KSB KWP P03 P12 Instructions

Dry-installed Volute Casing Pump
KWP
Bearing bracket P03ax to P12sx
Installation/Operating
Manual
Order number:
Order item number:
Mat. No.:
Legal information/Copyright
Installation/Operating Manual KWP
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or
processed for any other purpose, nor otherwise transmitted, published or made available to a third party without
the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft, Frankenthal 16.07.2013

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 ...................................................................................................... 10
2.6 Safety awareness ............................................................................................10
2.7 Safety information for the operator/user ..................................................... 10
2.8 Safety information for maintenance, inspection and installation work ..... 10
2.9 Unauthorised modes of operation ................................................................ 11
2.10 Explosion protection ...................................................................................... 11
3 Transport/Temporary Storage/Disposal .............................................13

3.1 Checking the condition upon delivery .......................................................... 13
3.2 Transport ......................................................................................................... 13
3.3 Storage/preservation ...................................................................................... 14
3.4 Return to supplier ........................................................................................... 15
3.5 Disposal ...........................................................................................................15
4 Description of the Pump (Set) ............................................................16

4.1 General description ........................................................................................ 16
4.2 Designation ..................................................................................................... 16
4.3 Name plate ...................................................................................................... 16
4.4 Design .............................................................................................................. 16
4.5 Materials .........................................................................................................19
4.6 Installation types ............................................................................................19
4.7 Configuration and function ........................................................................... 20
4.8 Noise characteristics .......................................................................................21
4.9 Scope of supply ............................................................................................... 21
4.10 Dimensions and weights ................................................................................21
5 Installation at Site ...............................................................................22

5.1 Safety regulations ........................................................................................... 22
5.2 Checks to be carried out prior to installation ............................................... 22
KWP 3 of 86
Contents
5.3 Installing the pump set .................................................................................. 22

5.4 Piping .............................................................................................................. 24
5.5 Enclosure/insulation .......................................................................................29
5.6 Checking the alignment of coupling/belt drive ............................................ 30
5.7 Aligning the pump and motor ...................................................................... 32
5.8 Electrical connection ...................................................................................... 35
5.9 Checking the direction of rotation ................................................................ 36
6 Commissioning/Start-up/Shutdown ...................................................38
6.1 Commissioning/start-up ................................................................................. 38
6.2 Operating limits .............................................................................................. 44
6.3 Shutdown/storage/preservation .................................................................... 46
6.4 Returning to service .......................................................................................46
7 Servicing/Maintenance .......................................................................47
7.1 Safety regulations ........................................................................................... 47
7.2 Maintenance/inspection ................................................................................. 48
7.3 Drainage/cleaning ..........................................................................................53
7.4 Dismantling the pump set .............................................................................. 53
7.5 Reassembling the pump set ........................................................................... 58
7.6 Tightening torques ......................................................................................... 68
7.7 Spare parts stock ............................................................................................. 69
8 Trouble-shooting ................................................................................74
9 Related Documents ............................................................................76

9.1 General assembly drawing with list of components .................................... 76
10 EC Declaration of Conformity ............................................................83
11 Certificate of Decontamination .........................................................84
Index ....................................................................................................85
4 of 86 KWP
Glossary
Glossary
Back pull-out design Pool of pumps

The complete back pull-out unit can be pulled Pumps which are purchased and stored
out without having to remove the pump casing independently of their later use
from the piping.
Pump
Back pull-out unit Machine without drive, additional components
Pump without pump casing; partly completed or accessories
machinery
Pump set
Certificate of decontamination Complete pump set consisting of pump, drive,
A certificate of decontamination is enclosed by additional components and accessories
the customer when returning the product to
the manufacturer to certify that the product
Suction lift line/suction head line
has been properly drained to eliminate any
environmental and health hazards arising from The line which is connected to the suction
components in contact with the fluid handled. nozzle
Discharge line
The line which is connected to the discharge
nozzle
KWP 5 of 86
1 General
1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics (⇨ Section 4.8 Page 21)
1.2 Installation of partly completed machinery

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

This manual is aimed at the target group of trained and qualified specialist technical
personnel.
1.4 Other applicable documents

Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
General arrangement drawing/ Description of mating and installation dimensions
outline drawing for the pump (set), weights
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 product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components1) Description of all pump components
Drawing for assembly Sectional drawing for fitting the shaft seal
For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
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
6 of 86 KWP
1 General
Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
KWP 7 of 86
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 specialist personnel/
operators responsible 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 not
taken into account in this manual.
2.3 Intended use

The pump (set) must only be operated within the operating limits described in the
other applicable documents. (⇨ Section 1.4 Page 6)
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate the pump (set) in partially assembled condition.
▪ Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model.
8 of 86 KWP
2 Safety
▪ Never operate the pump without the fluid 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.
▪ Only use the different impeller types in combination with the fluids described
below.
Table 4: Applications of impeller types
Impeller type Suitable for the following fluids
Closed channel Contaminated, solids-laden fluids not
impeller liable to plait and containing no or very
(K impeller) little entrapped gas
Open multi- For uncontaminated or slightly

vane impeller contaminated fluids as well as fluids
(O impeller) liable to form deposits and bunch, with
little entrapped gas.
Open free flow Fluids containing larger solids and stringy

impeller material as well as fluids with entrapped
(F impeller) air or gas
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 transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. 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.
KWP 9 of 86
2 Safety
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
▪ Safety regulations for handling hazardous substances
▪ Applicable standards and laws
2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any contact guards during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪ If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation 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.
▪ Only carry out work on the pump (set) during standstill of the pump.
▪ 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 53)
10 of 86 KWP
2 Safety
▪ 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 38)
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.
2.10 Explosion protection

Always observe the information on explosion protection given in this section when
! DANGER operating the pump in potentially explosive atmospheres.
Only pumps/pump sets marked as explosion-proof and identified as such in the data
sheet may be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof pump sets to EC
Directive 94/9/EC (ATEX).
Especially adhere to the sections in this manual marked with the Ex symbol and the
following sections (⇨ Section 2.10.1 Page 11) to (⇨ Section 2.10.4 Page 12) (⇨ Section
2.10.3 Page 12) .
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
Never operate the pump set outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.
2.10.1 Marking
Pump The marking on the pump refers to the pump part only.
Example of such marking: II 2 G c TX
Refer to the Temperature Limits table for the temperatures permitted for the
individual pump variants. (⇨ Section 2.10.2 Page 11)
Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor The motor must be considered separately.
2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on the
surface of the pump casing, at the shaft seal and in the bearing areas.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated in addition, the operator of the system is
responsible for observing the specified temperature classes and fluid temperature
(operating temperature).
The table below lists the temperature classes and the resulting theoretical
temperature limits of the fluid handled (a possible temperature rise in the shaft seal
area has already been taken into account).
The temperature class specifies the maximum permissible temperature at the surface
of the pump set during operation. For the permissible operating temperature of the
pump in question refer to the data sheet.
KWP 11 of 86
2 Safety
Table 5: Temperature limits

Temperature class to EN 13463-1 Maximum permissible fluid
temperature
T1 Maximum 400 °C2)
T2 280 °C
T3 185 °C
T4 120 °C
T5 85 °C
T6 Only after consultation
with the manufacturer
Temperature class T5 Based on an ambient temperature of 40 °C and proper maintenance and operation,
compliance with temperature class T5 is warranted in the area of the rolling element
bearings. If the ambient temperature exceeds 40 °C, contact the manufacturer.
Temperature class T6 A special design is required to comply with the requirements of temperature class T6
in the bearing area.
Misuse, malfunctions or non-compliance with the instructions may result in
substantially higher temperatures.
If the pump is to be operated at a higher temperature, if there is no data sheet or if
the pump is part of a pool of pumps, contact KSB for the maximum permissible
operating temperature.
2.10.3 Monitoring equipment

The pump (set) must only be operated within the limits specified in the data sheet
and on the name plate.
If the system operator cannot warrant compliance with these operating limits,
appropriate monitoring devices must be used.
Check whether monitoring equipment is required to ensure that the pump set
functions properly.
Contact KSB for further information on monitoring equipment.
2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.2.3.1 Page 45) refer to water and water-
like fluids handled. Longer operating periods with these fluids and at the flow rates
indicated will not cause an additional increase in the temperatures at the pump
surface. However, if the physical properties of the fluids handled differ from those of
water, it is essential to check whether additional heat build-up may occur and if the
minimum flow rate must therefore be increased. The calculation formula in
(⇨ Section 6.2.3.1 Page 45) can be used to check whether additional heat build-up
may lead to a dangerous temperature increase at the pump surface.
2) Depending on the material variant
12 of 86 KWP
3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in the specified position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Give due attention to the weight data and the centre of gravity.
▷ Observe the applicable local health and safety regulations.
▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
To transport the pump/pump set or back pull-out unit suspend it from the lifting
tackle as shown.
Fig. 1: Transporting the back pull-out unit
Fig. 2: Transporting the pump
KWP 13 of 86
Fig. 3: Transporting a pump set with belt drive (figure 3Z and 4H)
Fig. 4: Pump set on baseplate with counter shaft and belt drive (figure 3H)
Fig. 5: Transporting a pump set on a baseplate (figure 3)
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
▷ Only remove caps/covers from the openings of the pump set at the time of
installation.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
14 of 86 KWP
If properly stored indoors, the pump set is protected for a maximum of 12 months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, observe the instructions
in. (⇨ Section 6.3.1 Page 46)
3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 53)
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 set 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).
Always indicate any safety and decontamination measures taken. (⇨ Section 11
Page 84)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
KSB web site at: www.ksb.com/certificate_of_decontamination
3.5 Disposal
WARNING
Fluids, consumables and supplies which are hot or pose a health hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set).
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.
KWP 15 of 86
4 Description of the Pump (Set)
4.1 General description

▪ Dry-installed volute casing pump
Pump for handling pre-treated sewage, waste water, all types of slurries (without
stringy material) and pulps up to 6 % bone dry.
4.2 Designation
Example: KWPK125-100-0250 DDDD10
Table 6: Key to the designation
Code Description
KWP Type series
K Impeller type, e.g. K = channel impeller
125 Nominal suction nozzle diameter [mm]
100 Nominal discharge nozzle diameter [mm]
0250 Nominal impeller diameter [mm]
DDDD Material variant, e.g. DDDD = NORIDUR
10 Design variant
4.3 Name plate
KSB Aktiengesellschaft
1 67227 Frankenthal 6
2012
KWPK125-100-0250 DDDD10
2
0520-5-P-10000-31
3
P-No. 997125086300550001 7
4
Q 21.0 m3/h H 13.0 m 8
5
n 1420 1/min 9
Mat-No. 01 109 223 ZN 3804 - D 52 x 74
Fig. 6: Name plate (example)

1 Type series, size, material, and 2 Customer-specific information
design variant (optional)
3 KSB order and order item number 4 Flow rate
5 Speed 6 Year of construction
7 Head 8 Pump input power (optional)
9 Further required information
(optional)
4.4 Design
Design
▪ Volute casing pump
▪ Back pull-out design
▪ Horizontal installation
▪ Single-stage
▪ Single-entry
Pump casing
▪ Radially split volute casing
16 of 86 KWP
▪ For combustible fluids: ductile materials containing less than 7.5% magnesium
(EN 13463-1)
▪ Volute casing with integrally cast pump feet
▪ Pump casing fitted with a wear plate
▪ Discharge cover available in the following versions:
1 2
D00481 D00475
D00476
Fig. 7: Discharge cover designs

1 Discharge cover with integrally cast 2 Discharge cover with bolted-on
stuffing box housing (cylindrical stuffing box housing (cylindrical
cover); material variants: GNNG, cover, split); material variants:
GDNG, DDDD, DKKM GHHH, HHHH
3 For mechanical seal: discharge cover
with conical seal chamber (A-type
cover); material variants: GNNG,
GDNG, DDDD, DKKM, GHHH, HHHH
Impeller type
▪ Various, application-based impeller types (⇨ Section 2.3 Page 8)
▪ Back vanes reduce axial thrust.
Bearings
▪ Oil-lubricated rolling element bearings
▪ Back pull-out bearing bracket partly with axially adjustable rotor to adjust the
clearance between impeller and wear plate
Bearings used Table 7: Standard bearings
Bearing bracket Rolling element bearings
Pump end3) Drive end4)
P03ax NU 409 2 x 7309 BG
P04ax NU 411 2 x 7311 BG
P05ax NU 413 2 x 7313 BG
P06x NU 413 2 x 7313 BG
P08sx NU 416 2 x 7319 BG
P10ax NU 324 2 x 7224 BG
P12sx NU 324 2 x 7224 BG
3) To DIN 5412
4) To DIN 628
KWP 17 of 86
Shaft seal
▪ Shaft fitted with a replaceable shaft protecting sleeve in the shaft seal area
▪ Gland packing
Uncooled gland packing with a)

connection for barrier fluid or
Cooled gland packing
flushing liquid (connections 10 A.
1 and 10 E.1)
▪ Commercial single and double mechanical seals
1 2
D00477 D00479
D00478
3
Fig. 8: Mechanical seals in conical seal chamber (A-type)
1 Single mechanical seal, unbalanced 2 Single mechanical seal with spring-
loaded stationary ring
3 Mechanical seal in tandem
arrangement, with quench
Drive
▪ Electric motor connected to the pump via a coupling or belt drive.
18 of 86 KWP
4.5 Materials
Table 8: Materials
Code Description
GNNG Standard design
▪ Entire pump made of GJL-250 5)
▪ Impeller and wear plate made of ERN
GDNG ▪ Like GNNG
▪ Impeller made of Noridur 1.4593
DDDD Entire hydraulic system made of Noridur 1.4593
DUUD ▪ Casing and discharge cover made of Noridur 1.4593
▪ Impeller and wear plate made of Noridur 1.4593 DAS
DKKM ▪ Casing made of Noridur 1.4593
▪ Impeller and wear plate made of CeramikPolySiC®
▪ Discharge cover made of NORICROM
DMKM ▪ Casing made of Noridur 1.4593
▪ Wear plate made of CeramikPolySiC®
▪ Impeller and discharge cover made of NORICROM
GHHH ▪ Casing made of GJL-250 6)
▪ Impeller, wear plate and discharge cover made of NORIHARD
HHHH Entire hydraulic system made of NORIHARD
4.6 Installation types

Table 9: Installation types
Installation type Drawing Description
Figure 3 Pump set with directly coupled motor
Figure 3Z Pump set with belt drive. Motor bracket

positioned in front of the pump
Figure 4H Pump set with belt drive. Motor support plate

positioned on the pump.
Figure 3H Pump set with belt drive and counter shaft.

Motor bracket positioned via counter shaft
5) Formerly JL1040
6) Formerly JL1040
KWP 19 of 86
4.7 Configuration and function
Fig. 9: Sectional drawing

1 Wear plate 2 Casing/discharge nozzle
3 Discharge cover 4 Bearing bracket lantern
5 Shaft 6 Bearing bracket
7 Casing/suction nozzle 8 Impeller
9 Shaft seal 10 Rolling element bearing, pump
end
11 Rolling element bearing, drive end
Design The horizontal, non-self-priming, radially split volute casing pump in back pull-out
design is designed with an axial fluid inlet and a radial outlet.
The rotor runs in an axially adjustable bearing assembly and is connected to the
motor by a shaft coupling.
Function The uniformly rotating impeller of the centrifugal pump transfers mechanical energy
to the fluid passing through the pump.
The fluid enters the pump axially via the suction nozzle (7) and is accelerated
outward by the rotating impeller (8). In the flow passage of the pump casing the
kinetic energy of the fluid is converted into pressure energy. The fluid leaves the
pump via the discharge nozzle (2).
The casing is fitted with a replaceable wear plate (1). The diagonal clearance gap
prevents frequent deflection of the clearance gap flow heading in the direction of
the suction nozzle. This ensures a longer service life if solids-laden fluids are handled.
Owing to the axially adjustable bearing assembly, the clearance gap can be set to an
optimum width.
The casing is closed by a discharge cover (3). The shaft (5) enters the casing via this
cover. A shaft seal (9) provides reliable sealing towards the atmosphere.
The shaft is supported by oil lubricated rolling element bearings (10 and 11). The
bearing bracket (6) is connected to the casing via a bearing bracket lantern (4).
Sealing The pump is sealed by a shaft seal. Variants:
▪ Mechanical seal (single seal or in tandem arrangement)
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▪ Gland packing with connection for barrier fluid or flushing liquid in the
cylindrical seal chamber
4.8 Noise characteristics

Table 10: Surface sound pressure level LpA7)8)
Rated power Pump Pump set9)

input 2900 min-1 1450 min-1 960/760 min-1 2900 min-1 1450 min-1 960/760 min-1
PN [kW] [dB] [dB] [dB] [dB] [dB] [dB]
1,1 54 52 51 63 57 55
2,2 55 53 52 65 59 53
3 57 55 54 67 61 59
4 58 57 55 69 62 61
5,5 60 58 57 70 64 63
7,5 61 59 58 71 65 64
11 63 61 60 73 67 66
15 64 62 61 74 68 67
18,5 65 63 62 75 69 68
22 66 64 63 75 69 68
30 67 65 64 76 71 69
37 68 66 65 77 71 70
45 69 67 66 77 72 71
55 70 68 67 78 73 71
75 - 69 68 - 74 72
90 - 70 69 - 74 73
110 - 71 70 - 75 73
132 - 72 71 - 75 74
160 - 73 72 - 76 74
200 - 75 74 - 76 75
250 - 76 75 - 80 79
4.9 Scope of supply

Depending on the model, the following items are included in the scope of supply:
▪ Pump
Drive ▪ Surface-cooled IEC frame three-phase squirrel-cage motor
Shaft coupling ▪ Flexible coupling with or without spacer sleeve or belt drive
Contact guard ▪ Coupling guard to EN 294 or belt guard
Baseplate ▪ Baseplate (to ISO 3661), cast or welded, for pump and motor, in torsion-resistant
design
Special accessories ▪ As required
4.10 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump/pump set.
7) 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 guaranteed: add +3 dB for measuring and constructional tolerance.
8) Increase for 60 Hz operation: 1750 1/min, + 1dB; 1160 1/min, no allowance
9) For belt-driven pump sets add 2 dB.
KWP 21 of 86
5 Installation at Site
5.1 Safety regulations
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
Damage to the pump set!
▷ Comply with the applicable local explosion protection regulations.
▷ Observe the information in the data sheet and on the name plates of pump and
motor.
5.2 Checks to be carried out prior to installation

Place of installation
WARNING
Installation on mounting surface which is unsecured and cannot support the load
Personal injury and damage to property!
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN 206-1.
▷ The mounting surface must have set and must be completely horizontal and
even.
▷ Observe the weights indicated.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.3 Installing the pump set

Always install the pump set in horizontal position.
DANGER
Excessive temperatures due to improper installation
Explosion hazard!
▷ Install the pump in horizontal position to ensure self-venting of the pump.
5.3.1 Installation on the foundation
1
L
2 3
Fig. 10: Fitting the shims
L Bolt-to-bolt distance 1 Shim
2 Shim if (L) > 800 mm 3 Foundation bolt
✓ The foundation has the required strength and characteristics.
22 of 86 KWP
✓ The foundation has been prepared in accordance with the dimensions given in
the outline drawing/general arrangement drawing.
1. Position the pump set on the foundation and level it with the help of a spirit
level placed on the shaft and discharge nozzle.
Permissible deviation: 0.2 mm/m.
2. Use shims (1) for height compensation, if necessary.
Always fit shims, if any, immediately to the left and right of the foundation
bolts (3) between the baseplate/foundation frame and the foundation.
For a bolt-to-bolt distance (L) > 800 mm fit additional shims (2) halfway
between the bolt holes.
All shims must lie perfectly flush.
3. Insert the foundation bolts (3) into the holes provided.
4. Use concrete to set the foundation bolts (3) into the foundation.
5. Wait until the concrete has set firmly, then level the baseplate.
6. Tighten the foundation bolts (3) evenly and firmly.
7. Grout the baseplate using low-shrinkage concrete with a standard particle size
and a water/cement ratio of ≤ 0.5.
Produce flowability with the help of a solvent.
Perform secondary treatment of the concrete to DIN 1045.
NOTE
For low-noise operation contact KSB to check whether the pump set can be
installed on anti-vibration mounts.
NOTE
Expansion joints can be fitted between the pump and the suction/discharge line.
5.3.2 Installation without foundation
4
Fig. 11: Adjusting the levelling elements
1, 3 Locknut 2 Levelling nut
4 Levelling element
✓ The installation surface has the required strength and characteristics.
1. Position the pump set on the levelling elements (4) and level it with the help of
a spirit level (on the shaft/discharge nozzle).
2. To adjust any differences in height, loosen the bolts and locknuts (1, 3) of the
levelling elements (4).
3. Turn the levelling nut (2) until any differences in height have been
compensated.
KWP 23 of 86
4. Re-tighten the locknuts (1, 3) at the levelling elements (4).
5.4 Piping
5.4.1 Connecting the piping
DANGER
Impermissible loads acting on the pump nozzles
Danger to life from leakage of hot, toxic, corrosive or flammable fluids!
▷ Do not use the pump as an anchorage point for the piping.
▷ 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.
▷ 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. However, such elements must not obstruct proper drainage or
hinder disassembly of the pump.
✓ The suction lift line has been laid with a rising slope, the suction head line with a
downward slope towards the pump.
✓ A flow stabilisation section having a length equivalent to at least twice the
diameter of the suction flange has been provided upstream of the suction flange.
✓ The nominal diameters of the pipelines are equal to or greater than the nominal
diameters of the pump nozzles.
✓ Adapters to larger nominal diameters are designed with a diffuser angle of
approx. 8° to avoid excessive pressure losses.
✓ The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the
suction and discharge nozzles of the pump.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Free the piping from any impurities.
▷ If necessary, install a filter.
▷ Comply with the instructions set out in (⇨ Section 7.2.2.2 Page 50) .
3. Check that the inside of the pump is free from any foreign objects. Remove any
foreign objects.
4. If required, install a filter in the piping (see drawing: Filter in the piping).
24 of 86 KWP
2
Fig. 12: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter made of corrosion-resistant material.
Use a filter with a filter area three times the cross-section of the piping.
Conical filters have proved suitable.
5. Connect the pump nozzles to the piping.
CAUTION
Aggressive flushing and pickling agents
Damage to the pump!
▷ Match the cleaning operation mode and duration for flushing and pickling
service to the casing and seal materials used.
5.4.2 Permissible forces and moments at the pump nozzles

[+] Fy The resulting permissible forces have
Fy been determined according to:
Fz Fz My
Mz
Fx Fx Mx
Fy
Fz
Fx
Forces and moments at the pump nozzles

The data on forces and moments apply to static piping loads only. If the limits are
exceeded, they must be checked and verified.
If a computerised strength analysis is required, values are available on request only.
The values are only applicable if the pump is installed on a completely grouted
baseplate and bolted to a rigid and level foundation.
Correction coefficients depending on material and temperature (see diagram below).
Material variants DDDD, DUUD, DKKM, DMKM: temperature-dependent correction

coefficients
For material variant DDDD and temperatures >20 °C reduce the values given in
(⇨ Section 5.4.2.1 Page 26) in accordance with the following diagram:
KWP 25 of 86
1
k=f(T)
0,98
0,91
0,9
0,84
0,8
0,81
0,7
0,6
0,5
0,4
0 20 50 100 150 200 250
T [°C]
Fig. 13: Correction coefficient for material variant DDDD

Calculation of forces and moments for T > 20 °C
Reduction formula:
Permissible force/moment = k (T) x force/moment from table
Example:
▪ Material = DDDD
▪ T = 100°C
▪ k = 0.98
5.4.2.1 Material variants DDDD, DUUD, DKKM, DMKM (NORIDUR 1.4593)

Table 11: Material variants DDDD, DUUD, DKKM, DMKM (NORIDUR 1.4593): permissible forces and moments at the
pump nozzles10)
Size Forces Moments
Suction nozzle Discharge nozzle Suction nozzle Discharge nozzle
Fx Fy Fz F res Fx F ytensile+ F ypressure - Fz F res Mx My Mz Mx My Mz
[N] [N] [N] [N] [N] [N] [N] [N] [N] [Nm] [Nm] [Nm] [Nm] [Nm] [Nm]
065-040-0250 3145 2065 2515 3235 1527 990 1975 1255 1975 2065 1525 1080 990 810 540
080-040-0315 3860 2515 3055 3950 1527 990 1975 1255 1975 2605 1975 1345 990 810 540
065-050-0200 3145 2065 2515 3235 1975 1255 2425 1615 2515 2065 1525 1080 1255 990 630
065-050-0201 3145 2065 2515 3235 1975 1255 2425 1615 2515 2065 1525 1080 1255 990 630
080-050-0400 3860 2515 3055 3950 1975 1255 2425 1615 2515 2605 1975 1345 1255 990 630
080-065-0200 3860 2515 3055 3950 2515 1615 3145 2065 3235 2605 1975 1345 2065 1525 1080
080-065-0201 3860 2515 3055 3950 2515 1615 3145 2065 3235 2605 1975 1345 2065 1525 1080
080-065-0313 3860 2515 3055 3950 2515 1615 3145 2065 3235 2605 1975 1345 2065 1525 1080
080-065-0315 3860 2515 3055 3950 2515 1615 3145 2065 3235 2605 1975 1345 2065 1525 1080
080-065-0400 3860 2515 3055 3950 2515 1615 3145 2065 3235 2605 1975 1345 2065 1525 1080
100-080-0250 4850 3145 3860 4940 3055 1975 3860 2515 3950 3595 2695 1795 2605 1975 1345
100-080-0251 4850 3145 3860 4940 3055 1975 3860 2515 3950 3595 2695 1795 2605 1975 1345
100-080-0311 4850 3145 3860 4940 3055 1975 3860 2515 3950 3595 2695 1795 2605 1975 1345
100-080-0315 4850 3145 3860 4940 3055 1975 3860 2515 3950 3595 2695 1795 2605 1975 1345
100-080-0400 4850 3145 3860 4940 3055 1975 3860 2515 3950 3595 2695 1795 2605 1975 1345
100-080-0403 4850 3145 3860 4940 3055 1975 3860 2515 3950 3595 2695 1795 2605 1975 1345
125-080-0500 6645 4310 5300 6825 3055 1975 3860 2515 3950 4940 3770 2515 2605 1975 1345
125-100-0250 6645 4310 5300 6825 3860 2425 4850 3145 5030 4940 3770 2515 3595 2695 1795
125-100-0251 6645 4310 5300 6825 3860 2425 4850 3145 5030 4940 3770 2515 3595 2695 1795
10) For temperatures >20 °C: adjust the values in accordance with the associated temperature adjustment diagram (correction
coefficient for material variant DDDD).
26 of 86 KWP
Size Forces Moments

125-100-0253 6645 4310 5300 6825 3860 2425 4850 3145 5030 4940 3770 2515 3595 2695 1795
125-100-0315 6645 4310 5300 6825 3860 2425 4850 3145 5030 4940 3770 2515 3595 2695 1795
125-100-0400 6645 4310 5300 6825 3860 2425 4850 3145 5030 4940 3770 2515 3595 2695 1795
125-100-0403 6645 4310 5300 6825 3860 2425 4850 3145 5030 4940 3770 2515 3595 2695 1795
150-125-0315 8445 5570 6735 8710 5300 3325 6645 4310 6825 6200 4760 3145 4940 3770 2515
150-125-0400 8445 5570 6735 8710 5300 3325 6645 4310 6825 6200 4760 3145 4940 3770 2515
150-125-0500 8445 5570 6735 8710 5300 3325 6645 4310 6825 6200 4760 3145 4940 3770 2515
150-125-0503 8445 5570 6735 8710 5300 3325 6645 4310 6825 6200 4760 3145 4940 3770 2515
150-150-0311 8445 5570 6735 8710 6735 4220 8445 5570 8710 6200 4760 3145 6200 4760 3145
150-150-0315 8445 5570 6735 8710 6735 4220 8445 5570 8710 6200 4760 3145 6200 4760 3145
150-150-0400 8445 5570 6735 8710 6735 4220 8445 5570 8710 6200 4760 3145 6200 4760 3145
150-150-0403 8445 5570 6735 8710 6735 4220 8445 5570 8710 6200 4760 3145 6200 4760 3145
200-200-0320 13205 8445 10240 13295 10240 6380 13205 8445 13295 9520 6915 4760 9520 6915 4760
200-200-0400 13205 8445 10240 13295 10240 6380 13205 8445 13295 9520 6915 4760 9520 6915 4760
200-200-0403 13205 8445 10240 13295 10240 6380 13205 8445 13295 9520 6915 4760 9520 6915 4760
200-200-0500 13205 8445 10240 13295 10240 6380 13205 8445 13295 9520 6915 4760 9520 6915 4760
200-200-0501 13205 8445 10240 13295 10240 6380 13205 8445 13295 9520 6915 4760 9520 6915 4760
200-200-0503 13205 8445 10240 13295 10240 6380 13205 8445 13295 9520 6915 4760 9520 6915 4760
250-250-0315 17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555
250-250-0400 17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555
250-250-0403 17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555
250-250-0500 17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555
250-250-0503 17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555
250-250-0630 17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555
250-250-0634 17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555
300-300-0400 21555 14370 17965 22995 17965 11045 21555 14370 22995 16435 12395 8085 16435 12395 8085
300-300-0500 21555 14370 17965 22995 17965 11045 21555 14370 22995 16435 12395 8085 16435 12395 8085
300-300-0503 21555 14370 17965 22995 17965 11045 21555 14370 22995 16435 12395 8085 16435 12395 8085
350-350-0400 23980 15630 19220 24790 19220 12035 23980 15630 24790 17155 12845 8445 17155 12845 8445
350-350-0500 23980 15630 19220 24790 19220 12035 23980 15630 24790 17155 12845 8445 17155 12845 8445
350-350-0630 23980 15630 19220 24790 19220 12035 23980 15630 24790 17155 12845 8445 17155 12845 8445
350-350-0633 23980 15630 19220 24790 19220 12035 23980 15630 24790 17155 12845 8445 17155 12845 8445
400-400-0500 24580 16750 20170 26210 20170 13300 24580 16750 26210 20375 15540 10825 20375 15540 10825
400-400-0533 24580 16750 20170 26210 20170 13300 24580 16750 26210 20375 15540 10825 20375 15540 10825
400-400-0583 24580 16750 20170 26210 20170 13300 24580 16750 26210 20375 15540 10825 20375 15540 10825
500-400-0710 25580 18635 21755 28645 20170 13300 24580 16750 26210 25050 19420 14285 20375 15540 10825
500-400-0713 25580 18635 21755 28645 20170 13300 24580 16750 26210 25050 19420 14285 20375 15540 10825
500-500-0544 25580 18635 21755 28645 21755 16600 25580 18635 28645 25050 19420 14285 25050 19420 14285
500-500-0630 25580 18635 21755 28645 21755 16600 25580 18635 28645 25050 19420 14285 25050 19420 14285
500-500-0633 25580 18635 21755 28645 21755 16600 25580 18635 28645 25050 19420 14285 25050 19420 14285
500-500-0637 25580 18635 21755 28645 21755 16600 25580 18635 28645 25050 19420 14285 25050 19420 14285
600-600-0663 26405 20170 23050 30625 23050 19900 26405 20170 30625 29340 23145 17995 29340 23145 17995
600-600-0669 26405 20170 23050 30625 23050 19900 26405 20170 30625 29340 23145 17995 29340 23145 17995
5.4.2.2 Material variants GNNG, GHHH, GDNG, HHHH (grey cast iron, NORIHARD)
Table 12: Material variants GNNG, GHHH, GDNG, HHHH (grey cast iron, NORIHARD): permissible forces and
moments at the pump nozzles11)
Size Forces Moments
065-040-0250 1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 550 450 300
080-040-0315 2150 1400 1700 2200 850 550 1100 700 1100 1450 1100 750 550 450 300
065-050-0200 1750 1150 1400 1800 1100 700 1350 900 1400 1150 850 600 700 550 350
065-050-0201 1750 1150 1400 1800 1100 700 1350 900 1400 1150 850 600 700 550 350
080-050-0400 2150 1400 1700 2200 1100 700 1350 900 1400 1450 1100 750 700 550 350
11) Temperature range: up to 200 °C (without loss); for other sizes please contact KSB
KWP 27 of 86
Size Forces Moments

080-065-0200 2150 1400 1700 2200 1400 900 1750 1150 1800 1450 1100 750 1150 850 600
080-065-0201 2150 1400 1700 2200 1400 900 1750 1150 1800 1450 1100 750 1150 850 600
080-065-0313 2150 1400 1700 2200 1400 900 1750 1150 1800 1450 1100 750 1150 850 600
080-065-0315 2150 1400 1700 2200 1400 900 1750 1150 1800 1450 1100 750 1150 850 600
080-065-0400 2150 1400 1700 2200 1400 900 1750 1150 1800 1450 1100 750 1150 850 600
100-080-0250 2700 1750 2150 2750 1700 1100 2150 1400 2200 2000 1500 1000 1450 1100 750
100-080-0251 2700 1750 2150 2750 1700 1100 2150 1400 2200 2000 1500 1000 1450 1100 750
100-080-0311 2700 1750 2150 2750 1700 1100 2150 1400 2200 2000 1500 1000 1450 1100 750
100-080-0315 2700 1750 2150 2750 1700 1100 2150 1400 2200 2000 1500 1000 1450 1100 750
100-080-0400 2700 1750 2150 2750 1700 1100 2150 1400 2200 2000 1500 1000 1450 1100 750
100-080-0403 2700 1750 2150 2750 1700 1100 2150 1400 2200 2000 1500 1000 1450 1100 750
125-080-0500 3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 750
125-100-0250 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
125-100-0251 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
125-100-0253 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
125-100-0315 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
125-100-0400 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
125-100-0403 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
150-125-0315 4700 3100 3750 4850 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400
150-125-0400 4700 3100 3750 4850 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400
150-125-0500 4700 3100 3750 4850 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400
150-125-0503 4700 3100 3750 4850 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400
150-150-0311 4700 3100 3750 4850 3750 2350 4700 3100 4850 3450 2650 1750 3450 2650 1750
150-150-0315 4700 3100 3750 4850 3750 2350 4700 3100 4850 3450 2650 1750 3450 2650 1750
150-150-0400 4700 3100 3750 4850 3750 2350 4700 3100 4850 3450 2650 1750 3450 2650 1750
150-150-0403 4700 3100 3750 4850 3750 2350 4700 3100 4850 3450 2650 1750 3450 2650 1750
200-200-0320 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
200-200-0400 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
200-200-0403 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
200-200-0500 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
200-200-0501 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
200-200-0503 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
250-250-0315 10000 6700 8000 10450 8000 5000 10000 6700 10450 7500 5700 3650 7500 5700 3650
250-250-0400 10000 6700 8000 10450 8000 5000 10000 6700 10450 7500 5700 3650 7500 5700 3650
250-250-0403 10000 6700 8000 10450 8000 5000 10000 6700 10450 7500 5700 3650 7500 5700 3650
250-250-0500 10000 6700 8000 10450 8000 5000 10000 6700 10450 7500 5700 3650 7500 5700 3650
250-250-0503 10000 6700 8000 10450 8000 5000 10000 6700 10450 7500 5700 3650 7500 5700 3650
250-250-0630 10000 6700 8000 10450 8000 5000 10000 6700 10450 7500 5700 3650 7500 5700 3650
250-250-0634 10000 6700 8000 10450 8000 5000 10000 6700 10450 7500 5700 3650 7500 5700 3650
300-300-0400 12000 8000 10000 12800 10000 6150 12000 8000 12800 9150 6900 4500 9150 6900 4500
300-300-0500 12000 8000 10000 12800 10000 6150 12000 8000 12800 9150 6900 4500 9150 6900 4500
300-300-0503 12000 8000 10000 12800 10000 6150 12000 8000 12800 9150 6900 4500 9150 6900 4500
350-350-0400 13350 8700 10700 13800 10700 6700 13350 8700 13800 9550 7150 4700 9550 7150 4700
350-350-0500 13350 8700 10700 13800 10700 6700 13350 8700 13800 9550 7150 4700 9550 7150 4700
350-350-0630 13350 8700 10700 13800 10700 6700 13350 8700 13800 9550 7150 4700 9550 7150 4700
350-350-0633 13350 8700 10700 13800 10700 6700 13350 8700 13800 9550 7150 4700 9550 7150 4700
400-400-0500 13900 10750 11950 16070 11950 6915 13900 10750 16070 9700 7950 6900 9700 7950 6900
400-400-0533 13900 10750 11950 16070 11950 6915 13900 10750 16070 9700 7950 6900 9700 7950 6900
400-400-0583 13900 10750 11950 16070 11950 6915 13900 10750 16070 9700 7950 6900 9700 7950 6900
500-400-0710 16600 13450 14950 21110 11950 6915 13900 10750 16070 14450 11800 10250 9700 7950 6900
500-400-0713 16600 13450 14950 21110 11950 6915 13900 10750 16070 14450 11800 10250 9700 7950 6900
500-500-0544 16600 13450 14950 21110 14950 8600 16600 13450 21110 14450 11800 10250 14450 11800 10250
500-500-0630 16600 13450 14950 21110 14950 8600 16600 13450 21110 14450 11800 10250 14450 11800 10250
500-500-0633 16600 13450 14950 21110 14950 8600 16600 13450 21110 14450 11800 10250 14450 11800 10250
500-500-0637 16600 13450 14950 21110 14950 8600 16600 13450 21110 14450 11800 10250 14450 11800 10250
600-600-0663 19900 16150 17950 24140 17950 10345 19900 16150 24140 20200 16600 14400 20200 16600 14400
28 of 86 KWP
5.4.3 Auxiliary connections
DANGER
Risk of potentially explosive atmosphere by mixing of incompatible fluids in the
auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure that the barrier fluid and quench liquid are compatible with the
fluid pumped.
WARNING
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing
liquid, etc.)
Risk of injury from escaping fluid!
Risk of burns!
Malfunction of the pump!
▷ Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the quantity, dimensions and locations of auxiliary
connections.
▷ Use the auxiliary connections provided.
5.5 Enclosure/insulation
DANGER
Risk of potentially explosive atmosphere due to insufficient venting
Explosion hazard!
▷ Make sure the space between the casing cover/discharge cover and the bearing
cover is sufficiently vented.
▷ Never close or cover the perforation of the bearing bracket guards (e.g. by
insulation).
WARNING
Unprotected rotating pulleys
Risk of injury by rotating pulleys!
▷ Always operate the pump set with a belt guard.
If the customer specifically requests not to include a belt guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a belt guard.
WARNING
The volute casing and casing/discharge cover take on the same temperature as the
fluid handled
Risk of burns!
▷ Insulate the volute casing.
▷ Fit protective equipment.
CAUTION
Heat build-up in the bearing bracket
Damage to the bearing!
▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover.
KWP 29 of 86
5.6 Checking the alignment of coupling/belt drive

After the pump set has been installed (⇨ Section 5.3 Page 22) and connected to the
piping (⇨ Section 5.4 Page 24) , check the alignment of the coupling or belt drive,
depending on the type of installation.
5.6.1 Checking the coupling alignment
DANGER
Inadmissible temperatures at the coupling or bearings due to misalignment of the
coupling
Explosion hazard!
Risk of burns!
▷ Make sure that the coupling is correctly aligned at all times.
CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷ Always check the coupling after the pump has been installed and connected to
the piping.
▷ Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
a) 1 b) 1
A B A B
A B A B
1 2 1 2
Fig. 14: Checking the coupling alignment: Coupling without spacer sleeve (a) or Coupling with spacer sleeve (b)
1 Straight-edge 2 Gauge
✓ The coupling guard and its footboard, if any, have been removed.
1. Loosen the support foot and re-tighten it without transmitting any stresses and
strains.
2. Place the straight-edge axially on both coupling halves.
3. Leave the straight-edge in this position and turn the coupling by hand.
The coupling is aligned correctly 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 0.1 mm, during standstill as well as at operating temperature and under
inlet pressure.
4. Check the distance (dimension see general arrangement drawing) between the
two coupling halves around the circumference.
The coupling is correctly aligned if the distance between the two coupling
halves is the same at all points around the circumference.
30 of 86 KWP
The radial and axial deviation between the two coupling halves must not
exceed 0.1 mm, during standstill as well as at operating temperature and under
inlet pressure.
5. If alignment is correct, re-install the coupling guard and its footboard, if any.
5.6.2 Checking the belt drive

Safety notes
CAUTION
Poorly checked and aligned motor connection
Increased wear, insufficient power transmission, loud running noises!
▷ Always use clean belts and pulleys without any signs of wear.
▷ Align the shaft end of pump/motor flush with the pulleys.
▷ For multiple V-belt drives: use V-belts of the same length.
▷ Tension the V-belts properly.
5.6.2.1 Checking the pulleys and V-belts

✓ Observe the information in (⇨ Section 5.6.2 Page 31) .
1. Remove the belt guard.
2. Check that pulleys and V-belts fulfil the following conditions:
- Pulleys are free from burrs, rust and dirt.
- V-belts are not worn.
- For multiple V-belt drives: all V-belts have the same length.
3. Replace any pulleys effected by burrs or rust.
4. Clean any dirty pulleys.
5. If replacing V-belts always replace the entire set of V-belts.
5.6.2.2 Checking the alignment of pump and motor shaft

✓ The notes and steps stated in (⇨ Section 5.6.2 Page 31) to (⇨ Section 5.6.2.1 Page
31) have been observed/carried out.
1. Measure the distance between the shaft stubs in two points with a straight-
edge.
The shafts are correctly aligned if the distances measured in both points are
equal (parallel axes).
2. If the distances differ, align the motor bracket by turning threaded rods
904.23/904.24 until equal distances are measured in both points.
5.6.2.3 Checking the alignment of the pulleys

✓ The notes and steps stated in (⇨ Section 5.6.2.1 Page 31) to (⇨ Section 5.6.2.2
Page 31) have been observed/carried out.
✓ Required tools: wedge gauge, straight-edge
1. Place the straight-edge (1) vertically on both pulleys.
1 2. Leave the straight-edge (1) in this position and turn the measuring point by
max. 1 mm hand.
Fig. 15: Checking the 3. Adjust the alignment, if required. (⇨ Section 7.5.9 Page 68)
pulley alignment 4. Re-fit the belt guard.
KWP 31 of 86
5.6.2.4 Checking the belt tension
Fig. 16: Tension check for V-belts

✓ The notes and steps stated in (⇨ Section 5.6.2 Page 31) to (⇨ Section 5.6.2.3 Page
1. Check the V-belt tension with a belt tension measuring tool (measuring tool not
included in the scope of supply).
2. If the tension is incorrect, tension the V-belt. (⇨ Section 5.7.3 Page 34)
Tension forces for V-belts

Table 13: Form for tension forces
Characteristic Value Unit
Test force [Fe] N
..........................................
Deflection distance of individual belts [ te] mm
..........................................
The set of V-belts consists of:
▪ Number of belts:
..........................................
▪ Dimension:
..........................................
▪ Effective length [LW] mm
..........................................
Diameter of large pulley [dwg] mm
..........................................
Diameter of small pulley [dwk] mm
..........................................
Speed [n]
..........................................
rpm
Distance between pulleys [anom.] mm
..........................................
5.7 Aligning the pump and motor
5.7.1 Motors with levelling screw

Any differences in shaft centre height between the pump and motor are adjusted
with levelling screws.
32 of 86 KWP
1
2
3
Fig. 17: Motor with levelling screw

1 Hexagon head bolt 2 Levelling screw
3 Lock nut
✓ The coupling is misaligned (⇨ Section 5.6.1 Page 30) .
✓ The coupling guard and footboard, if any, have been removed.
1. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at the
baseplate.
2. Turn the levelling screws (2) by hand or by means of an open-end wrench until
the coupling alignment is correct and all motor feet rest squarely on the
baseplate.
3. Re-tighten the hexagon head bolts (1) at the motor and the locknuts (3) at the
baseplate.
4. Check proper functioning of coupling/shaft.
Check that coupling/shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
▷ 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).
5. Re-install the coupling guard and footboard, if any.
6. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
5.7.2 Motors without levelling screw

Any differences in shaft centre height between the pump and the motor are
compensated by means of shims.
KWP 33 of 86
1
Fig. 18: Pump set with shim
1 Shim
✓ Misalignment of the coupling (⇨ Section 5.6.1 Page 30) .
✓ The coupling guard and footboard, if any, have been removed.
1. Unscrew the hexagon head bolts at the motor.
2. Insert shims (1) underneath the motor feet until the difference in shaft centre
height has been compensated.
3. Re-tighten the hexagon head bolts.
4. 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
▷ 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).
5. Reinstall the coupling guard and footboard, if any.
6. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
5.7.3 Pump sets with belt drive
CAUTION
Incorrect tension
Insufficient power transmission! Increased wear of the V-belt!
▷ Always ensure correct tensioning of the V-belt.
✓ The belt guard has been removed.
✓ The tension of the V-belt is too low or too high (⇨ Section 5.6.2.4 Page 32) .
1. Move motor bracket 81-54.01 up or down by turning threaded rods
904.23/904.24 until the V-belt is tensioned correctly.
Tension forces (⇨ Section 5.6.2.4 Page 32)
2. Check the V-belt tension with a belt tension measuring tool (measuring tool not
included in the scope of supply).
3. Check the tension again between ½ hour and 1 hour after initial operation.
4. If the tension is too low or too high, re-adjust the motor bracket and check the
tension again.
34 of 86 KWP
WARNING
Unprotected rotating pulleys
Risk of injury by rotating pulleys!
▷ Always operate the pump set with a belt guard.
If the customer specifically requests not to include a belt guard in KSB's
▷ Observe all relevant regulations for selecting a belt guard.
5. Re-fit the belt guard.
6. Check the distance between V-belt and belt guard.
The belt guard must not touch the V-belt.
5.8 Electrical connection
DANGER
Incorrect electrical installation
Explosion hazard!
▷ For electrical installation, also observe the requirements of IEC 60079-14.
▷ Always connect explosion-proof motors via a motor protection switch.
DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method.
NOTE
A motor protection device is recommended.
5.8.1 Setting the time relay
CAUTION
Switchover between star and delta on three-phase motors with star-delta starting
takes too long.
Damage to the pump (set)!
▷ Keep switch-over intervals between star and delta as short as possible.
Table 14: Time relay settings for star-delta starting:
Motor rating Y time to be set
≤ 30 kW <3s
> 30 kW <5s
KWP 35 of 86
5.8.2 Connecting the motor
NOTE
In compliance with IEC 60034-8, three-phase motors are always wired for clockwise
rotation (looking at the motor shaft stub).
The pump's direction of rotation is indicated by an arrow on the pump.
1. Match the motor's direction of rotation to that of the pump.
2. Observe the manufacturer's product literature supplied with the motor.
5.8.3 Earthing
DANGER
Electrostatic charging
Explosion hazard!
▷ Connect the PE conductor to the earthing terminal provided.
▷ Provide for potential equalisation between the pump set and foundation.
5.9 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.
WARNING
Hands inside the pump casing
Risk of injuries, damage to the pump!
▷ Always disconnect the pump set from the power supply and secure it against
unintentional start-up before inserting your hands or other objects into the
pump.
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
▷ Separate the pump from the motor to check the direction of rotation.
CAUTION
Drive and pump running in the wrong direction of rotation
Damage to the pump!
▷ Refer to the arrow indicating the direction of rotation on the pump.
▷ Check the direction of rotation. If required, check the electrical connection and
correct the direction of rotation.
The correct direction of rotation of the motor and pump is clockwise (seen from the
drive end).
1. Start the motor and stop it again immediately to determine the motor's
direction of rotation.
36 of 86 KWP
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 is running in the wrong direction of rotation, check the electrical
connection of the motor and switchgear, if any.
KWP 37 of 86
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/start-up
6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the following
conditions are met:
▪ The pump set has been properly connected to the electric power supply and is
equipped with all protection devices.
▪ The pump has been primed with the fluid to be handled. (⇨ Section 6.1.4 Page
40)
▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 36)
▪ All auxiliary connections required are connected and operational.
▪ The lubricants have been checked.
▪ After prolonged shutdown of the pump (set), the activities described in
(⇨ Section 6.4 Page 46) have been carried out.
6.1.2 Filling in lubricants

Oil-lubricated bearings Fill the bearing bracket with lubricating oil.
Oil quality see (⇨ Section 7.2.3.1.2 Page 51)
Oil quantity see (⇨ Section 7.2.3.1.3 Page 52)
Filling the constant-level oiler with lubricating oil (oil-lubricated bearings only)
✓ The constant-level oiler is screwed into the upper tapping hole of the bearing
bracket.
NOTE
If no constant-level oiler is provided on the bearing bracket, the oil level can be
read in the middle of the oil level sight glass arranged at the side of the bearing
bracket (optional).
Figure 4H: if access to the vent nozzle is difficult or impossible, the oil can be filled
in through the connection elbow of the constant-level oiler.
Make sure that the indicated oil level is within the scale.
CAUTION
Insufficient quantity of lubricating oil in the reservoir of the constant-level oiler
Damage to the bearings!
▷ Regularly check the oil level.
▷ Always fill the oil reservoir completely.
▷ Keep the oil reservoir properly filled at all times.
38 of 86 KWP
1 2
3 4 5
Fig. 19: Bearing bracket with constant-level oiler
1 Constant-level oiler 2 Vent plug
3 Connection elbow of the constant- 4 Screw plug
level oiler
5 Bearing bracket
1. Pull out the vent plug (2).
2. Hinge down the reservoir of the constant-level oiler (1) from the bearing
bracket (5) and hold it in this position.
3. Fill in oil through the hole for the vent plug until the oil reaches the connection
elbow of the constant-level oiler (3).
4. Completely fill the reservoir of the constant-level oiler (1).
5. Snap the constant-level oiler (1) back into its operating position.
6. Fit the vent plug (2) again.
7. After approximately 5 minutes, check the oil level in the glass reservoir of the
constant-level oiler (1).
The oil reservoir must be properly filled at all times to provide a constant oil
level. Repeat steps 1 - 6, if necessary.
8. To check the function of the constant-level oiler (1), slowly drain some oil via
the screw plug (4) until air bubbles can be seen in the oil reservoir.
NOTE
An excessively high oil level can lead to a temperature rise and to leakage of the
fluid handled or oil.
6.1.3 Shaft seal
DANGER
Impermissibly high temperatures at gland packings
Explosion hazard!
▷ Always use suitable temperature monitoring for gland packings.
▷ Gland packing must be tightened correctly.
Shaft seals are fitted prior to delivery.
Observe the instructions on dismantling (⇨ Section 7.4.6 Page 56) or assembly
(⇨ Section 7.5.4 Page 60) .
Cooling the gland packing

When handling hot fluids, the gland packing must be cooled.
KWP 39 of 86
Table 15: Gland packing cooling

Characteristic Value
Fluid temperature ≥ 105 °C generally
≥ 90 °C and contaminated fluids
Cooling water quantity at an inlet 0.5 to 5 l/min depending on the fluid
temperature of 20 °C: temperature
Connections See general arrangement drawing
Reservoir of non- If applicable, fill the reservoir of non-pressurised external fluid in accordance with
pressurised external fluid the general arrangement drawing.
Double mechanical seal Prior to starting up the pump, apply barrier pressure or supply flushing/quench liquid
as specified in the general arrangement drawing.
External liquid feed Apply the quantities and pressures specified in the data sheet and the general
arrangement drawing.
6.1.4 Priming and venting the pump
DANGER
Risk of potentially explosive atmosphere by mixing of incompatible fluids in the
auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure that the barrier fluid and quench liquid are compatible with the
fluid pumped.
DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.
DANGER
Shaft seal failure caused by insufficient lubrication
Hot or toxic fluid could escape!
Damage to the pump!
▷ Before starting up the pump set, vent the pump and suction line and prime
both with the fluid to be handled.
1. Vent the pump and suction line and prime both with the fluid to be handled.
2. Fully open the shut-off element in the suction line.
3. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc).
6.1.5 Water cooling
CAUTION
Deposit-forming, aggressive cooling water
Damage to the pump!
▷ Observe the cooling water quality.
Observe the following quality data of the cooling water:
▪ Not deposit-forming
▪ Not aggressive
40 of 86 KWP
▪ Free from suspended solids

▪ Hardness on average 5 °dH (~1 mmol/l)
▪ pH > 8
▪ Conditioned and neutral with regard to mechanical corrosion
▪ Inlet temperature tE=10 to 30 °C
Outlet temperature tA= 45 °C max.
6.1.6 Final check

1. Remove the coupling/belt guard and coupling guard footboard, if any.
2. Check the coupling/belt drive alignment, re-align if necessary. (⇨ Section 5.6
Page 30) or (⇨ Section 5.7 Page 32)
3. Check proper functioning of coupling, shaft and belt drive.
Check that coupling/shaft can be easily rotated by hand.
4. Fit the coupling/belt guard and coupling guard footboard, if any.
5. Check the distance between coupling and coupling guard/pulleys and belt
guard.
The coupling guard must not touch the coupling, the belt guard must not touch
the pulleys.
6.1.7 Start-up
DANGER
Non-compliance with the permissible pressure and temperature limits if the pump is
operated with the suction and/or discharge line closed.
Explosion hazard!
Leakage of hot or toxic fluids!
▷ Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷ Only start up the pump set with the discharge-side shut-off element slightly or
fully open.
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. (⇨ Section 6.1.4 Page 40)
▷ Always operate the pump within the permissible operating range.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
✓ The system piping has been cleaned.
✓ Pump, suction line and inlet tank, if any, have been vented and primed with the
fluid to be handled.
✓ The lines for priming and venting have been closed.
KWP 41 of 86
CAUTION
Start-up against open discharge line
Motor overload!
▷ Make sure the motor has sufficient power reserves.
▷ Use a soft starter.
▷ Use speed control.
1. Fully open the shut-off element in the suction head/suction lift line.
2. Close or slightly open the shut-off element in the discharge line.
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 comply with the duty
point.
CAUTION
Misalignment of pump and coupling and/or belt drive
Damage to pump, motor and coupling!
▷ When the operating temperature has been reached, switch off the pump set
and check the coupling and/or belt drive alignment.
5. Check the alignment of coupling and belt drive, if any, and re-align if necessary.
6.1.8 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 The gland packing must drip slightly during operation.
Continuously check the throughflow of any barrier fluid and flushing liquid
connections provided.
DANGER
Excessive temperatures caused by gland packings
Explosion hazard!
▷ Pack glands properly.
▷ If the gland packing has been tightened to the limit, the gland has to be
completely repacked.
▷ Always use suitable temperature monitoring for gland packings.
Pure graphite packing If pure graphite packing rings are used, there must always be some leakage.
Table 16: Leakage rate of the pure graphite packing (rings)
Limits Leakage
Minimum 10 cm³/min
Maximum 20 cm³/min
Adjusting the leakage
Prior to commissioning 1. Only lightly tighten the nuts of the gland follower by hand.
2. Use a feeler gauge to verify that the gland follower is mounted centred and at
a right angle to the shaft.
⇨ The gland must leak after the pump has been primed.
After five minutes of
operation
42 of 86 KWP
WARNING
Unprotected rotating parts
Risk of personal injury!
▷ Do not touch rotating parts.
▷ When the pump is running, perform any work with utmost caution.
The leakage can be reduced.
1. Tighten the nuts on 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:
Immediately switch off pump set!
Loosen gland follower and repeat commissioning.
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 packing at minimum fluid pressure.
6.1.9 Shutdown
✓ The shut-off element in the suction line is and remains open.
✓ On pump sets with double mechanical seal, apply the required pressure specified
in the general arrangement drawing to the mechanical seal chamber also during
standstill.
✓ Quench liquid supply must also be ensured during pump standstill.
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 in the discharge line may remain open, provided the site's requirements
and regulations are taken into account and observed.
NOTE
If shut-off is not possible, the pump will run in reverse direction.
The reverse runaway speed must be lower than the rated speed.
CAUTION
Risk of freezing during pump shutdown
Damage to the pump!
▷ Drain the pump and cooling/heating chambers (if any) or protect them against
freezing.
For prolonged shutdown periods:
1. Close the shut-off element in the suction line.
2. Close any auxiliary connections.
If the fluid to be handled is fed in under vacuum, also supply the shaft seal with
barrier fluid during standstill.
Only turn off the cooling liquid supply after the pump has cooled down.
KWP 43 of 86
3. Drain the pump. (⇨ Section 7.3 Page 53)
6.2 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature, fluid handled and
speed
Explosion hazard!
Hot or toxic fluid could escape!
▷ Comply with the operating data indicated in the data sheet.
▷ Never use the pump for handling fluids it is not designed for.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures, pressures or rotational speeds
exceeding those specified in the data sheet or on the name plate unless the
written consent of the manufacturer has been obtained.
6.2.1 Ambient temperature
CAUTION
Operation outside the permissible ambient temperature
▷ Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
Table 17: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 40 °C
Minimum See data sheet.
6.2.2 Frequency of starts
DANGER
Excessive surface temperature of the motor
Explosion hazard!
Damage to the motor!
▷ In case of explosion-proof motors, observe the frequency of starts specified in
the manufacturer's product literature.
The frequency of starts is usually determined by the maximum temperature increase

of the motor. This largely depends on the power reserves of the motor in steady-
state operation and on the starting conditions (DOL, star-delta, moments of inertia,
etc). If the start-ups are evenly spaced over the period indicated, the following limits
serve as orientation for start-up with the discharge-side gate valve slightly open:
Table 18: Frequency of starts
Motor rating Maximum number of start-ups
[kW] [Start-ups/hour]
up to 12 15
up to 100 10
more than 100 5
44 of 86 KWP
CAUTION
Re-starting while motor is still running down
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
6.2.3 Fluid handled
6.2.3.1 Flow rate

Unless specified otherwise in the characteristic curves or in the data sheets, the
following applies:
▪ Short-time operation: Qmin12) = 0.1 × Qopt 13)
▪ Continuous operation: Qmin12) = 0.3 × Qopt 13)
▪ 2-pole operation: Qmax14) = 1.1 × Qopt 13)
▪ 4-pole operation: Qmax14) = 1.25 × Qopt13)
The data refer to water and water-like fluids. Longer operating periods with these
fluids and at the flow rates indicated will not cause an additional increase in the
temperatures on the pump surface. However, if the physical properties of the fluids
handled are different from water, the calculation formula below must be used to
check if an additional heat build-up may lead to a dangerous temperature increase at
the pump surface. If necessary, the minimum flow must be increased.
×
×
×
Table 19: Key

Symbol Description Unit
c Specific heat capacity J/kg K
g Gravitational constant m/s²
H Pump head m
Tf Temperature of the fluid handled °C
To Temperature at the casing surface °C
Pump efficiency at duty point -
Temperature difference K
6.2.3.2 Density of the fluid handled

The power input of the pump increases in proportion to the density of the fluid
handled.
CAUTION
Impermissibly high density of the fluid handled
Motor overload!
▷ Observe the information on fluid density indicated in the data sheet.
▷ Make sure the motor has sufficient power reserves.
12) Minimum permissible flow rate

13) Flow rate at best efficiency point
14) Maximum permissible flow rate
KWP 45 of 86
6.2.3.3 Abrasive fluids

Do not exceed the maximum permissible solids content specified in the data sheet.
When the pump handles fluids containing abrasive substances, increased wear of the
hydraulic system and shaft seal are to be expected. In this case, reduce the commonly
recommended inspection intervals.
Permissible operating range for highly abrasive fluids: Q= 0.8 ... 1.1 x Qopt
6.3 Shutdown/storage/preservation
6.3.1 Measures to be taken for shutdown

The pump (set) remains installed
✓ Sufficient fluid is supplied for the operation check run of the pump.
1. Start up the pump (set) regularly between once a month and once every three
months for approximately five minutes during prolonged shutdown periods.
This will prevent the formation of deposits within the pump and the pump
intake area.
The pump (set) is removed and stored
✓ The pump has been properly drained (⇨ Section 7.3 Page 53) 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 exposed machined parts and surfaces of the pump (with
silicone-free oil or grease, food-approved, if required) to protect them against
corrosion.
Observe the additional instructions. (⇨ Section 3.3 Page 14)
If the pump set is to be stored temporarily, only preserve the wetted components
made of low-alloy materials. Commercially available preservatives can be used for
this purpose. Observe the manufacturer's instructions for application/removal.
Observe any additional instructions and information provided. (⇨ Section 3 Page 13)
6.4 Returning to service

For returning the pump to service observe the sections on commissioning/start-up
(⇨ Section 6.1 Page 38) and the operating limits. (⇨ Section 6.2 Page 44)
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (⇨ Section 7 Page 47)
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant
and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer
seals.
46 of 86 KWP
7 Servicing/Maintenance
7.1 Safety regulations
DANGER
Sparks produced during servicing work
Explosion hazard!
▷ Observe the safety regulations in force at the place of installation!
▷ Always perform maintenance work on explosion-proof pump sets outside
potentially explosive atmospheres.
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
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
WARNING
Fluids and supplies posing a health hazard and/or hot fluids or supplies
Risk of injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps which handle fluids posing a health hazard.
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tipping or falling over.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump (set) with a minimum of maintenance
expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".
Never use force when dismantling and reassembling the pump set.
KWP 47 of 86
7.2 Maintenance/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
Incorrectly serviced shaft seal
Explosion hazard!
Leakage of hot, toxic fluids!
Risk of burns!
Fire hazard!
▷ Regularly service the shaft seal.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
Fire hazard!
Risk of burns!
▷ Regularly check the lubricant level.
▷ Regularly check the rolling element bearings for running noises.
DANGER
Incorrectly serviced barrier fluid system
Explosion hazard!
Fire hazard!
Hot and/or toxic fluids could escape!
▷ Service the barrier fluid system regularly.
▷ Monitor the barrier fluid pressure.
CAUTION
Increased wear due to dry running
▷ 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.
48 of 86 KWP
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 44)
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 6.1.2 Page 38)
▪ Check the shaft seal. (⇨ Section 6.1.8 Page 42)
▪ Check the static seals for 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.
▪ Cooling system
Take the pump out of service at least once a year to thoroughly clean the cooling
system.
▪ Monitor the stand-by pump.
To make sure that the stand-by pumps are ready for operation, start them up
once a week.
▪ Monitor the bearing temperature.
The bearing temperature must not exceed 90 °C (measured on the outside of the
bearing bracket).
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured
on the outside of the motor housing).
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 Checking the coupling

Check the flexible elements of the coupling. Replace the relevant parts in due time if
there is any sign of wear and check the alignment.
KWP 49 of 86
7.2.2.2 Cleaning filters
CAUTION
Insufficient inlet pressure due to clogged filter in the suction line
Damage to the pump!
▷ Monitor contamination of filter with suitable means (e.g. differential pressure
gauge).
▷ Clean filter at appropriate intervals.
7.2.2.3 Checking the bearing seals
DANGER
Excessive temperatures caused by mechanical contact
Risk of explosion!
▷ Check correct seating of axial sealing rings mounted on the shaft.
Only gentle contact of the sealing lip shall be established.
7.2.2.4 Visual inspection through the inspection hole (optional)

If there are problems with clogging, the inside of the casing and the impeller can be
checked via the inspection hole.
WARNING
handled.
WARNING
Hands or foreign objects inside the pump casing
Risk of injuries, damage to the pump!
▷ Check that the inside of the pump is free from any foreign objects. Remove any
foreign objects.
▷ Never insert your hands or any other objects into the pump, if the pump set has
not been disconnected from the power supply and secured against
unintentional start-up.
If a problem has occurred which requires visual inspection, observe the following
instructions:
900.02
920.17
550.04
164.02
412.05
Fig. 20: Inspection hole in the casing

Opening the inspection hole
▪ Close the shut-off element on the suction side.
50 of 86 KWP
▪ Switch off the drive and make sure it cannot be re-started unintentionally.
▪ Close the shut-off element on the discharge side.
▪ Open the drain plug (auxiliary connection 6B).
▪ Collect and dispose of any liquid residues.
▪ Unscrew nuts 920.17 at the inspection hole and remove inspection cover 164.02.
▪ Perform a visual inspection with a lamp or similar.
Closing the inspection hole

▪ Fit new O-ring 412.05.
▪ Fit inspection cover 164.02.
▪ Place discs 550.04 and nuts 920.17 on screws 900.02 and tighten.
▪ Observe the instructions on commissioning/start-up.
7.2.3 Lubrication and lubricant change of rolling element bearings
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
Fire hazard!
▷ Regularly check the condition of the lubricant.
7.2.3.1 Oil lubrication

The rolling element bearings are lubricated with mineral oil.
7.2.3.1.1 Intervals
Table 20: Oil change intervals
Oil change Interval15)
Bearing bracket up to Bearing bracket up to
P04ax P05ax
Change of initial oil fill After 300 operating hours After 300 operating hours
Further oil changes After 6000 operating After 8000 operating
hours16) hours16)
If the oil is contaminated, change the oil more frequently, as required.
7.2.3.1.2 Oil quality

Lubricants ▪ SAE 20W/20HD
or
▪ CLP 68 to DIN 51 517
Table 21: Lubricant characteristics
Name Properties
Lubricating oil CL68 or CLP68 to Kinematic viscosity at 40 °C 68±6 mm²/s
DIN 51517 Flash point (to Cleveland) +175 °C
15) At temperatures up to 90 °C at the bearing

16) At least once a year
KWP 51 of 86
Name Properties
Solidification point (pour point) -9 °C
Application temperature17) 0-175 °C
7.2.3.1.3 Oil quantity

Table 22: Standard bearings
Bearing bracket Rolling element bearings Oil quantity
Pump end18) Driveend19) [l]
P03ax NU 409 2 x 7309 BG 0,5
P04ax NU 411 2 x 7311 BG 0,6
P05ax NU 413 2 x 7313 BG 1,8
P06x NU 413 2 x 7313 BG 1,8
P08sx NU 416 2 x 7319 BG 4,5
P10ax NU 324 2 x 7224 BG 4
P12sx NU 324 2 x 7224 BG 4
7.2.3.1.4 Changing the oil
WARNING
Lubricants posing a health hazard and/or hot lubricants
▷ When draining the lubricant take appropriate measures to protect persons and
the environment.
▷ Collect and dispose of any lubricants.
1 2 3
Fig. 21: Bearing bracket with constant-level oiler
1 Constant-level oiler 2 Screw plug
3 Bearing bracket
✓ A suitable container for the used oil is on hand.
1. Place the container underneath the screw plug.
2. Undo the screw plug (2) at the bearing bracket (3) and drain the oil.
3. Once the bearing bracket (3) has been drained, re-insert and re-tighten the
screw plug (2).
4. Re-fill with oil.
17) For ambient temperatures below 0 °C use a different suitable type of lubricating oil. Contact KSB.
18) To DIN 5412
19) To DIN 628
52 of 86 KWP
7.3 Drainage/cleaning
WARNING
handled.
If the fluids handled by the pump (set) 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 be flushed through,
neutralised, and anhydrous inert gas must be blown through the pump for drying
purposes.
Use connection 6B to drain the fluid handled (see auxiliary connections).
7.4 Dismantling the pump set
7.4.1 General information/Safety regulations
WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
WARNING
Improper lifting/moving of heavy assemblies or components
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
Observe the general safety instructions and information. (⇨ Section 7.1 Page 47)
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly observe the general assembly drawing. (⇨ Section 9.1
Page 76)
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".
KWP 53 of 86
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set.
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 53)
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
NOTE
After a prolonged period of operation the individual components may be hard to
pull off the shaft. If this is the case, use a brand name penetrating agent and/or - if
possible - an appropriate puller.
7.4.2 Preparing the pump set

1. De-energise the pump set and secure it against unintentional start-up.
2. Disconnect and remove all auxiliary pipework.
3. Remove the coupling guard or belt guard.
4. Remove the coupling spacer, if any.
5. Drain the oil fill of oil-lubricated bearings (⇨ Section 7.2.3.1.4 Page 52) .
7.4.3 Dismantling the motor
WARNING
Motor tipping over
Risk of squashing hands and feet!
▷ Suspend or support the motor to prevent it from tipping over.
Version with coupling
NOTE
On pump sets with spacer-type couplings, the back pull-out unit can be removed
while the motor remains bolted to the baseplate.
✓ The notes and steps stated in (⇨ Section 7.4.1 Page 53) to (⇨ Section 7.4.2 Page
1. Disconnect the motor from the power supply.
2. Undo the coupling fasteners.
3. Unbolt the motor from the baseplate.
4. Shift the motor to separate it from the pump.
Version with belt drive

1. Disconnect the motor from the power supply.
2. Lower motor support plate 81-54.01 by turning threaded rods 904.23/904.24
and nuts 920.63/920.64 until the V-belts slacken.
3. Remove the V-belts.
4. Unbolt the motor from the motor support plate by removing hexagon bolts
901.62 and discs 550.62.
5. Lift the motor off the motor support plate.
54 of 86 KWP
6. Undo hexagon nuts 920.23/920.24 at the pump or motor stand (Figure 3Z).
7. Remove the motor support plate from the pump or baseplate (Figure 3Z) and
put it down.
8. Undo bushing 540.02 at pump-end pulley 882.01.
9. Take pulley 882.01 off shaft 210.
7.4.4 Removing the back pull-out unit

✓ On pump sets with belt drive or pump sets with coupling without spacer, the
motor has been removed.
WARNING
Back pull-out unit tipping over
▷ Suspend or support the back pull-out unit at the pump end.
1. Loop a rope tightly around bearing bracket lantern 344.
2. Unbolt and remove support foot 183 from the baseplate.
3. Undo hexagon nuts 920.01 at the volute casing.
4. Pull the back pull-out unit out of volute casing 101.
NOTE
Forcing screws 901.31 can be used to facilitate disassembly.
Clean the threads of the forcing screws before using them.
5. Place the back pull-out unit on a clean and level surface.

6. Remove and dispose of joint ring 411.10.
7.4.5 Dismantling the impeller
CAUTION
Improper removal/fitting of fragile, shock-sensitive CeramikPolySiC® impellers and
wear plates
Damage to the pump, especially the impeller and wear plate!
▷ Never use a hammer on components made of CeramikPolySiC®, apply blows or
press them down with force.
▷ Always use suitable lifting tackle (e.g. straps, loops) for transporting
components made of CeramikPolySiC®.
▷ Never use chains to transport components made of CeramikPolySiC®.
Bearing brackets P03ax, P04ax, P05ax, P06x

✓ The back pull-out unit is kept in a clean and level assembly area.
1. Undo impeller screw 906 (right-hand thread).
2. Remove and dispose of O-ring 412.03.
3. Remove impeller 230 with an impeller removal device.
4. Place impeller 230 on a clean and level surface.
5. Remove keys 940.1 from shaft 210.
KWP 55 of 86
Bearing brackets P08sx, P10ax, P12sx

1. Remove impeller hub cap 260.01.
2. Remove and dispose of O-ring 412.03.
3. Bend open lock washer 931.02.
4. Undo hexagon head bolt 901.87.
5. Remove the lock washer and disc 550.87.
6. Remove impeller 230 with an impeller removal device.
7. Place impeller 230 on a clean and level surface.
8. Remove keys 940.1 from shaft 210.
7.4.6 Removing the shaft seal
7.4.6.1 Dismantling the mechanical seal – type 4K

1. Clamp the bearing vertically to the drive-side shaft end.
2. Pull off the shaft sleeve with the mating ring and O-ring, using an extractor in
the removal groove in shaft protecting sleeve 524.01.
3. Pull the mating ring out of the shaft sleeve.
4. Undo hexagon head bolts 901.22. Then remove discharge cover 163 with joint
ring 411.10 and the primary ring with the secondary seal and the spring
arrangement from the bearing bracket lantern.
5. Push the primary ring with the secondary seal out of the discharge cover.
6. Undo the screws with springs and thrust ring.
7.4.6.2 Dismantling the packed gland

1. Undo hexagon nuts 920.02 at gland follower 452.01.
2. Remove gland follower 452.01.
Make sure not to damage discs 550.01.
3. Undo hexagon head bolts 901.22. Then remove discharge cover 163 from the
bearing bracket lantern 344.
4. Remove discharge cover 163 with gland packing and drip plate 463.01.
5. Remove gland packing from packing chamber.
6. Push out neck bush 456.01.
7.4.7 Dismantling the bearings

1. Undo hexagon nuts 920.04 and remove bearing bracket lantern 344.
2. Pull shaft protecting sleeve 524.01 with O-ring 412.06 off shaft 210.
3. Bend open and pull off thrower 507.01
4. Undo the hexagon socket head cap screw in the coupling hub.
5. Pull the coupling hub off shaft 210 with a puller.
56 of 86 KWP
6. Remove key 940.02.

7. Undo hexagon socket head cap screws 914.01/914.02. Then remove bearing
cover 360.01 with gasket 400.01 and shaft seal ring 421.01 at the pump end.
NOTE
Bearing brackets P08sx, P10ax, P12sx only
▷ Remove V-ring 411.77.
▷ Undo hexagon socket head cap screws 914.01.
▷ Remove bearing cover 360.01 with gasket 400.01, thrower 507.11 and O-ring
412.36.
8. Use grub screws 904.01 (for bearing brackets P08sx/P10ax/P12sx: forcing screws
901.91) to carefully drive shaft 210 with bearing carrier 382, angular contact
ball bearing 320.02 and the inner ring of cylindrical roller bearing 322.01 out of
bearing bracket 330 towards the drive end.
9. Place shaft 210 with rolling element bearings on a suitable surface.
10. Remove support disc 550.23 and circlips 932.01/932.03.
11. Bearing brackets P08sx/P10ax/P12sx: remove V-ring 411.78.
12. Remove the outer ring of cylindrical roller bearing 322.01 (roller cage) from
bearing bracket 330.
13. Pull bearing carrier 382 with O-ring 412.02 and shaft seal ring 421.01 off
angular contact ball bearing 320.02.
14. Bend open lock washer 931.01.
15. Undo keywayed nut 920.21 (right-hand thread!)
16. Remove lock washer 931.01.
17. Bearing brackets P08sx/P10ax/P12sx: remove thrower 507.12.
WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
18. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical
roller bearing 322.01 to 80 °C, and pull them off shaft 210.
7.4.8 Removing the wear plate
NOTE
Wear plates made of CeramikPolySiC® are permanently fastened to pump casing
101 and have to be dismantled from pump casing 101 for replacement.
CAUTION
wear plates
KWP 57 of 86
1. Unscrew hexagon head bolts 901.03 or hexagon socket head cap screws 914.05.
2. Remove joint rings 411.13.
3. Remove wear plate 135.01 with O-rings 412.25/412.75.
7.5 Reassembling the pump set
7.5.1 General information/Safety regulations
WARNING
Improper lifting/moving of heavy assemblies or components
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
CAUTION
Improper reassembly
Damage to the pump!
▷ Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
▷ Use original spare parts only.
Sequence Always reassemble the pump in accordance with the corresponding general assembly
drawing.
Sealing elements ▪ Gaskets
– Always use new gaskets, making sure that they have the same thickness as
the old ones.
– Always fit gaskets of asbestos-free materials or graphite without using
lubricants (e.g. copper grease, graphite paste).
▪ O-rings
– Never use O-rings that have been glued together from material sold by the
metre.
CAUTION
Contact of O-ring with graphite or similar material
Fluid could escape!
▷ Do not coat O-ring with graphite or similar material.
▷ Use animal fats or lubricants based on silicone or PTFE.
▪ Assembly adhesives
– For gaskets, avoid the use of assembly adhesives, if possible.
– If assembly adhesives are required, use a commercially available contact
adhesive (e.g. "Pattex").
– Only apply adhesive at selected points and in thin layers.
– Never use quick-setting adhesives (cyanoacrylate adhesives).
– Coat the locating surfaces of the individual components and screwed
connections with graphite or similar before reassembly.
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual. (⇨ Section 7.6
Page 68)
58 of 86 KWP
7.5.2 Fitting the wear plate
NOTE
Wear plates made of CeramikPolySiC® are permanently fastened to pump casing
101 and have to be dismantled from pump casing 101 for replacement.
CAUTION
wear plates
✓ The individual parts have been placed in a clean and level assembly area.
✓ All dismantled parts have been cleaned and checked for wear.
✓ Any damaged or worn parts have been replaced by original spare parts.
✓ The sealing surfaces have been cleaned.
✓ The notes and steps stated in (⇨ Section 7.1 Page 47) have been observed/carried
out.
1. Fit O-rings 412.25/412.75 on wear plate 135.01.
2. Insert wear plate 135.01 into the pump casing.
3. Screw wear plate 135.01 to the pump casing with hexagon head bolts 914.05 or
hexagon socket head cap screws 914.05 and O-rings 412.05/.75 or joint rings
411.13.
Tightening torque (⇨ Section 7.6.1 Page 68)
7.5.3 Fitting the bearings

✓ The individual parts have been placed in a clean and level assembly area.
WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
1. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical
roller bearing 322.01 to approx. 80 ℃ in an oil bath.
2. Bearing brackets P10ax/P12sx: fit bush 500.21 on the shaft.
3. Slide angular contact ball bearing 320.02 and the inner ring of cylindrical roller
bearing 322.01 onto shaft 210 until they will not go any further.
NOTE
Angular contact ball bearings must be installed in back-to-back arrangement.
Angular contact ball bearings installed in pairs must always be from the same
manufacturer.
KWP 59 of 86
4. Use a C-spanner to tighten slotted round nut 920.21 without lock washer
931.01.
5. Let angular contact ball bearing 320.02 cool down to approximately 5 °C above
ambient temperature.
6. Re-tighten slotted round nut 920.21, then unscrew it again.
7. Apply a few spots of a suitable lubricant (e.g. Molykote) to the contact faces of
lock washer 931.01 and keywayed nut 920.21.
8. Bearing brackets P08sx/P10ax/P12sx: remove thrower 507.12.
9. Fit lock washer 931.01.
10. Tighten slotted round nut 920.21.
11. Bend back lock washer 931.01.
12. Pull bearing carrier 382 on angular contact ball bearing 320.02.
13. Fit support disc 550.23.
14. Fit circlips 932.01/932.03 in the bearing carrier/bearing bracket.
15. Fit the outer ring of angular contact ball bearing 322.01.
16. Carefully push pre-assembled shaft 210 with bearing carrier 382, O-ring 412.02
and lip seal 421.02 from the drive end into bearing bracket 330 up to the stop.
Make sure the oil return bores are positioned correctly.
17. Tighten hexagon socket head cap screws 914.02 (bearing brackets P08sx/P10ax/
P12sx: hexagon head bolt 901.95).
18. Insert studs 902.04.
19. Bearing brackets P08sx/P10ax/P12sx : fit V-ring 411.78 and hexagon forcing
screws 901.91.
Make sure the external surfaces of V-rings 411.77/.78 are flush with the external
surface of the bearing cover/bearing carrier.
20. Fit O-ring 412.36 and disc 507.11.
21. Fit pump-end bearing cover 360.01 with joint ring 400.01.
Take care not to damage lip seal 421.01.
Bearing brackets P08sx/P10ax/P12sx: fit V-ring 411.77 instead of lip seal.
22. Tighten hexagon socket head cap screws 914.01 at the pump end.
23. Fit bearing bracket lantern 344 with studs 902.04.
24. Tighten hexagon nuts 920.04 at the flange of bearing bracket 330.
25. Fit keys 940.02.
26. Slide the coupling hub onto the shaft end.
27. Secure the coupling hub with an adjusting screw.
28. Fit thrower 507.01, if any.
7.5.4 Fitting the shaft seal
7.5.4.1 Installing the mechanical seal

The following rules must be observed when installing the mechanical seal:
▪ For installing the mechanical seal, proceed as shown in the seal installation
drawing.
▪ Work cleanly and accurately.
▪ Only remove the protective wrapping of the contact faces immediately before
installation takes place.
▪ Prevent any damage to the sealing surfaces or O-rings.
▪ After inserting the mating ring, check that it is plane-parallel in relation to the
casing part.
60 of 86 KWP
▪ The surface of the shaft protecting sleeve must be absolutely clean and smooth,
and the sleeve's mounting edge must be chamfered.
▪ When sliding the rotating assembly onto the shaft protecting sleeve, take
appropriate steps to protect the surface of the shaft protecting sleeve from
damage.
▪ On pumps with double mechanical seal, properly vent the mechanical seal
chamber and apply the required pressure specified in the general arrangement
drawing (also during standstill).
▪ Quench liquid supply must also be ensured during pump standstill.
Fitting the mechanical seal – type 4K

✓ The bearing assembly and the individual parts of mechanical seal 433 are kept in
a clean and level assembly area.
1. Insert thrust ring 474 into the turned recess on the rear side of the discharge
cover.
2. Push springs 477 onto hexagon socket head cap screws 914.
3. Apply a thread-locking compound to the threads of screws 914
(recommendation).
4. Thread socket head cap screws 914 with fitted springs 477 through the holes in
thrust ring 474 and fasten them inside the pump cover.
Make sure that thrust ring 474 can move freely. Do not screw on the thrust ring.
CAUTION
Contact of O-ring with lubricant made of mineral grease or oil
Damage to the O-ring!
▷ Make sure that O-rings made of ethylene propylene rubber cannot come into
contact with mineral oil or mineral grease.
▷ Make sure that O-rings made of silicone rubber cannot come into contact with
silicone oil or silicone grease.
5. Coat O-ring 412.02 and the groove in the casing cover with a suitable lubricant.
6. Insert O-ring 412.02 into the groove of the casing cover.
7. Carefully install primary ring 472.
Make sure that thrust ring 474 can move freely.
8. Mount the complete discharge cover with joint ring 411.10 on bearing bracket
lantern 344.
9. Tighten hexagon head bolts 901.22.
10. Insert O-ring 412.01 for mating ring 475 into shaft sleeve 523.
CAUTION
Use of grease or other permanent lubricants
Hinders torque transmission! Overheating of and damage to the pump!
▷ If required, use soft soap to reduce friction.
Do not use grease or other permanent lubricants.
▷ Do not coat seal faces with grease or oil.
11. Carefully push in mating ring 475.
KWP 61 of 86
12. For bearing brackets P08sx/P10ax/P12sx (sizes 80, 100, 120):

fit two torque-transmitting pins into the mating ring location of shaft sleeve
523.
Make sure the two pins will engage in the recesses provided in the mating ring.
13. Dry and clean the seal faces.
14. Slip shaft sleeve 523 with mating ring 475 onto the pump shaft until it abuts
against the shaft shoulder.
7.5.4.2 Packing the gland

Gland packing chamber
l2 l1
Ø di Ø da
UG1258354
Fig. 22: Dimensions of the packing chamber / Number of packing rings

Table 23: Gland packing chamber
Bearing Gland packing chamber Number of packing
bracket rings
Ødi Øda □ l1 l2 with without
lantern lantern
ring ring
P03ax 45 65 10 64 8 420) 6
P04ax 55 75 10 64 8 420) 6
P05ax 70 95 12,5 79 8 420) 6
P06x 80 105 12,5 79 10 420) 6
P08sx 100 132 16 103 10 420) 6
P10ax 120 152 16 103 7 420) 6
P12sx 140 172 16 103 7 420) 6
20) For model 4 (see illustration "Available models"): 1 spacer ring and 3 packing rings
62 of 86 KWP
Models
1 2
3 4
Fig. 23: Available models
1 P3 arrangement 2 P3 arrangement
Gland packing with barrier fluid Gland packing with barrier fluid
connection21) connection22)
3 P6 arrangement 4 P4 arrangement
Gland packing with barrier fluid Gland packing with flushing liquid
connection connection
Procedure For variants with pure graphite packings see supplementary operating instructions.
Always use pre-compressed packing rings.
✓ The bearing assembly as well as the individual parts are kept in a clean and level
assembly area.
1. Screw stuffing box housing 451.01 (if any) to discharge cover 163.
2. Press neck bush 456.01 into the discharge cover.
3. For packings with barrier fluid connection (see illustration "Available models" 1,
2 and 4) also fit lantern ring 458.01 in its specified location.
4. Insert the first packing ring, ensuring that its cut edge is in horizontal position.
5. Hold the packing ring in place and slide shaft protecting sleeve 524 (chamfered
side first) into the gland packing chamber from the pump end.
21) For material variants GHHH and HHHH

22) For all material variants except GHHH, HHHH
KWP 63 of 86
6. Slightly expand the inside diameter of the packing ring by moving shaft
protecting sleeve 524 back and forth. Then pull out the shaft protecting sleeve.
Insert each subsequent packing ring separately with its joint offset by approx.
90° in relation to the previous one. Repeat the expansion procedure.
Insert lantern ring 458.01, if any, in its specified location (see illustration
"Available models").
When the last packing ring has been inserted, shaft protecting sleeve 524
remains in the packing chamber.
7. Insert stuffing box ring 454.01 so that the joint face is in vertical position to
gland follower 452.01.
8. Fit gland follower 452.01 and lightly fasten it by hand with the two hexagon
nuts 920.02; watch discs 550.01.
9. Install the completely packed discharge cover 163 with joint ring 411.10 and
shaft protecting sleeve 524 in the pump and screw it to bearing bracket lantern
344.
10. Tighten hexagon head bolts 901.22.
7.5.5 Fitting the impeller

Bearing brackets P03ax, P04ax, P05ax, P06x
CAUTION
wear plates
✓ The bearing assembly with shaft seal as well as the individual parts are kept in a
clean and level assembly area.
✓ All disassembled parts have been cleaned and checked for wear.
✓ Impeller bore, shaft and keyways are clean and free from burrs.
1. Insert keys 940.01 into the shaft keyway.
2. Fit O-ring 412.06 on shaft sleeve 524.01.
3. Mount the impeller with an impeller mounting and removal device.
4. Insert O-ring 412.03.
5. Insert and tighten impeller screw 906.
6. Check the axial rotor alignment and re-align it, if required.
Make sure the distance between the back vane/impeller 230 and discharge
cover 163 is ≤ 1.5 mm.
Bearing brackets P08sx, P10ax, P12sx

✓ The assembled bearing/mechanical seal as well as the individual parts are kept in
a clean and level assembly area.
✓ All disassembled parts have been cleaned and checked for wear.
64 of 86 KWP

✓ Impeller bore, shaft and keyways are clean and free from burrs.
1. Insert keys 940.01 into the shaft keyway.
2. Fit O-ring 412.06 on shaft sleeve 524.01.
3. Mount the impeller with an impeller mounting and removal device.
4. Fit disc 550.87 and lockwasher 931.02.
5. Tighten hexagon head bolt 901.87.
6. Fit impeller hub cap 260 with O-ring 412.03.
7. Check the axial rotor alignment and re-align, if required.
Make sure the distance between the back vane/impeller 230 and discharge
cover 163 is ≤ 1.5 mm.
7.5.6 Installing the back pull-out unit
CAUTION
wear plates
✓ For back pull-out units supplied without coupling: Fit the coupling in accordance
with the manufacturer's instructions.
1. Mount support foot 183.
2. If required, suspend or support the back pull-out unit to prevent it from tipping
over.
3. Push the back pull-out unit with new gasket 411.10 into pump casing 101.
Make sure that the impeller does not abut the wear plate.
4. Tighten nuts 920.01.
5. Bolt support foot 183 to the baseplate.
KWP 65 of 86
7.5.7 Adjusting the diagonal gap
1 2 3
D00472 D00473 D00474
Fig. 24: KWP clearances

1 Impeller type K 2 Impeller type O
3 Impeller type F
Table 24: Clearances between impeller and wear plate / between back vane and
discharge cover
Impeller type Nominal diameter of the Clearance
discharge nozzle
KWP K < DN 300 0.50 mm + 0.1
DN 300 to DN 600 0.60 mm + 0.1
KWP O - 0.50 mm + 0.1
KWP F - 1.50 mm + 0.1
NOTE
If the clearance indicated is exceeded by more than 0.5 mm the diagonal gap must
be re-adjusted as described below.
Closed impeller (KWP K) and open impeller (KWP O)

1. Undo grub screws 904.01 or (for bearing brackets P10ax, P12sx) hexagon head
bolts 901.91.
2. Use hexagon socket head cap screws 914.02 to shift the bearing carrier together
with the rotor towards the pump end until they rest against wear plate 135.01.
3. Measure the axial clearance between bearing bracket 330 and bearing carrier
382.
4. Undo hexagon socket head cap screws 914.02 or (for bearing brackets P10ax,
P12sx) hexagon head bolts 901.95.
5. Use grub screws 904.01 or (for bearing brackets P10ax, P12sx) hexagon head
bolts 901.91 to pull the rotor back out towards the drive.
6. Adjust the clearance between the impeller and the wear plate as indicated in
figure 22 and the table on clearances.
7. Bearing brackets P03ax, P04ax, P05ax, P06x
Lock the rotor by tightening hexagon socket head cap screws 914.02. The
adjusted clearance remains secured by the grub screws.
Bearing bracket P08sx
Lock the rotor in position by tightening hexagon head bolts 901.95. The
adjusted clearance remains secured by grub screws 904.01.
Make sure the remaining gap between the bearing bracket and the bearing
carrier is free from grease. Then close it with acrylate sealant.
Bearing brackets P10ax, P12sx
66 of 86 KWP
Fasten the rotor by inserting shims 89-4.12 at hexagon bolts 901.95.

Tighten hexagon head bolts 901.95.
The adjusted clearance remains secured by hexagon head bolts 901.91.
Make sure the remaining gap between the bearing bracket and the bearing
carrier is free from grease. Then close it with acrylate sealant.
Free flow impeller (KWP F)

1. Undo hexagon socket head cap screws 914.02.
2. Screw in grub screws 904.01 to pull back the rotor until it will not go any
further (impeller back vanes at discharge cover 163).
3. Measure the axial clearance between bearing bracket 330 and bearing carrier
382.
4. Undo grub screws 904.01 and use hexagon socket head cap screws 914.02 to
push the rotor 1.5 mm towards the pump end.
5. Lock the rotor in position by tightening grub screws 904.01.
Remaining steps to be completed (for all impeller types)

1. Fit forcing screws 901.30 on bearing bracket lantern 344 and forcing screws
901.31 on discharge cover 330.
2. For components which are not rotation-symmetrical, fit guard 680.11
(perforated plate) to bearing bracket lantern 344.
Threaded holes 12 x M6 x 10 are provided.
7.5.8 Mounting the motor

Version with coupling
NOTE
Steps 1 and 2 do not apply to versions with spacer-type coupling.
1. Shift the motor to align and connect it with the pump via (⇨ Section 5.7 Page
32) the coupling.
2. Fasten the motor to the baseplate.
3. Align the pump and motor. (⇨ Section 5.7 Page 32)
4. Connect the motor to the power supply (refer to manufacturer's product
literature).
Version with belt drive
WARNING
Motor tipping over
▷ Suspend or support the motor to prevent it from tipping over.
1. Position motor support plate 81-54.01 on pump or baseplate.
2. Install motor support plate with threaded rods and hexagon nuts 920.23/920.24
on pump or baseplate.
KWP 67 of 86
3. Position and align the motor on the motor support plate.

4. Fasten the motor with hexagon bolts 901.62 and discs 550.6.
7.5.9 Installing the belt drive
CAUTION
Poorly checked and aligned motor connection
Increased wear, insufficient power transmission, loud running noises!
▷ Always use clean pulleys without any signs of wear.
▷ Align the shaft end of pump/motor flush with the pulleys.
▷ For multiple V-belt drives:
- If replacing V-belts always replace the entire set of V-belts.
- Use V-belts of the same length.
▷ Only pull on V-belts if this is possible without using any force.
▷ Only pull on V-belts by hand. Do not use any tools (e.g. levers).
▷ Tension the V-belts properly (⇨ Section 5.6.2 Page 31) .
CAUTION
Swelling of V-belts due to aggressive ambient conditions
Reduced service life of V-belts!
▷ Protect V-belts suitably from oil mist, dripping oil and other chemical
influences.
1. Use bush 540.02 to fit V-belt pulley 882.01 on pump shaft 210.
2. Use bush 540.03 to fit V-belt pulley 882.02 on the motor shaft.
3. Align pulleys 882.01/882.02 so that they are flush with each other. (⇨ Section
5.6.2 Page 31)
4. Move grub screws 590.23/590.24 and hexagon nuts 920.63/64 to position motor
support plate 81-54.01 in such a way that the V-belts can be pulled onto pulleys
882.01/882.02 without any force.
5. Pull V-belts on pulleys 882.01/882.02.
The use of belt wax or similar substances is not necessary.
6. Tension the V-belts. (⇨ Section 5.6.2 Page 31) (⇨ Section 5.7.3 Page 34)
7. Fit belt guard.
8. Connect the motor to the power supply (refer to manufacturer's product
literature).
7.6 Tightening torques
7.6.1 Tightening torques of the pump

Casing bolts
CAUTION
Use of an impact screw driver on Norihard casings (NH 153)
Damage to screws/bolts and threads!
▷ Never use an impact screw driver.
▷ Make sure that the studs can be screwed in easily for the entire length of the
thread.
68 of 86 KWP
Table 25: Tightening torques for screwed connections23)24)

Material C35E+QT A4-70 8.8 A2A
Stamp mark YK/Y A4-70/ A4-70 8.8/ 8
Thread Tightening torques [Nm]
M8 - 16 23
M10 - 30 46
M12 40 55 80
M16 100 140 190
M20 190 200 380
Impeller screw
Table 26: Tightening torque for the impeller screw (part No. 906 and 901.87)23)
Bearings Tightening torque MA
[Nm]
P03ax 50
P04ax 50
P05ax 120
P06x 180
P08sx/P10ax/P12sx 360
7.7 Spare parts stock
7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:
▪ Type series
▪ Size
▪ KSB order number
▪ Material variant
▪ Year of construction
Refer to the name plate for all data.
Also specify the following data:
▪ Description
▪ Part No.
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)
Refer to the general assembly drawing for part numbers and descriptions. (⇨ Section
9.1 Page 76)
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 27: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
1 2 3 4 5 6 and 7 8 and 9 10 and
more
135.01 Wear plate25) 1 2 2 2 3 3 4 50%
210 Shaft 1 1 1 1 2 2 2 20%
23) For unlubricated screws at room temperature

24) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.
25) For KWP 250-250-315, 300-300-400, 350-350-400 and 400-400-500: casing wear ring instead of wear plate
KWP 69 of 86
Part No. Description Number of pumps (including stand-by pumps)

1 2 3 4 5 6 and 7 8 and 9 10 and
more
230 Impeller 1 1 1 1 2 2 2 20%
320.02 Angular contact ball bearing (set) 1 1 1 2 2 2 3 25%
322.01 Cylindrical roller bearing 1 1 1 2 2 2 3 25%
330 Bearing bracket, complete - - - - - - 1 2
433.01 Mechanical seal, complete 26) 1 1 1 2 2 2 3 25%

Primary ring26) 1 2 3 4 5 6 7 90%
Mating ring26) 1 2 3 4 5 6 7 90%
Secondary seal at mating ring26) 1 2 3 4 5 7 9 100%
Secondary seal at primary ring26) 1 2 3 4 5 7 9 100%
Spring (set)26) 1 1 1 1 1 2 2 20%
Variants with gland packing
456.01 Neck bush 1 1 1 2 2 2 3 30%
461.01 Gland packing (set) 2 4 4 6 6 6 8 100%
524.01 Shaft protecting sleeve 1 2 2 2 3 3 4 50%
--- Sealing elements for pump casing 2 4 6 8 8 9 12 150%
(set)
26) Optional
70 of 86 KWP
7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.
Table 28: Interchangeability of pump components
Description
Rolling element bearings

Wear plate, suction side
Bearing bracket lantern
Shaft protecting sleeve

Stuffing box housing
Stuffing box ring
Casing wear ring

Bearing bracket
Discharge cover
Gland follower
Gland packing
Impeller screw
Pump casing
Lantern ring
Thrower
Impeller
Shaft
Part number
101 135.01 163 210 230 320/ 330 344 451.01 452.01 454.01 458.01 461 502.01 507 524.01 906
Size
322
Bearing bracket P03ax
065-040-0250 1 1 1 1 1 1 1 1 1 1 1 1 1 - 1 1 1
065-050-0200 2 2 2 1 2 1 1 2 1 1 1 1 1 - 1 1 1
065-050-0201 2 2 2 1 33 1 1 2 1 1 1 1 1 - 1 1 1
080-065-0200 3 3 2 1 3 1 1 2 1 1 1 1 1 - 1 1 1
080-065-0201 3 3 2 1 34 1 1 2 1 1 1 1 1 - 1 1 1
100-080-0250 4 4 1 1 4 1 1 1 1 1 1 1 1 - 1 1 1
100-080-0251 4 4 1 1 35 1 1 1 1 1 1 1 1 - 1 1 1
080-040-0315 5 5 3 2 5 2 2 3 2 2 2 2 2 - 2 2 2
080-050-0400 6 6 4 2 6 2 2 4 2 2 2 2 2 - 2 2 2
080-065-0315 7 7 3 2 7 2 2 3 2 2 2 2 2 - 2 2 2
080-065-0313 7 30 3 2 36 2 2 3 2 2 2 2 2 - 2 2 2
080-065-0400 8 8 4 2 8 2 2 4 2 2 2 2 2 - 2 2 2
100-080-0315 9 9 3 2 9 2 2 3 2 2 2 2 2 - 2 2 2
100-080-0311 9 9 3 2 37 2 2 3 2 2 2 2 2 - 2 2 2
125-100-0250 10 10 5 2 10 2 2 1 2 2 2 2 2 - 2 2 2
125-100-0251 10 10 5 2 38 2 2 1 2 2 2 2 2 - 2 2 2
125-100-0253 10 31 5 2 39 2 2 1 2 2 2 2 2 - 2 2 2
125-100-0315 11 11 3 2 11 2 2 3 2 2 2 2 2 - 2 2 2
100-080-0400 12 12 6 3 12 3 3 5 3 3 3 3 3 - 3 3 3
100-080-0403 12 32 6 3 40 3 3 5 3 3 3 3 3 - 3 3 3
125-100-0400 13 13 6 3 13 3 3 5 3 3 3 3 3 - 3 3 3
125-100-0403 13 33 6 3 41 3 3 5 3 3 3 3 3 - 3 3 3
150-150-0315 16 16 7 3 16 3 3 6 3 3 3 3 3 - 3 3 3
150-150-0311 16 16 7 3 42 3 3 6 3 3 3 3 3 - 3 3 3
150-150-0400 17 17 6 3 17 3 3 5 3 3 3 3 3 - 3 3 3
200-200-0320 18 18 7 3 18 3 3 6 3 3 3 3 3 - 3 3 3
Bearing bracket P06x
125-080-0500 19 19 8 4 19 4 4 7 4 4 4 4 4 - 4 4 4
150-125-0500 20 20 9 4 20 4 4 7 4 4 4 4 4 - 4 4 4
150-125-0503 20 34 9 4 43 4 4 7 4 4 4 4 4 - 4 4 4
200-200-0400 21 21 10 4 21 4 4 5 4 4 4 4 4 - 4 4 4
200-200-0403 21 35 10 4 44 4 4 5 4 4 4 4 4 - 4 4 4
250-250-0315 22 - 11 4 22 4 4 6 4 4 4 4 4 33 4 4 4
200-200-0500 23 22 12 4 23 5 5 8 5 5 5 5 5 - 5 5 5
200-200-0501 33 36 12 4 45 5 5 8 5 5 5 5 5 - 5 5 5
200-200-0503 23 37 12 4 46 5 5 8 5 5 5 5 5 - 5 5 5
250-250-0400 24 23 13 4 24 5 5 9 5 5 5 5 5 - 5 5 5
250-250-0403 24 38 13 4 47 5 5 9 5 5 5 5 5 - 5 5 5
250-250-0500 25 24 12 4 25 5 5 8 5 5 5 5 5 - 5 5 5
250-250-0503 25 39 12 4 48 5 5 8 5 5 5 5 5 - 5 5 5
250-250-0505 25 40 12 4 49 5 5 8 5 5 5 5 5 - 5 5 5
250-250-0630 26 25 14 4 26 5 5 9 5 5 5 5 5 - 5 5 5
250-250-0634 26 41 14 4 50 5 5 9 5 5 5 5 5 - 5 5 5
300-300-0400 27 - 13 4 27 5 5 9 5 5 5 5 5 34 5 5 6
300-300-0500 28 26 12 4 28 5 5 8 5 5 5 5 5 - 5 5 5
300-300-0503 33 42 12 4 51 5 5 8 5 5 5 5 5 - 5 5 5
350-350-0400 29 - 13 4 29 5 5 9 5 5 5 5 5 35 5 5 5
350-350-0500 30 27 12 4 30 5 5 8 5 5 5 5 5 - 5 5 5
350-350-0503 30 43 12 4 52 5 5 8 5 5 5 5 5 - 5 5 5
KWP 71 of 86
Description


Stuffing box ring
Casing wear ring

Bearing bracket
Discharge cover
Gland follower
Gland packing
Impeller screw
Pump casing
Lantern ring
Thrower
Impeller
Shaft
Part number
101 135.01 163 210 230 320/ 330 344 451.01 452.01 454.01 458.01 461 502.01 507 524.01 906
Size
322
350-350-0504 30 44 12 4 53 5 5 8 5 5 5 5 5 - 5 5 5
350-350-0630 31 28 14 4 31 5 5 9 5 5 5 5 5 - 5 5 5
350-350-0633 31 45 14 4 54 5 5 9 5 5 5 5 5 - 5 5 5
400-400-0500 32 29 12 4 32 5 5 8 5 5 5 5 5 - 5 5 5
400-400-0503 32 46 12 4 55 5 5 8 5 5 5 5 5 - 5 5 5
200-200-0500 23 22 15 5 56 6 6 8 6 6 6 6 6 - 6 6 5
200-200-0501 33 36 15 5 57 6 6 8 6 6 6 6 6 - 6 6 5
200-200-0503 23 37 15 5 58 6 6 8 6 6 6 6 6 - 6 6 5
250-250-0400 24 23 16 5 59 6 6 9 6 6 6 6 6 - 6 6 5
250-250-0403 24 38 16 5 60 6 6 9 6 6 6 6 6 - 6 6 5
250-250-0500 25 24 15 5 61 6 6 8 6 6 6 6 6 - 6 6 5
250-250-0503 25 39 15 5 62 6 6 8 6 6 6 6 6 - 6 6 5
250-250-0505 25 40 15 5 63 6 6 8 6 6 6 6 6 - 6 6 5
250-250-0630 26 25 17 5 64 6 6 10 6 6 6 6 6 - 6 6 5
250-250-0634 26 41 17 5 65 6 6 10 6 6 6 6 6 - 6 6 5
300-300-0400 27 - 16 5 66 6 6 9 6 6 6 6 6 34 6 6 6
300-300-0500 28 26 15 5 67 6 6 8 6 6 6 6 6 - 6 6 5
300-300-0503 33 42 15 5 68 6 6 8 6 6 6 6 6 - 6 6 5
350-350-0400 29 - 16 5 69 6 6 9 6 6 6 6 6 35 6 6 7
350-350-0500 30 27 15 5 70 6 6 8 6 6 6 6 6 - 6 6 5
350-350-0503 30 43 15 5 71 6 6 8 6 6 6 6 6 - 6 6 5
350-350-0504 30 44 15 5 72 6 6 8 6 6 6 6 6 - 6 6 5
350-350-0630 31 28 17 5 73 6 6 10 6 6 6 6 6 - 6 6 5
350-350-0633 31 45 17 5 74 6 6 10 6 6 6 6 6 - 6 6 5
400-400-0500 32 - 15 5 75 6 6 8 6 6 6 6 6 36 6 6 5
400-400-0503 32 - 15 5 76 6 6 8 6 6 6 6 6 37 6 6 5
400-400-0533 34 47 20 5 77 6 6 11 6 6 6 6 6 - 6 6 5
400-400-0583 35 48 21 5 78 6 6 10 6 6 6 6 6 - 6 6 5
500-400-0710 36 49 22 5 79 6 6 10 6 6 6 6 6 - 6 6 5
500-400-0713 36 50 22 5 80 6 6 10 6 6 6 6 6 - 6 6 5
500-500-0544 37 51 23 5 81 6 6 10 6 6 6 6 6 - 6 6 5
500-500-0630 38 52 17 5 82 6 6 10 6 6 6 6 6 - 6 6 5
500-500-0633 38 53 17 5 83 6 6 10 6 6 6 6 6 - 6 6 5
500-500-0634 38 54 17 5 84 6 6 10 6 6 6 6 6 - 6 6 5
500-500-0635 38 55 17 5 85 6 6 10 6 6 6 6 6 - 6 6 5
500-500-0637 38 56 17 5 86 6 6 10 6 6 6 6 6 - 6 6 5
200-200-0500 23 22 18 6 87 6 6 8 7 7 7 7 7 - 7 7 5
200-200-0501 33 36 18 6 88 6 6 8 7 7 7 7 7 - 7 7 5
200-200-0503 23 37 18 6 89 6 6 8 7 7 7 7 7 - 7 7 5
250-250-0500 25 24 18 6 90 6 6 8 7 7 7 7 7 - 7 7 5
250-250-0505 25 39 18 6 91 6 6 8 7 7 7 7 7 - 7 7 5
250-250-0503 25 40 18 6 92 6 6 8 7 7 7 7 7 - 7 7 5
250-250-0630 26 25 19 6 93 6 6 10 7 7 7 7 7 - 7 7 5
250-250-0634 26 41 19 6 94 6 6 10 7 7 7 7 7 - 7 7 5
300-300-0500 28 26 18 6 95 6 6 8 7 7 7 7 7 - 7 7 5
300-300-0503 33 42 18 6 96 6 6 8 7 7 7 7 7 - 7 7 5
350-350-0500 30 27 18 6 97 6 6 8 7 7 7 7 7 - 7 7 5
350-350-0503 30 43 18 6 98 6 6 8 7 7 7 7 7 - 7 7 5
350-350-0504 30 44 18 6 99 6 6 8 7 7 7 7 7 - 7 7 5
350-350-0630 31 28 19 6 100 6 6 10 7 7 7 7 7 - 7 7 5
350-350-0633 31 45 19 6 101 6 6 10 7 7 7 7 7 - 7 7 5
400-400-0500 32 - 18 6 102 6 6 8 7 7 7 7 7 36 7 7 5
400-400-0503 32 - 18 6 103 6 6 8 7 7 7 7 7 37 7 7 5
400-400-0533 34 47 24 6 104 6 6 11 7 7 7 7 7 - 7 7 5
400-400-0583 35 48 25 6 105 6 6 10 7 7 7 7 7 - 7 7 5
500-400-0710 36 49 26 6 106 6 6 10 7 7 7 7 7 - 7 7 5
72 of 86 KWP
Description


Stuffing box ring
Casing wear ring

Bearing bracket
Discharge cover
Gland follower
Gland packing
Impeller screw
Pump casing
Lantern ring
Thrower
Impeller
Shaft
Part number
101 135.01 163 210 230 320/ 330 344 451.01 452.01 454.01 458.01 461 502.01 507 524.01 906
Size
322
500-400-0713 36 50 26 6 107 6 6 10 7 7 7 7 7 - 7 7 5
500-500-0544 37 51 27 6 108 6 6 10 7 7 7 7 7 - 7 7 5
500-500-0630 38 52 19 6 109 6 6 10 7 7 7 7 7 - 7 7 5
500-500-0633 38 53 19 6 110 6 6 10 7 7 7 7 7 - 7 7 5
500-500-0634 38 54 19 6 111 6 6 10 7 7 7 7 7 - 7 7 5
500-500-0635 38 55 19 6 112 6 6 10 7 7 7 7 7 - 7 7 5
500-500-0637 38 56 19 6 113 6 6 10 7 7 7 7 7 - 7 7 5
600-600-0663 39 57 28 7 114 6 6 10 - - - - - - 7 8 5
600-600-0669 39 57 28 7 115 6 6 10 - - - - - - 7 8 5
KWP 73 of 86
8 Trouble-shooting
8 Trouble-shooting
WARNING
Improper remedial work on the pump (set)
Risk of injury!
▷ For any work performed in order to remedy faults on the pump (set) observe
the relevant information given in this operating manual or the product
literature provided by the accessories manufacturers.
If problems occur that are not described in the following table, consultation with
KSB’s customer service is required.
A Pump delivers insufficient flow rate
B Motor is overloaded
C Excessive pump discharge pressure
D Increased bearing temperature
E Leakage at the pump
F Excessive leakage at the shaft seal
G Vibrations during pump operation
H Impermissible rise of temperature inside the pump
Table 29: Trouble-shooting
A B C D E F G H Possible cause Remedy27)
✘ Pump delivers against an excessively Re-adjust to duty point.
high pressure.
✘ Excessively high back pressure Check system for impurities.
Increase speed (turbine, I.C. engine).
✘ ✘ ✘ Pump or piping are not completely Vent and/or prime.
vented or primed.
✘ Supply line or impeller clogged Remove deposits in the pump and/or piping.
✘ Formation of air pockets in the piping Alter piping layout.
Fit vent valve.
✘ ✘ ✘ Pump is warped or sympathetic Check the piping connections and secure
vibrations in the piping. fixing of pump; if required, reduce distances
between the pipe clamps.
Fix the pipelines using anti-vibration material.
✘ ✘ ✘ Suction lift is too high/ Check/alter fluid level.
NPSHavailable (positive suction head) is too Fully open the shut-off element in the supply
low. line.
Change suction line, if the friction losses in
the suction line are too high.
Check any strainers installed/suction opening.
Observe permissible speed of pressure fall.
✘ Increased axial thrust28) Correct rotor adjustment.
✘ Air intake at the shaft seal. Fit new shaft seal.
✘ Wrong direction of rotation Check the electrical connection of the motor
and the control system, if any.
✘ ✘ Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
✘ Speed is too low. Increase speed.
✘ Defective bearing(s) Fit new bearing(s).
✘ ✘ ✘ Flow rate is too low. Increase the minimum flow rate.
✘ ✘ Wear of internal components Replace worn components by new ones.
✘ ✘ Pump back pressure is lower than Re-adjust to duty point.
specified in the purchase order.
27) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
28) Contact KSB.
74 of 86 KWP
8 Trouble-shooting
A B C D E FG H Possible cause Remedy27)

✘ Density or viscosity of fluid handled Contact KSB.
higher than stated in purchase order
✘ Use of unsuitable materials Change the material combination.
✘ ✘ Speed is too high. Reduce speed.
✘ Tie bolts/sealing element defective Fit new seal between volute casing and
discharge cover.
Re-tighten the bolts.
✘ Worn shaft seal Fit new shaft seal.
✘ ✘ Score marks or roughness on shaft Replace shaft protecting sleeve/shaft sleeve.
protecting sleeve/shaft sleeve Replace shaft seal.
Check balancing line.
Check throttling bush/throttling sleeve
clearances.
✘ Lack of cooling liquid or dirty cooling Increase cooling liquid quantity.
chamber Clean out cooling chamber.
Purify/clean cooling liquid.
✘ Stuffing box cover, seal cover have been Correct.
tightened incorrectly and/or wrong
packing material.
✘ Vibrations during pump operation Correct suction conditions.
Re-align the pump set.
Re-balance the impeller.
Increase pressure at the pump suction nozzle.
✘ ✘ ✘ The pump set is misaligned. Check the coupling; realign if required.
✘ Insufficient or excessive quantity of Top up, reduce or change lubricant.
lubricant or unsuitable lubricant.
✘ Non-compliance with specified coupling Correct distance according to general
distance arrangement drawing.
✘ Operating voltage is too low. Increase voltage.
Check voltage drop in the power cable.
✘ Rotor out of balance Clean rotor.
Re-balance rotor.
27) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
KWP 75 of 86
9 Related Documents
9 Related Documents
9.1 General assembly drawing with list of components
9.1.1 Bearing brackets P03ax to P06x
Fig. 25: Bearing brackets P03ax to P06x
76 of 86 KWP
9 Related Documents
9.1.2 Bearing brackets P08sx to P12sx
Fig. 26: Bearing brackets P08sx to P12sx
KWP 77 of 86
9 Related Documents
Fig. 27: Bearing brackets P10ax to P12sx: sizes 500-400-710 and 500-400-713
78 of 86 KWP
9 Related Documents
Fig. 28: Bearing bracket P12sx: sizes 600-660-663 and 600-600-669
KWP 79 of 86
9 Related Documents
9.1.3 Shaft seals
a) b)
Fig. 29: Shaft seals P03ax to P12sx: a) 4K mechanical seal; b) coolable gland packing
Fig. 30: 4K-120M mechanical seal29)
9.1.4 List of components

Table 30: List of components30)
Part No. Comprising Description
101 101 Pump casing
411.01/.02/.03/.1031) Joint ring
901.01 Hexagon head bolt
902.01/.27 Stud
903.01/.02/.0331) Screw plugs
920.01/.27 Hexagon nut
135.0132) 135.01 Wear plate
411.12/.13/.57 Joint ring
412.05/.75 O-ring
902.08/.90 Stud
29) Only for sizes 600-600-663 or 600-600-669

30) Depending on the design
31) If any
32) For 250-250-0315, 300-300-0400, 350-350-0400 and 400-400-0500, casing wear ring 502.01 instead of wear plate
80 of 86 KWP
9 Related Documents

920.08/.90 Hexagon nut
914.05 Hexagon socket head cap screw
162 162 Suction cover
900.06 Eyebolt
901.44 Forcing screw
904.97 Grub screw
163 163 A-type discharge cover
412.35/.50 O-ring
900.07 Eyebolt
901.22/.30/.31 Forcing screw
902.15 Stud
920.15 Hexagon nut
163 163 Discharge cover with integrally cast stuffing box
housing
411.16/.17 Joint ring
463.01 Drip plate
550.01 Disc
902.02 Stud
903.16/.17 Screw plug
920.02 Nut
163 163 Discharge cover (with bolted-on stuffing box housing)
400.05 Gasket
411.26 Joint ring
183 183 Support foot
592.02 Base
930.01 Safety device (spring washer)
89-4.02 Shims
210 210 Shaft
500.21 Ring
920.21 Slotted round nut
931.01 Lock washer
940.01/.02 Key
230 230 Impeller
260 260 Impeller hub cap
412.03 O-ring
550.87 Disc
931.02 Lock washer
320.02 320.02 Angular contact ball bearing
322.01 322.01 Cylindrical roller bearing
330 330 Bearing bracket
330 330 Bearing bracket, complete
360.01 Bearing cover
382 Bearing carrier
400.01 Gasket
411.46 Joint ring
411.77/.78 V-ring
412.02/.36 O-ring
421.01/.02 Lip seal
507.01/.12 Thrower
550.23 Support disc
638 Constant-level oiler
672 Vent plug
901.91/.95 Hexagon head bolt
903.10/.46 Screw plug
914.01/.02 Hexagon socket head cap screw
932.01./.02/.03 Circlip
KWP 81 of 86
9 Related Documents

344 344 Bearing bracket lantern
901.31 Forcing screw
902.04 Stud
920.04 Hexagon nut
360.01 360.01 Bearing cover
400.01 Gasket
507.11 Thrower
412.36 O-ring
382 382 Bearing carrier
412.02 O-ring
89-4.12 Shims
411.77/.78 411.77/.78 V-ring
433.02 82-5.01 Adapter
433.02 4K mechanical seal
412.51/.52/.53 O-ring
472.53 Primary ring
474.53 Thrust ring
475.52 Mating ring
477.53 Spring
560.52 Pin
914.53/.54 Shaft sleeve
451.01 451.01 Stuffing box housing
400.05 Gasket
411.16/.17/.18/.19/.26 Joint ring
463.01 Drip plate
550.01 Disc
902.02 Stud
903.16/.17/.18/.19 Screw plug
920.01 Hexagon nut
452.01 452.01 Gland follower
454.01 454.01 Stuffing box ring, split
456.01 456.01 Neck bush
458.01 458.01 Lantern ring, split
461.01 461.01 Gland packing
502.01 502.01 Casing wear ring
507.01/.11/.12 507.01/.11/.12 Thrower
524.01 524.01 Shaft protecting sleeve
412.06 O-ring
900.06/.07 900.06/.07 Eyebolt
906 906 Impeller screw
412.03 O-ring
99-9 99-9 Set of sealing elements
400.01 Gasket
411.01/.02/.03/.10/.12/.13/.46./57 Joint ring
412.02/.03/.05/.06/.35/.50/.75 O-ring
82 of 86 KWP
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 product:
KWP, KWPR, KWP-Bloc
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100,
– EN 809/A1
Person authorised to compile the technical file:
Name
Function
Address (company)
Address (Street, No.)
Address (post or ZIP code, city) (country)
The EC Declaration of Conformity was issued in/on:
Place, date
..............................33).............................
Name
Function
Company
Address
Address
33) A signed, legally binding declaration of conformity is supplied with the product.
KWP 83 of 86
11 Certificate of Decontamination
11 Certificate of Decontamination
Type ................................................................................................................................
Order number/
Order item number34) ................................................................................................................................
Delivery date ................................................................................................................................
Field of application: ................................................................................................................................
Fluid pumped34): ................................................................................................................................
Please tick where applicable34):
⃞ ⃞ ⃞ ⃞
Radioactive Explosive Corrosive Toxic
⃞ ⃞ ⃞ ⃞
Harmful Bio-hazardous Highly flammable Safe
Reason for return34): ................................................................................................................................
Comments: ................................................................................................................................
................................................................................................................................
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We hereby declare that this product is free from hazardous chemicals, biological or radioactive substances.
On seal-less pumps, the rotor has been removed from the pump for cleaning.
⃞ No special safety precautions are required for further handling.

⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:
...............................................................................................................................................................
...............................................................................................................................................................
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with
the relevant legal provisions.
.................................................................... ....................................................... .......................................................

Place, date and signature Address Company stamp
34) Required fields
84 of 86 KWP
Index
Index
A Misuse 9
Monitoring equipment 12
Abrasive fluids 46
Auxiliary connections 29
N
B Name plate 16
Noise characteristics 21
Bearing temperature 49
Bearings 17
O
C Oil lubrication
Intervals 51
Certificate of decontamination 84 Oil quality 51
Commissioning/start-up 38 Operating limits 8, 44
Configuration and function 20 Order number 6
Constant-level oiler 38 Ordering spare parts 69
Coupling 49 Other applicable documents 6
Coupling alignment 30
P
D Partly completed machinery 6
Design 16 Permissible forces and moments at the pump nozzles
Designation 16 25
Diametral clearances 66 Piping 24
Direction of rotation 36 Preservation 15, 46
Dismantling 53 Priming and venting 40
Disposal 15 Product description 19
Pump casing 16
Pure graphite packing ring 42
E
Explosion protection 11, 22, 29, 30, 33, 34, 35, 36, 39,
40, 41, 42, 44, 47, 48, 49, 50, 51 R
Reassembly 53
Return to supplier 15
F Returning to service 46
Filter 24, 50 Running noises 48, 49
Final check 41
Flow rate 45
Frequency of starts 44 S
Safety 8
Safety awareness 10
G Scope of supply 21
Gland packing 42 Servicing/maintenance 47
Shaft seal 18
Shutdown 43, 46
I Start-up 41
Impeller type 17 Storage 15, 46
Installation
Installation on a foundation 22
Installation without foundation 23 T
Installation at site 22 Temperature limits 11
Intended use 8 Tightening torques 68
Interchangeability of pump components 71 Transport 13
Trouble-shooting 74
L
List of components 80 W
Water cooling 40
M
Mechanical seal 42
KWP 85 of 86
2361.8/10 (01317114)
KSB Aktiengesellschaft
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.com

KSB KWP P03 P12 Instructions

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KSB KWP P03 P12 Instructions

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Dry-installed Volute Casing Pump

Original operating manual

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft, Frankenthal 16.07.2013

3 Transport/Temporary Storage/Disposal .............................................13

4 Description of the Pump (Set) ............................................................16

5 Installation at Site ...............................................................................22

5.3 Installing the pump set .................................................................................. 22

9 Related Documents ............................................................................76

10 EC Declaration of Conformity ............................................................83

11 Certificate of Decontamination .........................................................84

Back pull-out design Pool of pumps

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

2.3 Intended use

▪ Never operate the pump without the fluid handled.

Open multi- For uncontaminated or slightly

Open free flow Fluids containing larger solids and stringy

Prevention of foreseeable misuse

2.4 Personnel qualification and training

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

2.6 Safety awareness

2.7 Safety information for the operator/user

2.8 Safety information for maintenance, inspection and installation work

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

2.9 Unauthorised modes of operation

2.10 Explosion protection

2.10.2 Temperature limits

Table 5: Temperature limits

2.10.3 Monitoring equipment

2.10.4 Operating limits

2) Depending on the material variant

3.1 Checking the condition upon delivery

Fig. 1: Transporting the back pull-out unit

Fig. 2: Transporting the pump

Fig. 5: Transporting a pump set on a baseplate (figure 3)

3.4 Return to supplier

4 Description of the Pump (Set)

4.1 General description

4.3 Name plate

Mat-No. 01 109 223 ZN 3804 - D 52 x 74

Fig. 6: Name plate (example)

Fig. 7: Discharge cover designs

Uncooled gland packing with a)

4.6 Installation types

Figure 3Z Pump set with belt drive. Motor bracket

Figure 4H Pump set with belt drive. Motor support plate

Figure 3H Pump set with belt drive and counter shaft.

4.7 Configuration and function

Fig. 9: Sectional drawing

4.8 Noise characteristics

Rated power Pump Pump set9)

4.9 Scope of supply

4.10 Dimensions and weights

5.1 Safety regulations

5.2 Checks to be carried out prior to installation

5.3 Installing the pump set