F, K M 16 ADS 1

100 - 251 E, F, K M 20 ADS 2

100 - 251 D M 16 ADS 3

100 - 252 F M 16 ADS 1

100 - 253 E, F, K M 20 ADS 2

100 - 253 D M 16 ADS 3

100 - 254 F, K M 16 ADS 1

100 - 255 E, K M 20 ADS 2

100 - 315 D M 20 ADS 4

100 - 316 D M 20 ADS 4

100 - 317 E M 20 ADS 2

100 - 400 K M 20 ADS 5

7 Servicing/Maintenance

47 of 72

Sewatec (60 Hz)

Size Impeller type Forcing screw (ADS)

Thread Code

100 - 401 E, F, K M 20 ADS 5

125 - 315 F, K M 20 ADS 2

125 - 317 E M 20 ADS 2

150 - 251 D M 16 ADS 3

150 - 253 D M 16 ADS 3

150 - 315 E, F, K M 20 ADS 2

150 - 315 D M 20 ADS 4

150 - 317 E, K M 20 ADS 2

150 - 400 D M 24 ADS 5

150 - 400 K M 20 ADS 5

150 - 401 D M 24 ADS 5

150 - 401 E, F, K M 20 ADS 5

150 - 403 K M 24 ADS 5

151 - 403 K M 24 ADS 5

200 - 315 K M 20 ADS 2

200 - 315 D M 20 ADS 4

200 - 316 K M 20 ADS 2

200 - 317 K M 20 ADS 2

200 - 318 K M 20 ADS 2

200 - 330 K M 20 ADS 5

200 - 400 D M 24 ADS 5

200 - 401 K M 20 ADS 5

200 - 402 K M 20 ADS 5

200 - 403 K M 20 ADS 5

250 - 400 D M 24 ADS 5

250 - 400 K M 20 ADS 5

250 - 401 K M 20 ADS 5

250 - 403 K M 20 ADS 5

300 - 400 D M 24 ADS 5

300 - 400 K M 20 ADS 5

300 - 401 K M 20 ADS 5

7 Servicing/Maintenance

48 of 72

Sewatec (60 Hz)

7.4.6 Removing the mechanical seals

210

163

433.02

515 / 932.03

433.01

330

Fig.17: Removing the mechanical seals

7.4.6.1 Removing the pump-end mechanical seal

ü The back pull-out unit and the impeller have been removed as described above.

1. Pull the rotating assembly of mechanical seal 433.01 off shaft 210.

2. Remove discharge cover 163 from bearing bracket 330.

3. Press the stationary seat of mechanical seal 433.02 out of discharge cover 163.

7.4.6.2 Removing the drive-end mechanical seal

ü The back pull-out unit and the impeller have been removed as described above.

1. Remove locking ring 515 or circlip 932.03.

2. Pull the rotating assembly of mechanical seal 433.01 off shaft 210.

7.4.6.3 Removing the KSB double cartridge seal

500

101-47

914.52

433

Fig.18: Removing the KSB double cartridge seal

7 Servicing/Maintenance

49 of 72

Sewatec (60 Hz)

433

932.59

412.28

Fig.19: Removing the mechanical seal

ü The back pull-out unit and the impeller have been removed as described above.

1. Fix discharge cover 163 to bearing bracket 330 using suitable bolts/screws and

washers.

2. Remove O-ring 412.28 from the shaft.

3. Slide puller 101-47 over the shoulder of mechanical seal 433 and lock with ring

500.

4. Press forcing screw 914.52 against shaft 210 and pull mechanical seal 433 out of

discharge cover 163.

7.4.7 Removing the shaft and rolling element bearings

360.02

932.03

210

321.01

321.02

932.20

330

Fig.20: Removing the shaft and rolling element bearings

ü The back pull-out unit, impeller and mechanical seal have been removed as

described.

1. Remove cover 360.02 and circlip 932.02.

2. Push shaft 210 with deep groove ball bearings 321.01/02 out of the bearing

bracket towards the drive end.

3. Remove circlip 932.20.

4. Pull deep groove ball bearings 321.01/02 off the shaft.

5. Remove the stationary seat of drive-end mechanical seal 433.01 from bearing

bracket 330.

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

7 Servicing/Maintenance

50 of 72

Sewatec (60 Hz)

CAUTION

Re-installing damaged components

Damage to the machine!

▷ Re-work damaged components or replace by new ones.

7.4.8 Removing the wear plate (for D impellers only)

914.12

135

101

Fig.21: Removing the wear plate

ü The back pull-out unit, the belt drive (if any) and the motor have been properly

removed from the pump casing.

ü The inside of the casing has been cleaned.

ü The wear plate needs to be replaced as a result of visual inspection.

1. Disconnect the pump casing from the piping.

2. Undo hexagon socket head cap screws 914.12.

3. Remove wear plate 135.01 and O-rings 412.34.

7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

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

heavy assemblies or components.

CAUTION

Improper reassembly

Damage to the pump!

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

engineering practice.

▷ Use original spare parts only.

Sequence

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

Sealing elements

Check O-rings for any damage and replace by new O-rings if required.

Never use O-rings that have been made by cutting an O-ring cord to size and gluing
the ends together.

Make sure that the sealing elements and sealing surfaces are clean.

Assembly adhesives

Coat the locating surfaces of the individual components and screwed connections
with graphite or similar before reassembly.

Tightening torques

For reassembly, tighten all screws and bolts as indicated.

Bearings

Only use specified bearings to DIN625 (part Nos. 320.01/.02).

7 Servicing/Maintenance

51 of 72

Sewatec (60 Hz)

Table20: Bearing assembly

Bearing bracket size Grease-packed deep groove ball

bearings, sealed for life

S01 6307 - 2 Z - C3

S02 6311 - 2 Z - C3

S03 6314 - 2 Z - C3

S04 6314 - 2 Z - C3

Checking the alignment

After assembly with the pump casing that has remained in the piping, check the
coupling alignment.

7.5.2 Re-installing shaft and rolling element bearings

When re-installing the shaft, replace deep groove ball bearings 321.01/02 if required.

(ðSection7.5.1,Page50)

360.02

932.03

210

321.01

321.02

932.20

330

Fig.22: Re-installing shaft and rolling element bearings

1. Slide deep groove ball bearings 321.01/02 onto shaft 210 until they abut against

the shaft shoulder.

2. Insert circlip 932.20 into shaft 210.

3. Insert pre-assembled shaft 210 into bearing bracket 330 from the drive end.

4. Press cover 360.02 into the bearing bracket.

7.5.3 Installing the mechanical seal

We recommend always using new original mechanical seals for re-assembly.

Observe the following to ensure trouble-free operation of the mechanical seal:

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

assembly takes place.

▪ Make sure the surface of the shaft is absolutely clean and undamaged.

▪ Immediately before installing the mechanical seal, wet the contact faces with a

drop of oil.

▪ For easier installation of bellows-type mechanical seals, wet the inside diameter

of the bellows with soapy water (not oil).

▪ To prevent any damage to the rubber bellows, place a thin foil (of approximately

0.0039 to 0.0118 inch [0.1 to 0.3mm] thickness) around the free shaft stub.
Slip the rotating assembly over the foil into its installation position.
Then remove the foil.

7 Servicing/Maintenance

52 of 72

Sewatec (60 Hz)

7.5.3.1 Installing the bellows-type mechanical seal

210

163

433.02

515 / 932.03

433.01

330

412.15 /

412.11

412.04 /

412.35

Fig.23: Installing the mechanical seals

ü The shaft and rolling element bearings have been properly installed in the

bearing bracket.

1. Slide drive-end mechanical seal 433.01 onto shaft 210 and secure it with locking

ring 515 or circlip 932.03.

2. Insert O-rings 412.04/412.35 and 412.15/412.11 into discharge cover 163, and

press them into bearing bracket 330 as far as they will go.

3. Slide pump-end mechanical seal 433.02 onto shaft 210.

For special mechanical seals with covered spring, tighten the socket head cap screw
at the rotating assembly before fitting the impeller. Observe installation dimension
"A".

A

Fig.24: Installation dimension "A"

Table21: Installation dimension "A"

Size Impeller type Installation dimension "A"

[inch] [mm]

050 - 215 F 1 1/

8

29,0

050 - 216 F 1 1/

8

29,0

050 - 250 F, K 1 1/

8

29,0

050 - 251 F, K 1 3/

16

38,5

065 - 215 F 1 1/

8

29,0

065 - 216 E 1 3/

16

38,5

065 - 217 F 1 1/

8

29,0

065 - 250 F, K 1 1/

8

29,0

065 - 253 F 1 3/

16

38,5

080 - 215 F 1 1/

8

29,0

7 Servicing/Maintenance

53 of 72

Sewatec (60 Hz)

Size Impeller type Installation dimension "A"

[inch] [mm]

080 - 216 F 1 1/

8

29,0

080 - 216 E 1 3/

16

38,5

080 - 217 F 1 1/

8

29,0

080 - 250 F, K 1 1/

8

29,0

080 - 252 F 1 1/

8

29,0

080 - 253 E, F 1 3/

16

38,5

080 - 315 F, K 1 3/

16

38,5

080 - 315 D 1 3/

16

38,5

080 - 316 D 1 3/

16

38,5

080 - 317 D 1 3/

16

38,5

100 - 215 F 1 1/

8

29,0

100 - 250 E, F, K 1 1/

8

29,0

100 - 251 E, F, K 1 3/

16

38,5

100 - 251 D 1 3/

16

38,5

100 - 252 F 1 1/

8

29,0

100 - 253 D, E, F, K 1 3/

16

38,5

100 - 254 F, K 1 1/

8

29,0

100 - 255 E, K 1 3/

16

38,5

100 - 315 D 1 3/

16

38,5

100 - 316 E 1 3/

16

38,5

100 - 317 E 1 3/

16

38,5

125 - 315 F, K 1 3/

16

38,5

125 - 317 E 1 3/

16

38,5

150 - 251 D 1 3/

16

38,5

150 - 253 D 1 3/

16

38,5

150 - 315 D, E, F, K 1 3/

16

38,5

150 - 317 E, K 1 3/

16

38,5

150 - 400 K 1 7/

8

48,3

150 - 401 E, F, K 1 7/

8

48,3

150 - 403 K 1 7/

8

48,3

151 - 403 K 1 7/

8

48,3

200 - 315 D, K 1 3/

16

38,5

200 - 316 K 1 3/

16

38,5

200 - 317 K 1 3/

16

38,5

200 - 318 K 1 3/

16

38,5

200 - 330 K 1 7/

8

48,3

200 - 401 K 1 7/

8

48,3

200 - 402 K 1 7/

8

48,3

200 - 403 K 1 7/

8

48,3

250 - 400 K 1 7/

8

48,3

250 - 401 K 1 7/

8

48,3

250 - 403 K 1 7/

8

48,3

300 - 400 K 1 7/

8

48,3

300 - 401 K 1 7/

8

48,3

7 Servicing/Maintenance

54 of 72

Sewatec (60 Hz)

7.5.3.2 Installing the KSB double cartridge seal

101-47

433

Fig.25: Installing the KSB double cartridge seal

433

932.59

412.28

Fig.26: Installing the mechanical seal

ü Install the mechanical seal as shown in the installation drawing.

ü The back pull-out unit of the pump has been placed in a clean and level assembly

area.

ü The KSB 4STQ double cartridge seal is fully assembled and undamaged.

1. Insert circlip 932.59 in the shaft groove and make sure that circlip 932.59 is

positioned correctly in the shaft groove. When fitting the circlip take care to
prevent damage to the shaft.

CAUTION

Use of grease or other permanent lubricants

Torque transmission impeded/ overheating of and damage to the pump!

▷ Never use grease or other permanent lubricants for fitting the torque-

transmitting elements of a mechanical seal.

▷ Use soft soap to reduce any friction caused during assembly.

▷ Never coat the mechanical seal faces with grease or oil.

2. Prior to assembly, wet the external elastomers (O-rings and gasket) and the

seats of the mechanical seal at the shaft, discharge cover 163 and seal housing
with a suitable lubricant (e.g. soap suds).

3. Press mechanical seal 433 into discharge cover 163 by hand as far as possible.

4. Fit mechanical seal 433 using mounting device 101-47. Check mechanical seal

position against reference dimensions "K" (see table: Reference dimension "K")
and correct the installation position if required.

5. Slide O-ring 412.28 onto the shaft until it abuts against the mechanical seal.

7 Servicing/Maintenance

55 of 72

Sewatec (60 Hz)

K

Fig.27: Reference dimension "K” from shaft end to KSB double cartridge seal

Table22: Reference dimension "K"

Size Reference dimension "K"

[inch] [mm]

50-215/216
65-215/217
80-215/216/217
100-215

0,944+/- 0,02 24+/- 0,5

65-216
80-216

1,259+/- 0,02 32+/- 0,5

50-250
65-250/252/253
80-250/252
100-250/252/254

1,496+/- 0,02 38+/- 0,5

50-251
65-253
80-253/315/316
100-251/253/255/315/316/317
125-315/317
150-315/317
200-315/316/317/318

1,614+/- 0,02 41+/- 0,5

7.5.4 Fitting the impeller

914.10

550.23

230

Fig.28: Fitting the impeller

ü The shaft and rolling element bearings have been properly installed.

ü The mechanical seals have been properly installed.

1. Slide impeller 230 onto the shaft end.

2. Screw in impeller screw 914.10 and disc 550.23. Tighten them with a torque

wrench.

NOTE

On shafts without a Helicoil thread insert secure the impeller screw with
Loctite243.

7 Servicing/Maintenance

56 of 72

Sewatec (60 Hz)

Table23: Tightening torque for impeller screw

Size Impeller type Thread Tightening torque

[ft lbs] [Nm]

050 - 215 F M 8 19,17 26

050 - 216 F M 8 19,17 26

050 - 250 F, K M 10 25,82 35

050 - 251 F, K M 16 110,64 150

065 - 215 F M 8 19,17 26

065 - 216 E M 10 25,82 35

065 - 217 F M 8 19,17 26

065 - 250 F, K M 10 25,82 35

065 - 253 F M 16 110,64 150

080 - 215 F M 8 19,17 26

080 - 216 F M 8 19,17 26

080 - 216 E M 10 25,82 35

080 - 217 F M 8 19,17 26

080 - 250 F, K M 10 25,82 35

080 - 252 F M 10 25,82 35

080 - 253 E, F M 16 110,64 150

080 - 315 D, F, K M 16 110,64 150

080 - 316 D M 16 110,64 150

080 - 317 D M 16 110,64 150

100 - 215 F M 8 19,17 26

100 - 250 E, F, K M 10 25,82 35

100 - 251 E, F, K M 16 110,64 150

100 - 251 D M 10 25,82 35

100 - 252 F M 10 25,82 35

100 - 253 D, E, F, K M 10 25,82 35

100 - 254 F, K M 10 25,82 35

100 - 255 E, K M 16 110,64 150

100 - 315 D M 16 110,64 150

100 - 316 E M 16 110,64 150

100 - 317 E M 16 110,64 150

125 - 315 F, K M 16 110,64 150

125 - 317 E M 16 110,64 150

150 - 251 D M 16 110,64 150

150 - 253 D M 16 110,64 150

150 - 315 D, E, F, K M 16 110,64 150

150 - 317 E, K M 16 110,64 150

150 - 400 K M 20 213,90 290

150 - 401 E, F, K M 20 213,90 290

150 - 403 K M 20 213,90 290

151 - 403 K M 20 213,90 290

200 - 315 D, K M 16 110,64 150

200 - 316 K M 16 110,64 150

200 - 317 K M 16 110,64 150

200 - 318 K M 16 110,64 150

200 - 330 K M 20 213,90 290

200 - 401 K M 20 213,90 290

200 - 402 K M 20 213,90 290

200 - 403 K M 20 213,90 290

7 Servicing/Maintenance

57 of 72

Sewatec (60 Hz)

Size Impeller type Thread Tightening torque

[ft lbs] [Nm]

250 - 400 K M 20 213,90 290

250 - 401 K M 20 213,90 290

250 - 403 K M 20 213,90 290

300 - 400 K M 20 213,90 290

300 - 401 K M 20 213,90 290

Note:

Make sure that the tapered fit of impeller and shaft is undamaged and installed free
from grease.
For pump size Sewatec D 150-251 first screw screwed coupling 852 into the shaft.

7.5.5 Installing the back pull-out unit

WARNING

Back pull-out unit tipping over

Risk of squashing hands and feet!

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

Version with casing wear ring

ü The shaft, rolling element bearings, mechanical seal and impeller have been

assembled properly.

502

904.01

101

230

0.02 inch
(0,5 mm)

Fig.29: Fitting the casing
wear ring

1. Insert casing wear ring 502 into pump casing 101.

2. Glue 3 pieces of cardboard 8) of approximately 0.079 inch (2mm) thickness and

0.59 inch (15 mm) length to the front face of the impeller.

ð In assembled condition, this will result in a clearance of 0.02 inch (0.5 mm).

between impeller and casing wear ring.

3. Insert the complete back pull-out unit into the pump casing.

4. Screw in grub screws 904.01, lock the casing wear ring in position.

5. Secure grub screws 904.01 with Loctite.

6. Evenly tighten screwed connection 902.01 between pump casing and bearing

bracket.

NOTE

Only adjust the clearances for bearing bracket versions S01, S02 and S03. Bearing
bracket S04 has a diametral clearance.

Version with wear plate (for D impellers only)

ü The shaft, rolling element bearings, mechanical seal and impeller have been

assembled properly.

ü The pump casing is not connected to the piping.

8) Use cardboard which easily dissolves in water.

7 Servicing/Maintenance

58 of 72

Sewatec (60 Hz)

914.12

412.34

914.24

135 412.33 230

101

0.016

+0.0079

inch

0,4

+0,2

mm

Fig.30: Fitting the wear plate

1. Fit wear plate 135 with two new O-rings 412.33/34.

2. Insert wear plate 135 into pump casing 101.

3. Fasten wear plate 135 to pump casing 101 with hexagon socket head cap screws

914.12.

4. Adjust the clearance between impeller 230 and wear plate 135 by tightening

and loosening screws 914.12 and 914.24.

ð Screw 914.24 pushes the wear plate in the direction of the impeller.

ð The clearance equals 0.016

+0.0079

inch [0.4

+0.2

mm] (measured on the suction

side from the outer surface of the impeller vane to the wear plate).

5. Insert the complete back pull-out unit into the pump casing.

6. Evenly tighten screwed connection 902.01 between pump casing and bearing

bracket.

7. Fasten the support foot to the baseplate with bolts 901.61 and discs 550.61.

7.5.6 Leak test

After reassembly of the pump, subject the mechanical seal area/lubricant supply
chamber to a leak test.

1. Tightly screw the testing device into the filler opening (auxiliary connection
13D). (ðSection5.5,Page25)

2. Test medium: compressed air
Test pressure: 11.6 psi (0.8 bar) max.
Test period: 2 minutes

ð The pressure must not drop during the test period.

ð If the pressure does drop, check the seals and screwed connections. Then

perform another leak test.

3. If the test has been successful, fill in the lubricant.

7.5.7 Mounting the motor

NOTE

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

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

2. Fasten the motor to the baseplate.

7 Servicing/Maintenance

59 of 72

Sewatec (60 Hz)

3. Align the pump and motor. (ðSection5.7,Page27)

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

literature).

7.6 Tightening torques

Table24: Tightening torques

Thread

316 SS / Duplex

[ft lbs]

Thread Tightening torque

A4-70 / 1.4462

[Nm]

1

/

4

5,16 M 6 7

5

/

16

12,54 M 8 17

3

/

8

25,82 M 10 35

1

/

2

44,25 M 12 60

5

/

8

110,64 M 16 150

13

/

16

213,90 M 20 290

15

/

16

205,05 / 368,8 M 24 278 / 500

1 1/

16

301,67 / 542,8 M 27 409 / 736

1 3/

16

408,62 / 737,6 M 30 554 / 1000

7.7 Spare parts stock

7.7.1 Ordering spare parts

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

▪ Order number

▪ Order item number

▪ Consecutive number

▪ Type series

▪ Size

▪ Material variant

▪ Seal code

▪ Year of construction

Refer to the name plate for all data.

Also supply the following data:

▪ Part No. and description

▪ Quantity of spare parts

▪ Shipping address

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

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

Table25: Quantity of spare parts for recommended spare parts stock

Part No. Description Number of pumps

(including stand-by pumps)

Spare part

Replacement part

Wear part

1 2 3 4 5 6 8 10 and

more

135 Wear plate 1 2 2 2 3 3 4 50 % - - ✘

163 Discharge cover 1 2 2 2 3 3 4 50 % ✘ - -

210 Shaft 1 1 1 2 2 2 3 30 % ✘ - -

7 Servicing/Maintenance

60 of 72

Sewatec (60 Hz)

Part No. Description Number of pumps

(including stand-by pumps)

Spare part

Replacement part

Wear part

1 2 3 4 5 6 8 10 and

more

230 Impeller 1 1 1 2 2 2 3 30 % - ✘ -

321.01/02 Rolling element bearing (set) 1 1 1 2 2 3 4 50 % - - ✘

330 Bearing bracket, complete - - - - - - 1 2 pcs. ✘ - -

433.01/02 Mechanical seal, complete (set) 1 2 3 4 4 4 6 90 % - - ✘

502.01 Casing wear ring 1 2 2 2 3 3 4 50 % - - ✘

503 Impeller wear ring 1 2 2 2 3 3 4 50 % - - ✘

Assembly for gland packing
consisting of:

▪ Neck bush

▪ Shaft protecting sleeve

▪ Lantern ring

1 1 1 2 2 2 3 40 % - ✘ -

Packing cord (4 rings) 4 4 6 8 8 9 12 100 % - - ✘

Sealing elements (set) 2 4 6 8 8 9 12 150 % - - ✘

Keeping a stock of wear parts and replacement parts is recommended also during the
warranty period.

8 Trouble-shooting

61 of 72

Sewatec (60 Hz)

8 Trouble-shooting

WARNING

Improper remedial work

Risk of personal injury!

▷ For any work performed in order to remedy faults observe the relevant

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

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

A

Pump delivers insufficient flow rate

B

Motor overload

C

Excessive discharge pressure

D

Increase in bearing temperature

E

Leakage at the pump

F

Excessive leakage at the shaft seal

G

Vibration during pump operation

H

Impermissible temperature increase in the pump

Table26: Trouble-shooting

A B C D E F G H Possible cause Remedy

9)

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

high pressure.

Re-adjust to duty point.

Check system for impurities.
Increase speed.

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

vented or primed.

Vent and/or prime.

✘ - - - - - - - Supply line or impeller clogged. Remove deposits in the pump and/or piping.

✘ - - - - - - - Formation of air pockets in the piping Alter piping layout.

Fit a vent valve.

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

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

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

available

(positive suction head) is too low.

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

- - - ✘ - - - - Increased axial thrust Contact KSB Service.

✘ - - - - - - - Air intake at the shaft seal Fit new shaft seal.

✘ - - - - - - - Wrong direction of rotation Interchange two of the phases of the power

cable.

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

Check power cable connections.

✘ - - - - - - - Speed is too low. Increase speed, request particulars.

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

- - - ✘ - - ✘ ✘ Insufficient flow rate Increase the minimum flow rate.

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

- ✘ - - - - ✘ - Pump back pressure is lower than
specified in the purchase order.

Re-adjust to duty point.

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

8 Trouble-shooting

62 of 72

Sewatec (60 Hz)

A B C D E F G H Possible cause Remedy

9)

- ✘ - - - - - - Density or viscosity of the fluid pumped
is higher than stated in the purchase
order.

Contact KSB.

- ✘ ✘ - - - - - Speed is too high. Reduce speed, request particulars.

- - - - ✘ - - - Tie bolts/sealing elements Tighten the bolts.

Replace sealing elements.

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

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

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

- - - ✘ - ✘ ✘ - The pump set is misaligned. Check the coupling/belt drive. Re-align if

required.

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

Correct distance according to the general
arrangement drawing.

- ✘ - - - - - - Insufficient operating voltage Increase the voltage.

9 Related Documents

63 of 72

Sewatec (60 Hz)

9 Related Documents

9.1 General assembly drawing: Sewatec with bearing brackets S01, S02, S03,
S04

411.02 903.02

903.03

411.03

101

502

914.10 /
906

550.23*

904.01**

433.02

230

903.01

411.01

163

412.04

412.15 411.46 903.46 433.01 903.22 210

515 /

932.03

932.20 411.22 183

932.02

940.02

360.02

901.01

550.01

902.01

920.01

903.90 411.90 321.01 330 321.02

Fig.31: General assembly drawing: Sewatec with bearing brackets S01, S02, S03, S04 with impeller typeE

Table27: List of components

Part number Description Part number Description

101 Pump casing 502 Casing wear ring

135 Wear plate 515 Taper lock ring

163 Discharge cover 550.01/.04/.23 Disc

164.02 Inspection cover 900.02 Bolt/screw

183 Support foot 901.01 Hexagon head bolt

210 Shaft 902.01 Stud

230 Impeller 903.01/.02/.03/.22/.46/.90 Screw plug

321.01/.02 Radial ball bearing 904.01 Grub screw

330 Bearing bracket 906 Impeller screw

360.02 Bearing cover 914.10/.12/.24 Hexagon socket head cap
screw

411.01/.02/.03/.22/.46/.90 Joint ring 920.01/.17 Nut

412.04/.05/.15/.34 O-ring 932.02/.03/.20 Circlip

433.01/.02 Mechanical seal

9 Related Documents

64 of 72

Sewatec (60 Hz)

9.2 Detailed views

9.2.1 Impeller types

260.01

914.10

Fig.32: F impeller

Table28: List of components

Part No. Description Part No. Description

260.01 Impeller hub cap 914.10 Hexagon socket head cap screw

502

13-6

X

Fig.33: K impeller

X

503

Fig.34: Detail X: impeller wear ring for K impeller

Table29: List of components

Part No. Description Part No. Description

13-6

10)

Casing insert 502

11)

Casing wear ring

503 Impeller wear ring

914.12

412.34
230

914.10

550.23

914.24

135

Fig.35: D impeller

10) Only for Sewatec 100-401 and 200-400

11) Not for Sewatec 100-401

9 Related Documents

65 of 72

Sewatec (60 Hz)

Table30: List of components

Part No. Description Part No. Description

230 Impeller 550.23 Disc

412.34 O-ring 914.10/.12/.24 Hexagon socket head cap screw

9.2.2 Inspection hole, bearing brackets S01 to S04

900.02

920.17

550.04

164.02

412.05

Fig.36: Inspection hole, bearing brackets S01 to S04

Table31: List of components

Part No. Description Part No. Description

164.02 Inspection cover 900.02 Bolt/screw

412.05 O-ring 920.17 Nut

550.04 Disc

9 Related Documents

66 of 72

Sewatec (60 Hz)

9.3 Exploded view: Sewatec with bearing brackets S01, S02, S03, S04

903.03

411.03

411.02

903.02

903.01

411.01

101

502

412.15

940.02

321.02

932.02

360.02

914.10

550.23

230

433.02

433.01

163

412.04

515

321.01

902.01

920.01

903.46

903.22

411.22

411.46

230

230

230

183

901.01

932.20

210

903.90

330

411.90

852*

Fig.37: Exploded view of the pump

* Screwed coupling 852 for Sewatec D 150-251 only

Table32: List of components

Part No. Description Part No. Description

101 Pump casing 502 Casing wear ring

163 Discharge cover 515 Locking ring

183 Support foot 550.23 Disc

210 Shaft 852

12)

Screwed coupling

230 Impeller 901.01 Hexagon head bolt

321.01/.02 Radial ball bearing 902.01 Stud

330 Bearing bracket 903.01/.02/.03/.22/.46/.90 Screw plug

360.02 Bearing cover 914.10 Hexagon socket head cap

screw

411.01/.02/.03/.22/.46/.90 Joint ring 920.01 Nut

412.04/.15 O-ring 932.02/.20 Circlip

433.01/.02 Mechanical seal 940.02 Key

12) For Sewatec D150-251 only

10 EU Declaration of Conformity

67 of 72

Sewatec (60 Hz)

10 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Sewabloc, Sewatec

KSB order number: ...................................................................................................

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Pump (set): EC Machinery Directive (2006/42/EC)

The manufacturer also declares that

▪ the following harmonized international standards have been applied:

– ISO 12100,

– EN 809

Responsible for compiling the technical documentation

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

The EU Declaration of Conformity was issued in/on:

Place, Date

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

13)

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

Name

Function

Company

Address

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

11 Certificate of Decontamination

68 of 72

Sewatec (60 Hz)

11 Certificate of Decontamination

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

Order number/

order item number

14)

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

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

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

Fluid handled

14)

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

Please check where applicable

14)

:

   

Radioactive Explosive Corrosive Toxic

   

Harmful Bio-hazardous Highly flammable Safe

Reason for return

14)

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

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 any hazardous chemicals as well as from biological and radioactive
substances.

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

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

 No special safety precautions are required for further handling.

 The following safety precautions are required for flushing fluids, fluid residues and disposal:

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

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

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

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

Place, date and signature Address Company stamp

14) Required fields

Index

69 of 72

Sewatec (60 Hz)

Index

B

Bearings16

C

Certificate of decontamination68
Commissioning/start-up33
Coupling alignment27

D

Design16
Designation15
Direction of rotation30
Dismantling44
Disposal14

E

Event of damage

Ordering spare parts59

Explosion protection26, 28, 38, 39

F

Fluid handled

Density36

I

Impeller type16
Installation

Installation on the foundation19
Installation at site19
Intended use8

K

Key to safety symbols/markings8

L

Lubricant

Quantity42

M

Maintenance39
Misuse9

O

Operating limits8, 34
Order number6
Other applicable documents6

P

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

nozzles22
Piping21
Preservation13
Priming and venting30
Product description15

R

Reassembly44
Return to supplier13
Returning to service37

S

Safety8
Safety awareness10
Scope of supply18
Shaft seal16

Spare part

Ordering spare parts59
Spare parts stock59
Storage13

T

Tightening torques59
Transport12

Trouble-shooting

Causes and remedies61

W

Warnings8

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)

Tel. [phone]

www.ksb.com

2580.8151/03-EN-US (01482072)