KSB - Etabloc - Iom - en
KSB - Etabloc - Iom - en
KSB - Etabloc - Iom - en
Etabloc
Installation/Operating
Manual
Order number:
Installation/Operating Manual Etabloc
Original operating manual
KSB Aktiengesellschaft
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced,
processed for any other purpose, nor otherwise transmitted to a third party without KSBs express
written consent.
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 information for the operator/user .................................................... 10
2.8 Safety information for maintenance, inspection and installation work ... 10
2.9 Unauthorised modes of operation ............................................................... 10
2.10 Explosion protection ..................................................................................... 10
Etabloc 3 of 64
Contents
6 Commissioning/Start-up/Shutdown ................................................. 26
6.1 Commissioning/start-up ................................................................................ 26
6.2 Operating limits ............................................................................................ 28
6.3 Shutdown/storage/preservation ................................................................... 30
6.4 Returning to service after storage ............................................................... 30
7 Servicing/Maintenance ...................................................................... 32
7.1 Safety regulations ......................................................................................... 32
7.2 Servicing/inspection ...................................................................................... 32
7.3 Drainage/disposal .......................................................................................... 34
7.4 Dismantling the pump set ............................................................................ 35
7.5 Reassembling the pump set .......................................................................... 37
7.6 Tightening torques ....................................................................................... 40
7.7 Spare parts stock ........................................................................................... 41
8 Trouble-shooting ............................................................................... 45
Index .................................................................................................. 63
4 of 64 Etabloc
Glossary
Glossary
Close-coupled design
Suction lift line/suction head line
Motor directly fitted to the pump via a flange
or a drive lantern The line which is connected to the suction
nozzle
Discharge line
The line which is connected to the discharge
nozzle
Etabloc 5 of 64
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. This manual describes the proper and safe use of this equipment
in all phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB Service centre to
maintain the right to claim under warranty.
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
Safety instructions
Result of an action
Cross-references
6 of 64 Etabloc
1 General
Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
Etabloc 7 of 64
2 Safety
2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
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.
8 of 64 Etabloc
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.
Etabloc 9 of 64
2 Safety
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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).
Especially adhere to the sections in this manual marked with the Ex symbol and the
following sections ( Section 2.10.1 Page 11) to ( Section 2.10.4 Page 12).
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
Never operate the pump (set) outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.
2.10.1 Marking
Pump The marking on the pump refers to the pump only.
Example of such marking: II 2 G c TX
Refer to the Temperature limits table for the temperatures permitted for the
individual pump variants. ( Section 2.10.2 Page 11)
Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor The motor has its own marking. The marking is maintained on the condition that the
temperatures the pump causes to develop at the motor flange and motor shaft are
permitted by the motor manufacturer.
The motors fitted by KSB on pumps with ATEX certification meet this condition.
Etabloc 11 of 64
2 Safety
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3 Transport/Temporary Storage/Disposal
3 Transport/Temporary Storage/Disposal
3.1 Transport
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.
CAUTION
Incorrect transport of the pump
Damage to the shaft seal!
For transport, lock the pump shaft with a suitable transport lock to prevent any
movement of the shaft.
Make sure shaft 210 of the pump without motor is locked for transport.
1. Undo bolts 900.
2. Remove cover plates 68-3 from drive lantern 341.
3. Insert washer plates 931 into the shaft groove.
4. Tighten screws 901.3.
To transport the pump/pump set suspend it from the lifting tackles as follows.
Etabloc 13 of 64
3 Transport/Temporary Storage/Disposal
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.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, observe the relevant
instructions. ( Section 6.3.1 Page 30)
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.
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3 Transport/Temporary Storage/Disposal
Etabloc 15 of 64
4 Description of the Pump (Set)
Pump for handling clean or aggressive fluids which are not chemically or
mechanically aggressive to the pump materials.
4.2 Designation
Example: Etabloc G (N) 125-250/1504 G10
Table 5: Key to the designation
Code Description
Etabloc Type series
G Casing material, e.g. JL 1040 2)
(N) Stub shaft version with standardised motor
125 Nominal discharge nozzle diameter [mm]
250 Nominal impeller diameter [mm]
150 Motor rating: kW x 10 (example 15 kW)
4 Number of motor poles
G10 Seal code, e.g. G10 = mechanical seal Q1Q1X4GG
Aktiengesellschaft
D-67227 Frankenthal
1 6
ETABLOC GN 125-250/1504 G10 7
2
8
9971372989 000300 / 02
3
Q 293,04 m/h l H 13,72 m 9
4
n 1459 1/min l 2008
5
1 mm/s
1 Type series, pump size and design 2 KSB order number (ten digits)
3 Flow rate 4 Speed
5 Kinematic viscosity of the fluid 6 Order item number (six digits)
handled
7 Consecutive number (two digits) 8 Head
9 Year of construction
2) To EN 1561 = GJL-250
3) Etabloc 32-23 double-stage
16 of 64 Etabloc
4 Description of the Pump (Set)
Horizontal/vertical installation
Back pull-out design
Ratings to EN 733
Etabloc GN, MN, SN, BN, Rigid connection between pump and motor
CN
Etabloc G, M Pump and motor on a common shaft
Pump casing
Radially split volute casing
Replaceable casing wear rings4)
Impeller type
Closed radial impeller
Shaft seal
Standardised mechanical seal to EN 12756
Shaft equipped with a replaceable shaft sleeve in the shaft seal area
Bearing
Radial ball bearings in the motor housing
Grease lubrication
6 7 8 9 10 11
Fig. 4: Sectional drawing
Etabloc 17 of 64
4 Description of the Pump (Set)
inlet. At the rear side of the impeller, the shaft (4) enters the casing via the casing
cover (3). The shaft passage through the casing cover is sealed towards the
atmosphere with a dynamic shaft seal (8). The shaft runs in rolling element bearings
(10 and 11), which are supported by the motor housing (5) linked with the pump
casing and/or casing cover (3) via the drive lantern (9).
Sealing The pump is sealed by a standardised mechanical seal.
5) Spatial average to ISO 3744 and EN 12639. Applies to non-cavitating pump operation in the range Q/Qopt = 0.8 - 1.1. If
noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.
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5 Installation at Site
5 Installation at Site
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.
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 (min. X0 to
DIN 1045).
Only place the pump set on a foundation whose concrete has set firmly.
Only place the pump set on level surfaces.
Refer to the weights given in the general arrangement drawing.
Fastening
Typical installation positions ( Section 9.1 Page 47)
Table 7: Fastening
Motor rating Type of fastening
Up to 4 kW (explosion-proof models Fastening via support foot or by fastening the
up to 3.3 kW) pump to the piping (with the support foot
removed)
From 5.5 kW (explosion-proof models Fastening via motor foot
from 4.6 kW)
Four poles, from 30 kW Fastening via pump foot and motor support
NOTE
On Etabloc GN, MN with motor sizes 132 or 160, the motor foot must be shimmed (20
mm shim height) for installation on a foundation.
On some pump/motor combinations of Etabloc G, M, GN and MN, the angle foot / the
motor feet need to be shimmed for installation on a foundation (see outline drawing).
1. Position the pump set on the foundation and fasten it (see table on Fastening).
2. Use a spirit level to align the pump set with the discharge nozzle.
Etabloc 19 of 64
5 Installation at Site
3. If the volute casing is turned, drill a drain hole in the volute casing, if required
(see table "Drain hole size").
4. Change the position of the pipe plugs for the condensation water holes on
Etabloc G or M depending on the installation position. ( Section 9.1 Page 47)
Table 8: Drain hole size
Sizes Drilled hole diameter
25-20 and 32-125.1 to 80-315 G 3/86)
32-23 and 100-160 to 150-250 G 1/27)
5.4 Piping
DANGER
Excessive 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.
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 of new installations).
2. Before installing the pump in the piping, remove the flange covers on the suction
and discharge nozzles of the pump.
6) G = ISO 228/1
7) G = ISO 228/1
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5 Installation at Site
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 7.2.2.2 Page 34).
3. If required, install a filter in the piping (see illustration: Filter in the piping)
1
2
Fig. 5: Filter in the piping
NOTE
Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of
corrosion-resistant material.
Use a filter three times the diameter of the piping.
Conical filters have proved suitable.
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.
NOTE
Where fluid has to be pumped out of a vessel under vacuum, it is recommended to install
a vacuum balance line.
Etabloc 21 of 64
5 Installation at Site
1 2 3 4
5 6
Fig. 6: Vacuum balance line
NOTE
An additional line fitted with a shut-off valve from the pump discharge nozzle to the
balance line facilitates venting of the pump before start-up.
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.
DANGER
An explosive atmosphere forms due to insufficient venting
Explosion hazard!
Make sure the space between the casing cover/discharge cover and the motor
flange is sufficiently vented.
Do not cover the perforated holes of the contact guards at the drive lantern
(e.g. by insulation).
WARNING
The volute casing and casing/discharge cover take on the same temperature as the fluid
handled
Risk of burning!
Insulate the volute casing.
Fit protective equipment.
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5 Installation at Site
CAUTION
Heat build-up inside the drive lantern
Damage to the bearing!
Never insulate the casing cover and the drive lantern.
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).
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.
Etabloc 23 of 64
5 Installation at Site
5.6.2 Earthing
DANGER
Electrostatic charging
Explosion hazard!
Fire hazard!
Damage to the pump set!
Connect the PE conductor to the earthing terminal provided.
WARNING
Hands or objects inside the pump casing
Risk of injuries, damage to the pump!
Never insert your hands or any other objects into the pump.
Check that the inside of the pump is free from any foreign objects.
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
Separate the pump from the motor to check the direction of rotation.
CAUTION
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 correct direction of rotation of motor and pump is clock-wise (seen from the
motor end).
1. Start the pump set 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.
24 of 64 Etabloc
5 Installation at Site
3. If the motor runs in the wrong direction of rotation, check the electrical
connection of the motor and the control system, if necessary.
Etabloc 25 of 64
6 Commissioning/Start-up/Shutdown
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/start-up
DANGER
An explosive atmosphere forms inside the pump
Explosion hazard!
Before starting up the pump, vent the suction line and the pump and prime
with the fluid to be handled.
CAUTION
Increased wear due to dry running
Damage to the pump set!
Never operate the pump set without liquid fill.
Never close the shut-off element in the suction line and/or supply line during
pump operation.
1. Vent the pump and suction line and fill them with the fluid to be handled.
Connection 6D can be used for venting (see drawing of auxiliary connections).
For vertical installation with the motor on top, use connection 5B (if any) for
venting (see drawing of auxiliary connections and ( Section 9.1 Page 47) .
2. Fully open the shut-off valve in the suction line.
3. Fully open all auxiliary feed lines (barrier fluid, flushing liquid, etc), if applicable.
4. Open the shut-off valve (3), if any, in the vacuum balance line (2) and close the
vacuum-tight shut-off valve (6), if any. ( Section 5.4.3 Page 21)
NOTE
For design-inherent reasons a remaining gas volume in the hydraulic system cannot be
excluded after the pump has been primed for commissioning/start-up. However, once the
motor is started up the pumping effect will immediately fill this volume with the fluid
handled.
26 of 64 Etabloc
6 Commissioning/Start-up/Shutdown
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.
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 piping system connected to the pump set has been cleaned.
Pump, suction line and inlet tank, if any, have been vented and filled with the
fluid to be pumped.
The filling and venting lines have been closed.
CAUTION
Start-up against open discharge line
Overloading of the motor!
Use a soft starter.
Use speed control.
Make sure the power reserve of the motor is sufficient.
1. Fully open the shut-off valve in the suction head/suction lift line.
2. Close or slightly open the shut-off valve in the discharge line.
3. Switch on the motor.
4. Immediately after the pump has reached full rotational speed, slowly open the
shut-off valve in the discharge line and adjust it to comply with the duty point.
DANGER
Seal leakage at operating temperature
Hot or toxic fluid could escape!
Once the operating temperature has been reached, re-tighten the hexagon nuts
between casing and casing cover.
5. 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.
Etabloc 27 of 64
6 Commissioning/Start-up/Shutdown
Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
6.1.5 Shutdown
CAUTION
Heat build-up inside the pump
Damage to the shaft seal!
Depending on the type of installation, the pump set requires sufficient after-run
time with the heat source switched off until the fluid handled has cooled
down.
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.
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.
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.
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
Observe the specified limits for permissible ambient temperatures.
28 of 64 Etabloc
6 Commissioning/Start-up/Shutdown
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 calculation formula below can be used to check if an additional heat build-up
could lead to a dangerous temperature increase at the pump surface.
Etabloc 29 of 64
6 Commissioning/Start-up/Shutdown
CAUTION
Impermissibly high density of the fluid handled
Motor overload!
Observe the information on fluid density indicated in the data sheet.
Make sure the power reserve of the motor is sufficient.
6.3 Shutdown/storage/preservation
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6 Commissioning/Start-up/Shutdown
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
As soon as the work is complete, re-install and/or re-activate any safety-relevant
and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer seals.
Etabloc 31 of 64
7 Servicing/Maintenance
7 Servicing/Maintenance
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!
Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
Make sure that the pump set cannot be started up accidentally.
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".
7.2 Servicing/inspection
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.
32 of 64 Etabloc
7 Servicing/Maintenance
DANGER
Incorrectly serviced shaft seal
Explosion hazard!
Fire hazard!
Leakage of hot, toxic fluids!
Damage to the pump set!
Regularly service the shaft seal.
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 rolling element bearings for running noises.
CAUTION
Increased wear due to dry running
Damage to the pump set!
Never operate the pump set without liquid fill.
Never close the shut-off element in the suction line and/or supply line during
pump operation.
CAUTION
Impermissibly high temperature of fluid handled
Damage to the pump!
Prolonged operation against a closed shut-off element is not permitted (heating
up of the fluid).
Observe the temperature limits in the data sheet and in the section on
Operating limits. ( Section 6.2 Page 28)
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 motor housing).
Etabloc 33 of 64
7 Servicing/Maintenance
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).
DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
Damage to the pump set!
Regularly check the cover plates, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.
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.
7.3 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.
1. For draining the fluid handled use connection 6B (see drawing of auxiliary
connections).
2. If noxious, explosive, hot or other hazardous fluids have been handled, flush the
pump.
Always flush and clean the pump before transporting it to the workshop. Provide
a cleaning record for the pump.
34 of 64 Etabloc
7 Servicing/Maintenance
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
Hot surface
Risk of personal injury!
Allow the pump set to cool down to ambient temperature.
Observe the general safety instructions and information. ( Section 7.1 Page 32)
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly observe the exploded view and the general assembly
drawing. ( Section 9.2 Page 50)
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".
DANGER
Insufficient preparation of work on the pump (set)
Risk of personal injury!
Properly shut down the pump set. ( Section 6.1.5 Page 28)
Close the shut-off elements in the suction and discharge line.
Drain the pump and release the pump pressure. ( Section 7.3 Page 34)
Close any auxiliary connections.
Allow the pump set to cool down to ambient temperature.
NOTE
After a prolonged period of operation the individual parts may be hard to pull off the
shaft. If this is the case, use a brand name penetrating agent and/or - if possible - an
appropriate pull-off device.
The notes and steps stated in ( Section 7.4.1 Page 35) to ( Section 7.4.2 Page
35) have been observed/carried out.
1. Disconnect the discharge and suction nozzle from the piping.
Etabloc 35 of 64
7 Servicing/Maintenance
2. Depending on the pump/motor size, unscrew the bolts that fix the support foot
and/or motor foot to the foundation.
3. Remove the complete pump set from the piping.
WARNING
Motor tipping over
Risk of squashing hands and feet!
Suspend or support the motor to prevent it from tipping over.
The notes and steps stated in ( Section 7.4.1 Page 35) to ( Section 7.4.2 Page
35) have been observed/carried out.
1. Depending on the pump/motor size, unscrew the bolts that fix the motor foot to
the foundation.
2. Undo screws 900.
3. Remove cover plates 68-3 from drive lantern 341.
4. Undo hexagon head bolts 901.3.
5. Insert both lockwashers 931 into the groove in shaft 210 ( Section 7.5.5 Page
39).
6. Tighten hexagon head bolts 901.3.
7. Remove the motor.
WARNING
Back pull-out unit tipping over
Risk of squashing hands and feet!
Suspend or support the back pull-out unit at the pump end.
The notes and steps stated in ( Section 7.4.1 Page 35) to ( Section 7.4.4 Page
36) have been observed/carried out.
1. If required, suspend or support the back pull-out unit to prevent it from tipping
over.
2. Undo nut 920.2 (with bolted discharge cover) or 920.4 (with clamped discharge
cover) at the volute casing.
3. Pull the back pull-out unit out of the volute casing.
4. Remove and dispose of gasket 400.1.
5. Place the back pull-out unit on a clean and level surface.
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7 Servicing/Maintenance
Etabloc 37 of 64
7 Servicing/Maintenance
The assembled bearing as well as the individual parts are kept in a clean and
level assembly area.
All disassembled parts have been cleaned and checked for wear.
Any damaged or worn parts have been replaced by original spare parts.
The sealing surfaces have been cleaned.
1. Clean shaft sleeve 523, and touch up any score marks or scratches with a
polishing cloth, if necessary.
If score marks or scratches are still visible, fit new shaft sleeve 523.
2. Push shaft sleeve 523 with new gasket 400.2 onto shaft 210.
3. Clean the seat ring location in discharge cover 163 and seat ring holder 476.
CAUTION
Elastomers in contact with oil/grease
Shaft seal failure!
Use water as assembly lubricant.
Never use oil or grease as assembly lubricant.
4. Carefully insert seat ring and seat ring carrier 476.
Make sure that pressure is applied evenly.
5. Fit discharge cover 163 into the locating surface of drive lantern 341 or, on
Etabloc G, M, into the locating surface of the motor flange.
6. Fit and tighten hexagon nuts 920.3 and 920.4, if applicable. ( Section 7.5.1 Page
37)
NOTE
To reduce friction forces when assembling the seal, wet the shaft sleeve and the seat
ring location with water.
7. Fit the rotating part of the mechanical seal (spring-loaded ring) to shaft sleeve
523.
Observe the following installation dimension b for mechanical seals with installation
dimension L1k to EN 12756 (design KU):
1 2 3 4
Fig. 7: Installation dimension b of mechanical seal
38 of 64 Etabloc
7 Servicing/Maintenance
WARNING
Back pull-out unit tipping over
Risk of squashing hands and feet!
Suspend or support the back pull-out unit at the pump end.
The notes and steps stated in ( Section 7.5.1 Page 37) to ( Section 7.5.3 Page
39) have been observed/carried out.
Any damaged or worn parts have been replaced by original spare parts.
The sealing surfaces have been cleaned.
1. If required, suspend or support the back pull-out unit to prevent it from tipping
over.
2. Fit new gasket 400.1 into the recess of volute casing 102.
3. Push the back pull-out unit into volute casing 102.
4. Depending on the pump size and motor size, fit support foot 183.
5. Tighten hexagon nut 920.2 (with bolted discharge cover) or 920.4 (with clamped
discharge cover) at the volute casing.
DANGER
Incorrect shaft connection
Explosion hazard!
Connect the shafts between pump and motor as described in this manual.
1 2 3
1167:455/4
4 5 6
Fig. 8: Fitting the motor shaft stub on the shaft
Etabloc 39 of 64
7 Servicing/Maintenance
The notes and steps stated in ( Section 7.5.1 Page 37) to ( Section 7.5.4 Page
39) have been observed/carried out.
1. Fit motor shaft stub on shaft 210 and make sure that the keyway of the motor
shaft end aligns with the slot in shaft 210 and that both are located opposite the
slot of taper lock ring 515 (see illustration: Fitting the motor shaft stub on the
shaft).
2. Tighten socket head cap screws 914.1. ( Section 7.6.1 Page 40)
3. Unscrew hexagon head bolts 901.3.
901.3
931
1167:456/3
B X F
B X
Bolts to be tightened
40 of 64 Etabloc
7 Servicing/Maintenance
Refer to the name plate for all data. ( Section 4.3 Page 16)
Refer to the exploded view or general assembly drawing for part numbers and
descriptions. ( Section 9.2 Page 50)
Etabloc 41 of 64
7 Servicing/Maintenance
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 17: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 10 and
more
210 Shaft10) 1 1 1 2 2 2 20 %
230 Impeller (including casing 1 1 1 2 2 2 20 %
wear ring 502.2) 11)
230.1/.2 Impeller (set) 12) 1 1 1 2 2 2 20 %
400.1/.2 Gasket13) 4 6 8 8 9 12 150 %
412.3 O-ring 12) 2 3 4 4 4 5 100 %
433 Mechanical seal 1 1 2 2 2 3 25 %
502.1 Casing wear ring 11) 2 2 2 3 3 4 50 %
523 Shaft sleeve 11) 2 2 2 3 3 4 50 %
42 of 64 Etabloc
7 Servicing/Maintenance
Mechanical seal
discharge side
Volute casing
Shaft sleeve
suction side
Impeller
Part No.
Shaft unit
2-pole
4-pole
225
225
112
25-20/... 25 X X X
32-23/... X X X X
32-125.1/... 1* 1 2 3 / / * 1* 1* X 1*
32-160.1/... 1* 1 3 4 / / 1 1* 1* 3* 1*
32-200.1/... 2* 2 4 5 / / 2 1* 1* 3* 1*
32-250.1/... 3* 3 5 6 / / 3 1* 1* 4 1*
32-125/... 1* 1 2 3 4 / / * 1* 1* X 1*
32-160/... 1* 2 4 / / 1 1* 1* 3* 1*
32-200/... 2* 2 3 5 6 / / 2 1* 1* 3* 1*
32-250/... 3* 3 4 6 / / 3 1* 1* 4 1*
40-125/... 1* 1 2 3 4 / / * 1* 2* X 1*
40-160/... 1* 2 4 5 6 / / * 1* 2* 3* 1*
40-200/... 2* 3 5 6 / / * 1* * 3* 1*
40-250/... 3* 4 6 7 / / * 1* 2* 4* 1*
40-315/... 35 * 8 9 * 2* 2* 12* 2*
50-125/... 25 1* 2 4 5 / / * 1* 3* 3* 1*
50-160/... 1* 3 5 6 / / * 1* 3* 3* 1*
50-200/... 2* 4 6 7 12 / / * 1* 3* 3* 2*
50-250/... 3* 4 12 / / * 1* 3* 4* 1*
50-315/... 35 4* 8 9 / * 2* 5* 10* 2*
65-125/... 25 1* 2 3 4 5 6 / / * 1* 5* 3* 1*
65-160/... 5* 3 4 6 / / * 1* 5* 9* 1*
65-200/... * 4 6 7 12 / / * 1* 5* 9* 1*
65-250/... 35 * 9 13 14 * 2* 9* 12* 2*
65-315/... 4* 9 10 * 2* 9* 10* 2*
80-160/... 25 5* 4 6 7 12 / / * 1* 6* 9* 1*
80-200/... 35 6* 8 9 13 15 * 2* 6* 10* 2*
80-250/... 7* 9 10 13 15 * 2* 6* 10* 2*
80-315/... 4* 10 11 13 * 2* 6* 10* 2*
80-400/... 55 10* / / / / / / / 16 / 17 * 3* * * 3*
100-160/... 35 6* 8 13 * 2* 7* 10* 2*
100-200/... 6* 9 13 15 * 2* 7* 10* 2*
100-250/... 7* 10 * 2* 7* 10* 2*
100-315/... 4* 11 13 * 2* 7* 10* 2*
100-400/... 55 10* / / / / / / / 16 / 17 * 3* 7* 8* 3*
125-200/... 35 8* 9 10 * 2* 8* 11* 2*
125-250/... 9* 10 11 13 * 2* 8* 11* 2*
125-315/... 55 11* / / / / / / / 16 / 17 * 3* 8* 8* 3*
Etabloc 43 of 64
7 Servicing/Maintenance
Etabloc Description
Shaft 14)
Mechanical seal
discharge side
Volute casing
Shaft sleeve
suction side
Impeller
Part No.
Shaft unit
2-pole
4-pole
225
225
112
125-400/... 10* / / / / / / / 16 / 17 * 3* 8* 8* 3*
150-200/... 35 8* 10 * 2* * 11* 2*
150-250/... 9* 10 11 13 * 2* 14* 13* 2*
150-315/... 55 11* / / / / / / / 16 / 17 * 3* 14* 8* 3*
44 of 64 Etabloc
8 Trouble-shooting
8 Trouble-shooting
A Pump delivers insufficient flow rate
B Motor is overloaded
C Motor protection switch trips the pump
D Excessive bearing temperature
E Leakage at the pump
F Excessive leakage at the shaft seal
G Vibrations during pump operation
H Impermissible rise of temperature inside the pump
Table 21: Trouble-shooting
A B C D E F G H Possible cause Remedy15)
X Pump delivers against an excessively Re-adjust to duty point.
high discharge pressure. Check plant for impurities.
Fit a larger impeller.16)
Increase the speed (turbine, I.C. engine).
X X X Pumpe bzw. Pump or piping are not Vent and/or prime.
completely vented or primed.
X Suction line or impeller clogged. Remove deposits in the pump and/or piping.
X Formation of air pockets in the piping Alter piping layout.
Fit a vent valve.
X X X Suction head is too high/NPSH available Check/alter liquid level.
(positive suction head) is too low. Fully open shut-off valve in the suction line.
Change suction line, if the friction losses in
the suction line are too high.
Check any strainers installed/suction opening.
X Wrong direction of rotation. Interchange two of the phases of the power
supply cable.
X X Wear of internal parts Replace worn components by new ones.
X X X Pump back pressure is lower than Re-adjust to duty point.
specified in the purchase order.
X Density or viscosity of the fluid pumped Contact KSB.
is higher than stated in the purchase
order.
X Defective seal. Fit new seal between volute casing and
discharge cover.
X Worn shaft seal Fit new shaft seal.
X X Score marks or roughness on shaft Fit new shaft sleeve.
sleeve. Fit new shaft seal.
X Vibrations during pump operation Correct suction conditions.
Increase pressure at the pump suction nozzle.
X X X Pump is warped or sympathetic Check pipeline connections and secure fixing
vibrations in the piping. of pump; if required, reduce the distances
between the pipe clamps.
Fix the pipelines using anti-vibration material.
X Increased axial thrust16) Clean balancing holes in the impeller.
Replace the casing wear rings.
X X Insufficient or excessive quantity of Top up, reduce or change lubricant.
lubricant or unsuitable lubricant.
X X Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
X Rotor is out of balance. Clean the impeller.
Re-balance the impeller.
15) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
16) Contact KSB.
Etabloc 45 of 64
8 Trouble-shooting
15) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
46 of 64 Etabloc
9 Related Documents
9 Related Documents
1165:21/4 o = open
x o o
x = closed
Motor foot fastened at the bottom
Motor sizes 132 = 5.5 kW to 180 = 22 kW
1167:72 o = open
x o o
x = closed
1167:22/5
Pump foot fastened at the top
Motor must be turned by 180.
o = open
x o o x = closed
Table 23: Typical installation positions of Etabloc GN, MN, BN17) , SN17) , CN17)
Examples Special features
Horizontal installation
Pump foot fastened at the bottom
Up to motor size 112 = 4 kW
1165:60
Etabloc 47 of 64
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1167:68
Table 24: Typical installation positions of Etabloc GN, MN, BN18) , SN18)
Examples Special features
Vertical installation
Pump foot fastened at the side
Up to motor size 112 = 4 kW
For vertical installation, fit a vent valve to prevent dry running of the
mechanical seal.
1167:73
1167:74
Vent valve
Model with vent valve for vertical installation.
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Table 25: Typical installation positions of Etabloc GN, MN, SN, BN, CN
Examples Special features
Horizontal installation
Motor foot fastened at the bottom/additional support
Motor sizes 200 = 30 kW to 225 = 45 kW
1167:71
Etabloc 49 of 64
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19) Up to motor size 112 = 4 kW only, (from motor size 132 = 5.5 kW with motor foot, not shown in exploded view)
20) For Etabloc pumps with shaft unit 25 only (shaft unit see data sheet).
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Etabloc 51 of 64
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21) Up to motor size 112 = 4 kW only, (from motor size 132 = 5.5 kW with motor foot, not shown in exploded view)
22) For Etabloc pumps with shaft unit 25 only (shaft unit see data sheet).
52 of 64 Etabloc
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Etabloc 53 of 64
9 Related Documents
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9 Related Documents
Etabloc 55 of 64
9 Related Documents
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9 Related Documents
Etabloc 57 of 64
9 Related Documents
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9 Related Documents
Etabloc 59 of 64
9 Related Documents
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10 EC Declaration of Conformity
10 EC Declaration of Conformity
is in conformity with the provisions of the following directives as applicable in their current version:
EC Machinery Directive 2006/42/EC
Etabloc 61 of 64
11 Certificate of Decontamination
11 Certificate of Decontamination
Type ................................................................................................................................
Order number/
Order item number37) ................................................................................................................................
radioactive explosive corrosive toxic
harmful bio-hazardous highly flammable safe
Comments: ................................................................................................................................
................................................................................................................................
The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing
at your disposal.
On sealless pumps, the rotor has been removed from the pump for cleaning.
...............................................................................................................................................................
...............................................................................................................................................................
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with
the relevant legal provisions.
62 of 64 Etabloc
Index
Index
A N
Abrasive fluids 30 Name plate 16
Noise characteristics 18
B
Bearing temperature 33 O
Operating limits 8, 28
Order number 6
C Ordering spare parts 41
Certificate of decontamination 62 Other applicable documents 6
Clearance gaps 34
Commissioning/start-up 26
P
Partly completed machinery 6
D Permissible forces at the pump nozzles 21
Design 16, 17 Piping 20
Designation 16 Place of installation 19
Direction of rotation 24 Preservation 14, 30
Dismantling 35 Product description 16
Disposal 14 Pump casing 17
E R
Exploded view 50, 52, 53, 54, 55, 57, 59, 60 Reassembly 35, 37
Explosion protection 11, 19, 22, 23, 24, 26, 27, 28, 29, Return to supplier 14
32, 33, 34, 39 Returning to service 30
F S
Filter 34 Safety 8
Frequency of starts 29 Safety awareness 9
Function 17 Scope of supply 18
Shaft seal 17
Shutdown 30
I Spare parts stock 42
Impeller type 17 Start-up 27
Installation 19 Storage 14, 30
Intended use 8
Interchangeability of pump components 43
T
Temperature limits 11
M Tightening torques 40
Maintenance 32 Transport 13
Mechanical seal 28 Trouble-shooting 45
Misuse 9 Typical installation positions 47
Monitoring equipment 12
Etabloc 63 of 64
1167.8/15-10
KSB Aktiengesellschaft
67225 Frankenthal Johann-Klein-Str. 9 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 Fax +49 6233 86-3401
www.ksb.com