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
RDLO/ RDLO V 3 of 84
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
4 of 84 RDLO/ RDLO V
Glossary
Glossary
Certificate of decontamination Non-drive end

A certificate of decontamination certifies that The side of the pump which faces away from
the pump (set) has been properly drained to the motor
eliminate any environmental and health
hazards arising from components in contact
Pump set
with the fluid handled.
Complete pump set consisting of pump, drive,
additional components and accessories
Discharge line
The line which is connected to the discharge
Suction lift line/suction head line
nozzle
The line which is connected to the suction
nozzle
Drive end
The side of the pump which faces the motor
Hydraulic system
The part of the pump in which the kinetic
energy is converted into pressure energy
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 Content
Data sheet 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
General assembly drawing1) Sectional drawing of the pump
Sub-supplier documentation1) Operating manuals and other documentation of
accessories and integrated machinery components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components 1) Description of all pump components
Installation instructions1) Instructions for assembling the supporting frame
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1) If agreed to be included in the scope of supply
1 General
Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
2 Safety
2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings
Symbol Description
! DANGER DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
! WARNING WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EC Directive
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.
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
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

Always observe the information on explosion protection given in this section when
! DANGER operating the pump (set) in potentially explosive atmospheres.
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.
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
▷ 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.
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!
Table 4: Transporting individual components
Transporting the pump (figure 0) Transporting the pump (figure 0)

vertically on the base frame
Transporting the base frame Transporting the supporting frame

(3E installation) (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.
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.
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 Drawing Description
installation
Figure 2E 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
4.2 Designation
Horizontally installed pump
Example: RDLO 600 - 600 A GB P F
Table 6: Key to the designation
Code Description
RDLO Type series
600 Nominal discharge nozzle diameter [mm]
600 Nominal impeller diameter [mm]
A Impeller type
GB Material combination, e.g. GB = grey cast iron/bronze
P Shaft seal, e.g. P = gland packing
F 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 Description
RDLO Type series
V Vertical design
600 Nominal discharge nozzle diameter [mm]
600 Nominal impeller diameter [mm]
A Impeller type
GB Material combination, e.g. GB = grey cast iron/bronze
P Shaft seal, e.g. P = gland packing
F Lubrication of bearings, e.g. F = grease
4.3 Name plate
Aktiengesellschaft
D-67227 Frankenthal
1 6
2009
2
RDLO 400 - 665 A 7
3
P-No. 9971507641 / 000100 8
4 Q 2400 m3/h H 65,00 m
9
5 n 991 1/min SNr. 253227
Gew. 3200 kg
Mat.-No. 01 111 383 ZN 3804 - D 74 x 105
Fig. 1: Example: Name plate
1 Designation of the pump set 2 Order number

3 Flow rate 4 Speed
5 Weight of Fig. 0 pump 6 Year of supply
7 Order item number 8 Head
9 Serial number
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 Explosion protection marking
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
4.5 Configuration and function
4 5
6
3 7
2 8
1 9
10
Fig. 3: Sectional drawing
1 Suction nozzle 2 Bearing housing

3 Rolling element bearing 4 Volute casing
5 Impeller 6 Clearance gap
7 Shaft 8 Rolling element bearing
9 Shaft seal 10 Discharge nozzle
Design 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.
Function 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).
Sealing 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)
Rated power Pump
input < 595 rpm 715 rpm 985 rpm 1480 rpm
PN [kW] [dB (A)] 740 rpm 1180 rpm 1780 rpm
[dB (A)] [dB (A)] [dB (A)]
100 70.6 71.7 72.8 73.8
150 72.8 73.8 74.9 75.8
200 74.3 75.3 76.3 77.3
250 75.5 76.4 77.5 78.4
300 76.5 77.4 78.4 79.3
2) Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.80 - 1.1 range and for non-
cavitating operation. If noise levels are to be warranted: Add an allowance of +3 dB for measuring and manufacturing
tolerances.
Rated power Pump

input < 595 rpm 715 rpm 985 rpm 1480 rpm
PN [kW] [dB (A)] 740 rpm 1180 rpm 1780 rpm
[dB (A)] [dB (A)] [dB (A)]
350 77.3 78.2 79.2 80.1
400 78.0 78.9 79.9 80.7
450 78.7 79.5 80.5 81.3
500 79.2 80.1 81.0 81.8
600 80.2 81.0 81.9 82.8
700 81.0 81.8 82.7 83.5
800 81.7 82.5 83.4 84.2
900 82.4 83.1 84.0 84.8
1000 82.9 83.7 84.5 85.3
1200 83.9 84.6 85.5 86.2
1400 84.7 85.4 86.3 87.0
1600 85.4 86.1 86.9 87.6
1800 86.0 86.7 87.5 88.2
2000 86.6 87.3 88.1 88.7
2250 87.2 87.9 88.7 89.3
2500 87.8 88.5 89.2 89.9
2750 88.3 88.9 89.7 90.3
3000 88.8 89.4 90.1 90.8
3500 89.6 90.2 90.9 91.5
4000 90.3 90.9 91.6 92.2
4500 90.9 91.5 92.2 92.8
5000 91.5 92.1 92.7 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.
NOTE
Some individual components weigh more than 25 kg. Refer to the indicated weights! (⇨
Section 9.1 Page 74)
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
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.
5.3.1 2E installation
DANGER
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
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.
⇨ 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).
DANGER
tongs.
Fig. 6: 3E installation - pump and motor on a common base frame

3) Refer to the general arrangement drawing for the required concrete quality.
2
3

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.
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
DANGER
tongs.
Fig. 8: Pump and motor on separate base plates

1
2
3

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.
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)
10. Lift the pump and motor onto the base frames with a suitable hoisting tackle
and align the shafts with each other.
12. Install the pump and the motor on the base frame in accordance with the
5.3.4 DJ installation
DANGER
tongs.
Fig. 10: Pump on its own base frame, drive on a different construction level
✓ The motor is installed on a separate base frame on a higher level in the building
in accordance with the manufacturer's operating instructions.
2
3

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.
7. Grout the base frame with a quick-setting, low-shrinkage concrete mixture. 6)
9. Install the pump on the base frame in accordance with the general arrangement
drawing.
10. Install the motor on the supporting frame.
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).
5.3.5 DP installation
DANGER
tongs.
Fig. 12: Pump on base frame and motor on supporting frame

Positioning the pump with pre-assembled base frame
✓ The relevant installation instructions for the supporting frame of the motor are
available.
1
2
3

4. Align the pump with the piping.
Installing the supporting frame of the motor

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
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 pre-
assembled 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.
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)
4. Grout the base frame with a quick-setting, low-shrinkage concrete mixture.7)
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.
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).
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.
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 b) 1
A B A B
A B A B
1 2 1 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.
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
Suction and discharge nozzles Suction and discharge nozzles
Material Cast iron Nodular cast iron/cast steel
Size Fx / Fy / Fz Mx / My / Mz Fx / Fy / Fz Mx / My / Mz
[N] [Nm] [N] [Nm]
350 - 575 5900 3300 8300 4600
350 - 690
Suction and discharge nozzles Suction and discharge nozzles

Material Cast iron Nodular cast iron/cast steel
Size Fx / Fy / Fz Mx / My / Mz Fx / Fy / Fz Mx / My / Mz
[N] [Nm] [N] [Nm]
400 - 525 6900 3800 9700 5300
400 - 580
400 - 665
400 - 705
400 - 935
500 - 585 8800 4900 12300 6900
500 - 685
500 - 835
500 - 860
500 - 1015
500 - 1035
600 - 600 10700 6000 15000 8400
600 - 705
600 - 885
600 - 1075
700 - 980 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
Table 10: Auxiliary connections

Connection Description Connection
type
1M.1 Connection for pressure measurement on the suction side G 1/2
1M.2 Connection for pressure measurement on the discharge G 1/2
side
4M.1 Connection for temperature measurement at the drive end G 1/2
4M.2 Connection for temperature measurement at the non- G 1/2
drive end
6B Connection for pump drain on the suction side G1
6B.1 Connection for pump drain on the suction side G1
6B.2 Connection for pump drain on the discharge side G1
6D Connection for venting the pump G1
8A Connection for leakage drain G 3/4
8A.1 Connection for leakage drain G 1/2
8A.3 Connection for leakage drain8) G 3/4
26M.1 Connection for vibration measurement at the drive end M8
26M.2 Connection for vibration measurement at the non-drive M8
end
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
5.9.1 Earthing
DANGER
Electrostatic charging
Explosion hazard!
Fire hazard!
▷ 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!
▷ 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.
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
900.2
903.11
Fig. 20: Transport lock
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 Grease-lubricated bearings have been packed with grease at the factory.
bearings 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)
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 Top up the bearing housing with lubricating oil.

bearings 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.
Bearing housing 672

with constant-level oiler
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.
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).
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!
▷ 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.
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 Values
Minimum 10 drops/min. (approx. 0.5 ml)
Maximum 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 The leakage can be reduced.

operation
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.
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.
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 Maximum material-dependent operating pressure
[bar]
Cast iron Nodular cast iron/cast steel
350 - 575 . 21.5
350 - 690 10.2 29.5
400 - 525 7.6 12.4
400 - 580 8.7 16.0
400 - 665 8.9 21.0
400 - 705 9.9 22.0
400 - 935 9.5 17.7
500 - 585 8.1 10.3
500 - 685 8.1 13.5
500 - 835 8.1 20.0
500 - 860 7.5 21.0
500 - 1015 8.5 21.0
500 - 1035 8.5 22.0
600 - 600 7.3 11.0
600 - 705 7.2 14.7
600 - 885 7.6 21.0
600 - 1075 8.4 22.5
700 - 980 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 0 °C
Maximum fluid temperature + 60 °C
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 start-
up.
General information on the hydraulic operating range

H
Qmin NPSHRequired
NPSHAvailable
HA
Q
Fig. 23: Pump operating range
HA System curve Qmin Minimum flow rate

NPSH Required pump inlet pressure NPSH Available pressure in the
Required Available
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
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 steady-
state 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)
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 safety-
relevant and protective devices.
NOTE
On pumps/pump sets older than 5 years we recommend replacing all elastomer seals.
7 Servicing/Maintenance
7.1 Safety regulations

DANGER
Improperly serviced pump set
Explosion hazard!
▷ 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
▷ 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.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
Fire hazard!
▷ 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!
▷ 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).
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!
▷ 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 Number of Time Maintenance work
persons
Daily 1 6 min. ▪ Check the leakage of the
mechanical seal or the leakage
rate of the gland packing.
1 6 min. ▪ Check the oil level and top up
the oil, if required (only for oil-
lubricated bearings)
Weekly 1 15 min. ▪ Check the pump operation.
(inlet pressure, head, bearing
temperature, noises and
vibrations)
Monthly 1 15 min. ▪ Verify the torsional clearance of
the coupling (see operating
instructions of the coupling).
1 15 min. ▪ Switch to a stand-by pump, if
any, or carry out a functional
check run (5 minutes).
Every 4,400 operating 1 15 min. ▪ Re-lubricate grease-packed
hours rolling element bearings, re-
lubrication quantity see (⇨
Section 7.2.2.5.1.5 Page 53)
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.
Table 15: Clearance gaps in [mm]
S
Pump size Maximum Minimum clearance Maximum clearance

permissible nominal gap gap
clearance gap
D2
(wear limit)
D2 - D1 S min S max.
D1
2
350 - 575 A / B 0.96 0.50 0.66
350 - 690 A / B 1.16 0.70 0.86
400 - 525 A / B 1.06 0.40 0.56
Fig. 24: Impeller clearance 400 - 580 A / B 1.16 0.50 0.66
gap
400 - 665 A / B 0.96 0.40 0.56
400 - 705 A / B 1.06 0.50 0.66
400 - 935 A 1.36 0.90 1.06
500 - 585 A / B 1.16 0.50 0.66
500 - 685 A / B 1.16 0.50 0.66
500 - 835 A / B 1.16 0.70 0.86
500 - 860 A / B 1.26 0.80 0.96
500 - 1015 A / B 1.46 1.00 1.16
500 - 1035 A / B 1.46 1.00 1.16
600 - 600 A / B 1.26 0.60 0.76
600 - 705 A / B 1.36 0.80 0.96
600 - 885 A / B 1.06 0.60 0.76
600 - 1075 A 1.46 1.00 1.16
700 - 980 A / B 1.26 0.70 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.
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!
▷ 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.
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 - Every 4,400 operating hours; at least every 2 years
pump set with
grease
▪ Change the grease - 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 Worked penetration Drop point Temperature range
at 25 °C in mm/10
Lithium 2 to 3 220-295 ≥ 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 Fixed bearing Radial bearing
Angular Lubrication Re-lubrication Deep groove Lubrication Re-lubrication
contact ball quantity quantity ball bearing quantity quantity
bearing [g] per 1 bearing [g]
per 2 bearings [g] [g]
350 - 575 7220 B UA 350 50 6220 C3 230 25
350 - 690 7220 B UA 350 50 6220 C3 230 25
400 - 525 7222 B UA 490 60 6222 C3 300 30
400 - 580 7220 B UA 350 50 6220 C3 230 25
400 - 665 7222 B UA 490 60 6222 C3 300 30
400 - 705 7220 B UA 350 50 6220 C3 230 25
400 - 935 7220 B UA 350 50 6220 C3 230 25
500 - 585 7222 B UA 490 60 6222 C3 300 30
500 - 685 7222 B UA 490 60 6222 C3 300 30
500 - 835 7326 B UA 1240 130 6326 C3 640 65
500 - 860 7326 B UA 1240 130 6326 C3 640 65
500 - 1015 7326 B UA 1240 130 6326 C3 640 65
500 - 1035 7326 B UA 1240 130 6326 C3 640 65
600 - 600 7222 B UA 490 60 6222 C3 300 30
600 - 705 7222 B UA 490 60 6222 C3 300 30
600 - 885 7330 B UA 1740 170 6330 C3 860 85
600 - 1075 7330 B UA 1740 170 6330 C3 860 85
700 - 980 7330 B UA 1740 170 6330 C3 860 85
For commissioning and returning the pump set to service after a prolonged
shutdown period, apply twice the re-lubrication quantity.
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.
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 First oil change All subsequent oil
bearing changes9)
up to 70 ℃ After 300 operating hours After 7500 operating hours
70 °C - 80 °C After 300 operating hours After 3700 operating hours
80 °C - 90 °C 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
Angular Bearing Constant-level Deep groove Bearing Constant-level
contact ball housing oiler ball bearing housing oiler
bearing per 1 bearing
per 2 bearings [l] [l] [l] [l]
350 - 575 7220 B UA 1.00 0.12 6220 C3 1.00 0.12
350 - 690 7220 B UA 1.00 0.12 6220 C3 1.00 0.12
400 - 525 7222 B UA 1.25 0.12 6222 C3 1.25 0.12
400 - 580 7220 B UA 1.00 0.12 6220 C3 1.00 0.12
400 - 665 7222 B UA 1.25 0.12 6222 C3 1.25 0.12
400 - 705 7220 B UA 1.00 0.12 6220 C3 1.00 0.12
400 - 935 7220 B UA 1.00 0.12 6220 C3 1.00 0.12
500 - 585 7222 B UA 1.25 0.12 6222 C3 1.25 0.12
500 - 685 7222 B UA 1.25 0.12 6222 C3 1.25 0.12
500 - 835 7326 B UA 2.20 0.12 6326 C3 2.20 0.12
500 - 860 7326 B UA 2.20 0.12 6326 C3 2.20 0.12
500 - 1015 7326 B UA 2.20 0.12 6326 C3 2.20 0.12
500 - 1035 7326 B UA 2.20 0.12 6326 C3 2.20 0.12
600 - 600 7222 B UA 1.25 0.12 6222 C3 1.25 0.12
600 - 705 7222 B UA 1.25 0.12 6222 C3 1.25 0.12
600 - 885 7330 B UA 2.30 0.12 6330 C3 2.30 0.12
600 - 1075 7330 B UA 2.30 0.12 6330 C3 2.30 0.12
700 - 980 7330 B UA 2.30 0.12 6330 C3 2.30 0.12
9) At least once a year
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)
▷ 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
WARNING
Unqualified personnel performing work on the pump (set)
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
WARNING
WARNING
Hot surface
▷ 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
▷ Always transport the pump (set) in horizontal position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ 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
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.
✓ 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.
✓ 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.
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
✓ 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)
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.
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 ✓ The rotor has been placed on a clean assembly surface and secured against
plain bearing 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.
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.
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
▷ Always transport the pump (set) in horizontal position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Observe the local accident prevention regulations.
▷ Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.
DANGER
Improper transport
WARNING
Unqualified personnel performing work on the pump (set)
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
WARNING
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 Always reassemble the pump in accordance with the corresponding general assembly
drawing and installation instructions.
O-rings/V-rings ▪ 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.
7.5.2 Fitting the rotor

✓ 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.
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.
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 ✓ The impeller has been fitted.
installation ✓ The shaft seal has been fitted.
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
this position, half round head grooved pin 561.2 will be pointing vertically
downwards.
b
c
Fig. 29: Position of the anti-vortex vane
a Anti-vortex vane at the shaft seal b Position of the grooved pin

housing
c Suction nozzle
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
Thread size Torque for keywayed nut (920.4)
M55x2 1 turn (360 degrees)
M80x2 1 1/4 turn (450 degrees)
Vertical installation with ✓ The impeller has been fitted.
rolling element bearing ✓ The shaft seal has been fitted.
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.
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.
b
c
a Anti-vortex vane at the shaft seal b Position of the grooved pin

housing
c Suction nozzle
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 ✓ The impeller has been fitted.
plain bearing ✓ The shaft seal has been fitted.
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.
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.
b
c
a Anti-vortex vane at the bearing b Position of the grooved pin

housing
c Suction nozzle
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
Use the following bearing sizes:
Table 23: Bearing sizes
Angular contact ball Deep-groove ball bearing
bearing 1 bearing per size
2 bearings per size
350 - 575 7220 B UA 6220 C3
350 - 690 7220 B UA 6220 C3
400 - 525 7222 B UA 6222 C3
400 - 580 7220 B UA 6220 C3
400 - 665 7222 B UA 6222 C3
400 - 705 7220 B UA 6220 C3
400 - 935 7220 B UA 6220 C3
500 - 585 7222 B UA 6222 C3
500 - 685 7222 B UA 6222 C3
500 - 835 7326 B UA 6326 C3
500 - 860 7326 B UA 6326 C3
500 - 1015 7326 B UA 6326 C3
500 - 1035 7326 B UA 6326 C3
600 - 600 7222 B UA 6222 C3
600 - 705 7222 B UA 6222 C3
600 - 885 7330 B UA 6330 C3
600 - 1075 7330 B UA 6330 C3
700 - 980 7330 B UA 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.

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 Refer to the corresponding sections on how to install the pump set. (⇨ Section 5.3
Page 21)
DJ, DP installation ✓ 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)
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 8 10 and
more
234 Impeller 1 1 1 2 2 2 20 %
502 Casing wear ring 2 2 2 3 3 4 50 %
503 Impeller wear ring 2 2 2 3 3 4 50 %
Shaft with keys and shaft nuts 1 1 1 2 2 2 20 %
320 Angular contact ball bearing 2 2 4 4 4 6 25 %
321 Deep-groove ball bearing 1 1 2 2 2 3 25 %
524 Shaft protecting sleeve 4 4 4 6 6 8 50 %
Set of seal elements 4 6 8 8 9 12 150 %
(set for the complete pump)
Design with mechanical seal
433 Mechanical seal:
Spring-loaded ring 4 6 8 10 12 14 90 %
Seat ring 4 6 8 10 12 14 90 %
O-ring 4 6 8 10 14 18 100 %
Secondary seal at seat ring 4 6 8 10 14 18 100 %
Set of springs 2 2 2 2 4 4 20 %
(set for one mechanical seal)
Design with gland packing (general)
461 Set of packing rings 4 4 6 6 6 8 100 %
(set for the complete pump)
458 Lantern ring 2 2 4 4 4 6 30 %
Design with gland packing for pump pressure < 7 bar
457 Neck ring 2 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 J K L M Possible cause Remedy 11)
X X X X X X X X X Duty point B does not match the ▪ Re-adjust to duty point.
Q and H performance data
calculated in advance.
X Pump and/or piping are not ▪ Vent.
completely vented or primed.
X X X X X X Supply line or impeller clogged ▪ Clean the impeller.
▪ Check system for impurities.
▪ Remove deposits in pump
and/or piping.
▪ Check any strainers
installed/suction opening.
X X X Formation of air pockets in the ▪ Correct the suction
piping conditions.
▪ Alter piping layout.
X X X X X Suction head too high (NSPH ▪ Check operating mode.
available too low) / water level ▪ Correct the suction
too low conditions.
▪ Increase suction head.
▪ Increase back pressure by
throttling.
▪ Install pump at a lower
level.
▪ Alter suction/inlet line, if
piping losses are too high.
X X X X Air intake at the shaft seal ▪ 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.
8 Trouble-shooting

X X X X X Wrong direction of rotation ▪ Interchange two of the
phases of the power cable.
▪ Check electrical connections.
▪ Check impeller position;
correct if necessary.
X X X Speed too low ▪ Increase the speed
▪ Check switchgears.
▪ Fit larger impeller.
X X X X Wear of internal parts ▪ Check duty point/pump
selection.
▪ Increase back pressure by
throttling.
▪ Check fluid handled for
contamination by chemicals;
check solids content.
▪ Replace worn parts by new
ones.
X X Pump pressure lower than ▪ Re-adjust to duty point.
specified in the purchase order ▪ Increase back pressure by
throttling.
X X Density or viscosity of fluid ▪ Reduce the speed.
handled higher than stated in ▪ In the case of persistent
purchase order overloading, turn down
impeller, if possible.
X X X X X Speed too high ▪ Reduce the speed.
▪ In the case of persistent
overloading, turn down
impeller, if possible.
X Tie bolts/seal elements ▪ Check.
▪ Tighten the bolts.
▪ Fit new seal elements.
▪ Check pipeline connections
and secure fixing of pump;
improve fixing of pipelines,
if necessary.
X Worn shaft seal ▪ Check flushing liquid/barrier
fluid.
▪ Clean barrier fluid duct,
▪ Replace shaft seal.
ones.
▪ Replace shaft protecting
sleeve.
8 Trouble-shooting

X X X X Unfavourable flow to pump ▪ Alter piping layout
suction nozzle ▪ 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.
X X Gland follower or seal cover ▪ Change.
tightened incorrectly; wrong ▪ Replace.
packing material
▪ Correct.
▪ Repack gland.
ones.
X X Lack of cooling liquid or dirty ▪ Check flushing liquid/barrier
cooling chamber fluid.
▪ Clean barrier fluid duct,
▪ Increase cooling liquid
quantity.
▪ Purify/clean cooling liquid.
X X Pump warped or sympathetic ▪ Re-align pump/drive.
vibrations in the piping ▪ Check pipeline connections
and secure fixing of pump;
improve fixing of pipelines,
if necessary.
▪ Fix pipelines using anti-
vibration material.
X Increased axial thrust ▪ Check duty point/pump
selection.
▪ Check operating mode.
▪ Check suction side flow
conditions.
X Insufficient or excessive quantity ▪ Clean the bearings.
of lubricant or unsuitable ▪ Top up, reduce or change
lubricant lubricant.
X X X X Motor is running on two phases ▪ Replace defective fuses.
only. ▪ Check electrical connections.
▪ Check switchgear.
X X X Rotor is out of balance. ▪ Clean impeller.
▪ Check run-out; re-align, if
necessary.
▪ Re-balance rotor.
X X X Defective bearing ▪ Replace.
8 Trouble-shooting

X X Insufficient flow rate ▪ 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 In star-delta operation, motor ▪ Check electrical connections.
stuck at star stage ▪ Check switchgear.
X X X Impermissible air or gas content ▪ Vent.
in fluid handled ▪ Check suction line for
leakage, seal if necessary.
X X X X X Air intake at pump inlet ▪ Correct the suction
conditions.
▪ Reduce flow velocity at
suction line inlet.
▪ Check suction line for
leakage, seal if necessary.
▪ Replace defective pipes.
X Cavitation (rattling noise) ▪ Correct the suction
conditions.
▪ Check operating mode.
▪ Install pump at a lower
level.
X X Foundation not rigid enough ▪ Check.
▪ Correct.
X X X X X Impermissible parallel operation ▪ Re-adjust to duty point.
▪ Adjust pump characteristic
H.
X X Shaft is out of true. ▪ Replace.
X X X X Impeller rubs against casing ▪ Check rotor.
components. ▪ 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.
8 Trouble-shooting
HA
B
HV
Eta
H
Hgeo
NPSH
NPSHA
Q
Fig. 33: Adjusting to the duty point
P Performance HA System curve

B Duty point Hv Hydraulic losses (system)
H Head NPSH Required inlet pressure
Eta Efficiency NPSHA Inlet pressure available in the system
Q Flow rate Hgeo Static head
9 Related Documents
9 Related Documents
9.1 Weights of individual components

DANGER
Improper transport
Table 26: Weights in kg

Size Volute casing Impeller Shaft Bearing housing Shaft seal Casing
Lower Upper Oil- Grease- housing wear ring
part part lubricated lubricated
350 - 575 1495 657 177 106 82 71 31 < 25
350 - 690 1630 745 223 106 82 71 31 < 25
400 - 525 1275 635 204 138 86 85 48 < 25
400 - 580 1425 670 195 106 82 71 40 < 25
400 - 665 1860 820 274 138 96 85 48 < 25
400 - 705 1495 695 255 106 82 71 40 < 25
400 - 935 2115 845 370 106 82 71 40 < 25
500 - 585 2675 1010 272 157 96 85 71 < 25
500 - 685 2610 1000 324 157 96 85 71 < 25
500 - 835 2860 1035 394 218 127 114 70 < 25
500 - 860 3050 1100 458 218 127 114 74 < 25
500 - 1015 3510 1230 591 218 127 114 70 < 25
500 - 1035 3260 1295 596 218 127 114 74 < 25
600 - 600 3000 1155 271 157 96 85 82 28
600 - 705 3195 985 343 157 96 85 82 < 25
600 - 885 3440 1260 544 306 146 131 90 26.2
600 - 1075 4215 1485 688 306 146 131 90 26.2
700 - 980 5120 1860 800 330 146 131 91 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.
902.1
441 903.2* 502 234 525.3 452* 920.2 525.1 681
903.5 412.3 903.1 102 561.1 412.2 524.1* 903.5 350.1
901.4
636
720.3
73-1 904.1
507.2 550.11
920.5
350.2
145
904.3
920.5
940.1
914.1 211
920.4
930.1 940.3
940.4
411.2
950.2
520 932
550.1
903.4
550.1
321
360.1
561.2
940.2 458* 412.1 411.1 320
(940.7)
903.6 457.1* 461* 680.1 903.4
903.7 900.1
550.4
903.3
903.8 41-1
Fig. 34: Horizontal installation: * = for variants with gland packing only
901.3
940.5 433 471 550.5
441 457.2 524.2 412.7 902.1 562.3

920.2
Fig. 35: Detailed view: mechanical seal
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. Description Part No. Description
102 Volute casing 524.1/.2 Shaft protecting sleeve
145 Connecting part 525.1/.3 Spacer sleeve
211 Pump shaft 550.1/.4/.5/.7/.11 Disc
234 Impeller 561.1/.2 Grooved pin
9 Related Documents

320 Rolling element bearing 562.3 Parallel pin
321 Radial ball bearing 636 Lubricating nipple
350.1/.2 Bearing housing 680.1 Guard
360.1 Bearing cover 681 Coupling guard
41-1 Sealing washer 73-1 Socket
411.1/.2 Joint ring 720.3 Special part
412.1/.2/.3/.7 O-ring 900.1 Bolt/screw
433 Mechanical seal 901.1/.3/.4/.5 Hexagon head bolt
441 Shaft seal housing 902.1 Stud
452 Gland follower 903.1/.2/.3/.4/.5/.6/.7/.8 Screwed plug
457.1/.2/.3 Gland ring 904.1/.2/.3 Grub screw
458 Lantern ring 914.1 Socket head cap screw
461 Gland packing 920.2/.4/.5 Nut
471 Seal cover 930.1 Safety device
502 Casing wear ring 932 Circlip
503 Impeller wear ring 940.1/.2/.3/.4/.5/.7 Key
507.2 Thrower 950.2 Spring
520 Sleeve
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.
902.1
903.9 681 932 411.2 940.3 636 525.1 360.1 920.2
901.4 507.2 550.1 145 211 320 411.1 412.1 350.1 561.2
904.1
920.5
903.5 550.11
680.1
900.1
550.4 458*
41-1
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
903.6 903.12
430 903.7
903.5
636
720.3
73-1
930.1
720.1 904.3 920.4 520 903.4 350.2 893.40
920.5 914.1
321 940.4 360.2 561.2
901.42 950.2 550.1 901.40
Fig. 39: Vertical installation
562.3
901.3 902.1
550.5 920.2
471
412.7
433
524.2
940.5 457.2
441
Fig. 40: Detailed view: mechanical seal
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
102 Volute casing 524.1/.2 Shaft protecting sleeve
145 Connecting part 525.1/.3 Spacer sleeve
211 Pump shaft 550.1/.4/.5/.6/.7/.11 Disc
234 Impeller 561.1/.2 Grooved pin
320 Rolling element bearing 562.3 Parallel pin
321 Radial ball bearing 636 Lubricating nipple
350.1/.2 Bearing housing 680.1/.3 Guard
360.1/.2 Bearing cover 681 Coupling guard
41-1 Sealing washer 73-1 Socket
411.1/.2 Joint ring 720.1/.3 Special part
412.1/.2/.3/.7/.10 O-ring 893.40 Sole plate
9 Related Documents

430 Shaft seal 900.1/.4 Screw
433 Mechanical seal 901.1/.3/.4/.5/.40/.42 Hexagon head bolt
441 Shaft seal housing 902.1 Stud
452 Gland follower 903.1/.2/.4/.5/.6/.7/.9/.12 Screwed plug
457.1/.2/.3 Gland ring 904.1/.2/.3 Grub screw
458 Lantern ring 914.1 Socket head cap screw
461 Gland packing 920.2/.4/.5 Nut
471 Seal cover 930.1 Safety device
502 Casing wear ring 932 Circlip
503 Impeller wear ring 940.1/.2/.3/.4/.5/.7 Key
507.1/.2 Thrower 950.2 Spring
520 Sleeve
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)
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 Address Company stamp
12) Required fields
Index
Index
A N
Abrasive fluids 45 Noise characteristics 18
B O
Bearing temperature 49 Oil lubrication
Bearings 17 Intervals 55
Operating limits 8, 43
Order number 6
C Other applicable documents 6
Certificate of decontamination 82
Commissioning/start-up 40
Constant-level oiler 39 P
Partly completed machinery 6
Permissible forces and moments at the pump nozzles
D 33
Design 17 Piping 30
Dismantling 57 Preservation 13
Disposal 14 Pump casing 17
E R
Explosion protection 11, 21, 32, 33, 35, 36, 40, 41, 42, Return to supplier 14
43, 46, 48, 49, 50, 52 Returning to service 46
Running noises 49
F
Filling and venting 40 S
Filter 31, 52 Safety 8
Frequency of starts 46 Safety awareness 9
Scope of supply 19
Shaft seal 17
G Spare parts 68
Gland packing 42 Spare parts stock 68
Grease lubrication Start-up 41
Grease quality 53 Storage 13
I T
Impeller type 17 Trouble-shooting 69
Installation 21, 61
Intended use 8
M
Maintenance/repair 48
Mechanical seal 42
Misuse 9
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

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Dry-installed Volute Casing Pump

KSB Aktiengesellschaft Frankenthal

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft Frankenthal 21.05.2010

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

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

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

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

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

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

11 Certificate of Decontamination ....................................................... 82

Certificate of decontamination Non-drive end

Noise characteristics (⇨ Section 4.6 Page 18)

1.2 Installation of partly completed machinery

1.3 Target group

1.4 Other applicable documents

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

2.1 Key to safety symbols/markings

2.3 Intended use

Prevention of foreseeable misuse

2.4 Personnel qualification and training

The responsibilities, competence and supervision of all personnel involved in

Deficits in knowledge must be rectified by sufficiently trained specialist personnel

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

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

2.6 Safety awareness

▪ Safety regulations for handling hazardous substances

2.7 Safety instructions for the operator/user

2.8 Safety information for maintenance, inspection and installation work

2.9 Unauthorised modes of operation

2.10 Explosion protection

Table 4: Transporting individual components

Transporting the pump (figure 0) Transporting the pump (figure 0)

Transporting the base frame Transporting the supporting frame

3.2 Storage and preservation

3.3 Return to supplier

1. Dismantle the pump (set).

4 Description of the Pump (Set)

4.1 General description

Figure 3E Pump and drive on a common baseframe

Figure 4E Pump and drive on separate baseframes

Figure DJ Pump on its own baseframe

Figure DP Pump on base frame and drive on

4.3 Name plate

Fig. 1: Example: Name plate

1 Designation of the pump set 2 Order number

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

1 Explosion protection marking

4.4 Design details

4.5 Configuration and function

Fig. 3: Sectional drawing

1 Suction nozzle 2 Bearing housing

4.6 Noise characteristics

Rated power Pump

4.7 Scope of supply