Rdlo - 1387 82_3-10 Intallation_operating Manual.pdf

Dry-installed Volute Casing Pump

RDLO/ RDLO V

Installation/Operating Manual

Legal information/Copyright Installation/Operating Manual RDLO/ RDLO V Original operating manual KSB Aktiengesellschaft Frankenthal All rights reserved. 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 KSB´s express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 21.05.2010

Contents

Contents Glossary ................................................................................................ 5 1

General ................................................................................................ 6

1.1

Principles .......................................................................................................... 6

1.2

Installation of partly completed machinery .................................................. 6

1.3

Target group ................................................................................................... 6

1.4

Other applicable documents .......................................................................... 6

1.5

Symbols ............................................................................................................ 6

2

Safety ................................................................................................... 8

2.1

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

2.2

General ............................................................................................................ 8

2.3

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

2.4

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

2.5

Consequences and risks caused by non-compliance with these operating instructions ...................................................................................................... 9

2.6

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

2.7

Safety instructions for the operator/user .................................................... 10

2.8

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

2.9

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

2.10

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

3

Transport/Temporary Storage/Disposal ........................................... 12

3.1

Transport ....................................................................................................... 12

3.2

Storage and preservation ............................................................................. 13

3.3

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

3.4

Disposal .......................................................................................................... 14

4

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

4.1

General description ....................................................................................... 15

4.2

Designation ................................................................................................... 16

4.3

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

4.4

Design details ................................................................................................ 17

4.5

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

4.6

Noise characteristics ...................................................................................... 18

4.7

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

4.8

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

5

Installation at Site ............................................................................. 21

5.1

Safety regulations ......................................................................................... 21

5.2

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

5.3

Installing the pump set ................................................................................. 21

5.4

Connecting the piping .................................................................................. 30

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Contents

5.5

Protective equipment ................................................................................... 31

5.6

Aligning the pump and motor ..................................................................... 32

5.7

Permissible forces and moments at the pump nozzles ............................... 33

5.8

Auxiliary connections .................................................................................... 34

5.9

Connection to power supply ........................................................................ 35

5.10

Checking the direction of rotation .............................................................. 36

5.11

Removing the transport lock ........................................................................ 36

5.12

Filling in lubricants ........................................................................................ 37

6

Commissioning/Start-up/Shutdown ................................................. 40

6.1

Commissioning/start-up ................................................................................ 40

6.2

Operating limits ............................................................................................ 43

6.3

Shutdown/storage/preservation ................................................................... 46

6.4

Returning to service after storage ............................................................... 46

7

Servicing/Maintenance ...................................................................... 48

7.1

Safety regulations ......................................................................................... 48

7.2

Servicing/inspection ...................................................................................... 48

7.3

Drainage/disposal .......................................................................................... 56

7.4

Dismantling the pump set ............................................................................ 56

7.5

Reassembling the pump set .......................................................................... 60

7.6

Spare parts stock ........................................................................................... 68

8

Trouble-shooting ............................................................................... 69

8.1

Explanation of faults ..................................................................................... 72

9

Related Documents ........................................................................... 74

9.1

Weights of individual components .............................................................. 74

9.2

General assembly drawing with list of components ................................... 75

10

EC Declaration of Conformity .......................................................... 81

11

Certificate of Decontamination ....................................................... 82 Index .................................................................................................. 83

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Glossary

Glossary Certificate of decontamination A certificate of decontamination certifies that the pump (set) has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled.

Discharge line The line which is connected to the discharge nozzle

Drive end

Non-drive end The side of the pump which faces away from the motor

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

Suction lift line/suction head line The line which is connected to the suction nozzle

The side of the pump which faces the motor

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

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1 General

1 General 1.1 Principles This manual is supplied as an integral part of the type series and variants indicated on the front cover. It 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, contact your nearest KSB service centre immediately to maintain the right to claim under warranty. Noise characteristics (⇨ Section 4.6 Page 18)

1.2 Installation of partly completed machinery To install partly completed machinery supplied by KSB, refer to the sub-sections under Servicing/Maintenance. (⇨ Section 7.5.2 Page 62)

1.3 Target group This manual is aimed at the target group of trained and qualified specialist technical personnel. (⇨ Section 2.4 Page 9)

1.4 Other applicable documents Table 1: Overview of other applicable documents Document Data sheet

Content Description of the technical data of the pump (set) General arrangement drawing/ Description of mating and installation dimensions outline drawing for the pump (set) Drawing of auxiliary connections Description of auxiliary connections Hydraulic characteristic curve Characteristic curves showing head, NPSH required, efficiency and power input Sectional drawing of the pump General assembly drawing1) Operating manuals and other documentation of Sub-supplier documentation1) accessories and integrated machinery components Description of spare parts Spare parts lists1) Description of auxiliary piping Piping layout1) 1) Description of all pump components List of components 1) Instructions for assembling the supporting frame Installation instructions

1.5 Symbols Table 2: Symbols used in this manual Symbol ✓ ⊳ ⇨ ⇨ 1)

If agreed to be included in the scope of supply

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Description Conditions which need to be fulfilled before proceeding with the step-by-step instructions Safety instructions Result of an action Cross-references

1 General

Symbol 1.

Description Step-by-step instructions

2. Note Recommendations and important information on how to handle the product

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2 Safety

2 Safety !

DANGER

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

2.1 Key to safety symbols/markings Table 3: Definition of safety symbols/markings Symbol !

DANGER

!

WARNING

CAUTION

Description DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury. WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury. CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions. Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with EC Directive 94/9/EC (ATEX). General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury. Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage. Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions.

2.2 General This manual contains general installation, operating and maintenance instructions that must be observed to ensure safe pump operation and prevent personal injury and damage to property. The safety information in all sections of this manual must be complied with. This manual must be read and completely understood by the responsible specialist personnel/operators prior to installation and commissioning. The contents of this manual must be available to the specialist personnel at the site at all times. Information attached directly to the pump must always be complied with and be kept in a perfectly legible condition at all times. This applies to, for example: ▪ Arrow indicating the direction of rotation ▪ Markings for connections ▪ Name plate The operator is responsible for ensuring compliance with all local regulations which are not taken into account in this manual.

2.3 Intended use The pump (set) must only be operated within the operating limits which are described in the other applicable documents. ▪ Only operate pumps/pump sets which are in perfect technical condition. ▪ Do not operate partially assembled pumps/pump sets.

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2 Safety ▪ Only use the pump to handle the fluids specified in the data sheet or product literature of the respective design variant. ▪ Never operate the pump without the fluid to be handled. ▪ Observe the minimum flow rates indicated in the data sheet or product literature (to prevent overheating, bearing damage, etc). ▪ Observe the maximum flow rates indicated in the data sheet or product literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc). ▪ Do not throttle the flow rate on the suction side of the pump (to prevent cavitation damage). ▪ Consult the manufacturer about any use or mode of operation not described in the data sheet or product literature. Prevention of foreseeable misuse ▪ Never open discharge-side shut-off elements further than permitted. – The maximum flow rate specified in the data sheet or product literature would be exceeded. – Risk of cavitation damage ▪ Never exceed the permissible operating limits specified in the data sheet or product literature regarding pressure, temperature, etc. ▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training All personnel involved must be fully qualified to install, operate, maintain and inspect the machinery this manual refers to. The responsibilities, competence and supervision of all personnel involved in 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.

2.5 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 and safety regulations ▪ Explosion protection regulations

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2 Safety ▪ Safety regulations for handling hazardous substances ▪ Applicable standards and laws

2.7 Safety instructions for the operator/user ▪ The operator shall fit contact guards for hot, cold or moving parts and check that the guards function properly. ▪ Never remove any contact guards when the pump is in operation. The only exception is the guard of the packing chamber. ▪ Connect an earth conductor to the metal jacket if the fluid is electrostatically charged. ▪ Provide 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.)

2.8 Safety information for maintenance, inspection and installation work ▪ Modifications or alterations of the pump are only permitted with the manufacturer's prior consent. ▪ Use only original spare parts or parts authorised by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for resulting damage. ▪ The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual. ▪ Carry out work on the pump (set) during standstill only. ▪ The pump casing must have cooled down to ambient temperature. ▪ Pump pressure must have been released and the pump must have been drained. ▪ When taking the pump set out of service always adhere to the procedure described in the manual. (⇨ Section 6.3 Page 46) ▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3 Page 56) ▪ As soon as the work is completed, re-install and/or re-activate any safety-relevant and protective devices. Before returning the product to service, observe all instructions on commissioning. (⇨ Section 6.1 Page 40)

2.9 Unauthorised modes of operation Never operate the pump (set) outside the limits stated in the data sheet and in this manual. The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use. (⇨ Section 2.3 Page 8)

2.10 Explosion protection !

DANGER

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Always observe the information on explosion protection given in this section when operating the pump (set) in potentially explosive atmospheres.

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2 Safety

Only pumps/pump sets marked as explosion-proof and identified as such in the data sheet may be used in potentially explosive atmospheres. Special conditions apply to the operation of explosion-proof pump sets to EC Directive 94/9/EC (ATEX). The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. Never operate the pump set outside the limits stated on the data sheet and on the name plate. Prevent impermissible modes of operation at all times. For information on application options of individual components (if any) in potentially explosive atmospheres, refer to the manufacturer's product literature. 2.10.1 Repair Special regulations apply to repair work on explosion-proof pumps. Modifications or alteration of the pump set may affect explosion protection and are only permitted after consultation with the manufacturer. Repair work at the flameproof joints must only be performed in accordance with the manufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 is not permitted.

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3 Transport/Temporary Storage/Disposal

3 Transport/Temporary Storage/Disposal 3.1 Transport

DANGER Lifting lugs of pump/motor/base frame overloaded Danger to life from falling parts! ▷ Never transport the completely assembled pump set. ▷ Always transport the pump set components (pump/motor/baseplate) individually. ▷ Refer to the weights of the individual components stated in the manufacturer's product literature.

DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump or components in the specified position. ▷ Never attach the lifting tackle to the free shaft end of the pump. ▷ Refer to the weights indicated for the individual components. ▷ Comply with the applicable health and safety regulations. ▷ Use a suitable, permitted load handling attachment, e.g. self-tightening lifting tongs.

DANGER Improper transport Risk of personal injury from lifting heavy components! ▷ Select hoisting tackles which are suitable for the component weight. ▷ Always use the attachment points provided for suspending components from the hoisting tackle. ▷ Comply with the applicable health and safety regulations. RDLO and RDLOV pump sets are generally supplied as individual components. Due to the weights of the individual components, the pump set is only assembled at the site. 1. Refer to the weights of the individual components stated in the general arrangement drawing and/or the manufacturer's product literature. 2. Select suitable hoisting tackle. Transport the pump and individual components as illustrated. Refer to the product literature of the motor sub-supplier for transporting the motor!

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3 Transport/Temporary Storage/Disposal

Table 4: Transporting individual components

Transporting the pump (figure 0)

Transporting the pump (figure 0) vertically on the base frame

Transporting the base frame (3E installation)

Transporting the supporting frame (DP installation)

3.2 Storage and preservation If commissioning is to take place some time after delivery, we recommend that the following measures be taken for pump storage:

CAUTION Damage during storage by 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 set! ▷ Only remove caps/covers from the openings of the pump set at the time of installation.

CAUTION Bearings in the same position for a prolonged period of time Damage to the rolling element bearings! ▷ Rotate the shaft by hand once a month with suitable tools. ▷ Store the pump in a vibration-free room.

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3 Transport/Temporary Storage/Disposal

CAUTION Pump stored too long or incorrectly Damage to the pump! ▷ Check especially the rolling element bearings and the lubricant. If any previous damage is suspected, replace the rolling element bearings. ▪ Store the pump and supplied components under dry, vibration-free conditions, if possible in its original packaging. ▪ The ambient temperatures for transport and storage must not be below -20 °C or above 60 °C. 1. Manually rotate the pump shaft once a month with suitable tools. 2. Spray the preservative through the suction and discharge nozzles. It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).

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

3.3 Return to supplier 1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 56) 2. Always flush and clean the pump, particularly if it has been used for handling noxious, explosive, hot or other hazardous fluids. 3. If the fluids handled by the pump leave residues which might lead to corrosion damage when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the pump set must also be neutralised, and anhydrous inert gas must be blown through the pump for drying purposes. 4. Always complete and enclose a certificate of decontamination when returning the pump (set). (⇨ Section 11 Page 82) It is imperative to indicate any safety and decontamination measures taken.

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

3.4 Disposal

WARNING Fluids posing a health hazard Hazardous to persons and the environment! ▷ Collect and properly dispose of flushing liquid and any fluid residues. ▷ Wear safety clothing and a protective mask, if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard. 1. Dismantle the pump (set). Collect greases and other lubricants during dismantling. 2. Separate and sort the pump materials, e.g. by: - Metals - Plastics - Electronic waste - Greases and other lubricants 3. Dispose of materials in accordance with local regulations or in another controlled manner.

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4 Description of the Pump (Set)

4 Description of the Pump (Set) 4.1 General description ▪ Volute casing pump installed in horizontal or vertical position ▪ Volute casing pump with double-entry radial impeller Pump for applications in water works, irrigation and drainage pumping systems, power stations and industrial water supply. Table 5: Types of installation Type of installation Figure 2E

Drawing

Description Pump and drive on separate foundation rails

Figure 3E

Pump and drive on a common baseframe

Figure 4E

Pump and drive on separate baseframes

Figure DJ

Pump on its own baseframe Drive on a different construction level

Figure DP

Pump on base frame and drive on supporting frame

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4 Description of the Pump (Set)

4.2 Designation Horizontally installed pump Example: RDLO 600 - 600 A GB P F Table 6: Key to the designation Code RDLO 600 600 A GB P F

Description Type series Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Impeller type Material combination, e.g. GB = grey cast iron/bronze Shaft seal, e.g. P = gland packing Lubrication of bearings, e.g. F = grease

Vertically installed pump Example: RDLO V 600 - 600 A GB P F Table 7: Key to the designation Code RDLO V 600 600 A GB P F

Description Type series Vertical design Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Impeller type Material combination, e.g. GB = grey cast iron/bronze Shaft seal, e.g. P = gland packing Lubrication of bearings, e.g. F = grease

4.3 Name plate Aktiengesellschaft D-67227 Frankenthal

1 2 3 4 5

6

2009 RDLO 400 - 665 A P-No. 9971507641 / 000100 Q 2400 m3/h H 65,00 m n 991 1/min SNr. 253227 Gew. 3200 kg Mat.-No.

01 111 383

7 8 9

ZN 3804 - D 74 x 105

Fig. 1: Example: Name plate 1 3 5 7 9

Designation of the pump set Flow rate Weight of Fig. 0 pump Order item number Serial number

2 4 6 8

Order number Speed Year of supply Head

Additional plate on explosion-proof pumps 1

II 2 G T4 Mat.-No.

01 064 970

ZN 3823 - 179

Fig. 2: Example: Additional plate on explosion-proof pumps 1

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Explosion protection marking

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4 Description of the Pump (Set)

CAUTION The explosion protection marking on the pump only refers to the pump part. Other components of the pump set, such as coupling and motor, must be regarded separately. An EC declaration by the manufacturer is required for each component.

4.4 Design details Design ▪ Volute casing pump ▪ Horizontal/vertical installation ▪ Single-stage ▪ Nominal diameter of the discharge nozzle: 350 mm to 700 mm Pump casing ▪ Axially split volute casing ▪ Volute casing with integrally cast pump feet ▪ Replaceable casing wear rings ▪ Mating dimensions to EN or ASME Impeller type ▪ Double-entry radial impeller Optionally with impeller wear rings Pump shaft ▪ Completely dry shaft for design with rolling element bearings ▪ Shaft protecting sleeves in the seal area Shaft seal ▪ Gland packing ▪ Balanced mechanical seal Bearings For horizontal installation: ▪ Grease-packed rolling element bearings ▪ Oil-lubricated rolling element bearings For vertical installation: ▪ Grease-packed rolling element bearings ▪ Bottom: product-lubricated rubber plain bearing / Top: grease-packed rolling element bearing

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4 Description of the Pump (Set)

4.5 Configuration and function 4

5

6 7

3 2

8 9

1

10

Fig. 3: Sectional drawing 1 3 5 7 9 Design

Function

Sealing

Suction nozzle Rolling element bearing Impeller Shaft Shaft seal

2 4 6 8 10

Bearing housing Volute casing Clearance gap Rolling element bearing Discharge nozzle

The pump is designed with a tangential fluid inlet and a tangential fluid outlet. The hydraulic system runs in its own bearings and is connected to the motor by a shaft coupling. The fluid enters the pump tangentially via a suction nozzle (1) and is accelerated outward in a cylindrical flow by the rotating impeller (5). The flow profile of the pump casing converts the kinetic energy of the fluid into pressure energy. The fluid is pumped to the discharge nozzle (10), where it leaves the pump. The clearance gap (6) prevents any fluid from flowing back from the casing into the inlet. The shaft (7) enters the hydraulic system through the volute casing (4). The shaft passage through the seal housing is sealed towards the atmosphere with a shaft seal (9). The shaft runs in rolling element bearings (3 and 8), which are supported by a bearing housing (2) and linked with the volute casing (4). The pump is sealed by a shaft seal. Standardised mechanical seal or gland packing

4.6 Noise characteristics Table 8: Surface sound pressure level LpA2)

2)

Rated power input PN [kW]

< 595 rpm [dB (A)]

Pump

100 150 200 250 300

70.6 72.8 74.3 75.5 76.5

715 rpm 740 rpm [dB (A)] 71.7 73.8 75.3 76.4 77.4

985 rpm 1180 rpm [dB (A)] 72.8 74.9 76.3 77.5 78.4

1480 rpm 1780 rpm [dB (A)] 73.8 75.8 77.3 78.4 79.3

Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.80 - 1.1 range and for noncavitating operation. If noise levels are to be warranted: Add an allowance of +3 dB for measuring and manufacturing tolerances.

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4 Description of the Pump (Set)

Rated power input PN [kW]

< 595 rpm [dB (A)]

Pump

350 400 450 500 600 700 800 900 1000 1200 1400 1600 1800 2000 2250 2500 2750 3000 3500 4000 4500 5000

77.3 78.0 78.7 79.2 80.2 81.0 81.7 82.4 82.9 83.9 84.7 85.4 86.0 86.6 87.2 87.8 88.3 88.8 89.6 90.3 90.9 91.5

715 rpm 740 rpm [dB (A)] 78.2 78.9 79.5 80.1 81.0 81.8 82.5 83.1 83.7 84.6 85.4 86.1 86.7 87.3 87.9 88.5 88.9 89.4 90.2 90.9 91.5 92.1

985 rpm 1180 rpm [dB (A)] 79.2 79.9 80.5 81.0 81.9 82.7 83.4 84.0 84.5 85.5 86.3 86.9 87.5 88.1 88.7 89.2 89.7 90.1 90.9 91.6 92.2 92.7

1480 rpm 1780 rpm [dB (A)] 80.1 80.7 81.3 81.8 82.8 83.5 84.2 84.8 85.3 86.2 87.0 87.6 88.2 88.7 89.3 89.9 90.3 90.8 91.5 92.2 92.8 93.3

4.7 Scope of supply Depending on the model, the following items are included in the scope of supply: ▪ Pump ▪ Drive ▪ Baseplate ▪ Coupling, coupling guard ▪ Cardan shaft ▪ Fasteners for pump and baseframe ▪ Optional accessories: – Vibration monitoring – PT 100 – Constant-level oiler – Pressure gauge – Measuring nipple for shock pulse measurement – Cyclone

4.8 Dimensions and weights For dimensions and weights please refer to the data sheet of the pump/pump set. ▪ Pump weight: See name plate of the pump. ▪ Motor weight: See motor documentation. ▪ Base frame weight: See weight indicated on the base frame.

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4 Description of the Pump (Set)

NOTE Some individual components weigh more than 25 kg. Refer to the indicated weights! (⇨ Section 9.1 Page 74)

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5 Installation at Site

5 Installation at Site 5.1 Safety regulations For all work involving assembly, reassembly and installation, observe the following safety information:

DANGER Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set! ▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information in the data sheet and on the name plates of pump and motor.

DANGER Improper transport Risk of personal injury from lifting heavy components! ▷ Select hoisting tackles which are suitable for the component weight. ▷ Always use the attachment points provided for suspending components from the hoisting tackle. ▷ Comply with the applicable health and safety regulations.

5.2 Checks to be carried out prior to installation Place of installation

WARNING Installation on foundations which are unsecured and cannot support the load Personal injury and damage to property! ▷ Make sure the foundation concrete is of sufficient strength in accordance with the general arrangement drawing. ▷ Only place the pump set on a foundation whose concrete has set firmly. ▷ Only place the pump set on a horizontal and level surface. ▷ Refer to the weights given in the general arrangement drawing. 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 Depending on the type of installation, several instructions need to be carried out: ▪ Prepare and install the base frame/supporting frame. ▪ Install the pump and motor on the prepared base frame/supporting frame. ▪ Check the alignment of pump and motor. ▪ Align the pump with the piping. ▪ Install and align the coupling. ▪ Connect the piping. ▪ Perform precision alignment of pump and motor ▪ Remove any transport locks.

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5 Installation at Site

5.3.1 2E installation

DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump or components in the specified position. ▷ Never attach the lifting tackle to the free shaft end of the pump. ▷ Refer to the weights indicated for the individual components. ▷ Comply with the applicable health and safety regulations. ▷ Use a suitable, permitted load handling attachment, e.g. self-tightening lifting tongs.

Fig. 4: 2E installation, pump and motor on separate foundation rails ✓ The relevant general arrangement drawing is available. ✓ The foundation has the required strength and characteristics. ✓ The foundation has been prepared in accordance with the dimensions given in the general arrangement drawing. 1

2 3 4

Fig. 5: Installation drawing 1. Fasten the pump to the foundation rails as per general arrangement drawing. 2. Screw levelling screws (2) into the foundation rails (1) in accordance with the general arrangement drawing. 3. Insert the foundation bolts (4) into the drilled holes of the foundation rails (1). 4. Place shims (3) into the foundation recesses for the foundation rails (1). 5. Place the pump on the foundation with the fitted foundation rails (1), the levelling screws (2) and the inserted foundation bolts (4). Position the levelling screws (2) on the shims (3) in upright position. 6. Align the pump with the motor and piping. ⇨ If the motor has already been fastened, align the pump with the piping and the motor. Always align the pump horizontally.

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5 Installation at Site ⇨ If the motor has not been fastened yet, the pump only needs to be roughly aligned with the motor. Align the pump with the piping. Always align the pump horizontally. 7. Grout the holes for the foundation bolts and the recesses of the foundation rails with quick-setting, low-shrinkage concrete as far as to the lower edge of the foundation rails.3) Make sure that the space underneath the foundation rails is completely grouted. 8. When the concrete has set, tighten the foundation bolts evenly to the tightening torque indicated in the general arrangement drawing. 9. Grout the recesses of the foundation rails with a quick-setting, low-shrinkage concrete mixture.3) 10. Install and align the coupling in accordance with the coupling manufacturer's operating instructions (see the manufacturer's product literature included with the supplied documentation). 5.3.2 3E installation

DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump or components in the specified position. ▷ Never attach the lifting tackle to the free shaft end of the pump. ▷ Refer to the weights indicated for the individual components. ▷ Comply with the applicable health and safety regulations. ▷ Use a suitable, permitted load handling attachment, e.g. self-tightening lifting tongs.

Fig. 6: 3E installation - pump and motor on a common base frame ✓ The relevant general arrangement drawing is available. ✓ The foundation has the required strength and characteristics. ✓ The foundation has been prepared in accordance with the dimensions given in the general arrangement drawing.

3)

Refer to the general arrangement drawing for the required concrete quality.

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5 Installation at Site

1 2

3

Fig. 7: Installation drawing 1.

Place the height adjusting spindles (3) next to the holes for the foundation bolts (2) in accordance with the general arrangement drawing.

2.

Insert the foundation bolts (2) into the drilled holes of the base frame (1).

3.

Place the base frame (1) with inserted foundation bolts (2) onto the height adjusting spindles (3). Use the spindles to align the base frame.

4.

Place the pump and motor onto the base frame and roughly align the shafts with each other. Roughly align the pump with the piping.

5.

Grout the holes for the foundation bolts with a quick-setting, low-shrinkage concrete mixture. 4)

6.

When the concrete has set, tighten the foundation bolts evenly until there is no clearance between the nuts and the base frame.

7.

Use suitable hoisting tackle to lift the pump and motor off the base frame.

8.

Grout the base frame with a quick-setting, low-shrinkage concrete mixture. 4) Make sure that the base frame is completely grouted and that no cavities remain.

9.

When the concrete has set, tighten the foundation bolts evenly to the tightening torque indicated in the general arrangement drawing.

10. Lift the pump and motor onto the base frame with a suitable hoisting tackle and align the shafts with each other. 11. Align and connect the pump with the piping. (⇨ Section 5.4 Page 30) 12. Install the pump and the motor on the base frame in accordance with the general arrangement drawing. 13. Install and align the coupling in accordance with the coupling manufacturer's operating instructions (see the manufacturer's product literature included with the supplied documentation).

4)

Refer to the general arrangement drawing for the required concrete quality.

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5.3.3 4E installation

DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump or components in the specified position. ▷ Never attach the lifting tackle to the free shaft end of the pump. ▷ Refer to the weights indicated for the individual components. ▷ Comply with the applicable health and safety regulations. ▷ Use a suitable, permitted load handling attachment, e.g. self-tightening lifting tongs.

Fig. 8: Pump and motor on separate base plates ✓ The relevant general arrangement drawing is available. ✓ The foundation has the required strength and characteristics. ✓ The foundation has been prepared in accordance with the dimensions given in the general arrangement drawing. 1 2

3

Fig. 9: Installation drawing

5)

1.

Place the height adjusting spindles (3) next to the holes for the foundation bolts (2) in accordance with the general arrangement drawing.

2.

Insert the foundation bolts (2) into the drilled holes of the base frames (1).

3.

Place the base frames (1) with inserted foundation bolts (2) onto the height adjusting spindles (3). Use the spindles to align the base frames.

4.

Place the pump and motor onto the base frame and roughly align the shafts with each other. Roughly align the pump with the piping.

5.

Grout the holes for the foundation bolts with a quick-setting, low-shrinkage concrete mixture. 5)

Refer to the general arrangement drawing for the required concrete quality.

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6.

When the concrete has set, tighten the foundation bolts evenly until there is no clearance between the nuts and the base frame.

7.

Use suitable hoisting tackle to lift the pump and motor off the base frame.

8.

Grout the base frames with a quick-setting, low-shrinkage concrete mixture. 5) Make sure that the base frame is completely grouted and that no cavities remain.

9.

When the concrete has set, tighten the foundation bolts evenly to the tightening torque indicated in the general arrangement drawing.

10. Lift the pump and motor onto the base frames with a suitable hoisting tackle and align the shafts with each other. 11. Align and connect the pump with the piping. (⇨ Section 5.4 Page 30) 12. Install the pump and the motor on the base frame in accordance with the general arrangement drawing. 13. Install and align the coupling in accordance with the coupling manufacturer's operating instructions (see the manufacturer's product literature included with the supplied documentation). 5.3.4 DJ installation

DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump or components in the specified position. ▷ Never attach the lifting tackle to the free shaft end of the pump. ▷ Refer to the weights indicated for the individual components. ▷ Comply with the applicable health and safety regulations. ▷ Use a suitable, permitted load handling attachment, e.g. self-tightening lifting tongs.

Fig. 10: Pump on its own base frame, drive on a different construction level ✓ The relevant general arrangement drawing is available. ✓ The foundation has the required strength and characteristics. ✓ The foundation has been prepared in accordance with the dimensions given in the general arrangement drawing. ✓ The motor is installed on a separate base frame on a higher level in the building in accordance with the manufacturer's operating instructions.

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1 2

3

Fig. 11: Installation drawing 1.

Place the height adjusting spindles (3) next to the holes for the foundation bolts (2) in accordance with the general arrangement drawing.

2.

Insert the foundation bolts (2) into the drilled holes of the base frame (1).

3.

Place the base frame (1) with inserted foundation bolts (2) onto the height adjusting spindles (3). Use the spindles to align the base frame.

4.

Align the pump with the motor and piping. ⇨ If the motor has already been fastened, align the pump with the piping and motor. ⇨ If the motor has not been fastened yet, the pump only needs to be roughly aligned with the motor. Align the pump with the piping. ⇨ If the motor is connected via a Cardan shaft, always observe the manufacturer's product literature included in the supplied documentation.

5.

Grout the holes for the foundation bolts with a quick-setting, low-shrinkage concrete mixture. 6)

6.

When the concrete has set, tighten the foundation bolts evenly until there is no clearance between the nuts and the base frame.

7.

Grout the base frame with a quick-setting, low-shrinkage concrete mixture. 6) Make sure that the base frame is completely grouted and that no cavities remain.

8.

When the concrete has set, tighten the foundation bolts evenly to the tightening torque indicated in the general arrangement drawing.

9.

Install the pump on the base frame in accordance with the general arrangement drawing.

10. Install the motor on the supporting frame. 11. Align and connect the pump with the piping. (⇨ Section 5.4 Page 30) 12. Install and align the coupling or Cardan shaft in accordance with the manufacturer's operating instructions (see the manufacturer's product literature included with the supplied documentation).

6)

Refer to the general arrangement drawing for the required concrete quality.

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5.3.5 DP installation

DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump or components in the specified position. ▷ Never attach the lifting tackle to the free shaft end of the pump. ▷ Refer to the weights indicated for the individual components. ▷ Comply with the applicable health and safety regulations. ▷ Use a suitable, permitted load handling attachment, e.g. self-tightening lifting tongs.

Fig. 12: Pump on base frame and motor on supporting frame Positioning the pump with pre-assembled base frame ✓ The relevant general arrangement drawing is available. ✓ The relevant installation instructions for the supporting frame of the motor are available. ✓ The foundation has the required strength and characteristics. ✓ The foundation has been prepared in accordance with the dimensions given in the general arrangement drawing. 1 2

3

Fig. 13: Installation drawing 1. Place the height adjusting spindles (3) next to the holes for the foundation bolts (2) in accordance with the general arrangement drawing.

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2. Insert the foundation bolts (2) into the drilled holes of the base frame (1). 3. Place the base frame (1) with inserted foundation bolts (2) onto the height adjusting spindles (3). Use the spindles to align the base frame. 4. Align the pump with the piping. Installing the supporting frame of the motor

1 2 3 4

Fig. 14: Installation drawing 1. Pre-assemble the supporting frame of the motor in accordance with the installation instructions for the supporting frame. 2. Screw levelling screws (2) into the foundation rails (1) in accordance with the general arrangement drawing. 3. Insert the foundation bolts (4) into the drilled holes of the foundation rails (1). 4. Place shims (3) into the recesses for the foundation rails (1) in the foundation. 5. Use suitable hoisting tackle to place the supporting frame of the motor with the pre-assembled foundation rails (1) on the foundation together with the levelling screws (2) and the inserted foundation bolts (4). Position the levelling screws (2) on the shims (3) in upright position.

DANGER Unsecured motor Danger from falling components ▷ Always secure the motor additionally with a crane until the supporting frame has been completely grouted and the concrete has reached its full strength. 6. Align the supporting frame of the motor with the pump. The motor can be preassembled to the supporting frame (see the manufacturer's product literature included in the supplied documentation). 7. Grout the holes for the foundation bolts and the recesses of the foundation rails with quick-setting, low-shrinkage concrete as far as to the lower edge of the foundation rails.7) Make sure that the space underneath the foundation rails is completely grouted. 8. When the concrete has set, tighten the foundation bolts evenly to the tightening torque indicated in the general arrangement drawing. 9. Grout the holes for the foundation bolts with a quick-setting, low-shrinkage concrete mixture. 7)

7)

Refer to the general arrangement drawing for the required concrete quality.

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10. When the concrete has set, the motor can be mounted on the supporting frame. Observe the motor manufacturer's operating instructions! Final assembly 1. Align the pump on the base frame with the motor on the supporting frame. Align and connect the pump with the piping. (⇨ Section 5.4 Page 30) 2. Grout the holes for the foundation bolts in the base frame of the pump with a quick-setting, low-shrinkage concrete mixture. 7) 3. When the concrete has set, tighten the foundation bolts evenly until there is no clearance between the nuts and the base frame. 4. Grout the base frame with a quick-setting, low-shrinkage concrete mixture.7) Make sure that the base frame is completely grouted and that no cavities remain. 5. When the concrete has set, tighten the foundation bolts evenly to the tightening torque indicated in the general arrangement drawing. 6. Install the pump on the base frame in accordance with the general arrangement drawing. 7. Mount the motor on the supporting frame in accordance with the general arrangement drawing. 8. Install and align the coupling in accordance with the coupling manufacturer's operating instructions (see the manufacturer's product literature included with the supplied documentation).

5.4 Connecting the piping

DANGER Impermissible loads acting on the pump nozzles Danger to life from leakage of hot, toxic, corrosive or flammable fluids! ▷ Do not use the pump as an anchorage point for the piping. ▷ Anchor the pipelines in close proximity to the pump and connect them without transmitting any stresses or strains. ▷ Observe the permissible forces and moments at the pump nozzles. (⇨ Section 5.7 Page 33) ▷ Take appropriate measures to compensate thermal expansion of the piping.

CAUTION Incorrect earthing during welding work at the piping Destruction of rolling element bearings (pitting effect)! ▷ Never earth the electric welding equipment on the pump or baseplate. ▷ Prevent current flowing through the rolling element bearings.

NOTE It is recommended to install check and shut-off elements in the system, depending on the type of plant and pump. However, such elements must not obstruct proper drainage or hinder disassembly of the pump. ✓ The suction lift line/suction head line has been laid with a rising/downward slope towards the pump. ✓ The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump nozzles. ✓ To prevent excessive pressure losses, adapters to larger diameters have a diffuser angle of approx. 8°. ✓ The pipelines have been anchored in close proximity to the pump and connected without transmitting any stresses or strains. 1. Thoroughly clean, flush and blow through all vessels, pipelines and connections (especially for new installations).

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

Fig. 15: Connection with expansion joints 3. If the owner/operator supplies an expansion joint, it has to be braced with external tie rods to prevent impermissible nozzle loads. It is impermissible to connect the pump with unbraced expansion joints.

CAUTION Welding beads, scale and other impurities in the piping Damage to the pump! ▷ Free the piping from any impurities. ▷ If necessary, install a filter. ▷ Observe the instructions in (⇨ Section 7.2.2.4 Page 52). 4. If required, install a filter in the piping. 5. Connect the pump nozzles to the piping.

CAUTION Aggressive flushing and pickling agents Damage to the pump! ▷ Match the cleaning operation mode and duration for flushing and pickling service to the casing and seal materials used.

5.5 Protective equipment

WARNING Failure to re-install or re-activate protective devices Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is completed, re-install and/or re-activate all safety-relevant and protective devices.

WARNING Volute casing and bearing housing take on the same temperature as the fluid handled. Risk of burns! ▷ Insulate the volute casing. ▷ Fit protective equipment.

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CAUTION Heat build-up in the bearing housing Damage to the bearing! ▷ Never insulate the bearing housing and bearing cover.

5.6 Aligning the pump and motor

DANGER Impermissible temperatures at the coupling or bearings caused by misalignment of the coupling Explosion hazard! ▷ Make sure that the coupling is correctly aligned at all times.

CAUTION Misalignment of pump and motor shafts Damage to pump, motor and coupling! ▷ Always check the coupling after the pump has been installed and connected to the piping. ▷ Also check the coupling of pump sets supplied with pump and motor mounted on the same baseplate.

a)

1

1

b)

A

B

A

B

A

B

A

B

1

1

2

2

Fig. 16: a) Checking the coupling alignment and b) Aligning a spacer-type coupling 1

Straight-edge

2

Wedge gauge

✓ The coupling guard and step guard, if any, have been removed. 1. Place the straight-edge axially on both coupling halves. 2. Leave the straight-edge 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 between the two coupling halves must not exceed 0.05 mm. Observe the coupling manufacturer's operating instructions! 3. In case of a misalignment unscrew the hexagon head bolts at the motor. 4. Insert shims underneath the motor feet until the difference in shaft centre height has been compensated. 5. Re-tighten the hexagon head bolts. 6. Check that the coupling and shaft can easily be rotated by hand.

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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). 7. Re-install the coupling guard and step guard, if any. 8. Check the distance between coupling and coupling guard. The coupling guard must not touch the coupling.

5.7 Permissible forces and moments at the pump nozzles

Fig. 17: Flange coordinates The resulting permissible forces have been determined according to:

The data on forces and moments apply to static pipelines only. If the limits are exceeded, check and verify the values. If a computerised 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. Table 9: Forces and moments at the pump nozzles Material Size 350 - 575 350 - 690

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Suction and discharge nozzles Cast iron Fx / Fy / Fz Mx / My / Mz [N] [Nm] 5900 3300

Suction and discharge nozzles Nodular cast iron/cast steel Fx / Fy / Fz Mx / My / Mz [N] [Nm] 8300 4600

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Material Size 400 - 525 400 - 580 400 - 665 400 - 705 400 - 935 500 - 585 500 - 685 500 - 835 500 - 860 500 - 1015 500 - 1035 600 - 600 600 - 705 600 - 885 600 - 1075 700 - 980

Suction and discharge nozzles Cast iron Fx / Fy / Fz Mx / My / Mz [N] [Nm] 6900 3800

Suction and discharge nozzles Nodular cast iron/cast steel Fx / Fy / Fz Mx / My / Mz [N] [Nm] 9700 5300

8800

4900

12300

6900

10700

6000

15000

8400

12600

7100

17600

9900

5.8 Auxiliary connections

WARNING Screwed plugs subjected to pressure Risk of injuries by parts flying off and escaping fluid! ▷ Never use screwed plugs for releasing pressure from the pump casing.

CAUTION Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing liquid, etc.) Malfunction of the pump! ▷ Refer to the general arrangement drawing, the piping layout and pump markings (if any) for the dimensions and locations of auxiliary connections. ▷ Use the auxiliary connections provided. The pump is supplied with a flushing line fitted at the factory. The following auxiliary connections are available:

Fig. 18: Auxiliary connections

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Table 10: Auxiliary connections Connection Description

Connection type G 1/2

1M.1

Connection for pressure measurement on the suction side

1M.2

Connection for pressure measurement on the discharge G 1/2 side Connection for temperature measurement at the drive end G 1/2

4M.1 4M.2

G 1/2

6B 6B.1 6B.2 6D 8A

Connection for temperature measurement at the nondrive end Connection for pump drain on the suction side Connection for pump drain on the suction side Connection for pump drain on the discharge side Connection for venting the pump Connection for leakage drain

8A.1

Connection for leakage drain

G 1/2

8A.3 26M.1 26M.2

drain8)

Connection for leakage Connection for vibration measurement at the drive end Connection for vibration measurement at the non-drive end

G1 G1 G1 G1 G 3/4 G 3/4 M8 M8

5.9 Connection to power supply

DANGER Incorrect electrical installation Explosion hazard! ▷ For electrical installation, also observe the requirements of IEC 60079-14. ▷ Always connect explosion-proof motors via a motor protection switch.

DANGER Work on the pump set by unqualified personnel Danger of death from electric shock! ▷ Always have the electrical connections installed by a trained electrician. ▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pump sets, IEC 60079 (DIN VDE 0165). ▷ Observe the motor manufacturer's operating instructions.

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 It is recommended to fit a motor protection device.

8)

Not applicable for models with a plain bearing

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5.9.1 Earthing

DANGER Electrostatic charging Explosion hazard! Fire hazard! Damage to the pump set! ▷ Connect the PE conductor to the earthing terminal provided.

5.10 Checking the direction of rotation

DANGER Temperature increase resulting from contact between rotating and stationary components Explosion hazard! Damage to the pump set! ▷ Never check the direction of rotation by starting up the unfilled pump set. ▷ Separate the pump from the motor to check the direction of rotation.

DANGER Rotating shaft during direction of rotation check Risk of personal injury! ▷ Maintain a safe distance to the pump set. ▷ Comply with the general health and safety regulations.

CAUTION Motor 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, interchange any two phases to correct the direction of rotation. ✓ The pump has been completely separated from the motor. ✓ All components at the motor (e.g. coupling half at the motor shaft) have been secured. 1. Start the motor and stop it again immediately to determine the motor's direction of rotation. 2. Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. 3. If the motor runs in the wrong direction of rotation, check the electrical connection of the motor and the control system, if applicable.

5.11 Removing the transport lock 5.11.1 Removing the transport lock at the mechanical seals Remove the transport lock at both mechanical seals. Remove three lockwashers per mechanical seal.

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550.5 901.3

524.2 Fig. 19: Transport lock 1. Slightly loosen bolt 901.3. 2. Turn lockwashers 550.5 to remove them from the groove in shaft protecting sleeve 524.2. 3. Secure lockwashers 550.5 again with bolts 901.3. 5.11.2 Removing the transport lock of vertical pumps This type of transport lock is only used for vertical pumps with product-lubricated plain bearing.

160 903.11 Fig. 20: Transport lock

900.2

1. Undo screw 900.2 at cover 160. 2. Close the drilled hole in cover 160 with plug 903.11.

5.12 Filling in lubricants

CAUTION Temporary storage of the pump set too long Formation of deposits or condensate, resinification or leakage of grease! ▷ Change the complete grease fill before returning the pump set to service. ▷ Replace the grease fill every time the bearings are dismantled. Grease-lubricated bearings

Grease-lubricated bearings have been packed with grease at the factory. Prior to commissioning, re-lubricate the bearings with doubled re-lubrication quantities. Grease quality see (⇨ Section 7.2.2.5.1.4 Page 53) Grease quantity see (⇨ Section 7.2.2.5.1.5 Page 53)

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Re-lubricating the pump with grease

CAUTION Contaminated lubricating nipples The lubricating grease could become contaminated! ▷ Clean the grease lubricating nipples beforeusing them for re-lubricating. 1. Clean the lubricating nipples, if contaminated. 2. Insert the grease press into the lubricating nipple. 3. Press in the grease. Oil-lubricated bearings

Top up the bearing housing with lubricating oil. Oil quality see (⇨ Section 7.2.2.5.2.3 Page 55) Oil quantity see (⇨ Section 7.2.2.5.2.4 Page 55) Filling the constant-level oiler with lubricating oil (oil-lubricated bearings only)

CAUTION Insufficient lubricating oil in the reservoir of the constant-level oiler Damage to the bearings! ▷ Regularly check the oil level. ▷ Always fill the oil reservoir completely. ▷ Keep the oil reservoir properly filled at all times.

NOTE An excessively high oil level can lead to a temperature rise and to leakage of the fluid handled or oil. Fitting the constant-level oiler

NOTE The installation position of the constant-level oiler depends on the direction of rotation of the pump. The pump is equipped with one constant-level oiler per bearing housing. If they have not already been fitted at the factory, fit them as follows: 1. Undo the screwed plug on the relevant side of the bearing housing. Watch the direction of rotation!

Fig. 21: Position of the constant-level oiler 2. Screw constant-level oiler 638 with nipple joint 720.2 into the bearing housing.

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Bearing housing with constant-level oiler

672

638

720.2

903.4 411.3 Fig. 22: Installation drawing for the constant-level oiler ✓ The constant-level oiler has been fitted. ✓ Screwed plug 903.4 has been screwed in. 1. Remove vent plug 672. 2. Pull the reservoir of the constant-level oiler upwards and off. 3. Fill oil through the opening for vent plug 672 until oil is visible at the bottom inside the fit of constant-level oiler 638. 4. Fill the reservoir of constant-level oiler 638 with oil and return it to its operating position. 5. After approximately 5 minutes, check the oil level in the glass reservoir of the constant-level oiler 638. The oil reservoir must be properly filled at all times to provide an optimum oil level. Repeat steps 1 - 5, if necessary.

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6 Commissioning/Start-up/Shutdown

6 Commissioning/Start-up/Shutdown 6.1 Commissioning/start-up 6.1.1 Prerequisites for commissioning/start-up Before starting up the pump set make sure that the following requirements are met: ▪ The pump set has been properly connected to the electric power supply and is equipped with all protection devices. (⇨ Section 5.9 Page 35) ▪ The pump has been primed with the fluid to be handled. (⇨ Section 6.1.2 Page 40) ▪ The direction of rotation has been checked. (⇨ Section 5.10 Page 36) ▪ All auxiliary connections required are connected and operational. (⇨ Section 5.8 Page 34) ▪ The transport lock has been removed. (⇨ Section 5.11 Page 36) ▪ The lubricants have been checked and filled in. (⇨ Section 5.12 Page 37) ▪ After prolonged shutdown of the pump (set), the activities described in (⇨ Section 6.4 Page 46) have been carried out. ▪ The coupling alignment has been checked. (⇨ Section 5.6 Page 32) 6.1.2 Filling and venting the pump

DANGER Risk of potentially explosive atmosphere inside the pump Explosion hazard! ▷ Before starting up the pump, vent the suction line and the pump and prime them with the fluid to be handled.

DANGER Shaft seal failure caused by dry running Hot fluid may escape! ▷ Before starting up the pump set, vent the pump and suction line and fill both with the fluid to be handled. 1. Close all drains and drain lines. 2. Vent the pump and suction line and fill both with the fluid to be handled. In case of suction lift operation, evacuate the pump. 3. Fully open the shut-off element in the suction line. 4. If the discharge line is equipped with a check valve, the shut-off element in the discharge line may remain open as long as there is some back pressure. If this is not the case, the shut-off element in the discharge line must be closed. 5. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc).

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6.1.3 Start-up

DANGER The permissible pressure and temperature limits will be exceeded if the pump is operated with the suction and discharge lines closed. Explosion hazard! Leakage of hot or toxic fluids! ▷ Never operate the pump with the shut-off elements in the suction line and/or discharge line closed. ▷ Only start up the pump set with the discharge-side gate valve slightly or fully open.

DANGER Excessive temperatures due to dry running or excessive gas content in the fluid handled Explosion hazard! Damage to the pump set! ▷ Never operate the pump set without liquid fill. ▷ Prime the pump as specified. ▷ Always operate the pump within the permissible operating range.

WARNING Pump set with high noise levels 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. (⇨ Section 4.6 Page 18)

CAUTION Abnormal noises, vibrations, temperatures or leakage Damage to the pump! ▷ Switch off the pump (set) immediately. ▷ Eliminate the causes before returning the pump set to service. ✓ The system piping has been cleaned. ✓ The pump, suction line and inlet tank, if any, have been vented and filled with the fluid to be handled. ✓ The filling and venting lines have been closed.

CAUTION Start-up against open discharge line Motor overload! ▷ Make sure the power reserve of the motor is sufficient. ▷ Use a soft starter. ▷ Use speed control. 1. Fully open the shut-off element in the suction head/suction lift line. 2. Close or slightly open the shut-off element in the discharge line. 3. Start up the motor. 4. Immediately after the pump has reached full rotational speed, slowly open the shut-off element in the discharge line and adjust it to the duty point.

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DANGER Seal leakage at operating temperature Hot or toxic fluid could escape! ▷ After the operating temperature has been reached and/or in the event of leakage, switch off the pump set and re-tighten the bolts between lantern and casing. ▷ Check the coupling alignment. Re-align the coupling if required. 6.1.4 Checking the shaft seal Mechanical seal

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

Gland packing

DANGER Temperatures at packed glands exceed permissible limits Explosion hazard! ▷ Gland packings are not approved for use in potentially explosive atmospheres. ▷ Immediately switch off the pump set. The packed gland must leak slightly during operation. The minimum leakage required depends on the fluid handled, pressure, slip velocity and temperature. Table 11: Leakage rates of the gland packing Quantity Minimum Maximum

Values 10 drops/min. (approx. 0.5 ml) 120 drops/min. (approx. 6 ml)

CAUTION Excessive leakage or no leakage at the packed gland Damage to the pump! ▷ Excessive leakage - Re-tighten the gland follower until the required leakage quantity is reached. ▷ No leakage - Switch off the pump set immediately.

WARNING Work in the immediate vicinity of rotating parts Risk of hand injuries! ▷ Always have this work performed by trained personnel. ▷ Take particular caution when performing this work. Adjusting the leakage Prior to commissioning

1. Only lightly tighten the nuts of the gland follower by hand. 2. Use a feeler gauge to verify that the gland follower is mounted centred and at a right angle to the shaft. ⇨ The gland must leak after the pump has been primed.

After five minutes of operation

The leakage can be reduced. 1. Tighten the nuts of the gland follower by 1/6 turn. 2. Monitor the leakage for another five minutes. Excessive leakage: Repeat steps 1 and 2 until the minimum value has been reached.

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Not enough leakage: Slightly loosen the nuts at the gland follower. No leakage: Switch off the pump set immediately! Loosen the gland follower and repeat start-up. Checking the leakage After the leakage has been adjusted, monitor the leakage for about two hours at maximum fluid temperature. Check that enough leakage occurs at the gland at minimum fluid pressure. 6.1.5 Shutdown

CAUTION Backflow of the fluid handled Motor or winding damage! Excessive reverse runaway speed of the motor! ▷ Observe the permissible reverse runaway speed of the motor. See the manufacturer's product literature included with the supplied documentation. ▷ Close the shut-off elements. ✓ The shut-off element in the suction line is and remains open. 1. Close the shut-off element in the discharge line. 2. Switch off the motor and make sure the pump set runs down smoothly to a standstill.

NOTE If the discharge line is equipped with a non-return or check valve, the shut-off element may remain open as long as there is back pressure. For prolonged shutdown periods: 1. Close the shut-off element in the suction line. 2. Close the auxiliary connections.

CAUTION Risk of freezing during prolonged pump shutdown periods Damage to the pump! ▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect them against freezing.

6.2 Operating limits

DANGER Non-compliance with operating limits for pressure, temperature and speed Explosion hazard! Hot or toxic fluid may escape! ▷ 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 Permissible operating pressure exceeded Damage to connections and seals! ▷ Never exceed the operating pressure specified in the data sheet. The maximum operating pressure depends on the pump size, pump material and nominal pressure of the flange design. Neither the maximum pressure depending on the pump size or material in the following table nor the maximum nominal pressure of the flange must be exceeded. Table 12: Maximum material-dependent operating pressure Size

350 - 575 350 - 690 400 - 525 400 - 580 400 - 665 400 - 705 400 - 935 500 - 585 500 - 685 500 - 835 500 - 860 500 - 1015 500 - 1035 600 - 600 600 - 705 600 - 885 600 - 1075 700 - 980

Maximum material-dependent operating pressure [bar] Cast iron Nodular cast iron/cast steel . 21.5 10.2 29.5 7.6 12.4 8.7 16.0 8.9 21.0 9.9 22.0 9.5 17.7 8.1 10.3 8.1 13.5 8.1 20.0 7.5 21.0 8.5 21.0 8.5 22.0 7.3 11.0 7.2 14.7 7.6 21.0 8.4 22.5 7.7 19.0

6.2.2 Temperature of the fluid handled

CAUTION Fluid temperature too high or too low Damage to the pump! ▷ Avoid prolonged operation against a closed shut-off element. ▷ Never operate the pump at temperatures above or below those specified in the data sheet or on the name plate unless the written consent of the manufacturer has been obtained. If the values are not indicated in the data sheet, the following temperature limits apply. The temperatures must neither be below nor above these limits. Table 13: Temperature limits of the fluid handled Minimum fluid temperature Maximum fluid temperature

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6.2.3 Abrasive fluids/solids

CAUTION Abrasive particles or solids in the fluid Damage to the pump! ▷ Comply with the operating data indicated in the data sheet. ▷ Flush the piping prior to commissioning. ▷ Install a filter in the system, if required. 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 are to be expected. In this case, reduce the intervals commonly recommended for servicing and maintenance.

NOTE Solids, especially long fibres, plastic residues or similar solids can lead to clogging of the barrier or flushing lines and to mechanical seal damage.

6.2.4 Hydraulic operating range

CAUTION Pump operated above or below the hydraulic operating limits Damage to the pump and motor ▷ Always observe the limits stated in the data sheet. ▷ Brief passage through the critical range below Qmin is permissible during startup. General information on the hydraulic operating range H

Qmin

NPSHRequired

NPSHAvailable HA Q Fig. 23: Pump operating range HA

System curve

Qmin

NPSH

Required pump inlet pressure NPSH

Required

Available

Minimum flow rate Available pressure in the system

The flow rate "Q" will set in automatically as a function of the discharge head H to be developed, in line with the pump's characteristic curve. The pump's permissible operating range has limits that are independent of each other in terms of their cause. Low flow operating limit This limit is indicated in the H/Q characteristic by Qmin or by discontinuation of the characteristic curve in the diagram. NPSH-related limits under off-design conditions The low flow and overload limits are determined by the ratio of NPSHrequired to

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NPSHavailable. The NPSH limits are calculated as follows: The intersections of NPSHrequired and NPSHavailable are projected onto the H/Q characteristic, where they represent the operating limits. If the pump set is operated outside its operating limits or system-related changes occur, check the NPSH. If necessary, consult the nearest customer service centre. 6.2.5 Frequency of starts

DANGER Excessive surface temperature of the motor Explosion hazard! Damage to the motor! ▷ In case of explosion-proof motors, observe the frequency of starts specified in the manufacturer's product literature.

CAUTION Re-start while motor is still running down Damage to the pump (set)! ▷ Do not re-start the pump set before the pump rotor has come to a standstill. The frequency of starts is usually determined by the maximum temperature increase of the motor. This largely depends on the power reserves of the motor in steadystate operation and on the starting conditions (d.o.l., star-delta, moments of inertia, etc). Observe the motor manufacturer's operating instructions.

6.3 Shutdown/storage/preservation The pump (set) remains installed ✓ Sufficient fluid is supplied for the operation check run of the pump. 1. Start up the pump (set) regularly between once a month and once every three months for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pump intake area. The pump (set) is removed from the pipe and stored ✓ The pump has been properly drained (⇨ Section 7.3 Page 56) and the safety instructions for dismantling the pump have been observed. 1. Spray-coat the inside wall of the pump casing, and in particular the impeller clearance areas, with a preservative. 2. Spray the preservative through the suction and discharge nozzles. It is advisable to then close the pump nozzles (e.g. with plastic caps or similar). 3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil and grease, food-approved if required) to protect them against corrosion. Observe the additional instructions. (⇨ Section 3.2 Page 13)

6.4 Returning to service after storage For returning the pump to service observe the sections on commissioning/start-up (⇨ Section 6.1 Page 40) and the operating limits (⇨ Section 6.2 Page 43) . In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. (⇨ Section 7 Page 48)

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WARNING Failure to re-install or re-activate protective devices Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is completed, re-install and/or re-activate any safetyrelevant 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 Improperly serviced pump set Explosion hazard! Damage to the pump set! ▷ Service the pump set regularly. ▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal and coupling. The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

WARNING Pump set started up inadvertently Risk of injury by moving parts! ▷ Make sure that the pump set cannot be started up accidentally. ▷ Always make sure the electrical connections are disconnected before carrying out work on the pump set.

WARNING Fluids posing a health hazard or hot fluids Risk of personal injury! ▷ Observe all relevant laws. ▷ When draining the fluid take appropriate measures to protect persons and the environment. ▷ Decontaminate pumps handling fluids posing a health hazard. 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.

NOTE All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/ contact". Never use force when dismantling and reassembling a pump set.

7.2 Servicing/inspection 7.2.1 Supervision of operation

DANGER Risk of potentially explosive atmosphere inside the pump Explosion hazard! ▷ The pump internals in contact with the fluid to be handled, including the seal chamber and auxiliary systems must be filled with the fluid to be handled at all times. ▷ Provide sufficient inlet pressure. ▷ Provide an appropriate monitoring system.

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DANGER Excessive temperatures as a result of bearings running hot or defective bearing seals Explosion hazard! Fire hazard! Damage to the pump set! ▷ Regularly check the lubricant level. ▷ Regularly check the rolling element bearings for running noises.

DANGER Excessive temperatures due to dry running Explosion hazard! Fire hazard! Damage to the pump set! ▷ Never operate the pump set without liquid fill. ▷ Never close the shut-off element in the suction line and/or supply line during pump operation.

CAUTION Impermissibly high temperature of fluid handled Damage to the pump! ▷ Prolonged operation against a closed shut-off element is not permitted (heating up of the fluid). ▷ Observe the temperature limits in the data sheet and in the section on Operating limits. (⇨ Section 6.2 Page 43) While the pump is in operation, observe and check the following: ▪ The pump must run quietly and free from vibrations at all times. ▪ In case of oil lubrication, ensure the oil level is correct. (⇨ Section 5.12 Page 37) ▪ Check the shaft seal. (⇨ Section 6.1.4 Page 42) ▪ Check the static seals for any leakage. ▪ Check the rolling element bearings for running noises. Vibrations, noise and an increase in current input occurring during unchanged operating conditions indicate wear. ▪ Monitor the correct functioning of any auxiliary connections. ▪ Monitor the stand-by pump. To make sure that the stand-by pumps are ready for operation, start them up once a month. ▪ Monitor the bearing temperature. The bearing temperature must not exceed 90 °C (measured on the outside of the bearing bracket). ▪ Check the flexible elements of the coupling and replace them, if required. ▪ Check any pressure gauges. ▪ Check the drive as described in the manufacturer's product literature. ▪ Check that the fitted coupling guard does not touch the coupling. ▪ Make sure that the earth connection is fitted and marked.

CAUTION Operation outside the permissible bearing temperature Damage to the pump! ▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured on the outside of the bearing bracket).

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

7.2.2 Inspection work

DANGER Excessive temperatures caused by friction, impact or frictional sparks Explosion hazard! Fire hazard! Damage to the pump set! ▷ Regularly check the coupling guard, plastic components and other guards of rotating parts for deformation and sufficient distance from rotating parts.

7.2.2.1 General information Check and service all components of the pump set as described in the corresponding operating instructions provided by the manufacturers. The manufacturer's product literature is filed with the order documents included with the delivery. 7.2.2.2 Routine maintenance and inspection intervals Table 14: Routine maintenance and inspection intervals Interval Daily

1

6 min.

Weekly

1

15 min.

Monthly

1

15 min.

1

15 min.

1

15 min.

Every 4,400 operating hours

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Maintenance work ▪ Check the leakage of the mechanical seal or the leakage rate of the gland packing. ▪ Check the oil level and top up the oil, if required (only for oillubricated bearings) ▪ Check the pump operation. (inlet pressure, head, bearing temperature, noises and vibrations) ▪ Verify the torsional clearance of the coupling (see operating instructions of the coupling). ▪ Switch to a stand-by pump, if any, or carry out a functional check run (5 minutes). ▪ Re-lubricate grease-packed rolling element bearings, relubrication quantity see (⇨ Section 7.2.2.5.1.5 Page 53)

7 Servicing/Maintenance

Interval

Number of Time Maintenance work persons Every 7,500 operating 1 15 min. ▪ Check oil-lubricated rolling hours element bearings (⇨ Section 7.2.2.5 Page 52) Every 4 years or if pump 2 6h ▪ Generally inspect and overhaul head drops the pump in accordance with the operating instructions. ▪ Check and replace, if necessary: – bearings, casing wear ring, impeller wear ring, shaft protecting sleeve – impeller and shaft – Fit new seal elements. 7.2.2.3 Checking the clearance gaps Excessive clearances will affect pump performance. Losses in efficiency and discharge head will occur. To check the clearance gaps, remove the rotor. If the clearance gap is larger than permitted, replace the casing wear ring and impeller wear ring.

S

Table 15: Clearance gaps in [mm]

D1

D2

Pump size

Fig. 24: Impeller clearance gap

Maximum Minimum clearance Maximum clearance permissible nominal gap gap clearance gap (wear limit) D2 - D1 S min S max. 2

350 - 575 A / B 350 - 690 A / B 400 - 525 A / B 400 - 580 A / B 400 - 665 A / B 400 - 705 A / B 400 - 935 A 500 - 585 A / B 500 - 685 A / B 500 - 835 A / B 500 - 860 A / B 500 - 1015 A / B 500 - 1035 A / B 600 - 600 A / B 600 - 705 A / B 600 - 885 A / B 600 - 1075 A 700 - 980 A / B

0.96 1.16 1.06 1.16 0.96 1.06 1.36 1.16 1.16 1.16 1.26 1.46 1.46 1.26 1.36 1.06 1.46 1.26

0.50 0.70 0.40 0.50 0.40 0.50 0.90 0.50 0.50 0.70 0.80 1.00 1.00 0.60 0.80 0.60 1.00 0.70

0.66 0.86 0.56 0.66 0.56 0.66 1.06 0.66 0.66 0.86 0.96 1.16 1.16 0.76 0.96 0.76 1.16 0.86

NOTE The listed maximum clearance gaps are based on an efficiency loss of approximately 3 % compared to the clearance gaps of the pump in as-new condition.

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7.2.2.4 Cleaning filters

CAUTION Insufficient inlet pressure due to clogged filter in the suction line Damage to the pump! ▷ Monitor contamination of filter with suitable means (e.g. differential pressure gauge). ▷ Clean filter in appropriate intervals. 7.2.2.5 Lubrication and lubricant change of rolling element bearings

DANGER Excessive temperatures as a result of bearings running hot or defective bearing seals Explosion hazard! Fire hazard! Damage to the pump set! ▷ Regularly check the bearing seals. ▷ Regularly check the oil level and top up the oil (for oil-lubricated bearings only).

CAUTION Temporary storage of the pump set too long Formation of deposits or condensate, resinification or leakage of grease! ▷ Change the complete grease fill before returning the pump set to service. ▷ Replace the grease fill every time the bearings are dismantled.

CAUTION Pump stored too long or incorrectly Damage to the pump! ▷ Check especially the rolling element bearings and the lubricant. If any previous damage is suspected, replace the rolling element bearings.

7.2.2.5.1 Grease lubrication The bearings are supplied packed with high-quality lithium-soap grease. 7.2.2.5.1.1 Re-lubricating the pump set with grease

WARNING Work in the immediate vicinity of rotating parts Risk of hand injuries! ▷ Always have this work performed by trained personnel. ▷ Take particular caution when performing this work.

CAUTION Contaminated lubricating nipples The lubricating grease could become contaminated! ▷ Clean the grease lubricating nipples beforeusing them for re-lubricating. 1. Clean the lubricating nipples, if contaminated. 2. Position the grease press on the lubricating nipple. 3. Press in the grease.

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7.2.2.5.1.2 Changing the grease ✓ The pump has been dismantled for changing the grease. (⇨ Section 7.4.4 Page 59) 1. Thoroughly clean bearing, bearing casing and bearing cover with petrol, benzene or a similar cleaning agent. Then free the components completely from the cleaning agent. 2. Completely fill the cavities between the rolling elements of the bearing with grease. 3. Fill the cavities in the bearing cover with grease until they are about 1/2 full. 7.2.2.5.1.3 Intervals ▪ Re-lubricate the pump set with grease ▪ Change the grease

- Every 4,400 operating hours; at least every 2 years

- Every time the pump is dismantled

7.2.2.5.1.4 Grease quality Table 16: Grease quality to DIN 51825 Soap basis

NLGI grade

Lithium

2 to 3

Worked penetration at 25 °C in mm/10 220-295

Drop point

Temperature range

≥ 175 °C

-30 ℃ to 120 ℃

7.2.2.5.1.5 Grease quantities The following grease quantities are required: Table 17: Quantities for lubrication and re-lubrication Size

350 - 575 350 - 690 400 - 525 400 - 580 400 - 665 400 - 705 400 - 935 500 - 585 500 - 685 500 - 835 500 - 860 500 - 1015 500 - 1035 600 - 600 600 - 705 600 - 885 600 - 1075 700 - 980

Angular contact ball bearing per 2 bearings 7220 B UA 7220 B UA 7222 B UA 7220 B UA 7222 B UA 7220 B UA 7220 B UA 7222 B UA 7222 B UA 7326 B UA 7326 B UA 7326 B UA 7326 B UA 7222 B UA 7222 B UA 7330 B UA 7330 B UA 7330 B UA

Fixed bearing Lubrication quantity [g] 350 350 490 350 490 350 350 490 490 1240 1240 1240 1240 490 490 1740 1740 1740

Re-lubrication quantity [g]

Deep groove ball bearing per 1 bearing

50 50 60 50 60 50 50 60 60 130 130 130 130 60 60 170 170 170

6220 C3 6220 C3 6222 C3 6220 C3 6222 C3 6220 C3 6220 C3 6222 C3 6222 C3 6326 C3 6326 C3 6326 C3 6326 C3 6222 C3 6222 C3 6330 C3 6330 C3 6330 C3

Radial bearing Lubrication quantity

Re-lubrication quantity [g]

[g] 230 230 300 230 300 230 230 300 300 640 640 640 640 300 300 860 860 860

25 25 30 25 30 25 25 30 30 65 65 65 65 30 30 85 85 85

For commissioning and returning the pump set to service after a prolonged shutdown period, apply twice the re-lubrication quantity.

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7.2.2.5.2 Oil lubrication The rolling element bearings are usually lubricated with mineral oil. 7.2.2.5.2.1 Changing the oil

CAUTION Insufficient lubricating oil in the reservoir of the constant-level oiler Damage to the bearings! ▷ Regularly check the oil level. ▷ Always fill the oil reservoir completely. ▷ Keep the oil reservoir properly filled at all times.

NOTE An excessively high oil level can lead to a temperature rise and to leakage of the fluid handled or oil. Oil is usually topped up during standstill of the pump. If it is unavoidable to top up the constant-level oiler with the pump running, temporary oil leakage may occur. Provide an appropriate drip collector.

WARNING Lubricants posing a health hazard Hazard to persons and the environment! ▷ When draining the lubricant take appropriate measures to protect persons and the environment. ▷ Observe all legal regulations on the disposal of liquids posing a health hazard. 672

638

720.2

903.4 411.3 Fig. 25: Constant-level oiler ✓ A suitable container for the used oil is on hand. 1. Place the container underneath screwed plug 903.4. 2. Remove screwed plug 903.4 with joint ring 411.3 at the bearing bracket and drain the oil. 3. Once the bearing bracket has been drained, re-insert and re-tighten screwed plug 903.4 with joint ring 411.3. 4. Remove vent plug 672. 5. Pull the reservoir of the constant-level oiler upwards and off. 6. Fill oil through the opening for vent plug 672 until oil is visible at the bottom inside the fit of constant-level oiler 638.

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7. Fill the reservoir of constant-level oiler 638 with oil and return it to its operating position. 8. After a short time check whether the oil level in the reservoir has dropped. Keep at least one third of the reservoir filled at all times. If the oil level is too low, top it up with oil. 7.2.2.5.2.2 Intervals Table 18: Oil change intervals Temperature at the bearing up to 70 ℃ 70 °C - 80 °C 80 °C - 90 °C

First oil change

All subsequent oil changes9) After 300 operating hours After 7500 operating hours After 300 operating hours After 3700 operating hours After 300 operating hours After 1800 operating hours

7.2.2.5.2.3 Oil quality Mineral oil of viscosity grade ISO VG 68 7.2.2.5.2.4 Oil quantity The following oil quantities are required: Table 19: Oil quantity Size

350 - 575 350 - 690 400 - 525 400 - 580 400 - 665 400 - 705 400 - 935 500 - 585 500 - 685 500 - 835 500 - 860 500 - 1015 500 - 1035 600 - 600 600 - 705 600 - 885 600 - 1075 700 - 980

9)

Angular contact ball bearing per 2 bearings 7220 B UA 7220 B UA 7222 B UA 7220 B UA 7222 B UA 7220 B UA 7220 B UA 7222 B UA 7222 B UA 7326 B UA 7326 B UA 7326 B UA 7326 B UA 7222 B UA 7222 B UA 7330 B UA 7330 B UA 7330 B UA

Fixed bearing Bearing housing

Constant-level oiler

[l] 1.00 1.00 1.25 1.00 1.25 1.00 1.00 1.25 1.25 2.20 2.20 2.20 2.20 1.25 1.25 2.30 2.30 2.30

[l] 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12

Deep groove ball bearing per 1 bearing 6220 C3 6220 C3 6222 C3 6220 C3 6222 C3 6220 C3 6220 C3 6222 C3 6222 C3 6326 C3 6326 C3 6326 C3 6326 C3 6222 C3 6222 C3 6330 C3 6330 C3 6330 C3

Radial bearing Bearing housing

Constant-level oiler

[l] 1.00 1.00 1.25 1.00 1.25 1.00 1.00 1.25 1.25 2.20 2.20 2.20 2.20 1.25 1.25 2.30 2.30 2.30

[l] 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12

At least once a year

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7.3 Drainage/disposal

WARNING Fluids posing a health hazard Hazardous to persons and the environment! ▷ Collect and properly dispose of flushing liquid and any fluid residues. ▷ Wear safety clothing and a protective mask, if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard. If the fluids handled by the pump (set) leave residues which might lead to corrosion when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the pump (set) must be flushed through, neutralised, and blown through with anhydrous inert gas for drying purposes. Use connection 6B to drain the fluid handled (see auxiliary connections).

7.4 Dismantling the pump set 7.4.1 General notes/Safety regulations

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 and discharge line. ▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 56) ▷ Close any auxiliary connections. ▷ Allow the pump set to cool down to ambient temperature.

DANGER Improper transport Risk of personal injury from lifting heavy components! ▷ Select hoisting tackles which are suitable for the component weight. ▷ Always use the attachment points provided for suspending components from the hoisting tackle. ▷ Comply with the applicable health and safety regulations.

WARNING Unqualified personnel performing work on the pump (set) Risk of personal injury! ▷ Always have repair and maintenance work performed by specially trained, qualified personnel.

WARNING Pump set started up inadvertently Risk of injury by moving parts! ▷ Make sure that the pump set cannot be started up accidentally. ▷ Always make sure the electrical connections are disconnected before carrying out work on the pump set.

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WARNING Hot surface Risk of personal injury! ▷ Allow the pump set to cool down to ambient temperature.

WARNING Components with sharp edges Risk of cutting or shearing injuries! ▷ Always use appropriate caution for installation and dismantling work. ▷ Wear work gloves. Generally observe the safety instructions and safety information. (⇨ Section 2.8 Page 10) For any work on the motor, observe the instructions of the relevant motor manufacturer. For dismantling and reassembly refer to the general assembly drawing. In the event of damage you can always contact our service staff. 7.4.2 Preparing the pump set

DANGER The pump (set) could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump (set) in horizontal position. ▷ Never attach the suspension arrangement to the free shaft end or the motor eyebolt. ▷ Refer to the weights given in the general arrangement drawing. ▷ Observe the local accident prevention regulations. ▷ Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.

NOTE Horizontal installation The pumps have been designed in such a way that the complete rotor can be removed and dismantled without the need to remove the suction and discharge line and without disturbing the alignment of the pump set.

NOTE Vertical installation For dismantling a vertically installed pump, the complete pump has to be removed and placed in horizontal position. Then, the complete rotor can be removed and dismantled. Preparing for dismantling ✓ The gate valves in the suction and discharge lines have been closed. ✓ The motor has been disconnected from the power supply and secured against inadvertent start-up. ✓ The pump has been drained. 1. Remove the flushing line and any auxiliary feed lines connected to the pump. 2. Remove coupling guard 681 as well as guard plates 680.1. and 680.210) 10)

If fitted

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3. Separate the pump-end coupling half as described in the operating instructions for the coupling. (See the manufacturer's product literature included with the supplied documentation.) Removing vertically installed pumps in DJ installation ✓ Hoisting tackle of suitable dimensions for the indicated component weights is available. ✓ The gate valves in the suction and discharge lines have been closed. ✓ The motor has been disconnected from the power supply and secured against inadvertent start-up. ✓ The pump has been drained. ✓ Any auxiliary feed lines have been removed. ✓ The pump has been separated from the motor. 1. Undo the connecting elements between the pump flanges and the pipes. 2. Suspend volute casing 102 from the hoisting tackle and secure it. 3. Undo screwed connection 920.40/920.43 between pump 655 and base frame 891. Lift up the pump and place it down in horizontal position on a suitable surface. Removing vertically installed pumps in DP installation ✓ Hoisting tackle of suitable dimensions for the indicated component weights is available. ✓ The gate valves in the suction and discharge lines have been closed. ✓ The motor has been disconnected from the power supply and secured against inadvertent start-up. ✓ The pump has been drained. ✓ Any auxiliary feed lines have been removed. ✓ The pump has been separated from the motor. 1. Undo the connecting elements between the motor and motor bracket 89-12.40. 2. Use suitably dimensioned hoisting tackle to lift up the motor and place it on a suitable surface. 3. Secure the motor bracket. Undo the connecting elements of motor carrier 901.45/920.45 and remove motor bracket 89-12.40. 4. Undo the connecting elements between the pump flanges and the pipes. 5. Suspend volute casing 102 from the hoisting tackle and secure it. 6. Undo screwed connection 920.40/920.43 between pump 655 and base frame 891. Lift up the pump and place it down in horizontal position on a suitable surface. 7.4.3 Removing the volute casing

Fig. 26: Removing the volute casing

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7 Servicing/Maintenance ✓ The pump has been placed in horizontal position on a solid and level surface. ✓ Suitably dimensioned hoisting tackle is available. 1. On pumps with oil-lubricated bearings, drain the oil. (⇨ Section 7.2.2.5.2.1 Page 54) 2. Suspend volute casing 102 from the hoisting tackle and secure it. 3. Remove screwed connection 901.4 or 901.40 between bearing housings 350.1 and 350.2 and the upper part of volute casing 102. 4. Remove bolts 901.1. from the casing split flange. Separate the upper part of volute casing 102 from the lower part of the volute casing with forcing screws 901.5 and lift it off with the hoisting tackle. Take care to lift the upper part up straight without tilting it. 5. Place volute casing 102 on a clean assembly surface. 7.4.4 Removing the rotor

Removing the rotor

Detailed view of the mechanical seal

✓ The upper part of the volute casing has been removed. ✓ Suitably dimensioned hoisting tackle is available. 1. Lock any mechanical seals. Swivel discs 550.5 into the groove in shaft protecting sleeve 524.2 and fasten them with bolts 901.3. 2. Remove screwed connection 901.4 or 901.40 between bearing housings 350.1 and 350.2 and the lower part of volute casing 102. 3. Use suitable hoisting tackle (e.g. looped ropes) to lift the lower part of the volute casing off and securely place it down in horizontal position. 7.4.5 Dismantling the rotor Dismantling the non-drive end Product-lubricated plain bearing

✓ The rotor has been placed on a clean assembly surface and secured against rolling off. ✓ The general assembly drawing is available. 1. Undo screwed connection 901.40. Use hoisting tackle to remove sole plate 893.40 with intermediate ring 509.40. 2. Remove nuts 920.6 and bearing cover 160. 3. Undo safety screw 914.1. Remove keywayed nut 920.3, disc spring 950.1 and disc 550.3. 4. Remove bearing housing 350.3 with inserted bearing bush 545. Pull shaft protecting sleeve 524.3 and spacer sleeve 525.4 off the shaft. 5. Use two M8 screws to pull the bearing bush out of the bearing housing.

Rolling element bearing

✓ The rotor has been placed on a clean assembly surface and secured against rolling off. ✓ The general assembly drawing is available.

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1. Undo nuts 920.5 fastening bearing cover 360.1 or 360.2 of the radial bearing (opposite the drive end). Pull off bearing housing 350.2. 2. Undo safety screw 914.1. Then undo and remove keywayed nut 920.4. 3. Remove disc spring 950 and deep-groove ball bearing 321 with sleeve 520 and disc 550.1 from pump shaft 211. 4. Remove bearing cover 360.1 or 360.2. 5. Remove V-ring 411.1 from spacer sleeve 525.1 and slide the spacer sleeve off the shaft. Dismantling the drive end ✓ The rotor has been placed on a clean assembly surface and secured against rolling off. ✓ The general assembly drawing is available. 1. Dismantle the pump-end coupling half as described in the operating instructions for the coupling. 2. Undo nuts 920.5 fastening bearing cover 360.1 of the fixed bearing. Pull off connecting part 145 and bearing housing 350.1. 3. Remove circlip 932 and pull both angular contact ball bearings 320 off pump shaft 211 with a suitable puller. 4. Take off bearing cover 360.1. 5. Remove V-ring 411.1 from spacer sleeve 525.1 and slide the spacer sleeve off the shaft. Gland packing

1. Undo nuts 920.2 at both sides of gland follower 452 (consisting of two parts). Remove the gland follower. 2. Pull out the packing rings with a packing extractor. 3. Pull shaft protecting sleeve 524.1 out of shaft seal housing 441.

Mechanical seal

1. As soon as the transport locks (locking discs 550.5) have been swivelled into position, the two shaft seal housings 441 with shaft protecting sleeve 524.2, mechanical seal 433 and seal cover 471 can be pulled off the shaft as a complete assembly unit. 2. Undo nuts 920.2 at both sides of seal cover 471 and pull the complete seal cover with mechanical seal and shaft protecting sleeve 524.2 out of shaft seal housing 441. Pulling off the impeller 1. Impeller 234 sits on the shaft with a sliding fit. Normally, it can be removed easily. If the impeller is hard to remove, it can be loosened by gently tapping the hub with a wooden mallet.

7.5 Reassembling the pump set 7.5.1 General notes/Safety regulations

DANGER The pump (set) could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump (set) in horizontal position. ▷ Never attach the suspension arrangement to the free shaft end or the motor eyebolt. ▷ Refer to the weights given in the general arrangement drawing. ▷ Observe the local accident prevention regulations. ▷ Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.

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DANGER Improper transport Risk of personal injury from lifting heavy components! ▷ Select hoisting tackles which are suitable for the component weight. ▷ Always use the attachment points provided for suspending components from the hoisting tackle. ▷ Comply with the applicable health and safety regulations.

WARNING Unqualified personnel performing work on the pump (set) Risk of personal injury! ▷ Always have repair and maintenance work performed by specially trained, qualified personnel.

WARNING Pump set started up inadvertently Risk of injury by moving parts! ▷ Make sure that the pump set cannot be started up accidentally. ▷ Always make sure the electrical connections are disconnected before carrying out work on the pump set.

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.

WARNING Components heated up for installation Risk of burns at hands! ▷ Wear protective gloves suitable for installation work. ▷ Let components cool down after installation. Generally observe the safety instructions and safety information. (⇨ Section 2.8 Page 10) For any work on the motor, observe the instructions of the relevant motor manufacturer. For dismantling and reassembly refer to the general assembly drawing. In the event of damage you can always contact our service staff. Sequence O-rings/V-rings

Always reassemble the pump in accordance with the corresponding general assembly drawing and installation instructions. ▪ Never use O-rings that have been glued together from material sold by the metre. ▪ Replace all O-rings and V-rings and clean their locating fits on the shaft. Fit all seal elements on the relevant components before starting with the assembly.

Assembly adhesives

▪ Observe the installation instructions regarding cleaning, lubricating and sealing agents. ▪ Remove any residues of liquid sealants before starting with the assembly. ▪ Coat the locating surfaces of the individual components and screwed connections with graphite or similar before reassembly.

Tightening torques

When reassembling the pump set, tighten all screws/bolts as indicated.

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7.5.2 Fitting the rotor ✓ Suitably dimensioned hoisting tackle is available. ✓ The pump shaft has been placed in horizontal position on a level and clean assembly surface and secured against rolling off. ✓ The corresponding general assembly drawing and installation instructions are available. 1. The locating surfaces, threads and sliding fits of pump shaft 211 have been cleaned. Assembly paste has been applied in accordance with the installation instructions. 2. Fit keys into the keyways of pump shaft 211. 3. Fit impeller 234. Verify the direction of rotation of the impeller!

Fig. 27: Direction of rotation of the impeller

NOTE Looking onto the shaft from the drive end Suction nozzle left = direction of rotation left (anti-clockwise) Suction nozzle right = direction of rotation right (clockwise) Watch the impeller vane position! 4. Fit the wear rings on the running surfaces of the impeller. Make sure that the chamfered side of the rings is facing outwards (facing the bearing). Fit the studs required to hold the wear rings in position. 5. Proceed with the assembly of the other components on the side of the fixed bearing or the drive end of the pump shaft. 6. Slide spacer sleeve 525.3 onto pump shaft 211. 7.5.2.1 Installing the mechanical seal 1. Assemble the mechanical seal in accordance with the manufacturer's operating instructions. Assemble it with shaft protecting sleeve 524.2, seal cover 471 and key 940.5. 2. To lock the mechanical seal, swivel discs 550.5 into the groove in shaft protecting sleeve 524.2 and fasten them with bolts 901.3. 3. Insert this assembly into shaft seal housing 441 and fasten it with screwed connection 902.1 and 920.2. 4. Push the complete assembly onto the shaft. 7.5.2.2 Packing the gland 1. First, slide shaft seal housing 441 and then shaft protecting sleeve 524.1 onto the shaft. 2. Use gland follower 452 (consisting of two parts) to push the individual packing rings into the gland packing chamber. Insert the packing rings in such a way that the joints of the packing rings are always offset by 90°-180°. Refer to the general assembly drawing for the number of rings and the position of gland ring 457.1 or lantern ring 458, if applicable. Preferably use compression-moulded packing rings.

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3. Position the gland follower and tighten it lightly to allow the packing rings in the gland packing chamber to adjust. 4. Loosen the gland follower to relieve the load on the packing. 7.5.2.3 Installing the bearings Re-assembling the drive end ✓ The impeller has been fitted. ✓ The shaft seal has been fitted. ✓ The corresponding general assembly drawing and installation instructions are available. 1. Slip spacer sleeve 525.1 onto the shaft. If thrower 507.2 has been removed in the dismantling process, fit it on the spacer sleeve in accordance with the installation instructions. Slip V-ring 411.1 and bearing cover 360.1 on the spacer sleeve. 2. Pre-heat the two angular contact ball bearings 320 (to maximum 80 °C) and slide them onto pump shaft 211. Prevent any one-sided pressure or impacts which have to be compensated by the outer rings. 3. Install the angular contact ball bearings in X-arrangement (face-to-face). Always make sure that the inner rings of the two angular contact ball bearings sit on each other without any axial clearance.

Fig. 28: X-arrangement of the bearings 4. Secure the bearings with disc 550.1 and circlip 932. Re-assembling the non-drive end Horizontal installation

✓ The impeller has been fitted. ✓ The shaft seal has been fitted. ✓ The corresponding general assembly drawing and installation instructions are available. 1. Fit spacer sleeve 525.3, shaft seal housing 441 complete with gland packing or mechanical seal, shaft protecting sleeve 524.1 or 524.2, seal cover 471, spacer sleeve 525.1 with thrower 507.2, V-ring 411.1 as well as bearing cover 360.1 at the non-drive end as described for the drive end. 2. Heat up deep-groove ball bearing 321 to maximum 80 °C and slide it onto sleeve 520. 3. Slip sleeve 520 with deep-groove ball bearing 321 and disc 550.1 onto pump shaft 211 with key 940.01 inserted. 4. Load the rotor parts elastically by means of keywayed nut 920.4 and disc spring 950.2. Use a suitable C-spanner to tighten disc spring 950.2 with keywayed nut 920.4 in accordance with the following table. 5. Loosen keywayed nut 920.4 and tighten it again. This prevents any impermissible reduction of the disc spring pre-load caused by settling of the components. 6. Tighten securing screw 914.1 together with serrated lockwasher 930.1 to secure keywayed nut 920.4 in position. 7. Position shaft seal housing 441 with the anti-vortex vanes at an angle of 45° or 50° off the horizontal, leading upwards as an extension of the suction nozzle. In

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this position, half round head grooved pin 561.2 will be pointing vertically downwards. a

b c

Fig. 29: Position of the anti-vortex vane a c

Anti-vortex vane at the shaft seal housing Suction nozzle

b

Position of the grooved pin

8. To insert the rotor, apply liquid sealant to the surfaces of the casing wear ring and the contact faces of shaft seal housing 441 as described in the installation instructions. Table 20: Torque for keywayed nut

Vertical installation with rolling element bearing

Thread size M55x2 M60x2 M80x2

Torque for keywayed nut (920.4) 1 turn (360 degrees) 1 turn (360 degrees) 1 1/4 turn (450 degrees)

M90x2

1 1/2 turn (540 degrees)

M100x2

1 1/2 turn (540 degrees)

✓ The impeller has been fitted. ✓ The shaft seal has been fitted. ✓ The corresponding general assembly drawing and installation instructions are available. 1. Fit spacer sleeve 525.3, shaft seal housing 441 complete with gland packing or mechanical seal, shaft protecting sleeve 524.1 or 524.2, seal cover 471, spacer sleeve 525.1 with thrower 507.1 incl. O-ring 412.10 and V-ring 411.1 as well as bearing cover 360.2 at the non-drive end as described for the drive end. 2. Seal the interface between bearing cover and bearing housing at the non-drive end with Loctite® 5203. Make sure that no Loctite® ingresses into the bearing chamber. 3. Heat up deep-groove ball bearing 321 to maximum 80 °C and slide it onto sleeve 520. 4. Slip sleeve 520 with deep-groove ball bearing 321 and disc 550.1 onto pump shaft 211 with key 940.01 inserted. 5. Load the rotor parts elastically by means of keywayed nut 920.4 and disc spring 950.2. Use a suitable C-spanner to tighten disc spring 950.2 with keywayed nut 920.4 in accordance with the following table. 6. Loosen keywayed nut 920.4 and tighten it again. This prevents any impermissible reduction of the disc spring pre-load caused by settling of the components. 7. Tighten securing screw 914.1 together with serrated lockwasher 930.1 to secure keywayed nut 920.4 in position. 8. Position shaft seal housing 441 with the anti-vortex vanes at an angle of 45° or 50° off the horizontal, leading upwards as an extension of the suction nozzle. In this position, half round head grooved pin 561.2 will be pointing vertically downwards.

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a

b c

Fig. 30: Position of the anti-vortex vane a c

Anti-vortex vane at the shaft seal housing Suction nozzle

b

Position of the grooved pin

9. To insert the rotor into the pump casing, apply liquid sealant to the surfaces of the casing wear ring and the contact faces of shaft seal housing 441 as described in the installation instructions. Table 21: Torque for keywayed nut

Vertical installation with plain bearing

Thread size M55x2 M60x2 M80x2

Torque for keywayed nut (920.4) 1 turn (360 degrees) 1 turn (360 degrees) 1 1/4 turn (450 degrees)

M90x2

1 1/2 turn (540 degrees)

M100x2

1 1/2 turn (540 degrees)

✓ The impeller has been fitted. ✓ The shaft seal has been fitted. ✓ The corresponding general assembly drawing and installation instructions are available. 1. Slide spacer sleeve 525.4 and shaft protecting sleeve 524.3 onto the shaft. Watch the position of keyway and key 940.1. 2. Insert bearing bush 545 and O-ring 412.4 into bearing housing 350.2 and slide this assembly onto shaft protecting sleeve 524.3. 3. Load the rotor parts elastically by means of disc 550.3, disc spring 950.1 and keywayed nut 920.3. Use a suitable C-spanner to tighten disc spring 950.1 with keywayed nut 920.3 in accordance with the following table. 4. Loosen keywayed nut 920.3 and tighten it again. This prevents any impermissible reduction of the disc spring pre-load caused by settling of the components. 5. Tighten securing screw 914.1 together with serrated lockwasher 930.1 to secure keywayed nut 920.4 in position. 6. Fit bearing cover 160 with inserted O-ring 412.9 and tighten it with nuts 920.6. 7. Position shaft seal housing 441 and bearing housing 350.3 with the anti-vortex vanes at an angle of 45° or 50° off the horizontal, leading upwards as an extension of the suction nozzle. In this position, half round head grooved pin 561.2 will be pointing vertically downwards.

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a

b c

Fig. 31: Position of the anti-vortex vane a c

Anti-vortex vane at the bearing housing Suction nozzle

b

Position of the grooved pin

8. To insert the rotor into the pump casing, apply liquid sealant to the surfaces of the casing wear ring as well as to the contact faces of shaft seal housing 441 and bearing housing 350.3 as described in the installation instructions. Table 22: Torque for the keywayed nut for product-lubricated mechanical seals Thread size M60x2

Torque for keywayed nut (920.3) 1 1/8 turn (405 degrees)

M80x2

1 1/2 turn (540 degrees)

M90x2

1 3/4 turn (630 degrees)

Use the following bearing sizes: Table 23: Bearing sizes Size

350 - 575 350 - 690 400 - 525 400 - 580 400 - 665 400 - 705 400 - 935 500 - 585 500 - 685 500 - 835 500 - 860 500 - 1015 500 - 1035 600 - 600 600 - 705 600 - 885 600 - 1075 700 - 980

Fixed bearing Angular contact ball bearing 2 bearings per size 7220 B UA 7220 B UA 7222 B UA 7220 B UA 7222 B UA 7220 B UA 7220 B UA 7222 B UA 7222 B UA 7326 B UA 7326 B UA 7326 B UA 7326 B UA 7222 B UA 7222 B UA 7330 B UA 7330 B UA 7330 B UA

Radial bearing Deep-groove ball bearing 1 bearing per size 6220 C3 6220 C3 6222 C3 6220 C3 6222 C3 6220 C3 6220 C3 6222 C3 6222 C3 6326 C3 6326 C3 6326 C3 6326 C3 6222 C3 6222 C3 6330 C3 6330 C3 6330 C3

7.5.2.4 Final assembly of the rotor ✓ The rotor has been assembled. ✓ The direction of rotation of the impeller has been verified. ✓ The position of the anti-vortex vanes of the shaft seal housing and/or bearing housing has been verified.

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7 Servicing/Maintenance ✓ The corresponding general assembly drawing and installation instructions are available. 1. Insert the rotor into the pump casing and align it. Make sure that the half round head grooved pins at casing wear rings 561.1 and 561.2 sit properly in the casing. A

A-A

B-B B

561.1 561.2

A

B

Fig. 32: Installation position of the half round head grooved pins 2. Fasten bearing housings 350.1 and 350.2 with hexagon head bolts 901.4 to the lower part of volute casing 102. 3. Position V-rings 411.1 correctly. Fit V-ring 411.2 and connecting part 145.

NOTE The V-rings are fitted correctly when they are fitted flush around the circumference. 4. Thoroughly clean both contact faces before mounting the upper part of volute casing 102. Apply a thin, evenly spread film of liquid sealant to the face of the lower casing part as described in the installation instructions. 5. Carefully mount the upper part of the volute casing. Centre it with the casing wear rings and shaft seal housing 441. 6. Tighten bolts 901.1 of the casing split flange diagonally, starting from the inside. Fasten bearing housings 350.1 and 350.2 with hexagon head bolts 901.4 to the upper part of volute casing 102. 7. Insert keys 940.3 into pump shaft 211 to install the coupling. 8. Fit cover plates 680 with the corresponding screws to the bearing brackets of volute casing 102. 7.5.3 Transporting the pump set on the baseplate 2E, 3E, 4E installation DJ, DP installation

Refer to the corresponding sections on how to install the pump set. (⇨ Section 5.3 Page 21) ✓ Suitably dimensioned hoisting tackle is available. ✓ The corresponding general assembly drawing and/or installation instructions are available. ✓ The pump has been completely assembled. 1. Use hoisting tackle to lift the pump, position it vertically and place it on the base frame. 2. Align the pump by means of levelling screws 901.50 and 901.41. Slide shims 89-4.40 and 89-4.41 between sole plate 893.40 and base frame 891 or between pump foot and support foot 183.40 and tighten nuts 920.40 and 920.43. 3. Tightening torques see installation instructions. 4. Proceed with the assembly as described in the corresponding sections. (⇨ Section 5.3.4 Page 26) (⇨ Section 5.3.5 Page 28)

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7.6 Spare parts stock 7.6.1 Ordering spare parts Always quote the following data when ordering replacement or spare parts: ▪ Type series ▪ Size ▪ KSB order number ▪ Material variant ▪ Year of construction Refer to the name plate for all data. Also supply the following data: ▪ Description ▪ Part No. ▪ Quantity of spare parts ▪ Delivery address ▪ Mode of dispatch (freight, mail, express freight, air freight) Refer to the general assembly drawing for part numbers and descriptions. 7.6.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 24: Quantity of spare parts for recommended spare parts stock Part No.

Description

Number of pumps (including stand-by pumps) 2 3 4 5 6

234 502 503

Impeller 1 Casing wear ring 2 Impeller wear ring 2 Shaft with keys and shaft nuts 1 320 Angular contact ball bearing 2 321 Deep-groove ball bearing 1 524 Shaft protecting sleeve 4 Set of seal elements 4 (set for the complete pump) Design with mechanical seal 433 Mechanical seal: Spring-loaded ring 4 Seat ring 4 O-ring 4 Secondary seal at seat ring 4 Set of springs 2 (set for one mechanical seal) Design with gland packing (general) 461 Set of packing rings 4 (set for the complete pump) 458 Lantern ring 2 Design with gland packing for pump pressure < 7 bar 457 Neck ring 2

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8

1 2 2 1 2 1 4 6

1 2 2 1 4 2 4 8

2 3 3 2 4 2 6 8

2 3 3 2 4 2 6 9

2 4 4 2 6 3 8 12

10 and more 20 % 50 % 50 % 20 % 25 % 25 % 50 % 150 %

6 6 6 6 2

8 8 8 8 2

10 10 10 10 2

12 12 14 14 4

14 14 18 18 4

90 % 90 % 100 % 100 % 20 %

4

6

6

6

8

100 %

2

4

4

4

6

30 %

2

4

4

4

6

30 %

8 Trouble-shooting

8 Trouble-shooting A

Pump pressure is too low

B

Excessive pump discharge pressure

C

Excessive flow rate

D

Pump delivers insufficient flow rate

E

Excessive power consumption

F

Pump is running but does not deliver

G

Pump stops during operation

H

Vibrations and noise during pump operation

I

Impermissible rise of temperature inside the pump

J

Excessive bearing temperature

K

Excessive leakage at the shaft seal

L

Motor is overloaded

M

Leakage at the pump

Table 25: Trouble-shooting A B C D E F G H I X X X X X X X X

X X

X

X X X X

J

K L M Possible cause Remedy 11) X Duty point B does not match the ▪ Re-adjust to duty point. Q and H performance data calculated in advance. Pump and/or piping are not ▪ Vent. completely vented or primed. Supply line or impeller clogged ▪ Clean the impeller. ▪ Check system for impurities. ▪ Remove deposits in pump and/or piping.

X

X

X X X

Formation of air pockets in the piping

X X X

Suction head too high (NSPH available too low) / water level too low

▪ Check any strainers installed/suction opening. ▪ Correct the suction conditions. ▪ Alter piping layout. ▪ Check operating mode. ▪ Correct the suction conditions. ▪ Increase suction head. ▪ Increase back pressure by throttling. ▪ Install pump at a lower level.

X

X

X X

Air intake at the shaft seal

▪ Alter suction/inlet line, if piping losses are too high. ▪ Clean barrier fluid duct, supply external barrier fluid, if necessary, or increase barrier fluid pressure. ▪ Check liquid supply chamber. ▪ Replace shaft seal. ▪ Replace shaft protecting sleeve.

11)

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

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A B C D E F X X X

G H X

I

J

K L M Possible cause X Wrong direction of rotation

Remedy 11) ▪ Interchange two of the phases of the power cable. ▪ Check electrical connections.

X

X

X

Speed too low

▪ Check impeller position; correct if necessary. ▪ Increase the speed ▪ Check switchgears.

X

X

X X

Wear of internal parts

▪ Fit larger impeller. ▪ Check duty point/pump selection. ▪ Increase back pressure by throttling. ▪ Check fluid handled for contamination by chemicals; check solids content.

X

X

X

X X

X

X

X

X

Pump pressure lower than specified in the purchase order Density or viscosity of fluid handled higher than stated in purchase order Speed too high

X Tie bolts/seal elements

▪ Replace worn parts by new ones. ▪ Re-adjust to duty point. ▪ Increase back pressure by throttling. ▪ Reduce the speed. ▪ In the case of persistent overloading, turn down impeller, if possible. ▪ Reduce the speed. ▪ In the case of persistent overloading, turn down impeller, if possible. ▪ Check. ▪ Tighten the bolts. ▪ Fit new seal elements.

X

Worn shaft seal

▪ Check pipeline connections and secure fixing of pump; improve fixing of pipelines, if necessary. ▪ Check flushing liquid/barrier fluid. ▪ Clean barrier fluid duct, supply external barrier fluid, if necessary, or increase barrier fluid pressure. ▪ Replace shaft seal. ▪ Replace worn parts by new ones. ▪ Replace shaft protecting sleeve.

11)

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

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A B C D E X X

F

G H X

I

J X

X

K L

X

M Possible cause Unfavourable flow to pump suction nozzle

Gland follower or seal cover tightened incorrectly; wrong packing material

Remedy 11) ▪ Alter piping layout ▪ Alter suction/inlet line, if piping losses are too high. ▪ Check whether pipe routing results in swirling or irregular flow (e.g. downstream of elbow) and correct, if necessary. ▪ Change. ▪ Replace. ▪ Correct. ▪ Repack gland.

X

X

Lack of cooling liquid or dirty cooling chamber

▪ Replace worn parts by new ones. ▪ Check flushing liquid/barrier fluid. ▪ Clean barrier fluid duct, supply external barrier fluid, if necessary, or increase barrier fluid pressure. ▪ Increase cooling liquid quantity.

X

X

Pump warped or sympathetic vibrations in the piping

X

Increased axial thrust

▪ Purify/clean cooling liquid. ▪ Re-align pump/drive. ▪ Check pipeline connections and secure fixing of pump; improve fixing of pipelines, if necessary. ▪ Fix pipelines using antivibration material. ▪ Check duty point/pump selection. ▪ Check operating mode.

X

X

X X

Insufficient or excessive quantity of lubricant or unsuitable lubricant X

X

X X

Motor is running on two phases only. Rotor is out of balance.

▪ Check suction side flow conditions. ▪ Clean the bearings. ▪ Top up, reduce or change lubricant. ▪ Replace defective fuses. ▪ Check electrical connections. ▪ Check switchgear. ▪ Clean impeller. ▪ Check run-out; re-align, if necessary.

X

11)

X X

Defective bearing

▪ Re-balance rotor. ▪ Replace.

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

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8 Trouble-shooting

A B C D E

F

G H I X X

J

K L

M Possible cause Insufficient flow rate

Remedy 11) ▪ Re-adjust to duty point. ▪ Fully open shut-off element in suction/inlet line. ▪ Fully open shut-off element in discharge line. ▪ Re-calculate or measure hydraulic losses HV.

X

X

X

X

X

In star-delta operation, motor stuck at star stage X

X

Impermissible air or gas content in fluid handled

X X X

Air intake at pump inlet

▪ Check electrical connections. ▪ Check switchgear. ▪ Vent. ▪ Check suction line for leakage, seal if necessary. ▪ Correct the suction conditions. ▪ Reduce flow velocity at suction line inlet. ▪ Increase suction head. ▪ Check suction line for leakage, seal if necessary.

X

Cavitation (rattling noise)

▪ Replace defective pipes. ▪ Correct the suction conditions. ▪ Check operating mode. ▪ Increase suction head.

X X

X

X

X X X

X

X X X X X

Foundation not rigid enough

▪ Install pump at a lower level. ▪ Check.

Impermissible parallel operation

▪ Correct. ▪ Re-adjust to duty point.

Shaft is out of true. Impeller rubs against casing components.

▪ Adjust pump characteristic H. ▪ Replace. ▪ Check rotor. ▪ Check impeller position. ▪ Verify that piping has been connected without transmitting any stresses or strains.

8.1 Explanation of faults The example illustrated in the diagram serves to facilitate understanding of the causes of faults/malfunctions and their remedies described in the Trouble-shooting section. Many operating faults/malfunctions on pumps are caused by hydraulic phenomena. The hydraulic behaviour of a pump is illustrated by its characteristic curves H, P, Eta and NPSH in combination with the system characteristic curves HA and NPSHA. The duty point B is given by the intersection between the system curve HA and the pump's characteristic curve H. If the cause of a fault or malfunction is unclear, consult your nearest KSB service centre. 11)

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

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P

HA B

HV

Hgeo

Eta NPSH

H NPSHA

Q Fig. 33: Adjusting to the duty point P

Performance

HA

System curve

B

Duty point

Hv

Hydraulic losses (system)

H Eta

Head Efficiency

NPSH NPSHA

Required inlet pressure Inlet pressure available in the system

Q

Flow rate

Hgeo

Static head

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9 Related Documents

9 Related Documents 9.1 Weights of individual components

DANGER Improper transport Risk of personal injury from lifting heavy components! ▷ Select hoisting tackles which are suitable for the component weight. ▷ Always use the attachment points provided for suspending components from the hoisting tackle. ▷ Comply with the applicable health and safety regulations.

Table 26: Weights in kg Size

350 - 575 350 - 690 400 - 525 400 - 580 400 - 665 400 - 705 400 - 935 500 - 585 500 - 685 500 - 835 500 - 860 500 - 1015 500 - 1035 600 - 600 600 - 705 600 - 885 600 - 1075 700 - 980

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Volute casing Lower Upper part part 1495 657 1630 745 1275 635 1425 670 1860 820 1495 695 2115 845 2675 1010 2610 1000 2860 1035 3050 1100 3510 1230 3260 1295 3000 1155 3195 985 3440 1260 4215 1485 5120 1860

Impeller

Shaft

177 223 204 195 274 255 370 272 324 394 458 591 596 271 343 544 688 800

106 106 138 106 138 106 106 157 157 218 218 218 218 157 157 306 306 330

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Bearing housing Shaft seal housing OilGreaselubricated lubricated 82 71 31 82 71 31 86 85 48 82 71 40 96 85 48 82 71 40 82 71 40 96 85 71 96 85 71 127 114 70 127 114 74 127 114 70 127 114 74 96 85 82 96 85 82 146 131 90 146 131 90 146 131 91

Casing wear ring < 25 < 25 < 25 < 25 < 25 < 25 < 25 < 25 < 25 < 25 < 25 < 25 < 25 28 < 25 26.2 26.2 32

9 Related Documents

9.2 General assembly drawing with list of components 9.2.1 Example of a horizontally installed volute casing pump A larger copy of the general assembly drawing is included with the documents supplied with the pump set. Refer to this larger drawing for dismantling/reassembly. 903.5

441 903.2* 502 234 412.3 903.1 102

902.1 525.3 452* 920.2 525.1 681 561.1 412.2 524.1* 903.5 350.1

901.4 636 720.3 73-1

940.1

940.4

904.1 550.11 920.5 145

507.2 350.2 904.3 920.5 914.1 920.4 930.1

211 940.3 411.2

950.2

932

520

550.1

903.4 550.1 321 360.1 561.2

940.2 458* (940.7) 457.1*

903.6 903.7 903.3 903.8

412.1 461*

411.1 680.1 900.1 550.4 41-1

320 903.4

Fig. 34: Horizontal installation: * = for variants with gland packing only 940.5

441

457.2

433

524.2

471

412.7

901.3 550.5

902.1 920.2

562.3

Fig. 35: Detailed view: mechanical seal

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9 Related Documents

441

457.3

903.2

461

452

524.1

Fig. 36: Detailed view: gland packing 234

502

503

904.2

Fig. 37: Detailed view: impeller with impeller wear ring (550.7) 901.1

901.5

102

Fig. 38: Detailed view: screwed connection of the casing split flange Table 27: List of components Part No. 102 145 211 234

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Description Volute casing Connecting part Pump shaft Impeller

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Part No. 524.1/.2 525.1/.3 550.1/.4/.5/.7/.11 561.1/.2

Description Shaft protecting sleeve Spacer sleeve Disc Grooved pin

9 Related Documents

Part No. 320 321 350.1/.2 360.1 41-1 411.1/.2 412.1/.2/.3/.7 433 441 452 457.1/.2/.3 458 461 471 502 503 507.2 520

Description Rolling element bearing Radial ball bearing Bearing housing Bearing cover Sealing washer Joint ring O-ring Mechanical seal Shaft seal housing Gland follower Gland ring Lantern ring Gland packing Seal cover Casing wear ring Impeller wear ring Thrower Sleeve

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Part No. 562.3 636 680.1 681 73-1 720.3 900.1 901.1/.3/.4/.5 902.1 903.1/.2/.3/.4/.5/.6/.7/.8 904.1/.2/.3 914.1 920.2/.4/.5 930.1 932 940.1/.2/.3/.4/.5/.7 950.2

Description Parallel pin Lubricating nipple Guard Coupling guard Socket Special part Bolt/screw Hexagon head bolt Stud Screwed plug Grub screw Socket head cap screw Nut Safety device Circlip Key Spring

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9 Related Documents

9.2.2 Example of a vertically installed volute casing pump A larger copy of the general assembly drawing is included with the documents supplied with the pump set. Refer to this larger drawing for dismantling/reassembly. 903.9 901.4

681

507.2

932

550.1

411.2

145

903.5 680.1 900.1 550.4 41-1

940.3

211

904.1 920.5 550.11

636 320

525.1

411.1

360.1

412.1

902.1 920.2

350.1

561.2

458* 461*

452*

457.1*

412.3

441

903.2*

561.1

524.1* 940.1 412.2

502

525.3 102 412.2 940.2 (940.7) 234 903.1 680.3 550.6 900.4 41-1 507.1 412.10

903.6 903.7

430 903.5 636 720.3 73-1

930.1 904.3 920.4 520 903.4 350.2 893.40 920.5 914.1 321 940.4 360.2 561.2 950.2 550.1 901.40

720.1 901.42

Fig. 39: Vertical installation 901.3 550.5

562.3 902.1 920.2

471 412.7 433 940.5

524.2 457.2 441

Fig. 40: Detailed view: mechanical seal

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RDLO/ RDLO V

903.12

9 Related Documents

524.1 452 461 903.2

457.3

441 Fig. 41: Detailed view: gland packing 904.2 503

(502) (234) Fig. 42: Detailed view: impeller with impeller wear ring (550.7) 901.1 901.5 (102)

Fig. 43: Detailed view: connecting elements of the volute casing Table 28: List of components Part No. 102 145 211 234 320 321 350.1/.2 360.1/.2 41-1 411.1/.2 412.1/.2/.3/.7/.10

Description Volute casing Connecting part Pump shaft Impeller Rolling element bearing Radial ball bearing Bearing housing Bearing cover Sealing washer Joint ring O-ring

RDLO/ RDLO V

Part No. 524.1/.2 525.1/.3 550.1/.4/.5/.6/.7/.11 561.1/.2 562.3 636 680.1/.3 681 73-1 720.1/.3 893.40

Description Shaft protecting sleeve Spacer sleeve Disc Grooved pin Parallel pin Lubricating nipple Guard Coupling guard Socket Special part Sole plate

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9 Related Documents

Part No. 430 433 441 452 457.1/.2/.3 458 461 471 502 503 507.1/.2 520

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Description Shaft seal Mechanical seal Shaft seal housing Gland follower Gland ring Lantern ring Gland packing Seal cover Casing wear ring Impeller wear ring Thrower Sleeve

RDLO/ RDLO V

Part No. 900.1/.4 901.1/.3/.4/.5/.40/.42 902.1 903.1/.2/.4/.5/.6/.7/.9/.12 904.1/.2/.3 914.1 920.2/.4/.5 930.1 932 940.1/.2/.3/.4/.5/.7 950.2

Description Screw Hexagon head bolt Stud Screwed plug Grub screw Socket head cap screw Nut Safety device Circlip Key Spring

10 EC Declaration of Conformity

10 EC Declaration of Conformity Manufacturer:

KSB Aktiengesellschaft Johann-Klein-Straße 9 67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

RDLO, RDLOV KSB order number: ...................................................................................................

▪ is in conformity with the provisions of the following directives as amended from time to time: – EC Machinery Directive 2006/42/EC The manufacturer also declares that ▪ the following harmonised international standards have been applied: – ISO 12100-1/A1, ISO 12100-2/A1, – ISO 14121-1, – EN 809/A1

Frankenthal, 29 December 2009 ........................................................... Name Function Responsible for compiling the technical documentation KSB Aktiengesellschaft Johann-Klein-Straße 9 67227 Frankenthal (Germany)

RDLO/ RDLO V

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11 Certificate of Decontamination

11 Certificate of Decontamination Type Order number/ Order item number12)

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

Delivery date

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

Field of application:

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

Fluid handled12) :

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

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

Please tick where applicable12) :

⃞ radioactive

⃞ explosive

⃞ corrosive

⃞ toxic

⃞ harmful

⃞ bio-hazardous

⃞ highly flammable

⃞ safe

Reason for return12) :

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

Comments:

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

The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal. On seal-less pumps, the rotor has been removed from the pump for cleaning. ⃞ ⃞

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

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

.................................................................... Place, date and signature

12)

....................................................... Address

Required fields

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RDLO/ RDLO V

....................................................... Company stamp

Index

Index

A

N

Abrasive fluids 45

Noise characteristics 18

B

O

Bearing temperature 49 Bearings 17

Oil lubrication Intervals 55 Operating limits 8, 43 Order number 6 Other applicable documents 6

C Certificate of decontamination 82 Commissioning/start-up 40 Constant-level oiler 39

P

Design 17 Dismantling 57 Disposal 14

Partly completed machinery 6 Permissible forces and moments at the pump nozzles 33 Piping 30 Preservation 13 Pump casing 17

E

R

Explosion protection 11, 21, 32, 33, 35, 36, 40, 41, 42, 43, 46, 48, 49, 50, 52

Return to supplier 14 Returning to service 46 Running noises 49

D

F

S

Filling and venting 40 Filter 31, 52 Frequency of starts 46

Safety 8 Safety awareness 9 Scope of supply 19 Shaft seal 17 Spare parts 68 Spare parts stock 68 Start-up 41 Storage 13

G Gland packing 42 Grease lubrication Grease quality 53

I

T

Impeller type 17 Installation 21, 61 Intended use 8

Trouble-shooting 69

M Maintenance/repair 48 Mechanical seal 42 Misuse 9

RDLO/ RDLO V

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1387.82 / 3 - 10 KSB Aktiengesellschaft P.O. Box 200743 • 06008 Halle (Saale) • Turmstraße 92 • 06110 Halle (Germany) Tel. +49 345 4826-0 • Fax +49 345 4826-4699 www.ksb.com