Binder 1001-1002

Process Pump
RPH
Installation/Operating Manual
9973172559/000100
P-1001/1002
Legal information/Copyright
Installation/Operating Manual RPH
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 20.01.2014

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 this manual ......... 9
2.6 Safety awareness ..............................................................................................9
2.7 Safety information for the operator/user ..................................................... 10
2.8 Safety information for maintenance, inspection and installation work ..... 10
2.9 Unauthorised modes of operation ................................................................ 10
2.10 Explosion protection ...................................................................................... 10
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 ........................................................................................... 14
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 details .................................................................................................. 16
4.5 Configuration and function ........................................................................... 18
4.6 Noise characteristics ...................................................................................... 19
4.7 Scope of supply ............................................................................................... 19
4.8 Dimensions and weights ................................................................................19
5 Installation at Site ...............................................................................20

5.1 Safety regulations ........................................................................................... 20
5.2 Checks to be carried out prior to installation ............................................... 20
5.3 Installing the pump set .................................................................................. 20
5.4 Piping .............................................................................................................. 21
RPH 3 of 76
Contents
5.5 Enclosure/insulation .......................................................................................24

5.6 Checking the coupling alignment ................................................................. 25
5.7 Aligning the pump and motor ...................................................................... 26
5.8 Electrical connection ...................................................................................... 27
5.9 Checking the direction of rotation ................................................................ 27
6 Commissioning/Start-up/Shutdown ...................................................29
6.1 Commissioning/start-up ................................................................................. 29
6.2 Operating limits .............................................................................................. 36
6.3 Shutdown/storage/preservation .................................................................... 38
6.4 Returning to service .......................................................................................38
7 Servicing/Maintenance .......................................................................40
7.1 Safety regulations ........................................................................................... 40
7.2 Maintenance/inspection ................................................................................. 41
7.3 Drainage/cleaning ..........................................................................................46
7.4 Dismantling the pump set .............................................................................. 46
7.5 Reassembling the pump set ........................................................................... 49
7.6 Tightening torques ......................................................................................... 53
7.7 Spare parts stock ............................................................................................. 57
8 Trouble-shooting ................................................................................61
9 Related Documents ............................................................................63

9.1 General assembly drawing with list of components .................................... 63
10 EC Declaration of Conformity ............................................................72
11 Certificate of Decontamination .........................................................73
Index ....................................................................................................74
4 of 76 RPH
Glossary
Glossary
Back pull-out design Hydraulic system

The complete back pull-out unit can be pulled The part of the pump in which the kinetic
out without having to remove the pump casing energy is converted into pressure energy
from the piping.
Pool of pumps
Back pull-out unit Pumps which are purchased and stored
Pump without pump casing; partly completed independently of their later use
machinery
Pump
Certificate of decontamination Machine without drive, additional components
A certificate of decontamination is enclosed by or accessories
the customer when returning the product to
the manufacturer to certify that the product
Pump set
has been properly drained to eliminate any
environmental and health hazards arising from Complete pump set consisting of pump, drive,
components in contact with the fluid handled. additional components and accessories
Discharge line Suction lift line/suction head line

The line which is connected to the discharge The line which is connected to the suction
nozzle nozzle
RPH 5 of 76
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 see (⇨ Section 4.6 Page 19)
1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, refer to the sub-sections
under Servicing/Maintenance. (⇨ Section 7.5.5 Page 52)
1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (⇨ Section 2.4 Page 9)
1.4 Other applicable documents

Table 1: Overview of other applicable documents
Document 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 76 RPH
1 General
Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
RPH 7 of 76
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 76 RPH
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.
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.
2.5 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with this operating manual 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
RPH 9 of 76
2 Safety
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 6.1.13 Page 35) (⇨ Section 6.3 Page 38)
▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3
Page 46)
▪ As soon as the work has been 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 29)
2.9 Unauthorised modes of operation

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

Always observe the information on explosion protection given in this section when
! DANGER operating the pump 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) .
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
10 of 76 RPH
2 Safety
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.
Table 4: 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.
2) Depending on the material variant
RPH 11 of 76
2 Safety
Contact KSB for further information on monitoring equipment.
2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.2.3.1 Page 37) 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 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 37) (flow rate) can be used to check whether an additional
heat build-up may lead to a dangerous temperature increase at the pump surface.
12 of 76 RPH
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
RPH 13 of 76
max. 90 °
Fig. 3: Transporting the complete pump set
max. 90 °
Fig. 4: Transporting the pump on the baseplate
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage 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.
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 38) .
3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 46)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
14 of 76 RPH
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 73)
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 and/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.
RPH 15 of 76
4 Description of the Pump (Set)
4.1 General description

▪ Process pump to API 610
Pump for handling the large variety of crude oil products in refineries as well as in
the chemical and petrochemical industry.
4.2 Designation
Example: RPH-H-I S1 80-280B
Table 5: Key to the designation
Code Description
RPH Type series
H Heatable model
I Version with auxiliary impeller (inducer)
S1 Material variant to API 610
80 Nominal discharge nozzle diameter [mm]
280 Nominal impeller diameter [mm]
B Special hydraulic system (type B)
4.3 Name plate
Aktiengesellschaft
67225 Frankenthal 1
16
Ord.-No. Year 2008 2
15
14 Ser.-No. 997186942100630001 Type RPH 100-280 3
13 Item-No. 107-P-102B Test pressure 7200 kPa 4
12 Q 110 m3/h H 70,00 m 5
11 n 2950 1/min t 60 °C 6
10 ρ 0,51 kg/dm3 MAWP 4800/85 kPa@°C
Shaft seal H75VK/85-PTA80
Bearings NU 213C3/2 * 7311BMUA
Impeller∅ mm max. min. rated
standard / 1st stage 295 230 243
Ident-No 00380 249
2nd stage
ZN 3823 - E 13
9 8 7
Fig. 5: Name plate (example)
1 Year of construction 2 Type series, size
3 Test pressure 4 Head
5 Application temperature 6 Maximum application
pressure@temperature
7 Impeller diameter when installed 8 Minimum impeller diameter
9 Maximum impeller diameter 10 Bearings
11 Shaft seal 12 Density of the fluid handled
13 Rated speed 14 Flow rate
15 Item number 16 KSB order number
4.4 Design details

Design
▪ Volute casing pump
▪ Horizontal installation
▪ Back pull-out design
16 of 76 RPH
▪ Single-stage
▪ Meets technical requirements to API 610, 11th edition / ISO 13709
Pump casing
▪ Volute casing with integrally cast pump feet
▪ Centreline pump feet
▪ Single or double volute, depending on the pump size
▪ Radially split volute casing
▪ Axial inlet nozzle, tangential discharge nozzle pointing vertically upwards.
(From DN 250 / from impeller diameter 500 / pump size 200-401: radial discharge
nozzle pointing vertically upwards)
▪ Volute casing with casing wear ring
▪ Casing cover (with casing wear ring, as required)
Optional:
▪ Casing and casing cover heatable/coolable, depending on size
Impeller type
▪ Closed radial impeller
▪ Impeller with impeller wear ring on the suction side
(if required also on the discharge side)
▪ Sealing gap and balancing holes balance axial forces.
Optional:
▪ Inducer to improve the NPSH value
Shaft seal
▪ Cartridge seal to API 682
Bearings
▪ Uncooled
Optional:
▪ Cooled bearing bracket
Drive-end bearing:
▪ Fixed bearing
▪ Paired angular contact ball bearings
▪ Oil bath lubrication
▪ Optional: oil mist lubrication
Pump-end bearing:
▪ Radial bearing
▪ Cylindrical roller bearing
▪ Absorbs radial loads only
▪ Oil bath lubrication
▪ Optional: oil mist lubrication
Bearing bracket Example: B03
designation Table 6: Bearing bracket designation
Designation Description
B Back pull-out bearing bracket
03 Size code (based on dimensions of seal chamber, shaft end
and bearings)
RPH 17 of 76
Bearings used Table 7: Bearing design

KSB designation FAG designation SKF designation
B.MUA B-MP-UA BECBM
Table 8: Standard bearing assembly
Bearing bracket Rolling element bearings
Pump end Motor end
B02 NU211C3 2 x 7309B-MUA
B03 NU213C3 2 x 7311B-MUA
B05 NU316C3 2 x 7315B-MUA
B06 NU324C3 2 x 7224B-MUA
B07 NU324C3 2 x 7324B-MUA
Table 9: Reinforced bearing assembly (triple bearing assembly)
Bearing bracket Rolling element bearings
Pump end Motor end
B02 NU211C3 3 x 7309B-MUA
B03 NU213C3 3 x 7311B-MUA
B05 NU316C3 3 x 7315B-MUA
B06 NU324C3 3 x 7224B-MUA
B07 NU324C3 3 x 7324B-MUA
4.5 Configuration and function

1 2 3 4 5
6 7 8 9 10
1 Clearance gap 2 Discharge nozzle

3 Casing cover 4 Shaft
5 Bearing bracket 6 Suction nozzle
7 Impeller 8 Shaft seal
9 Rolling element bearing, pump 10 Rolling element bearing, motor
end end
Design The pump is designed with an axial fluid inlet and a radial or tangential outlet. The
hydraulic system runs in its own bearings and is connected to the motor by a shaft
coupling.
18 of 76 RPH
Function The fluid enters the pump axially via the suction nozzle (6) and is accelerated
outward by the rotating impeller (7). In the flow passage of the pump casing the
kinetic energy of the fluid is converted into pressure energy. The fluid is pumped to
the discharge nozzle (2), where it leaves the pump. The clearance gap (1) prevents
any fluid from flowing back from the pump casing into the suction nozzle. At the
rear side of the impeller, the shaft (4) enters the hydraulic system via the casing cover
(3). The shaft passage through the cover is sealed to atmosphere with a shaft seal (8).
The shaft runs in rolling element bearings (9 and 10), which are supported by a
bearing bracket (5) connected to the casing cover.
Sealing The pump is sealed by a standardised mechanical seal.
4.6 Noise characteristics

Table 10: Surface sound pressure level LpA3)4)
Rated Pump Pump set

power 960 rpm 1450 rpm 2900 rpm 960 rpm 1450 rpm 2900 rpm
input 760 rpm 760 rpm
PN [kW] [dB] [dB] [dB] [dB]
[dB] [dB]
1,5 52 53 54 56 58 63
2,2 53 55 56 58 60 66
3 55 56 57 60 62 68
4 56 58 59 61 63 69
5,5 58 59 61 62 65 71
7,5 59 61 62 64 66 72
11 61 63 64 65 68 74
15 63 65 66 67 69 75
18,5 64 66 67 68 70 76
22 65 67 68 68 71 77
30 66 68 70 70 72 78
37 67 70 71 70 73 79
45 68 71 72 71 74 80
55 69 72 73 72 74 80
75 71 73 75 73 76 81
90 71 74 76 73 76 82
110 72 75 77 74 77 82
132 73 76 78 75 77 83
160 74 77 79 75 78 84
200 75 78 80 76 79 84
250 - 79 81 - 80 85
4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:
▪ Pump
Coupling ▪ Torsion-resistant flexible disc coupling
Contact guard ▪ Coupling guard
Baseplate ▪ Welded baseplate for the complete unit (pump and motor), in torsion-resistant
design
Special accessories ▪ As required
4.8 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump/pump set.
3) Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.8 - 1.1 range and for non-
cavitating operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.
4) Increase for 60 Hz operation: 3500 rpm +3 dB, 1750 rpm +1 dB, 1160 rpm ±0 dB
RPH 19 of 76
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 a foundation
1
L
2 3
Fig. 6: 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.
20 of 76 RPH
✓ 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 the pump set can be mounted on vibration dampers upon
confirmation by the manufacturer. In this case, only fasten the flexible elements at
the baseplate after the piping has been connected.
NOTE
Expansion joints can be fitted between the pump and the suction/discharge line.
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.
▷ The pipelines have been anchored in close proximity to the pump and
connected without transmitting any stresses or strains.
▷ Observe permissible forces and moments at the pump nozzles. (⇨ Section 5.4.2
Page 23)
▷ 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.
RPH 21 of 76
NOTE
It is recommended to install check and shut-off elements in the system, depending
on the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
✓ The suction lift line 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 at least equal to the nominal
diameters of the pump nozzles.
✓ Adapters to larger diameters have a diffuser angle of approximately 8° to
prevent excessive pressure losses.
✓ The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
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 7.2.2.3 Page 44) .
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.
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 figure: Filter in the piping).
2
Fig. 7: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter)
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.
22 of 76 RPH
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
Fig. 8: Coordinate system of forces and moments

1 Discharge nozzle 2 Suction nozzle
3 Shaft centreline
The pumps are designed to withstand twice the piping forces and moments required
by API 610.
Table 11: Forces and moments at the pump nozzles
Suction nozzle Discharge nozzle
Forces Moments Forces Moments
[N] [Nm] [N] [Nm]
Size
Fx Fy Fz Fres Mx My Mz Mres Fx Fy Fz Fres Mx My Mz Mres

25-180 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
25-230 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
40-180 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
40-230 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
40-280 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
40-181 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
40-231 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
40-281 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
40-361 1780 1420 1160 2560 920 460 700 1240 1420 1160 1780 2560 920 460 700 1240
50-180 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240
50-230 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240
50-280 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240
50-360 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240
50-450 2660 2140 1780 3860 1900 940 1440 2560 1420 1160 1780 2560 920 460 700 1240
80-180 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560
80-230 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560
80-280 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560
80-360 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560
80-450 3560 2840 2320 5120 2660 1360 2000 3600 2140 1780 2660 3860 1900 940 1440 2560
100-180 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600
100-230 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600
100-280 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600
100-360 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600
100-450 6220 4980 4100 8960 4600 2360 3520 6260 2840 2320 3560 5120 2660 1360 2000 3600
150-230 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260
150-280 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260
150-360 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260
150-450 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260
150-501 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260
RPH 23 of 76
Suction nozzle Discharge nozzle

Forces Moments Forces Moments
[N] [Nm] [N] [Nm]
Size
Fx Fy Fz Fres Mx My Mz Mres Fx Fy Fz Fres Mx My Mz Mres

150-630 9780 7560 6220 13840 7060 3520 5160 9420 4980 4100 6220 8960 4600 2360 3520 6260
200-280 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420
200-360 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420
200-401 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420
200-450 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420
200-501 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420
200-670 13340 10680 8900 19260 10040 4880 7600 13500 7560 6220 9780 13840 7060 3520 5160 9420
250-401 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500
250-501 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500
250-630 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500
250-710 16000 13340 10680 23400 12200 5960 9220 16420 10680 8900 13340 19260 10040 4880 7600 13500
300-400 17800 14240 11560 25560 12740 6240 9500 17080 13340 10680 16000 23400 12200 5960 9220 16420
300-500 17800 14240 11560 25560 12740 6240 9500 17080 13340 10680 16000 23400 12200 5960 9220 16420
300-630 17800 14240 11560 25560 12740 6240 9500 17080 13340 10680 16000 23400 12200 5960 9220 16420
350-400 17800 14240 11560 25560 12740 6240 9500 17080 14240 11560 17800 25560 12740 6240 9500 17080
350-500 17800 14240 11560 25560 12740 6240 9500 17080 14240 11560 17800 25560 12740 6240 9500 17080
350-650 20460 16900 13340 29700 14640 7340 10840 19640 14240 11560 17800 25560 12740 6240 9500 17080
350-710 20460 16900 13340 29700 14640 7340 10840 19640 14240 11560 17800 25560 12740 6240 9500 17080
400-504 20460 16900 13340 29700 14640 7340 10840 19640 16900 13340 20460 29700 14640 7340 10840 19640
400-506 20460 16900 13340 29700 14640 7340 10840 19640 16900 13340 20460 29700 14640 7340 10840 19640
400-710 20460 16900 13340 29700 14640 7340 10840 19640 16900 13340 20460 29700 14640 7340 10840 19640
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).
24 of 76 RPH
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 casing cover and the bearing bracket.
5.6 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.
Checking the coupling alignment with a dial gauge
Fig. 9: Checking the spacer-type coupling with a dial gauge

1. Mark the installation position of the coupling by dotting marks (balancing
condition).
2. Remove the coupling spacer.
NOTE
While the pump's coupling is disengaged, also check the direction of rotation.
(⇨ Section 5.9 Page 27)
RPH 25 of 76
3. Check the alignment of the coupling halves with a dial gauge (see drawing
"Checking the spacer-type coupling with a dial gauge").
Admissible run-out of coupling face (axial) maximum 0.1 mm.
Admissible radial deviation, measured over the complete circumference,
maximum 0.2 mm.
5.7 Aligning the pump and motor

After having installed the pump set and connected the piping, check the coupling
alignment and, if required, re-align the pump set (with the motor).
Any differences in shaft centre height between the pump and the motor are
compensated by means of shims.
1
Fig. 10: Pump set with shim
1 Shim
✓ The coupling guard and its footboard, if any, have been removed.
1. Check the coupling alignment.
2. Loosen the hexagon head bolts at the motor.
3. Insert shims underneath the motor feet until the difference in shaft centreline
height has been compensated.
4. Re-tighten the hexagon head bolts.
5. Check proper functioning of coupling/shaft.
Check that coupling/shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.
6. Fit the coupling guard and its footboard, if any.
7. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
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).
26 of 76 RPH
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 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.
5.9 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.
RPH 27 of 76
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 of model with auxiliary impeller (inducer)
Damage to the pump!
▷ 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 motor and pump is in clock-wise direction (seen
from the motor end).
1. Start the pump set and stop it again immediately to determine the motor's
direction of rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction
of rotation on the pump.
3. If the direction of rotation is incorrect, check the connection of the motor and
the switchgear, if any.
28 of 76 RPH
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
31)
▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 27)
▪ 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 38) have been carried out.
6.1.2 Filling in the lubricant

Oil-lubricated bearings Fill the bearing bracket with lubricating oil.
▪ Oil quality (⇨ Section 7.2.3.1.2 Page 44)
▪ Oil quantity (⇨ Section 7.2.3.1.3 Page 45)
NOTE
On uncooled bearing brackets, first remove the reservoir of the constant level oiler.
Then screw in the connection elbow separately.
Filling the constant level oiler with lubricating oil (oil bath 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.
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.
RPH 29 of 76
1 2
3 4 5 6
Fig. 11: 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 6 Oil level sight glass
1. Remove the protective cage.
2. Unscrew the vent plug (2).
3. Hinge down the reservoir of the constant level oiler (1) from the bearing
bracket (5) and hold it in this position.
4. Fill in oil through the hole for the vent plug until the oil reaches the connection
elbow of the constant level oiler (3).
5. Completely fill the reservoir of the constant level oiler (1).
6. Snap the constant level oiler (1) back into its operating position.
7. Screw the vent plug (2) back in.
8. Fit the protective cage.
9. 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 - 8, if necessary.
10. 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.
30 of 76 RPH
Connecting the oil mist lubrication system (for oil mist lubrication only)
Bearings with oil mist
lubrication
Fig. 12: Oil mist lubrication

✓ Always observe the instructions of the lubricating system manufacturer
(especially on dosing and oil quantity).
1. Remove plugs 916.N3.
2. Connect the lines of the oil mist lubrication system.
3. Remove drain plug 916.46.
4. Connect the drain line (returning the oil back into the oil mist system).
5. Screw in plug 916.N1.
NOTE
Plug 916.N1 replaces vent plug 913.03.
6.1.3 Shaft seal

Shaft seals are fitted prior to delivery.
Observe the instructions on dismantling (⇨ Section 7.4.6 Page 48) or assembly
(⇨ Section 7.5.3 Page 51) .
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 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.
RPH 31 of 76
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 Final check

1. Remove the coupling guard and the footboard for the coupling guard, if any.
2. Check the coupling alignment; re-align the coupling if required.
3. Check that the coupling and shaft can easily be rotated by hand.
4. Re-install the coupling guard and the footboard for the coupling guard, if any.
5. Check the distance between the coupling and coupling guard.
The coupling and coupling guard must not come into contact.
6.1.6 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
▪ 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.
6.1.7 Cooling of the pump

The casing cover, the bearing bracket and the casing support on the baseplate can be
cooled.
Observe the following quality data of the cooling water:
▪ Maximum permissible cooling liquid pressure: 10 bar
32 of 76 RPH
▪ Maximum permissible cooling liquid test pressure: 15 bar

▪ Observe the specified cooling liquid quantity.
6.1.8 Cooling of the shaft seal
CAUTION
Vaporisation pressure of fluid handled higher than atmospheric pressure
Damage to the shaft seal/pump!
▷ Cool the shaft seal.
▷ Provide sufficient quantities of cooling liquid (see table).
NOTE
The vaporisation pressure varies depending on the fluid handled, the system
pressure and the material of the shaft seal (e.g. hot water).
Table 12: Cooling liquid quantities:

Fluid temperature Cooling liquid quantities
[°C] [m3/h]5)
Casing cover < 250 0,3
< 400 0,6
Bearing bracket 2006)/250 to 3157) 0.2
> 3158)
Support on baseplate > 250 0.2
6.1.8.1 Cooling of the heat exchanger

For mechanical seals with product circulation observe the following for the heat
exchanger:
Table 13: Cooling liquid quantity depending on the bearing bracket
At speed n Cooling liquid
[rpm] [m3/h]
Bearing bracket
B02 B03 B05 B06 B07
1750/1450 0.35 0.5 0.6 0.8 0.8
3500/2900 1.2 1.2 1.8 - -
6.1.9 Heating
DANGER
Excessive surface temperature
Explosion hazard!
Risk of burns!
▷ Observe the permissible temperature classes. (⇨ Section 2.10.2 Page 11)
5) The cooling liquid quantities indicated are based on Δt = max. 15 °C.

6) For n = 3500 rpm and n = 2900 rpm in conjunction with triple bearing assembly. In all other cases from 250 °C!
7) Water cooling or fan wheel
8) Water cooling (and fan wheel optional)
RPH 33 of 76
CAUTION
Time for warming up the pump too short
Damage to the pump!
▷ Check that the pump is sufficiently warmed up throughout.
The casing cover can be heated with hot water or steam. Observe the following data
for the heating medium:
▪ Maximum permissible temperature t = 150 °C
▪ Maximum permissible pressure p = 10 bar
▪ Seal casing cover with O-rings made of EP.
CAUTION
Lack of heating medium
Damage to the pump!
▷ Provide sufficient quantities of a suitable heating medium.
6.1.10 Heating up/keeping warm the pump (set)
CAUTION
Pump blockage
Damage to the pump!
▷ Prior to pump start-up, heat up the pump as described in the manual.
Observe the following when heating up the pump (set) and keeping it warm:
▪ Make sure that the temperature is increased continuously.
▪ Max. heating speed: 10 °C/min (10 K/min)
Fluid temperatures above When the pump is used for handling fluids at temperatures above 150 °C make sure
150 °C that the pump has been heated throughout before starting it up.
Temperature difference The temperature difference between the pump's surface and the fluid handled must
not exceed 100 °C (100 K) when the pump is started up.
6.1.11 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 31)
▷ Always operate the pump within the permissible operating range.
34 of 76 RPH
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 pumped.
✓ The lines for priming and venting have been closed.
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 rated 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
Damage to pump, motor and coupling!
▷ When the operating temperature has been reached, switch off the pump set
and check the coupling alignment.
5. Check the coupling alignment and re-align the coupling, if required.
6.1.12 Checking the shaft seal

Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
6.1.13 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.
✓ Also ensure quench liquid supply is ON 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.
RPH 35 of 76
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.
For prolonged shutdown periods:

1. Close the shut-off element in the suction line.
2. Close the 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.
CAUTION
Risk of freezing during prolonged pump shutdown periods
Damage to the pump!
▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect
them against freezing.
6.2 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature, 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

Observe the following parameters and values during operation:
Table 14: Permissible ambient temperatures
Permissible ambient temperature Temperature
Maximum 43 °C
Minimum See data sheet
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
▷ Observe the specified limits for permissible ambient temperatures.
36 of 76 RPH
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 15: 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
CAUTION
Re-starting while motor is still running down
Damage to the pump (set)!
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
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:
Qmax9) See characteristic curves.
Qmin10)= 0.3 × Qopt11)
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 differ from those of 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 16: Key

Symbol Description Unit
c Specific heat capacity J/kg K
g Gravitational constant m/s²
9) Maximum permissible flow rate

10) Minimum permissible flow rate
11) Best efficiency point
RPH 37 of 76
Symbol Description Unit

H Pump discharge head m
Tf Fluid temperature °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 pump input power changes 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.
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.
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 from the pipe and stored
✓ The pump has been properly drained (⇨ Section 7.3 Page 46) and the safety
instructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page
46)
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 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 and grease, food-approved if required) to protect them against
corrosion.
Also observe (⇨ 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 29) and the operating limits. (⇨ Section 6.2 Page 36)
38 of 76 RPH
In addition, carry out all servicing/maintenance operations before returning the

pump (set) to service. (⇨ Section 7 Page 40)
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.
RPH 39 of 76
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 at an explosion-proof pump (set) outside of
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, pump set and pump parts with a
minimum of servicing/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.
40 of 76 RPH
7.2 Maintenance/inspection
7.2.1 Supervision of operation
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 shaft seal
Explosion hazard!
Leakage of hot, toxic fluids!
Risk of burns!
Fire hazard!
▷ Regularly service the shaft seal.
DANGER
Incorrectly serviced barrier fluid system
Explosion hazard!
Fire hazard!
Leakage of hot and/or toxic fluids!
▷ Regularly service the barrier fluid system.
▷ 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.
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 36)
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.
▪ Check the shaft seal.
▪ Check the static seals for leakage.
RPH 41 of 76
▪ 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.
▪ Keep the stand-by pump warm.
Observe the following conditions to make sure stand-by pumps are operational
and kept warm:
– All cooling points are in operation.
– The permissible nozzle forces and moments are not exceeded.
– In extreme cases, contact the manufacturer.
▪ 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 bearing bracket).
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.
7.2.2.2 Checking the clearances gaps

For checking the clearances gaps remove impeller 230, if required. (⇨ Section 7.4.5
Page 47)
If the clearance is larger than permitted (see the following table), replace casing
wear ring 502.01/502.02 and/or impeller wear ring 503.01/503.02.
The clearances given refer to the diameter.
42 of 76 RPH
Table 17: Clearances between impeller and casing and/or between impeller and casing cover
Size Suction-side casing wear ring Discharge-side casing wear ring
Inner nominal Clearance Minimum Inner nominal Clearance Minimum
diameter (standard) clearance to diameter (standard) clearance to
(rounded) API 610 (rounded) API 610
[mm] [mm] [mm] [mm] [mm] [mm]
25-180 70 0,5-0,05 0,30 70 0,5-0,05 0,30
25-230 70 0,5-0,05 0,30 70 0,5-0,05 0,30
40-180 80 0,5-0,050 0,33 80 0,5-0,05 0,33
40-230 80 0,5-0,05 0,33 80 0,5-0,05 0,33
40-280 85 0,6-0,05 0,33 120 0,6-0,05 0,40
40-181 95 0,6-0,05 0,35 95 0,6-0,05 0,35
40-231 95 0,6-0,05 0,35 95 0,6-0,05 0,35
40-281 95 0,6-0,05 0,35 120 0,6-0,05 0,40
40-361 95 0,6-0,05 0,35 165 0,6-0,05 0,45
50-180 120 0,6-0,05 0,40 120 0,6-0,05 0,40
50-230 120 0,6-0,05 0,40 120 0,6-0,05 0,40
50-280 120 0,6-0,05 0,40 120 0,6-0,05 0,40
50-360 120 0,6-0,05 0,40 165 0,6-0,05 0,45
50-450 120 0,6-0,05 0,40 195 0,6-0,08 0,48
80-180 135 0,6-0,05 0,43 135 0,6-0,05 0,43
80-230 135 0,6-0,05 0,43 135 0,6-0,05 0,43
80-280 135 0,6-0,05 0,43 135 0,6-0,05 0,43
80-360 135 0,6-0,05 0,43 165 0,6-0,05 0,45
80-450 135 0,6-0,05 0,43 195 0,6-0,08 0,48
100-180 165 0,4-0,05 0,45 165 0,4-0,05 0,45
100-230 165 0,6-0,05 0,45 165 0,6-0,05 0,45
100-280 165 0,6-0,05 0,45 165 0,6-0,05 0,45
100-360 165 0,6-0,05 0,45 165 0,6-0,05 0,45
100-450 175 0,6-0,05 0,45 195 0,7-0,08 0,48
150-230 195 0,7-0,08 0,48 195 0,7-0,08 0,48
150-280 195 0,7-0,08 0,48 195 0,7-0,08 0,48
150-360 195 0,7-0,08 0,48 195 0,7-0,08 0,48
150-450 200 0,7-0,08 0,48 235 0,7-0,08 0,53
150-501 225 0,6-0,08 0,50 225 0,6-0,08 0,50
150-630 240 0,7-0,08 0,53 290 0,7-0,08 0,58
200-280 225 0,7-0,08 0,50 225 0,7-0,08 0,50
200-360 235 0,7-0,08 0,53 280 0,7-0,08 0,58
200-450 235 0,7-0,08 0,53 280 0,7-0,08 0,58
200-401 250 0,6-0,05 0,53 250 0,6-0,05 0,53
200-501 255 0,6-0,08 0,55 255 0,6-0,08 0,55
200-670 290 0,6-0,05 0,58 290 0,6-0,05 0,58
250-401 330 0,75-0,08 0,63 330 075-0,08 0,63
250-501 310 0,6-0,08 0,60 310 0,6-0,08 0,60
250-630 330 0,75-0,100 0,63 340 0,75-0,1 0,63
250-710 310 0,7-0,08 0,60 340 0,85-0,1 0,63
300-400 330 0,75-0,08 0,63 330 0,75-0,08 0,63
300-500 350 0,75-0,1 0,65 350 0,75-0,1 0,65
300-630 360 0,85-0,1 0,65 340 0,75-0,1 0,63
250-400A 380 0,85-0,1 0,68 340 0,85-0,1 0,63
350-400B 350 0,85-0,1 0,65 340 0,85-0,1 0,63
350-500 380 0,85-0,1 0,68 380 0,85-0,1 0,68
350-630 400 0,85-0,1 0,7 400 0,85-0,1 0,7
350-710 400 0,85-0,1 0,7 400 0,85-0,1 0,7
400-504 410 0,85-0,1 0,7 410 0,85-0,1 0,7
RPH 43 of 76
Size Suction-side casing wear ring Discharge-side casing wear ring

Inner nominal Clearance Minimum Inner nominal Clearance Minimum
diameter (standard) clearance to diameter (standard) clearance to
(rounded) API 610 (rounded) API 610
[mm] [mm] [mm] [mm] [mm] [mm]
400-506 440 0,85-0,1 0,73 440 0,85-0,1 0,73
400-710 440 0,85-0,1 0,73 500 0,85-0,1 0,80
7.2.2.3 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.
7.2.3 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 usually lubricated with mineral oil.
7.2.3.1.1 Intervals
Table 18: Oil change intervals
Temperature at the First oil change All subsequent oil
bearing changes12)
up to 70 ℃ After 300 operating hours Every 8500 operating hours
70 °C - 80 °C After 300 operating hours Every 4200 operating hours
80 °C - 90 °C After 300 operating hours Every 2000 operating hours
7.2.3.1.2 Oil quality

Table 19: Oil quality
Designation Symbol to DIN Properties
51502
CLP46 lubricating oil □ Kinematic viscosity 46±4 mm²/s
to DIN 51517 at 40 °C
or Flash point (to +175 ℃
HD 20W/20 SAE Cleveland)
12) At least once a year
44 of 76 RPH
Designation Symbol to DIN Properties

51502
Solidification point -15 ℃
(pour point)
Application Higher than
temperature13) permissible bearing
temperature
7.2.3.1.3 Oil quantity

Bearing bracket Oil quantity bearing bracket
[l]
B02 0.9
B03 1.8
B05 2.5
B06 5.7
B07 4.7
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. 13: 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.
13) For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.
RPH 45 of 76
7.3 Drainage/cleaning
WARNING
Fluids, consumables and supplies which are hot and/or pose a health hazard
▷ Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
If the pump set has handled fluids whose residues could lead to corrosion in the
presence of atmospheric humidity or could ignite upon contact with oxygen, the
pump set must be neutralised, and anhydrous inert gas must be blown through the
pump to ensure drying.
Use connection 6B to drain the fluid handled (see auxiliary connections).
7.4 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 Page 40)
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly refer to the general assembly drawing.
In the event of damage you can always contact our service staff.
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set. (⇨ Section 6.1.13 Page 35)
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 46)
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
46 of 76 RPH
7.4.2 Preparing the pump set

1. Interrupt the power supply and secure the pump against unintentional start-up.
2. Disconnect and remove all auxiliary pipework.
3. Remove the coupling guard.
4. Remove the coupling spacer, if any.
5. Drain the oil fill of oil-lubricated bearings.
7.4.3 Removing the motor
NOTE
On pump sets with spacer-type couplings, the back pull-out unit can be removed
while the motor remains bolted to the baseplate.
WARNING
Motor tipping over
▷ Suspend or support the motor to prevent it from tipping over.
1. Disconnect the motor from the power supply.
2. Unbolt the motor from the baseplate.
3. Shift the motor to separate it from the pump.
7.4.4 Removing the back pull-out unit

✓ At pump sets without spacer-type coupling, the motor has been removed.
WARNING
Back pull-out unit tipping over
▷ Suspend or support the bearing bracket at the pump end.
1. If required, suspend or support bearing bracket 330 to prevent it from tipping
over.
2. Remove hexagon nut 920.01 at volute casing 102.
3. Use forcing screws 901.30 to pull the back pull-out unit out of volute casing 102.
4. Remove and dispose of joint ring 411.10.
5. Place the back pull-out unit on a clean and level surface.
7.4.5 Removing the impeller
7.4.5.1 Loosening the impeller — for bearing brackets B02 to B05

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to (⇨ Section 7.4.4 Page
47) have been observed/carried out.
✓ The back pull-out unit has been placed in a clean and level assembly area.
1. Unscrew impeller nut 922.01 with threaded insert (right-hand thread).
For versions with auxiliary impeller: Unscrew auxiliary impeller 23-2 with the
threaded insert (right-hand thread).
2. Remove and dispose of joint ring 411.31, if any
3. Remove lock washer 931.02.
RPH 47 of 76
7.4.5.2 Loosening the impeller — for bearing brackets B06 and B07
1. Unscrew and remove impeller hub cap 260 (right-hand thread).
For versions with auxiliary impeller: Unscrew and remove impeller hub cap
260.01 (right-hand thread).
2. Remove and dispose of joint ring 411.31.
For versions with auxiliary impeller: Remove and dispose of joint ring 411.59.
3. Bend open lock washer 931.02.
4. Remove impeller screw 906 with lock washer 931.02 and disc 550.87.
For versions with auxiliary impeller: Pull auxiliary impeller 23-2 off the shaft.
Remove keys 940.03 from shaft 210. Remove and dispose of joint ring 411.31.
7.4.5.3 Removing the impeller — for all bearing bracket sizes

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to and (⇨ Section 7.4.5.2
Page 48) have been observed/carried out.
1. Remove impeller 230 with an impeller removal tool.
2. Place impeller 230 on a clean and level surface.
3. Remove keys 940.01 from shaft 210.
4. If throttling bush 542.02 is fitted, undo grub screws 904.38.
5. Remove throttling bush 542.02, if any.
7.4.6 Removing the cartridge seal

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 46) to (⇨ Section 7.4.5.3 Page
✓ The back pull-out unit is kept in a clean and level assembly area.
1. If assembling jigs are provided, loosen the hexagon head bolts for fitting the
assembling jigs.
2. Engage assembling jigs, if any, in the groove of shaft protecting sleeve 524.01
and re-tighten the hexagon head bolts.
3. Loosen hexagon head bolts 920.15 at casing cover 161.
4. Use forcing screws 901.31 to remove bearing bracket 330.
At the same time, pull shaft protecting sleeve 524.01 (if any) with complete
cartridge seal 433 off shaft 210.
5. Take care not to damage O-rings 412.01/.31, if any.
6. Undo hexagon nut 920.02 and remove seal cover 471.01 and/or the seal
cartridge.
Observe the seal installation drawing of the mechanical seal.
7.4.7 Dismantling the bearings

✓ The bearing bracket has been placed in a clean and level assembly area.
1. Undo the hexagon socket head cap screw in the coupling hub.
2. Pull the coupling half off the pump shaft with a puller.
3. Remove key 940.02.
4. Remove fan hood 882, fan hub 485.02 and fan wheel 831.02, if any.
5. Undo hexagon nut 920.02 and remove seal cover 471.01 and/or the seal
cartridge.
6. Undo grub screws 904.41/.42 and remove throwers 507.01/.02.
48 of 76 RPH
7. Undo hexagon socket head cap screws 914.01 and remove pump-end bearing
cover 360.01 as well as joint ring 400.01.
8. Undo hexagon head bolts 901.37 and remove motor-end bearing cover 360.02
as well as O-ring 412.22, if required.
9. Carefully drive shaft 210 together with angular contact ball bearing 320.02 and
the inner ring of cylindrical roller bearing 322.01, including oil thrower 508.01,
if any, out of the bearing bracket towards the drive end.
10. Remove cylindrical roller bearing 322.01 (roller cage) from bearing bracket 330.
11. If oil thrower 508.01 is fitted, remove grub screw 904.20 and pull the oil
thrower off the shaft.
12. Bend open lock washer 931.01 behind slotted round nut 920.21 on shaft 210.
13. Unscrew slotted round nut 920.21 (right-hand thread) and remove lock washer
931.01.
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.
14. 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.
7.5 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.
RPH 49 of 76
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.
7.5.2 Fitting the bearings

✓ 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.
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
rolling element bearing 322.01 to approximately 80 ℃ in an oil bath or by
means of an induction heater.
2. Guide angular contact ball bearing 320.02 onto shaft 210 as far as it will go.
3. Slide the inner ring of cylindrical roller bearing 322.01 onto shaft 210 as far as it
will go.
4. For bearing brackets B03 and B05 make sure that disc 550 is positioned
correctly.
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.
5. Use a C-spanner to tighten slotted round nut 920.21 (right-hand thread)
without lock washer 931.01.
6. Let angular contact ball bearing 320.01 cool down to approximately 5 °C above
ambient temperature.
7. Re-tighten slotted round nut 920.21, then unscrew it again.
8. Apply a few spots of a suitable lubricant (e.g. Molykote) to the contact faces of
lock washer 931.01 and slotted round nut 920.21.
9. Fit lock washer 931.01.
10. Tighten slotted round nut 920.21.
11. Bend back lock washer 931.01.
12. If provided, slide oil thrower 508.01 on shaft 210.
50 of 76 RPH
13. Screw grub screw 904.20 into oil thrower 508.01.

14. Guide cylindrical roller bearing 322.01 (roller cage) into bearing bracket 330.
15. Carefully insert shaft 210 together with angular contact ball bearing 320.02 and
the inner ring of cylindrical roller bearing 322.01, including oil thrower 508.01
(if any) into bearing bracket 330 towards the pump end.
16. Insert O-ring 412.22 into the groove of motor-end bearing cover 360.02.
17. Insert motor-end bearing cover 360.02 with O-ring 412.22 into bearing bracket
330 from the motor end.
18. Screw hexagon head bolts 901.37 with bearing cover 360.02 into bearing
bracket 330 from the motor end.
19. Fit pump-end bearing cover 360.01 with joint ring 400.01.
20. Screw socket head cap screws 914.01 into bearing bracket 330.
21. Slide thrower 507.01 onto shaft 210 from the pump end, leaving a 2 mm gap
between the thrower and pump-end bearing cover 360.01.
22. Screw grub screw 904.41 into pump-end thrower 507.01.
23. Slide thrower 507.02 onto shaft 210 from the motor end, leaving a 2 mm gap
between the thrower and motor-end bearing cover 360.02.
24. Screw grub screw 904.41 into motor-end thrower 507.02.
25. Fit fan hood 882, fan hub 485.02 and fan wheel 831.02, if any.
26. From the motor end, insert key 940.02 into the keyway at the shaft end.
27. Pull the coupling half onto the shaft end.
28. Screw the socket head cap screw into the coupling hub.
7.5.3 Fitting the shaft seal
7.5.3.1 Installing the cartridge seal

Always observe the following points when installing the cartridge seal:
▪ Install the cartridge seal as described in the seal installation drawing.
▪ Work cleanly and accurately.
▪ Prevent any damage to the sealing surfaces or O-rings.
1. Fit seal cover 471 and/or seal cartridge and tighten hexagon head bolts 920.02.
2. Guide casing cover 161 with cartridge seal 433 onto the shaft from the pump
end.
3. Carefully guide complete pre-assembled bearing bracket 330 over the studs
902.15 which have been screwed into casing cover 161.
4. On cooled versions, make sure not not damage O-rings 412.01/.31 at casing
cover 161.
5. Screw casing cover 161 to the complete bearing cover 330 with hexagon nuts
920.15.
7.5.4 Fitting the impeller
7.5.4.1 Fitting the impeller — for all bearing bracket sizes

✓ The pre-assembly (motor, shaft, bearing bracket, casing cover) has been placed in
a clean and level assembly area.
RPH 51 of 76
✓ All dismantled parts have been cleaned and checked for wear.
1. If applicable, guide throttling bush 542.02 onto impeller 230.
2. Screw grub screws 904.38 into throttling bush 542.02.
3. Slide joint ring 411.32, if any, onto shaft 210.
4. Place key 940.01 into the keyway of shaft 210.
5. Slide impeller 230 onto shaft 210.
Also see
● Fitting the shaft seal [⇨ 51]
7.5.4.2 Fastening the impeller — for bearing brackets B02 to B05

1. Insert lock washer 931.02.
2. Insert new joint ring 411.31, if applicable.
3. Screw impeller nut 922.01 with threaded insert (right-hand thread) onto shaft
210.
For versions with auxiliary impeller: Screw auxiliary impeller 23-2 with threaded
insert (right-hand thread) onto shaft 210.
Observe the tightening torques. (⇨ Section 7.6.1 Page 53)
4. Bend back the lock washer.
7.5.4.3 Fastening the impeller — for bearing brackets B06 and B07
1. Only for versions with auxiliary impeller: Insert keys 940.03 into shaft 210. Insert
a new joint ring 411.31 into impeller 210. Guide auxiliary impeller 23-2 onto the
shaft.
2. Insert disc 550.87 and lock washer 931.02.
3. Screw impeller screw 906 into shaft 210.
4. Observe the tightening torques. (⇨ Section 7.6.1 Page 53)
5. Bend back lock washer 931.02.
6. Insert new joint ring 411.31 into impeller 230.
For versions with auxiliary impeller: Place a new joint ring 411.59 on auxiliary
impeller 23-2. Screw impeller hub cap 260.01 onto auxiliary impeller 23-2.
7. Screw impeller hub cap 260 into impeller 230 (right-hand thread).
7.5.5 Installing the back pull-out unit
WARNING
Back pull-out unit tipping over
▷ Suspend or support the bearing bracket at the pump end.
51) (⇨ Section 7.5.4 Page 51) have been observed/carried out.
52 of 76 RPH

✓ For back pull-out units without coupling, fit the coupling in accordance with the
manufacturer's instructions.
1. If required, suspend or support the back pull-out unit to prevent it from tipping
over. Then slide it into volute casing 102 with a new gasket 411.10.
2. Tighten nut 920.01 at volute casing 102. Observe the tightening torques.
(⇨ Section 7.6.1 Page 53)
Also see
● Fastening the impeller — for bearing brackets B06 and B07 [⇨ 52]
7.5.6 Mounting the motor
NOTE
Steps 1 and 2 do not apply to versions with spacer-type coupling.
1. Shift the motor to connect it to the pump via the coupling.

2. Fasten the motor to the baseplate.
3. Align pump and motor.
4. 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

Use a torque wrench to tighten the screwed connections (902.01/920.01) between the
volute casing and the casing cover.
RPH 53 of 76
Table 20: Tightening torques of screwed connections

Material A 193 Grade B7/ A 193 Grade 10.9 -- CF6M/Type 316
(Asia and B16 / B7/B16
Americas) A 540 Grade B24
Material 1.7709/1.6772 C35E+QT 8.8 A4-70 1.4571/1.4021

(Europe) (Monix 3K)
Stud14) Stud14) 902.15 Hexagon head Stud14) 902.02 Impeller nut 922.01
bolt 901.37 or impeller screw 906
902.01
[Nm]Tightening torque15)16)
[Nm]Tightening torque15)
Bearing bracket
Quantity
Quantity
Quantity
Quantity
Quantity
Thread
Thread
Thread
Thread
Thread
Size
B02S 25-180 12 M 16 16318)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5 8020)

28019)
25-230 16 M 16 16318)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5 8020)
28019)
40-180 12 M 16 16318)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5 8020)
28019)
40-230 16 M 16 16318)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 14x1.5 8020)
28019)
B02L 40-181 12 M 16 16318)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5 13020)
28019)
40-231 16 M 16 16318)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5 13020)
28019)
40-280 16 M 20 33018)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5 13020)
56519)
40-281 16 M 20 33018)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5 13020)
56519)
40-361 20 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 16x1.5 13020)
56519)
50-180 12 M 16 16318)/ 4 M 16 83 4 M 10 45 4 M 16 133 1 M 16x1.5 13020)
28019)
B03 50-230 12 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
50-280 16 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
50-360 20 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
50-450 20 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 20x1.5 250 20)
97019)
80-180 12 M 16 16318)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
28019)
14) Stud to DIN 938/DIN 939 with hexagon nuts to ISO 4032.
15) These values are determined on the basis of a friction coefficient of μ = 0.12.
16) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.
17) Re-tighten impeller nut 922.01 or impeller screw 906 some 20 to 30 minutes after assembly. Bend back lock washer 931.02.
18) Values for 1.7709 / A 193 Grade B7/B16 /
19) Values for 1.6772 (Monix 3K) / A 540 Grade B24
20) Values for 1.4571 / A 276 Type 316Ti
54 of 76 RPH

Material 1.7709/1.6772 C35E+QT 8.8 A4-70 1.4571/1.4021

(Europe) (Monix 3K)
902.01
Bearing bracket
Quantity
Quantity
Quantity
Quantity
Quantity
Thread
Thread
Thread
Thread
Thread
Size
80-230 12 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)

56519)
80-280 16 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
80-360 20 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
100-180 12 M 16 16318)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
28019)
100-230 12 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
100-280 16 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
150-230 12 M 20 33018)/ 4 M 20 168 4 M 12 77 4 M 16 133 1 M 20x1.5 25020)
56519)
B05S 80-450 20 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5 35020)
97019)
150-280 12 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5 35020)
97019)
100-360 16 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5 35020)
97019)
100-450 20 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5 35020)
97019)
150-360 16 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5 35020)
97019)
200-280 12 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 24x1.5 35020)
97019)
B05L 150-450 20 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
97019)
150-501 30 M 16 16318)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
28019)
200-360 16 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
97019)
200-450 20 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
97019)
RPH 55 of 76

Material 1.7709/1.6772 C35E+QT 8.8 A4-70 1.4571/1.4021

(Europe) (Monix 3K)
902.01
Bearing bracket
Quantity
Quantity
Quantity
Quantity
Quantity
Thread
Thread
Thread
Thread
Thread
Size
200-401 24 M 16 16318)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)

28019)
200-501 24 M 20 33018)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
56519)
250-401 24 M 16 16318)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
28019)
250-501 24 M 20 33018)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
56519)
300-400 24 M 20 33018)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
56519)
300-500 24 M 20 33018)/ 4 M 24 290 4 M 16 190 4 M 16 133 1 M 30x1.5 60020)
56519)
B06 150-630 20 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
200-670 24 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
250-630 20 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
250-710 24 M 24 56518)/ 4 M 24 290 4 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
300-630 20 M 24 56518)/ 4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
350-400 16 M 24 56518)/ 4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
350-500 20 M 24 56518)/ 4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
350-630 20 M 24 56518)/ 4 M 24 290 8 M 16 190 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
B07 350-710 24 M 24 56518)/ 4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
400-504 20 M 24 56518)/ 4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
21) Values for 1.4021 / A 276 Type 420
56 of 76 RPH

Material 1.7709/1.6772 C35E+QT 8.8 A4-70 1.4571/1.4021

(Europe) (Monix 3K)
902.01
Bearing bracket
Quantity
Quantity
Quantity
Quantity
Quantity
Thread
Thread
Thread
Thread
Thread
Size
400-506 20 M 24 56518)/ 4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5 30020)/

97019) 40021)
400-710 24 M 24 56518)/ 4 M 24 290 10 M 12 77 4 M 20 270 1 M 30x1.5 30020)/
97019) 40021)
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. (⇨ Section 4.3 Page 16)
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 63)
RPH 57 of 76
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 21: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 10 and
more
210 Shaft 1 1 1 2 2 2 20 %
230 Impeller 1 1 1 2 2 2 20 %
23-2 Auxiliary impeller 1 1 1 2 2 2 20 %
320.02 Angular contact ball bearing 1 1 2 2 2 3 25 %
(set)
322.01 Cylindrical roller bearing 1 1 2 2 2 3 25 %
330 Bearing bracket - - - - - 1 2
502.01/.0222) Casing wear ring 2 2 2 3 3 4 50 %
503.01/.0222) Impeller wear ring 2 2 2 3 3 4 50 %
542.02 Throttling bush 1 1 2 2 2 3 30 %
- Sealing elements 4 6 8 8 9 10 100 %
433 Mechanical seal, complete 1 1 2 2 2 3 25 %
22) If any
58 of 76 RPH
7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.
Table 22: Interchangeability of pump components
Part description
Casing wear ring, discharge side
Impeller wear ring, suction side

Casing wear ring, suction side
Angular contact ball bearing
Bearing cover, motor end

Bearing cover, pump end
Cylindrical roller bearing
Impeller, discharge side

Casing cover, uncooled
Casing cover, cooled
Thrower, motor end

Thrower, pump end
Impeller hub cap
Bearing bracket
Mechanical seal
Throttling bush
Impeller screw
Volute casing
Impeller nut
Oil thrower
Seal cover
Joint ring
Impeller
Shaft
Bearing bracket
Pump size
Part No.
320.02
322.01
360.01
360.02
411.10
471.01
502.01
502.02
503.01
503.02
507.01
507.02
508.01
542.01
922.01
102
161
210
230
260
330
433
906
B02S 25-180 1 1 1 1 1 - 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 - 1
25-230 2 2 2 1 2 - 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 - 1
40-180 3 1 1 1 3 - 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 - 1
40-230 4 2 2 1 4 - 1 1 1 1 1 2 1 1 2 2 2 2 1 1 1 1 - 1
B02L 40-181 6 3 3 2 6 - 1 1 1 1 1 1 1 1 4 4 4 4 1 1 1 2 - 2
40-280 5 5 5 2 5 - 1 1 1 1 1 3 1 1 3 5 3 5 1 1 1 2 - 2
40-231 7 4 4 2 7 - 2 2 2 2 2 2 1 1 4 4 4 4 1 1 1 2 - 2
40-281 8 5 5 2 8 - 2 2 2 2 2 3 1 1 4 5 5 5 1 1 1 2 - 2
40-361 9 6 6 2 9 - 2 2 2 2 2 4 1 1 4 7 4 7 1 1 1 2 - 2
50-180 10 7 7 2 10 - 2 2 2 2 2 1 1 1 5 5 5 5 1 1 1 2 - 2
B03 50-230 11 8 8 3 11 - 2 2 2 2 2 2 2 2 5 5 5 5 2 2 2 3 - 3
50-280 12 9 9 3 12 - 2 2 2 2 2 3 2 2 5 5 5 5 2 2 2 3 - 3
50-360 13 10 10 3 13 - 2 2 2 2 2 4 2 2 5 7 5 7 2 2 2 3 - 3
50-450 14 11 11 3 14 - 2 2 2 2 2 5 2 2 5 9 5 9 2 2 2 3 - 3
80-180 15 12 12 3 15 - 2 2 2 2 2 2 2 2 6 6 6 6 2 2 2 3 - 3
80-230 16 12 12 3 16 - 2 2 2 2 2 2 2 2 6 6 6 6 2 2 2 3 - 3
80-280 17 9 9 3 17 - 2 2 2 2 2 3 2 2 6 6 6 6 2 2 2 3 - 3
80-360 18 13 13 3 18 - 2 2 2 2 2 4 2 2 6 7 6 7 2 2 2 3 - 3
100-180 19 15 15 3 19 - 2 2 2 2 2 5 2 2 7 7 7 7 2 2 2 3 - 3
100-230 20 16 16 3 20 - 2 2 2 2 2 5 2 2 7 7 7 7 2 2 2 3 - 3
100-280 21 17 17 3 21 - 2 2 2 2 2 3 2 2 7 7 7 7 2 2 2 3 - 3
150-230 22 20 20 3 22 - 2 2 2 2 2 2 2 2 9 9 9 9 2 2 2 3 - 3
B05S 80-450 23 14 14 4 23 - 3 3 3 3 3 5 3 3 6 6 6 6 3 3 3 4 - 4
100-360 24 18 18 4 24 - 3 3 3 3 3 4 3 3 7 7 7 7 3 3 3 4 - 4
100-450 25 19 19 4 25 - 3 3 3 3 3 5 3 3 8 8 8 8 3 3 3 4 - 4
150-280 26 21 21 4 26 - 3 3 3 3 3 3 3 3 9 9 9 9 3 3 3 4 - 4
150-360 27 22 22 4 27 - 3 3 3 3 3 4 3 3 9 9 9 9 3 3 3 4 - 4
200-280 28 24 24 4 28 - 3 3 3 3 3 5 3 3 11 11 11 11 3 3 3 4 - 4
B05L 150-450 29 23 23 5 29 - 3 3 3 4 3 5 3 3 10 12 10 12 3 3 3 5 - 5
150-501 32 27 27 5 32 - 3 3 3 3 3 6 3 3 11 11 11 11 3 3 3 5 - 5
200-360 30 25 25 5 30 - 3 3 3 4 3 4 3 3 12 13 12 13 3 3 3 5 - 5
200-401 33 28 28 5 33 - 3 3 3 3 3 7 3 3 14 14 14 14 3 3 3 5 - 5
200-450 31 26 26 5 31 - 3 3 3 4 3 5 3 3 12 13 12 13 3 3 3 5 - 5
200-501 34 29 29 5 34 - 3 3 3 3 3 6 3 3 15 15 15 15 3 3 3 5 - 5
250-401 35 30 30 5 35 - 3 3 3 3 3 7 3 3 16 16 16 16 3 3 3 5 - 5
250-501 36 31 31 5 36 - 3 3 3 3 3 6 3 3 17 17 17 17 3 3 3 5 - 5
300-400 41 36 36 5 41 - 3 3 3 3 3 7 3 3 21 22 21 22 3 3 3 5 - 5
300-500 42 37 37 5 42 - 3 3 3 3 3 8 3 3 25 26 25 26 3 3 3 5 - 5
B06 150-630 37 32 32 6 37 1 4 4 4 4 4 8 4 4 18 19 18 19 4 4 4 6 1 -
200-670 38 33 33 6 38 1 4 4 4 4 4 9 4 4 20 20 20 20 4 4 4 6 1 -
RPH 59 of 76
B07
Bearing bracket
60 of 76
400-710
400-506
400-504
350-710
350-630
350-500
350-400
300-630
250-710
250-630
Pump size
50
49
48
47
46
45
44
43
40
39
102 Volute casing
Part No.
37
38
38
37
36
38
37
36
35
34
Casing cover, uncooled
37
38
38
37
36
38
37
36
35
34
161 Casing cover, cooled
Part description
8
8
8
8
6
6
7
6
6
6
210 Shaft
RPH
50
49
48
47
46
45
44
43
40
39
230 Impeller
1
1
1
1
1
1
1
1
1
1
260 Impeller hub cap
5
5
5
5
4
4
4
4
4
4
320.02 Angular contact ball bearing
5
5
5
5
4
4
4
4
4
4
322.01 Cylindrical roller bearing
5
5
5
5
4
4
4
4
4
4 330 Bearing bracket
5
5
5
5
4
4
4
4
4
4
360.01 Bearing cover, pump end
5
5
5
5
4
4
4
4
4
4
360.02 Bearing cover, motor end
8
9
7
9
9
8
10
11
11
10
411.10 Joint ring
5
5
5
5
4
4
4
4
4
4
433 Mechanical seal
5
5
5
5
4
4
4
4
4
4
471.01 Seal cover

38
36
34
34
32
29
29
27
23
21
502.01 Casing wear ring, suction side

39
36
34
34
32
29
30
28
24
22
502.02 Casing wear ring, discharge side

37
37
35
35
33
27
27
27
23
21
503.01 Impeller wear ring, suction side

40
37
35
35
33
27
31
28
24
22
503.02 Impeller, discharge side

5
5
5
5
4
4
4
4
4
4
507.01 Thrower, pump end

5
5
5
5
4
4
4
4
4
4
507.02 Thrower, motor end

5
5
5
5
4
4
4
4
4
4
508.01 Oil thrower

7
7
7
7
6
6
6
6
6
6
542.01 Throttling bush

1
1
1
1
1
1
1
1
1
1
906 Impeller screw

-
-
-
-
-
-
-
-
-
-
922.01 Impeller nut

8 Trouble-shooting
8 Trouble-shooting
WARNING
Improper work to remedy faults at the pump (set)
Risk of injury!
▷ For any work to remedy faults at the pump (set) observe the relevant
information in this manual or in the relevant accessory manufacturer's
documentation.
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 23: Trouble-shooting
A B C D E F G H Possible cause Remedy23)
✘ Pump delivers against an excessively Re-adjust to duty point.
high pressure. Check system for impurities.
Fit a larger impeller.24)
Increase the 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.
✘ ✘ ✘ Suction lift is too high/NPSHavailable Check/alter fluid level.
(positive suction head) is too low. Install pump at a lower level.
Fully open the shut-off element in the suction
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.
✘ Air intake at the shaft seal. Clean barrier fluid duct, supply external
barrier fluid, if necessary, or increase barrier
fluid pressure.
Replace shaft seal.
✘ Wrong direction of rotation Check the electrical connection of the motor
and the control system, if any.
✘ Speed is too low.24)
- Operation with frequency inverter - Increase voltage/frequency at the frequency
- Operation without frequency inverter inverter in the permissible range.
- Check voltage.
✘ ✘ Impeller Replace worn components by new ones.
✘ ✘ Pump back pressure is lower than Re-adjust to duty point.
specified in the purchase order. In the case of persistent overloading, turn
down impeller.24)
✘ Density or viscosity of fluid handled Contact KSB.
higher than stated in purchase order
23) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
24) Contact KSB.
RPH 61 of 76
8 Trouble-shooting
A B C D E F G H Possible cause Remedy23)

✘ ✘ Speed is too high. Reduce speed.24)
✘ Defective gasket Fit new gasket between volute casing and
discharge cover.
✘ Worn shaft seal Fit new shaft seal.
Check flushing liquid/barrier fluid.
✘ Vibrations during pump operation Correct suction conditions.
Re-align the pump.
Re-balance the impeller.
Increase pressure at the pump suction nozzle.
✘ ✘ ✘ The pump set is misaligned. Re-align.
✘ ✘ ✘ 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.
✘ ✘ Insufficient or excessive quantity of Top up, reduce or change lubricant.
lubricant or unsuitable lubricant.
✘ Non-compliance with specified Correct distance according to general
coupling distance arrangement drawing.
✘ ✘ Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
✘ Rotor out of balance Clean the impeller.
Re-balance the impeller.
✘ Defective bearing(s) Fit new bearing(s).
✘ ✘ Flow rate is too low. Increase the minimum flow rate.
✘ Incorrect inflow of circulation liquid. Increase the free cross-section.
23) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
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9 Related Documents
9.1 General assembly drawing with list of components

411.67
931.02 916.16
922.01 502.01 411.31 904.07 904.38 920.01 904.41 914.01 360.01 642 931.01 412.22 904.42 831.02 904.37 210
503.01 102 904.04 940.01 902.01 411.32 330 400.01 913.03 69-10 920.21 901.37 485.02 940.02
720-12
638
a)
b) D01040/3
411.41 744.07
724.01 723.21
916.19
901.20 904.06 723.23 411.01 503.02 542.02 916.18 901.30 901.31 507.01 916.46 525.09 832 360.02 901.80
920.20 710.21 904.03 902.42 230 502.02 411.10 412.01 902.15 920.02 322.01 320.02 901.84 904.43 507.02
550.20 920.42 920.15 902.02 550 550.74
550.42 412.31
Fig. 14: Bearing brackets B02 to B05, a) uncooled and b) cooled
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260
550.87
906 916.16 931.01
931.02 502.01 411.31 904.07 904.38 920.01 161 904.41 914.01 360.01 642 169-10 412.22 904.42 831.02 904.37 210
503.01 102 904.04 940.01 902.01 411.32 330 400.01 913.03 638 920.21 901.37 485.02 940.02
a)
b) D01042/3
724.01 723.21
411.41 744.07
901.20 904.06 723.23 411.01 503.02 542.02 901.30 901.31 902.02 507.01 916.46 525.09 832 360.02 901.80
920.20 710.21 904.03 902.42 230 502.02 916.19 902.15 412.31 920.02 322.01 320.02 901.84 904.43 507.02
550.20 920.42 916.18 920.15 550.74
550.42 411.10 412.01
Fig. 15: Bearing brackets B06 and B07, a) uncooled and b) cooled
Table 24: List of components
Part No. Comprising Description
102 102 Volute casing
411.10 Joint ring
502.01 Casing wear ring
902.01 Stud
904.03 Grub screw
916.0125) Plug
920.01 Hexagon nut
161 161 Casing cover
411.10 Joint ring
412.01/.3126) O-ring
502.0233) Casing wear ring
901.30 Hexagon head bolt
902.15 Stud
904.0433) Grub screw
916.16 Plug
920.15 Hexagon nut
210 210 Shaft
920.21 Slotted round nut
931.01 Lock washer
940.01/.02 Key
230 230 Impeller
931.02 Lock washer
25) Not shown in drawing

26) For cooled design only
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503.01/.02 Impeller wear ring
904.06/.07 Grub screw
411.3127)/.3227)/.6727)28) Joint ring
26029) 260 Impeller hub cap
550.87 Disc
906 Impeller screw
320.02/55030) 320.0231) Angular contact ball bearing
55032) Adjusting washer
322.01 322.01 Cylindrical roller bearing
69.10 Protective cage
360.01/.02 Bearing cover
400.01 Gasket
412.22 O-ring
638 Constant level oiler
642 Oil level sight glass
710.21 Pipe
901.31/.37 Hexagon head bolt
913.03 Vent plug
916.46 Plug
914.01 Hexagon socket head cap screw
360.01/.02 360.01/.02 Bearing cover
400.01 Gasket
412.22 O-ring
502.01/.0233) 502.01/.02 Casing wear ring
904.03/.0433) Grub screw
503.01/.0233) 503.01/.02 Impeller wear ring
904.06/.0733) Grub screw
507.01/.02 507.01/.02 Thrower
542.02 542.02 Throttling bush
904.38 Grub screw
638 638 Constant level oiler
70-328) 70-3 Drain line
411.01 Joint ring
902.42 Stud
920.42 Hexagon nut
550.42 Disc
723.23 Flange
744.07 Gate valve
710.21 Pipe
723.21 Flange
411.41 Joint ring
724.01 Blind flange
920.20 Hexagon nut
550.20 Disc
831.0228) 831.02 Fan impeller
832 Fan hood
485.02 Fan hub
27) For bearing brackets B02 to B05 only

28) Optional
29) For bearing brackets B06 and B07 only
33) For impellers with balancing of axial thrust only
RPH 65 of 76
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904.37 Grub screw
922.0127) 922.01 Impeller nut
931.02 Lock washer
99-925) 99-925) Set of sealing elements, complete
9.1.1 Bearing brackets B02 to B05

411.67
931.02 916.16
922.01 502.01 411.31 904.07 904.38 920.01 904.41 914.01 360.01 642 931.01 412.22 904.42 831.02 904.37 210
503.01 102 904.04 940.01 902.01 411.32 330 400.01 913.03 69-10 920.21 901.37 485.02 940.02
720-12
638
a)
b) D01040/3
411.41 744.07
724.01 723.21
916.19
901.20 904.06 723.23 411.01 503.02 542.02 916.18 901.30 901.31 507.01 916.46 525.09 832 360.02 901.80
920.20 710.21 904.03 902.42 230 502.02 411.10 412.01 902.15 920.02 322.01 320.02 901.84 904.43 507.02
550.20 920.42 920.15 902.02 550 550.74
550.42 412.31
Fig. 16: Bearing brackets B02 to B05, a) uncooled and b) cooled

Table 25: List of components, bearing brackets B02 to B05
411.10 Joint ring
902.01 Stud
904.03 Grub screw
916.0134) Screw plug
920.01 Hexagon nut
411.10 Joint ring
412.01/.3135) O-ring
502.0233) Casing wear ring
902.15 Stud

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916.16 Screw plug
920.15 Hexagon nut
210 210 Shaft
931.01 Lock washer
940.01/.02 Key
230 230 Impeller
931.02 Lock washer
411.31/.32/.6736) Joint ring
320.02/55037) Angular contact ball bearing with disc 550 (adjusting washer)
400.01 Gasket
412.22 O-ring
710.21 Pipe
913.03 Vent plug
916.46 Screw plug
360.01/.02 360.01/.02 Bearing cover
400.01 Gasket
412.22 O-ring
502.01/.0238) 502.01/.02 Casing wear ring
904.03/.0433) Grub screw
503.01/.0233) 503.01/.02 Impeller wear ring
904.06/.0733) Grub screw
507.01/.02 507.01/.02 Thrower
904.38 Grub screw
70-328) 70-3 Drain line
411.01 Joint ring
902.42 Stud
920.42 Hexagon nut
550.42 Disc
723.23 Flange
744.07 Gate valve
710.21 Pipe
723.21 Flange
411.41 Joint ring
724.01 Blind flange
920.20 Hexagon nut
550.20 Disc
831.0228) 831.02 Fan impeller
832 Fan hood
485.02 Fan hub
904.37 Grub screw
36) Optional
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922.01 922.01 Impeller nut
9.1.2 Bearing brackets B06 and B07

260
550.87
906 916.16 931.01
931.02 502.01 411.31 904.07 904.38 920.01 161 904.41 914.01 360.01 642 169-10 412.22 904.42 831.02 904.37 210
503.01 102 904.04 940.01 902.01 411.32 330 400.01 913.03 638 920.21 901.37 485.02 940.02
a)
b) D01042/3
724.01 723.21
411.41 744.07
901.20 904.06 723.23 411.01 503.02 542.02 901.30 901.31 902.02 507.01 916.46 525.09 832 360.02 901.80
920.20 710.21 904.03 902.42 230 502.02 916.19 902.15 412.31 920.02 322.01 320.02 901.84 904.43 507.02
550.20 920.42 916.18 920.15 550.74
550.42 411.10 412.01
Fig. 17: Bearing brackets B06 and B07, a) uncooled and b) cooled
Table 26: List of components for pumps sets with bearing brackets B06 and B07
411.10 Joint ring
902.01 Stud
904.03 Grub screw
916.0139) Screw plug
920.01 Hexagon nut
411.10 Joint ring
412.01/.3140) O-ring
502.02 41) Casing wear ring
902.15 Stud
916.16 Screw plug

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920.15 Hexagon nut
210 210 Shaft
931.01 Lock washer
940.01/.02 Key
230 230 Impeller
411.31/.3242) Joint ring
260 260 Impeller hub cap
320.02 320.02 Angular contact ball bearing
400.01 Gasket
412.22 O-ring
710.21 Pipe
913.03 Vent plug
916.46 Screw plug
360.01/.02 33) 360.01/.0233) Bearing cover
400.01 Gasket
412.22 O-ring
502.01/.02 33) 502.01/.0233) Casing wear ring
904.03/.0441) Grub screw
503.01/.02 503.01/.02 Impeller wear ring
904.06/.0741) Grub screw
507.01/.02 507.01/.02 Thrower
904.38 Grub screw
550.87 550.87 Disc
70-342) 70-342) Drain line
411.01 Joint ring
902.42 Stud
920.42 Hexagon nut
550.42 Disc
723.23 Flange
744.07 Gate valve
710.21 Pipe
723.21 Flange
411.41 Joint ring
24.01 Blind flange
920.20 Hexagon nut
550.20 Disc
831.0242) 831.0242) Fan impeller
832 Fan hood
485.02 Fan hub
904.37 Grub screw
906 906 Impeller screw
42) Optional
RPH 69 of 76
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931.02 931.02 Lock washer
9.1.3 Design variants

Table 27: Design variants
Design Detailed view
Design with coolable bearing
bracket
D01044
Design with thrower
904.20 508.01 D01047
Design with plug

916.01
D01044
Design with welded drain
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Design Detailed view

Design with bearings in tandem
arrangement
D01043
320.02
Design with heatable casing
D01126
Design with auxiliary impeller
23-2
RPH 71 of 76
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:
RPH
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
▪ Applied national technical standards and specifications, in particular:
– DIN EN ISO 13709
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
..............................43).............................
Name
Function
Company
Address
43) A signed, legally binding declaration of conformity is supplied with the product.
72 of 76 RPH
11 Certificate of Decontamination
11 Certificate of Decontamination
Type: ................................................................................................................................
Order number/
Order item number44): ................................................................................................................................
Delivery date: ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled44): ................................................................................................................................
Please tick where applicable44):
⃞ ⃞ ⃞ ⃞
Radioactive Explosive Corrosive Toxic
⃞ ⃞ ⃞ ⃞
Harmful Bio-hazardous Highly flammable Safe
Reason for return44): ................................................................................................................................
Comments: ................................................................................................................................
................................................................................................................................
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We herewith declare that this product is free from hazardous chemicals, biological and 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
44) Required fields
RPH 73 of 76
Index
Index
A L
Abrasive fluids 38 List of components 64, 66, 68
Auxiliary connections 24
M
B Maintenance 40
Back pull-out unit 47 Mechanical seal 35
Bearing temperature 42 Misuse 9
Bearings 17 Monitoring equipment 11
C N
Certificate of decontamination 73 Name plate 16
Clearances 43 Noise characteristics 19
Commissioning/start-up 29
Constant level oiler 29
Coupling 42 O
Oil lubrication
Intervals 44
D Oil quality 44
Design 16, 18 Operating limits 8, 36
Designation 16 Order number 6
Direction of rotation 28 Ordering spare parts 57
Disassembly 46 Other applicable documents 6
Disposal 15
P
E Partly completed machinery 6
Explosion protection 10, 20, 24, 25, 26, 27, 32, 33, 34, Piping 22
36, 37, 40, 41, 42, 44 Preservation 14, 38
Priming and venting 32
Product description 16
F Pump casing 17
Filter 22, 44
Final check 32
Flow rate 37 R
Fluid handled Return to supplier 14
Density 38 Returning to service 39
Frequency of starts 37 Running noises 41, 42
Function 18
S
H Safety 8
Heating 34 Safety awareness 9
Heating speed 34 Scope of supply 19
Heating up 34 Shaft seal 17
Shutdown 35, 38
Start-up 35
I Storage 14, 38
Impeller type 17
Installation at site 20
Installation type T
Installation on a foundation 20 Temperature difference 34
Intended use 8 Temperature limits 11
Interchangeability of pump components 59 Tightening torques 53
Transport 13
Trouble-shooting 61
K
Keeping warm 34
74 of 76 RPH
Index
W
Water cooling 32
RPH 75 of 76
1316.8014/06-EN
KSB Aktiengesellschaft
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.com
Low voltage motors
Installation, operation, maintenance and safety manual
More languages – see web site www.abb.com/motors&generators > Motors > Document library
Low voltage motors
Installation, operation, maintenance and safety manual
Contents Page
1. Introduction..................................................................................................................................5
1.1 Declaration of Conformity.....................................................................................................5
1.2 Validity..................................................................................................................................5
2. Safety considerations..................................................................................................................5
3. Handling........................................................................................................................................6
3.1 Reception check...................................................................................................................6
3.2 Transportation and storage...................................................................................................6
3.3 Lifting...................................................................................................................................6
3.4 Motor weight........................................................................................................................6
4. Installation and commissioning..................................................................................................7
4.1 General.................................................................................................................................7
4.2 Motors with other than ball bearings.....................................................................................7
4.3 Insulation resistance check...................................................................................................7
4.4 Foundation...........................................................................................................................7
4.5 Balancing and fitting coupling halves and pulleys..................................................................7
4.6 Mounting and alignment of the motor...................................................................................8
4.7 Radial forces and belt drives.................................................................................................8
4.8 Motors with drain plugs for condensation.............................................................................8
4.9 Cabling and electrical connections........................................................................................8
4.9.1 Connections for different starting methods............................................................9
4.9.2 Connections of auxiliaries......................................................................................9
4.10 Terminals and direction of rotation........................................................................................9
5. Operation ...................................................................................................................................10
5.1 General...............................................................................................................................10
Low voltage motors manual, 3GZF500730-85 Rev F 02-2015 | ABB Motors and Generators 3
6. Low voltage motors in variable speed operation...................................................................11
6.1 Introduction........................................................................................................................11
6.2 Winding insulation...............................................................................................................11
6.2.1 Selection of winding insulation for ABB converters...............................................11
6.2.2 Selection of winding insulation with all other converters.......................................11
6.3 Thermal protection..............................................................................................................11
6.4 Bearing currents.................................................................................................................11
6.4.1 Elimination of bearing currents with ABB converters............................................11
6.4.2 Elimination of bearing currents with all other converters.......................................12
6.5 Cabling, grounding and EMC..............................................................................................12
6.6 Operating speed.................................................................................................................12
6.7 Motor in variable speed applications...................................................................................12
6.7.1 General...............................................................................................................12
6.7.2 Motor loadability with AC_8_ _ – series of converters with DTC control................12
6.7.3 Motor loadability with AC_5_ _ – series of converter............................................12
6.7.4 Motor loadability with other voltage source PWM-type converters.......................12
6.7.5 Short time overloads...........................................................................................13
6.8 Rating plates......................................................................................................................13
6.9 Commissioning the variable speed application....................................................................13
7. Maintenance...............................................................................................................................14
7.1 General inspection..............................................................................................................14
7.1.1 Standby motors...................................................................................................14
7.2 Lubrication.........................................................................................................................14
7.2.1 Motors with permanently greased bearings.........................................................14
7.2.2 Motors with regreasable bearings........................................................................15
7.2.3 Lubrication intervals and amounts.......................................................................15
7.2.4 Lubricants...........................................................................................................17
8. After Sales Support....................................................................................................................18
8.1 Spare parts.........................................................................................................................18
8.2 Dismantling, re-assembly and rewinding.............................................................................18
8.3 Bearings.............................................................................................................................18
9. Environmental requirements.....................................................................................................18
10. Troubleshooting.........................................................................................................................19
11. Figures........................................................................................................................................21
4 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev F 02-2015
1. Introduction 2. Safety considerations
The motor is intended for installation and use by qualified
NOTE!
personnel, familiar with health and safety requirements and
These instructions must be followed to ensure
national legislation.
safe and proper installation, operation and
maintenance of the motor. They should be brought Safety equipment necessary for the prevention of accidents
to the attention of anyone who installs, operates at the installation and operating site must be provided in
or maintains the motor or associated equipment. accordance with local regulations.
The motor is intended for installation and use by
qualified personnel, familiar with health and safety
requirements and national legislation. Ignoring these WARNING!
instructions may invalidate all applicable warranties. Emergency stop controls must be equipped with
restart lockouts. After emergency stop a new start
command can take effect only after the restart
1.1 Declaration of Conformity lockout has been intentionally reset.
The conformity of the end product according to Directive

2006/42/EC (Machinery) has to be established by the
commissioning party when the motor is fitted to the Points to be observed:
machinery. 1. Do not step on the motor.
2. The temperature of the outer casing of the motor
1.2 Validity may be hot to the touch during normal operation and
especially after shut-down.
These instructions are valid for the following ABB electrical 3. Some special motor applications may require additional
machine types, in both motor and generator operation: instructions (e.g. when supplied by frequency
converter).
series MT*, MXMA,
4. Observe rotating parts of the motor.
series M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*, 5. Do not open terminal boxes while energized.
M2V*/M3V*
in frame sizes 56 - 450.
There is a separate manual for e.g. Ex motors ‘Low voltage

motors for explosive atmospheres: Installation, operation
and maintenance and safety manual (3GZF500730-47)
Additional information is required for some machine types

due to special application and/or design considerations.
Additional manual is available for the following motors:

– roller table motors
– water cooled motors
– smoke extraction motors
– brake motors
– motors for high ambient temperatures
– motors in marine applications for mounting on open deck
of ships or offshore units
3. Handling Lifting eyebolts must be tightened before lifting. If needed,
the position of the eyebolt can be adjusted using suitable
washers as spacers.
3.1 Reception check
Ensure that proper lifting equipment is used and that the
Immediately upon receipt, check the motor for external sizes of the hooks are suitable for the lifting lugs.
damage (e.g. shaft-ends, flanges and painted surfaces)
and, if found, inform the forwarding agent without delay. Care must be taken not to damage auxiliary equipment and
cables connected to the motor.
Check all rating plate data, especially voltage and winding
connections (star or delta). The type of bearing is specified Remove eventual transport jigs fixing the motor to the
on the rating plate of all motors except the smallest frame pallet.
sizes.
Specific lifting instructions are available from ABB.
In the case of a variable speed drive application check
the maximum loadability allowed according to frequency
stamped on the motor’s second rating plate. WARNING!
During lifting, mounting or maintenance work, all
necessary safety considerations shall be in place
3.2 Transportation and storage and special attention to be taken that nobody will be
The motor should always be stored indoors (above subject to lifted load.
–20 °C), in dry, vibration-free and dust-free conditions.
During transportation, shocks, falls and humidity should
be avoided. In other conditions, please contact ABB. 3.4 Motor weight
Unprotected machined surfaces (shaft-ends and flanges) The total motor weight can vary within the same frame size
should be treated against corrosion. (center height) depending on different output, mounting
arrangement and auxiliaries.
It is recommended that shafts are rotated periodically by
hand to prevent grease migration. The following table shows estimated maximum weights
for machines in their basic versions as a function of frame
Anti-condensation heaters, if fitted, are recommended to material.
be used to avoid water condensing in the motor.
The actual weight of all ABB’s motors, except the smallest
The motor must not be subject to any external vibrations at frame sizes (56 and 63), is shown on the rating plate
standstill so as to avoid causing damage to the bearings.
Frame size Aluminum Cast iron Add.
Motors fitted with cylindrical-roller and/or angular contact for brake
bearings must be fitted with locking devices during Weight kg Weight kg
transport. 56 4.5 - -
63 6 - -
3.3 Lifting 71 8 13 5
80 14 20 8
All ABB motors above 25 kg are equipped with lifting lugs 90 20 30 10
or eyebolts. 100 32 40 16
112 36 50 20
Only the main lifting lugs or eyebolts of the motor should be
132 93 90 30
used for lifting the motor. They must not be used to lift the
160 149 130 30
motor when it is attached to other equipment.
180 162 190 45
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 200 245 275 55
fans) or terminal boxes must not be used for lifting the 225 300 360 75
motor. Because of different output, mounting arrangements 250 386 405 75
280 425 800 -
and auxiliary equipment, motors with the same frame may
315 - 1700 -
have a different center of gravity.
355 - 2700 -
Damaged lifting lugs must not be used. Check that 400 - 3500 -
eyebolts or integrated lifting lugs are undamaged before 450 - 4500 -
lifting.
If the motor is equipped with a separate fan, contact ABB
for the weight.
4. Installation and commissioning
WARNING! WARNING!
Disconnect and lock out before working on the To avoid risk of electrical shock, the motor frame
motor or the driven equipment. must be grounded and the windings should be
discharged against the frame immediately after each
measurement.
4.1 General
All rating plate values must be carefully checked to ensure If the reference resistance value is not attained, the
that the motor protection and connection will be properly winding is too damp and must be oven dried. The oven
done. temperature should be 90 °C for 12-16 hours followed by
105 °C for 6-8 hours.
4.2 Motors with other than If fitted drain hole plugs must be removed and closing
ball bearings valves must be opened during heating. After heating, make
sure the plugs are refitted. Even if the drain plugs are fitted,
Remove transport locking if employed. Turn the shaft of the it is recommended to disassemble the end shields and
motor by hand to check free rotation, if possible. terminal box covers for the drying process.
Windings drenched in seawater normally need to be

Motors equipped with roller bearings:
rewound.
Running the motor with no radial force applied to the shaft
may damage the roller bearing due to “sliding”, 4.4 Foundation
Motors equipped with angular contact bearing: The end user has full responsibility for preparation of the
foundation.
Running the motor with no axial force applied in the right
direction in relation to the shaft may damage the angular Metal foundations should be painted to avoid corrosion.
contact bearing.
Foundations must be even and sufficiently rigid to
withstand possible short circuit forces.
WARNING!
For motors with angular contact bearings the axial They must be designed and dimensioned to avoid the
force must not by any means change direction. transfer of vibration to the motor and vibration caused by
resonance. See figure below.
The type of bearing is specified on the rating plate.

Ruler
Motors equipped with regreasing nipples:

When starting the motor for the first time, or after long
storage, apply the specified quantity of grease. Note! Height difference shall
not exceed ± 0,1mm referred
See section “7.2.2 Motors with re-greasable bearings” for to any other motor foot
more details.
When fitted in a vertical position with the shaft pointing

downwards, the motor must have a protective cover
to prevent foreign objects and fluid from falling into the
ventilation openings. This task can also be achieved by Foot location
a separate cover not fixed to the motor. In this case, the
motor must have a warning label.
4.3 Insulation resistance check 4.5 Balancing and fitting

Measure insulation resistance before commissioning and
when winding dampness is suspected.
coupling halves and pulleys
As standard, balancing of the motor has been carried out
Insulation resistance, corrected to 25 °C, may not in any using half key.
cases be below 1 MΩ (measured with 500 or 1000 VDC).
The insulation resistance value is halved for each 20 °C Coupling halves or pulleys must be balanced after
increase in temperature. Figure 1 can be used for the machining the keyways. Balancing must be done in
insulation correction to the desired temperature. accordance with the balancing method specified for the
motor.
Coupling halves and pulleys must be fitted on the shaft by 4.8 Motors with drain plugs
using suitable equipment and tools which do not damage
the bearings and seals. for condensation
Never fit a coupling half or pulley by hammering or Check that drain holes and plugs face downwards. In
removing it by using a lever pressed against the body of the vertical position mounted motors, the drain plugs may be in
motor. horizontal position.
Motors with sealable plastic drain plugs are delivered in an

4.6 Mounting and alignment open position. In very dusty environments, all drain holes
should be closed.
of the motor
Ensure that there is enough space for free airflow around
the motor. It is recommended to have a clearance between
4.9 Cabling and electrical
the fan cover and the wall etc. of at least ½ of the air connections
intake of the fan cover. Additional information may be
found from the product catalog or from the dimension The terminal box on standard single speed motors normally
drawings available on our web pages: www.abb.com/ contains six winding terminals and at least one earth
motors&generators. terminal.
Correct alignment is essential to avoid bearing, vibration In addition to the main winding and earthing terminals, the
and possible shaft failures. terminal box can also contain connections for thermistors,
heating elements or other auxiliary devices.
Mount the motor on the foundation using the appropriate
bolts or studs and place shim plates between the Suitable cable lugs must be used for the connection of all
foundation and the feet. main cables. Cables for auxiliaries can be connected into
their terminal blocks as such.
Align the motor using appropriate methods.
Motors are intended for fixed installation only. Unless
If applicable, drill locating holes and fix the locating pins into otherwise specified, cable entry threads are metric. The IP
position. class of the cable gland must be at least the same as those
of the terminal boxes.
Mounting accuracy of coupling half: check that clearance
b is less than 0.05 mm and that the difference a1 to a2 is Certified conduit hub or cable connector has to be used at
also less than 0.05 mm. See figure 2. the time of installation.
Re-check the alignment after final tightening of the bolts or

studs. NOTE!
Cables should be mechanically protected and
Do not exceed permissible loading values for bearings as clamped close to the terminal box to fulfill the
stated in the product catalogs. appropriate requirements of IEC/EN 60079-0 and
local installation standards.
Check that the motor has sufficient airflow. Ensure that no
nearby objects or direct sunshine radiate additional heat to
the motor.
Unused cable entries must be closed with blanking
For flange mounted motors (e.g. B5, B35, V1), make sure elements according to the IP class of the terminal box.
that the construction allows sufficient air flow on the outer
surface of the flange. The degree of protection and diameter are specified in the
documents relating to the cable gland.
4.7 Radial forces and belt drives WARNING!

Belts must be tightened according to the instructions of the Use appropriate cable glands and seals in the cable
supplier of the driven equipment. However, do not exceed entries according to the type and diameter of the
the maximum belt forces (i.e. radial bearing loading) stated cable.
in the relevant product catalogs.
Earthing must be carried out according to local regulations

WARNING! before the motor is connected to the supply voltage.
Excessive belt tension will damage bearings and can
cause shaft damage. The earth terminal on the frame has to be connected to
PE (protective earth) with a cable as shown in Table 5 of
IEC/EN 60034-1:
Minimum cross-sectional area of protective Direct-on-line starting (DOL):
conductors Y or D winding connections may be used.
Cross-sectional area of phase Minimum cross-sectional area For example, 690 VY, 400 VD indicates Y-connection for
conductors of the installation, of the corresponding protective 690 V and D-connection for 400 V.
S, [mm2] conductor, SP, [mm2]
4 4 Star/Delta (Wye/Delta) starting (Y/D):
6 6
10 10
The supply voltage must be equal to the rated voltage of
16 16
the motor when using a D-connection.
25 25
Remove all connection links from the terminal block.
35 25
50 25 Other starting methods and severe starting
70 35 conditions:
95 50 In cases where other starting methods e.g. converter or
120 70 soft starter will be used in the duty types of S1 and S2, it
150 70 is considered that the device is “isolated from the power
185 95 system when the electrical machine is running” as in the
240 120 standard IEC 60079-0 and thermal protection is optional.
300 150
400 185
4.9.2 Connections of auxiliaries
In addition, earthing or bonding connection facilities on
the outside of electrical apparatus must provide effective If a motor is equipped with thermistors or other RTDs
connection of a conductor with a cross-sectional area of at (Pt100, thermal relays, etc.) and auxiliary devices, it is
least 4 mm2. recommended they be used and connected by appropriate
means. For certain applications, it is mandatory to use
The cable connection between the network and motor thermal protection. More detailed information can be found
terminals must meet the requirements stated in the in the documents delivered with the motor. Connection
national standards for installation or in the standard diagrams for auxiliary elements and connection parts can
IEC/EN 60204-1 according to the rated current indicated be found inside the terminal box.
on the rating plate.
The maximum measuring voltage for the thermistors is
2.5 V. The maximum measuring current for Pt100 is 5 mA.
NOTE!
Using a higher measuring voltage or current may cause
When the ambient temperature exceeds +50 °C,
errors in readings or a damaged temperature detector.
cables having permissible operating temperature
of +90 °C as minimum shall be used. Also all other The insulation of thermal sensors fulfills the requirements of
conversion factors depending on the installation basic insulation.
conditions shall be taken into account while sizing
the cables.
Ensure that the motor protection corresponds to the

4.10 Terminals and direction
environment and weather conditions. For example, make of rotation
sure that water cannot enter the motor or the terminal
boxes. The shaft rotates clockwise when viewing the shaft face at
the motor drive end, and the line phase sequence - L1, L2,
The seals of terminal boxes must be placed correctly in L3 - is connected to the terminals as shown in figure 3.
the slots provided to ensure the correct IP class. A leak
could lead to penetration of dust or water, creating a risk of To alter the direction of rotation, interchange any two
flashover to live elements. connections on the supply cables.
If the motor has a unidirectional fan, ensure that it rotates in

4.9.1 Connections for different starting the same direction as the arrow marked on the motor.
methods
The terminal box on standard single speed motors normally
contains six winding terminals and at least one earth
terminal. This enables the use of DOL- or Y/D –starting.
For two-speed and special motors, the supply connection

must follow the instructions inside the terminal box or in the
motor manual.
The voltage and connection are stamped on the rating

plate.
5. Operation
5.1 General
The motors are designed for the following conditions unless
otherwise stated on the rating plate:
– Motors are to be installed in fixed installations only.

– Normal ambient temperature range is from –20 °C to
+40 °C.
– Maximum altitude is 1000 m above sea level.
– The variation of the supply voltage and frequency may
not exceed the limits mentioned in relevant standards.
Tolerance for supply voltage is ±5 %, and for frequency
±2 % according to the figure 4 (EN / IEC 60034-1,
paragraph 7.3, Zone A). Both extreme values are not
supposed to occur at the same time.
The motor can only be used in applications for which

it is intended. The rated nominal values and operation
conditions are shown on the motor rating plates. In
addition, all requirements of this manual and other related
instructions and standards must be followed.
If these limits are exceeded, motor data and construction

data must be checked. Please contact ABB for further
information.
WARNING!
Ignoring any instructions or maintenance of the
apparatus may jeopardize safety and thus prevent
the use of the motor.
6. Low voltage motors in variable speed operation
6.1 Introduction 6.2.2 Selection of winding insulation with
all other converters
This part of the manual provides additional instructions for
motors used in frequency converter supplies. The motor The voltage stresses must be limited below accepted limits.
is intended to operate from a single frequency converter Please contact the system supplier to ensure the safety of
supply and not motors running in parallel from one the application. The influence of possible filters must be
frequency converter. Instructions given by the converter taken into account while dimensioning the motor.
manufacturer shall be followed.
Additional information may be required by ABB to decide

on the suitability for some motor types used in special
6.3 Thermal protection
applications or with special design modifications. Most of the motors covered by this manual are equipped
with PTC thermistors or other type of RTD’s in the stator
windings. It is recommended to connect those to the
6.2 Winding insulation frequency converter. Read more in chapter 4.9.2.
Variable speed drives create higher voltage stresses

than the sinusoidal supply on the winding of the motor.
Therefore, the winding insulation of the motor as well as
6.4 Bearing currents
the filter at the converter output must be dimensioned Insulated bearings or bearing constructions, common
according following instructions. mode filters and suitable cabling and grounding methods
must be used according to the following instructions and
6.2.1 Selection of winding insulation for using table 6.1.
ABB converters
6.4.1 Elimination of bearing currents with
In the case of ABB e.g. AC_8_ _-series and AC_5_ _-series
single drives with a diode supply unit (uncontrolled DC
ABB converters
voltage), the selection of winding insulation and filters can In case of ABB frequency converter e.g. AC_8_ _- and
be made according to table 6.1. AC_5_ _-series with a diode supply unit, the methods
according to table 6.1 must be used to avoid harmful
bearing currents in motors.
PN < 100 kW PN ≥ 100 kW or PN ≥ 350 kW or

IEC315 ≤ Frame size ≤ IEC355 IEC400 ≤ Frame size ≤ IEC450
UN ≤ 500 V Standard motor Standard motor Standard motor
+ Insulated N-bearing + Insulated N-bearing
+ Common mode filter
500V >UN ≤ 600V Standard motor Standard motor Standard motor
+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
OR + Insulated N-bearing + dU/dt –filter (reactor)
Reinforced insulation OR + Common mode filter
Reinforced insulation OR
+ Insulated N-bearing Reinforced insulation
+ Insulated N-bearing
500V >UN ≤ 600V Standard motor Standard motor Standard motor
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
600V >UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation

+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
+ Insulated N-bearing + dU/dt –filter (reactor)
600V >UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
Table 6.1 Selection of winding insulation for ABB converters
Please contact ABB for more information on resistor braking and converters with controlled supply units.
NOTE!
6.7 Motors in variable speed
Insulated bearings which have aluminum oxide applications
coated inner and/or outer bores or ceramic rolling
elements are recommended. Aluminum oxide
6.7.1 General
coatings shall also be treated with a sealant to
prevent dirt and humidity penetrating into the porous With ABB’s frequency converters, the motors can be
coating. For the exact type of bearing insulation, see dimensioned by using ABB’s DriveSize dimensioning
the motor’s rating plate. Changing the bearing type program. The tool is downloadable from the ABB website
or insulation method without ABB’s permission is (www.abb.com/motors&generators).
prohibited. For application supplied by other converters, the motors
must be dimensioned manually. For more information,
6.4.2 Elimination of bearing currents with please contact ABB.
all other converters The loadability curves (or load capacity curves) are based
The user is responsible for protecting the motor and driven on nominal supply voltage. Operation in under or over
equipment from harmful bearing currents. Instructions voltage conditions may influence on the performance of the
described in chapter 6.4.1 can be used as guideline, but application.
their effectiveness cannot be guaranteed in all cases.
6.7.2 Motor loadability with AC_8_ _ – series
6.5 Cabling, grounding and EMC of converters with DTC control
The loadability curves presented in Figures 5a - 5d are
To provide proper grounding and to ensure compliance
valid for ABB AC_8_ _-series converters with uncontrolled
with any applicable EMC requirements, motors above
DC-voltage and DTC-control. The figures show the
30 kW shall be cabled by shielded symmetrical cables and
approximate maximum continuous output torque of the
EMC glands, i.e. cable glands providing 360° bonding.
motors as a function of supply frequency. The output
Symmetrical and shielded cables are highly recommended torque is given as a percentage of the nominal torque of
also for smaller motors. Make the 360° grounding the motor. The values are indicative and exact values are
arrangement at all the cable entries as described in the available on request.
instructions for the glands. Twist the cable shields into
bundles and connect to the nearest ground terminal/bus
NOTE!
bar inside the terminal box, converter cabinet, etc.
The maximum speed of the motor and application
may not be exceeded!
NOTE!
Proper cable glands providing 360° bonding must
be used at all termination points such as motor, 6.7.3 Motor loadability with AC_5_ _ – series
converter, possible safety switch, etc. of converter
The loadability curves presented in Figures 6a - 6d are
valid for AC_5_ _ -series converters. The figures show
For motors of frame size IEC 280 and above, additional
the approximate maximum continuous output torque of
potential equalization between the motor frame and the
the motors as a function of supply frequency. The output
driven equipment is needed, unless both are mounted on
torque is given as a percentage of the nominal torque of
a common steel base. In this case, the high frequency
the motor. The values are indicative and exact values are
conductivity of the connection provided by the steel
available on request.
base should be checked by, for example, measuring the
potential difference between the components.
NOTE!
More information about grounding and cabling of variable
The maximum speed of the motor and application
speed drives can be found in the manual “Grounding and
may not be exceeded!
cabling of the drive system” (Code: 3AFY 61201998).
6.7.4 Motor loadability with other voltage

6.6 Operating speed source PWM-type converters
For speeds higher than the nominal speed stated on the For other converters, with uncontrolled DC voltage and
motor’s rating plate or in the respective product catalog, minimum switching frequency of 3 kHz (200…500 V), the
ensure that either the highest permissible rotational speed dimensioning instructions as mentioned in chapter 6.7.3
of the motor or the critical speed of the whole application is can be used as guidelines. However, it shall be noted that
not exceeded. the actual thermal loadability can also be lower. Please
contact the manufacturer of the converter or the system
supplier.
NOTE!
6.9 Commissioning the variable
The actual thermal loadability of a motor may be speed application
lower than shown by guideline curves.
The commissioning of the variable speed application must
6.7.5 Short time overloads be done according to the instructions of the frequency
converter and local laws and regulations. The requirements
ABB motors can usually be temporarily overloaded as well and limitations set by the application must also be taken
as used in intermittent duties. The most convenient method into account.
to dimension such applications is to use the DriveSize tool.
All parameters needed for setting the converter must be
6.8 Rating plates taken from the motor rating plates. The most often needed
parameters are:
The usage of ABB’s motors in variable speed applications
do not usually require additional rating plates. The – nominal voltage
parameters required for commissioning the converter – nominal current
can be found from the main rating plate. In some special – nominal frequency
applications, however, the motors can be equipped with – nominal speed
additional rating plates for variable speed applications. – nominal power
Those include the following information:
– speed range NOTE!

– power range In case of missing or inaccurate information, do not
– voltage and current range operate the motor before ensuring correct settings!
– type of torque (constant or quadratic)
– and converter type and required minimum switching
frequency. ABB recommends using all the suitable protective features
provided by the converter to improve the safety of the
application. Converters usually provide features such as
(names and availability of features depend on manufacturer
and model of the converter):
– minimum speed
– maximum speed
– acceleration and deceleration times
– maximum current
– maximum torque
– stall protection
7. Maintenance 2. The bearing must be greased while rotating the shaft
every year (to be reported). If the motor has been
provided with roller bearing at the driven end, the
WARNING! transport lock must be removed before rotating the
Voltage may be connected at standstill inside the shaft. The transport locking must be remounted in case
terminal box for heating elements or direct winding of transportation.
heating. 3. All vibrations must be avoided to prevent a bearing from
failing. All instructions in the motor instruction manual for
commissioning and maintenance have to be followed.
The warranty will not cover the winding and bearing
7.1 General inspection damages if these instructions have not been followed.
1. Inspect the motor at regular intervals, at least once a
year. The frequency of checks depends on, for example,
the humidity level of the ambient air and on the local 7.2 Lubrication
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.
2. Keep the motor clean and ensure free ventilation WARNING!
airflow. If the motor is used in a dusty environment, Beware of all rotating parts!
the ventilation system must be regularly checked and
cleaned.
3. Check the condition of shaft seals (e.g. V-ring or radial WARNING!
seal) and replace if necessary. Grease can cause skin irritation and eye
inflammation. Follow all safety precautions specified
4. Check the condition of connections and mounting and
by the manufacturer of the grease.
assembly bolts.
5. Check the bearing condition by listening for any unusual
noise, vibration measurement, bearing temperature, Bearing types are specified in the respective product
inspection of spent grease or SPM bearing monitoring. catalogs and on the rating plate of all motors, except
Pay special attention to bearings when their calculated smaller frame sizes.
rated life time is coming to an end.
Reliability is a vital issue for bearing lubrication intervals.
When signs of wear are noticed, dismantle the motor, ABB uses mainly the L1 -principle (i.e. that 99 % of the
check the parts and replace if necessary. When bearings motors are certain to make the life time) for lubrication.
are changed, replacement bearings must be of the same
type as those originally fitted. The shaft seals have to be
replaced with seals of the same quality and characteristics 7.2.1 Motors with permanently greased
as the originals when changing bearings. bearings
Bearings are usually permanently greased bearings of 1Z,
In the case of the IP 55 motor and when the motor
2Z, 2RS or equivalent.
has been delivered with a plug closed, it is advisable to
periodically open the drain plugs in order to ensure that As a guide, adequate lubrication for sizes up to 250 can
the way out for condensation is not blocked and allows be achieved for the following duration, according to L1.
condensation to escape from the motor. This operation For duties with higher ambient temperatures, please
must be done when the motor is at a standstill and has contact ABB. The informative formula to change the
been made safe to work on. L1 values roughly to L10 values: L10 = 2.0 x L1.
7.1.1 Standby motors

If the motor is in standby for a longer period of time on
a ship or in other vibrating environment the following
measures have to be taken:
1. The shaft must be rotated regularly every 2 weeks (to

be reported) by means of starting up of the system. In
case a start-up is not possible, for any reason, at least
the shaft has to be turned by hand in order to achieve
a different position once a week. Vibrations caused by
other vessel's equipment will cause bearing pitting which
should be minimized by regular operation/hand turning.
Duty hours for permanently greased bearings at ambient Regreasing while the motor is at a standstill
temperatures of 25 °C and 40 °C are: If it is not possible to re-grease the bearings while the
motors are running, lubrication can be carried out while the
Duty hours Duty hours motor is at a standstill.
Frame size Poles at 25° C at 40° C – In this case, use only half the amount of grease and then
56 2 52 000 33 000 run the motor for a few minutes at full speed.
56 4-8 65 000 41 000 – When the motor has stopped, apply the rest of the
63 2 49 000 31 000 specified amount of grease to the bearing.
63 4-8 63 000 40 000 – After 1-2 running hours, close the grease outlet plug or
71 2 67 000 42 000 closing valve, if fitted.
71 4-8 100 000 56 000 B. Automatic lubrication
80-90 2 100 000 65 000
80-90 4-8 100 000 96 000 The grease outlet plug must be removed permanently with
100-112 2 89 000 56 000 automatic lubrication or open closing valve, if fitted.
100-112 4-8 100 000 89 000
ABB recommends only the use of electromechanical
132 2 67 000 42 000
systems.
132 4-8 100 000 77 000
160 2 60 000 38 000 The amount of grease per lubrication interval stated in the
160 4-8 100 000 74 000 table should be multiplied by three if a central lubrication
180 2 55 000 34 000 system is used. When using a smaller automatic re-grease
180 4-8 100 000 70 000 unit (one or two cartridges per motor) the normal amount of
200 2 41 000 25 000 grease can be used.
200 4-8 95 000 60 000 When 2-pole motors are automatically re-greased, the note
225 2 36 000 23 000 concerning lubricant recommendations for 2-pole motors in
225 4-8 88 000 56 000 the Lubricants chapter should be followed.
250 2 31 000 20 000
250 4-8 80 000 50 000 The used grease should be suitable for automatic
lubrication. The automatic lubrication system deliverer and
Data is valid up to 60 Hz. the grease manufacturer’s recommendations should check.
7.2.2 Motors with regreasable bearings Calculation example of amount of grease for
automatic lubrication system
Lubrication information plate and general lubrication Central lubrication system: Motor IEC M3_P 315_ 4-pole in
advice 50 Hz network, re-lubrication interval according to Table is
If the motor is equipped with a lubrication information plate, 7600 h/55 g (DE) and 7600 h/40g (NDE):
follow the given values.
(DE) RLI = 55 g/7600h*3*24 = 0,52 g/day
Greasing intervals regarding mounting, ambient
temperature and rotational speed are defined on the (NDE) RLI = 40 g/7600*3*24 = 038 g/day
lubrication information plate.
Calculation example of amount of grease for single
During the first start or after a bearing lubrication a automation lubrication unit (cartridge)
temporary temperature rise may appear, approximately 10 (DE) RLI = 55 g/7600h*24 = 0,17 g/day
to 20 hours.
(NDE) RLI = 40 g/7600*24 = 0,13 g/day
Some motors may be equipped with a collector for old
grease. Follow the special instructions given for the RLI = Re-lubricaion interval, DE = Drive end, NDE = Non drive end
equipment.
A. Manual lubrication 7.2.3 Lubrication intervals and amounts

Regreasing while the motor is running Lubrication intervals for vertical motors are half of the values
– Remove grease outlet plug or open closing valve if fitted. shown in the table below.
– Be sure that the lubrication channel is open.
As a guide, adequate lubrication can be achieved for the
– Inject the specified amount of grease into the bearing.
following duration, according to L1. For duties with higher
– Let the motor run for 1-2 hours to ensure that all excess
ambient temperatures please contact ABB. The informative
grease is forced out of the bearing. Close the grease
formula to change the L1 values roughly to L10 values is L10
outlet plug or closing valve, if fitted.
= 2.0 x L1, with manual lubrication.
The lubrication intervals are based on a bearing operating

temperature of 80 °C (ambient temperature +25 °C).
Higher speed operation, e.g. in frequency converter
NOTE!
applications, or lower speed with heavy load will require
An increase in the ambient temperature raises the
shorter lubrication intervals.
temperature of the bearings correspondingly. The
interval values should be halved for a 15 °C increase
in bearing temperature and may be doubled for a WARNING!
15 °C decrease in bearing temperature. The maximum operating temperature of the grease
and bearings, +110 °C, must not be exceeded.
The designed maximum speed of the motor must
not be exceeded.
Amount
Frame 3600 3000 1800 1500 1000 500-900
of grease kW kW kW kW
size r/min r/min r/min r/min r/min r/min
g/bearing
Ball bearings, lubrication intervals in duty hours
112 10 all 10 000 13 000 all 18 000 21 000 all 2 5 000 all 28 000
132 15 all 9 000 11 000 all 17 000 19 000 all 23 000 all 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 all 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 all 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 all 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 all 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 all 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 all 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 all 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 all 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 all 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 all 7 000
2801) 60 all 2 000 3 500 - - - - - - -
2801) 60 - - - all 8 000 10 500 all 14 000 all 17 000
280 35 all 1 900 3 200 - - - -
280 40 - - all 7 800 9 600 all 13 900 all 15 000
315 35 all 1 900 3 200 - - - -
315 55 - - all 5 900 7 600 all 11 800 all 12 900
355 35 all 1 900 3 200 - - - -
355 70 - - all 4 000 5 600 all 9 600 all 10 700
400 40 all 1 500 2 700 - - - -
400 85 - - all 3 200 4 700 all 8 600 all 9 700
450 40 all 1 500 2 700 - - - -
450 95 - - all 2 500 3 900 all 7 700 all 8 700
Roller bearings, lubrication intervals in duty hours

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 all 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 all 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 all 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 all 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 all 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 all 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 all 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 all 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 all 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 all 3 500
2801) 60 all 1 000 1 750 - - - - - - -
2801) 70 - - - all 4 000 5 250 all 7 000 all 8 500
280 35 all 900 1 600 - - - -
280 40 - - all 4 000 5 300 all 7 000 all 8 500
315 35 all 900 1 600 - - - -
315 55 - - all 2 900 3 800 all 5 900 all 6 500
355 35 all 900 1 600 - - - -
355 70 - - all 2 000 2 800 all 4 800 all 5 400
400 40 all - 1 300 - - - -
400 85 - - all 1 600 2 400 all 4 300 all 4 800
450 40 all - 1 300 - - - -
450 95 - - all 1 300 2 000 all 3 800 all 4 400
1)
M3AA
7.2.4 Lubricants The following greases can be used for high speed cast iron
motors but not mixed with lithium complex greases:
WARNING! - Klüber Klüber Quiet BQH 72-102 (polyurea base)

Do not mix different types of grease. - Lubcon Turmogrease PU703 (polyurea base)
Incompatible lubricants may cause bearing damage.
If other lubricants are used, check with the manufacturer
that the qualities correspond to those of the above
When re-greasing, use only special ball bearing grease with mentioned lubricants. The lubrication intervals are based
the following properties: on the listed high performance greases above. Using other
greases can reduce the interval.
– good quality grease with lithium complex soap and with
mineral- or PAO-oil
– base oil viscosity 100-160 cST at 40 °C
– consistency NLGI grade 1.5 - 3 *)
– temperature range –30 °C - +120 °C, continuously
*) A stiffer end of scale is recommended for vertical

mounted motors or in hot conditions.
The above mentioned grease specification is valid if the

ambient temperature is above –30 °C or below +55 °C,
and the bearing temperature is below 110 °C; otherwise,
consult ABB regarding suitable grease.
Grease with the correct properties is available from all major

lubricant manufacturers.
Admixtures are recommended, but a written guarantee

must be obtained from the lubricant manufacturer,
especially concerning EP admixtures, that admixtures do
not damage bearings or the properties of lubricants at the
operating temperature range.
WARNING!
Lubricants containing EP admixtures are not
recommended in high bearing temperatures in frame
sizes 280 to 450.
The following high performance greases can be used:

– Mobil Unirex N2 or N3 (lithium complex base)
– Mobil Mobilith SHC 100 (lithium complex base)
– Shell Gadus S5 V 100 2 (lithium complex base)
– Klüber Klüberplex BEM 41-132 (special lithium base)
– FAG Arcanol TEMP110 (lithium complex base)
– Lubcon Turmogrease L 802 EP PLUS
(special lithium base)
– Total Multiplex S2 A (lithium complex base)
– Rhenus Rhenus LKZ 2 (lithium complex base)
NOTE!
Always use high speed grease for high speed 2-pole
motors where the speed factor is higher than
480,000 (calculated as Dm x n where Dm = average
bearing diameter, mm; n = rotational speed, r/min).
8. After Sales Support 9. Environmental
requirements
8.1 Spare parts
Most of ABB’s motors have a sound pressure level not
Unless otherwise stated, spare parts must be original parts
exceeding 82 dB (A) (± 3 dB) at 50 Hz.
or approved by ABB.
Values for specific motors can be found in the relevant
When ordering spare parts, the motor serial number, full
product catalogs. At 60 Hz sinusoidal supply, the values are
type designation and product code, as stated on the rating
approximately 4 dB(A) higher compared to 50 Hz values
plate, must be specified.
stated in the product catalogs.
For sound pressure levels at frequency converter supplies,

8.2 Dismantling, re-assembly please contact ABB.
and rewinding When motor(s) need to be scrapped or recycled,
Rewinding should always be carried out by qualified repair appropriate means, local regulations and laws must be
shops. followed.
Smoke venting and other special motors should not be

rewound without first contacting ABB.
8.3 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by heating

or using special tools.
Bearing replacement is described in detail in a separate

instruction leaflet available from the ABB Sales Office.
Any directions placed on the motor, such as labels, must

be followed. The bearing types indicated on the rating plate
must not be changed.
NOTE!
Any repair by the end user, unless expressly
approved by the manufacturer, releases the
manufacturer from responsibility to conformity.
10. Troubleshooting
These instructions do not cover all details or variations
in equipment nor provide information for every possible
condition to be met in connection with installation,
operation or maintenance. Should additional information be
required, please contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be
handled by qualified persons who have the proper tools
and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor rating plate
and load factor.
Improper line connections Check connections against diagram supplied with motor.
Open circuit in winding or Indicated by humming sound when switch is closed. Check for loose
control switch wiring connections and ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator
Poor stator coil connection Indicated by blown fuses. Motor must be rewound.
Remove end shields and locate fault.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check connection.
Open circuit Fuses blown. Check overload relay, stator and push buttons.
Motor runs and Power failure Check for loose connections to line, fuses and control.
then dies down
Motor does not Not applied properly Consult equipment supplier for proper type.
accelerate up to Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce load.
nominal speed because of line drop Check connections. Check conductors for proper size.
Starting load too high Check the motor’s starts against “no load”.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as
repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
TROUBLE CAUSE WHAT TO DO
Motor takes too Excessive load Reduce load.
long to accelerate Low voltage during start Check for high resistance. Make sure that an adequate cable size
and/or draws high is used.
current
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
direction
Motor overheats Overload Reduce load.
while running Frame or ventilation openings may be Open vent holes and check for a continuous stream of air
full of dirt and prevent proper ventilation from the motor.
of motor
Motor may have one phase open Check to make sure that all leads and cables are well connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor
Balancing weights shifted Rebalance rotor.
Contradiction between balancing of Rebalance coupling or rotor.
rotor and coupling (half key - full key)
Poly phase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft Move pulley closer to motor bearing.
shoulder
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in kerosene and
contaminated replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.
11. Figures
100
Key
50
X-axis: Winding temperature, Celsius Degrees
Y-axis: Insulation Resistance Temperature Coefficient,

ktc
10 1) To correct observed insulation resistance, Ri,
to 40 °C multiply it by the temperature coefficient
5 ktc. Ri 40 °C = Ri x
1.0
0.5
1)
0.1
0.05
-10 0 10 20 30 40 50 60 70 80 90 100
Figure 1. Diagram illustrating the insulation resistance dependence from the temperature and how to correct the
measured insulation resistance to the temperature of 40 °C.
a1 b
a2
Figure 2. Mounting of half-coupling or pulley
Figure 3. Connection of terminals for main supply
Y
1.10
Key
X axis frequency p.u.
Y axis voltage p.u.
1.05 1 zone A
2 zone B (outside zone A)
1.03 3 rating point
1
3
1.09
X
0.95 0.98 1.00 1.02
2
0.93
0.95
0.90
Figure 4. Voltage and frequency deviation in zones A and B
Guideline loadability curves with converters with DTC control
Figure 5a. Conventer with DTC control, 50 Hz, Figure 5b. Conventer with DTC control, 60 Hz,
temperature rise B temperature rise B
Figure 5c. Conventer with DTC control, 50 Hz, Figure 5d. Conventer with DTC control, 60 Hz,
temperature rise F temperature rise F
Guideline loadability curves with other voltage source PWM type
Figure 6a. Other voltage source PWM type converter, Figure 6b. Other voltage source PWM type converter,
50 Hz, temperature rise B 60 Hz, temperature rise B
Figure 6c. Other voltage source PWM type converter, 50 Figure 6d. Other voltage source PWM type converter,
Hz, temperature rise F 60 Hz, temperature rise F
Contact us
3GZF500730-85 Rev F EN 02-2015

www.abb.com/motors&generators We reserve the right to make technical changes or modify the
contents of this document without prior notice. With regard to
purchase orders, the agreed particulars shall prevail. ABB does not
accept any responsibility what so ever
for potential errors or possible lack of information in this document.
We reserve all rights in this document and in the subject matter and
illustrations contained herein. Any reproduction,disclosure to third
parties or utilization of its contents – in whole or in parts – is forbidden
without prior written consent of ABB.
© Copyright 2015 ABB.

All rights reserved.
Monitoring System
Resistance Thermometer
PT100
CPKN, CPKNO, CPKN-CHs
HPK, HPK-L
MegaCPK
RPH
Supplementary Operating
Manual
9973172559/000100
P-1001/1002
Supplementary Operating Manual Resistance Thermometer PT100

Contents
Contents
1 Supplementary Operating Manual ......................................................4

1.1 General .............................................................................................................. 4
1.2 Technical data ................................................................................................... 4
1.3 Scope of supply ................................................................................................. 4
1.4 Function ............................................................................................................ 5
1.5 Installing the PT100 resistance thermometer in the pump ............................ 5
1.6 Connections ......................................................................................................6
1.7 Electrical connection ........................................................................................ 7
Resistance Thermometer PT100 3 of 8

1 Supplementary Operating Manual
1.1 General
This supplementary operating manual accompanies the operating/installation
manual. All information contained in the operating/installation manual must be
observed.
Table 1: Relevant operating manuals
Type series Reference number of the operating/installation
manual
CPKN 2730.8, 2713.813, 2730.89
CPKN-CHs 2730.84
CPKNO 2730.88
HPK 1121.8, 1121.817
HPK-L 1136.8
MegaCPK 2731.8
RPH 1316.8014
1.2 Technical data

Table 2: Technical data (TR55)
Characteristic Value
Sensor type PT100 resistance thermometer
Permissible measuring range (input -50 ... +450 °C
signal)
Output signal 80 to 268 Ohm
Head transmitter Without
Type TR 55
Sensor tolerance Class B to IEC 60751
Sealing, sensor tip/support tube Not pressure-proof
Sensor tip Spring-loaded (spring travel approx. 3 to
4 mm)
Wiring 1×4-wire
Process connection G1/4 B (for RPH: G1/2 B) / Clamping ring
Permissible ambient temperature T3/ T4: -40 ... +100 °C
T5: -40 ... +95 °C
T6: -40 ... +80 °C
Nominal length, depending on overall 75, 85 and 125 mm
length
Table 3: Technical data of connection head (TR55)
Design, head JS
Enclosure, head IP54
Material Aluminium
Cable connection M16×1.5
Table 4: Characteristic values for explosion protection (TR 55)
Explosion protection, intrinsic safety Ex ib IIC T6
CE conformity marking TÜV 10ATEX 555793 X
Maximum supply current li = 550 mA
Maximum supply power PmaxSensor = 500 mW
Maximum supply voltage Ui = 30 V
1.3 Scope of supply

The following items are included in the scope of supply:
4 of 8 Resistance Thermometer PT100

▪ PT100 resistance thermometer (various installation lengths)

▪ Compression fitting G1/4 B or G1/2 B
1.4 Function
Resistance thermometers are temperature sensors that measure the change in
electrical resistance of metals with changing temperature. Resistance thermometers
use a very thin layer of platinum film on a ceramic substrate. The nominal resistance
of these measuring elements at 0 °C is 100 ohms.
Interpretation of readings
The nominal resistance of the PT100 resistance thermometer at 0 °C is 100 ohms.
Equation for calculating the resistance value at any temperature (T):
Temperature range: T = 0 - 850 °C
R (T) = 100+0.39083×T -5.775×10-5×T2
Sample calculation:
T = 80 °C Measured temperature: T = 80 °C
R (T) = 100+0.39083×80 -5.775×10-5×802

R (T) = 130.8968 Ω
The PT100 resistance thermometer has a resistance of approximately 130.9 ohms at a
temperature of 80 °C.
T = 20 °C Measured temperature: T = 20 °C
R (T) = 100+0.39083×20 -5.775×10-5×202

R (T) = 107.7935 Ω
The PT100 resistance thermometer has a resistance of approximately 107.8 ohms at a
temperature of 20 °C.
1.5 Installing the PT100 resistance thermometer in the pump

1. Remove the screw plug from the 4M.3 connection (⇨ Section 1.6 Page 6) .
2. Screw the compression fitting up to the stop.
3. Insert the PT100 resistance thermometer into the fitting up to the stop, i.e. until
the tip of the PT100 thermometer touches the measurement surface.
4. Turn the connection head of the PT100 resistance thermometer to the required
position.
5. Pull the PT100 resistance thermometer back by approximately 1 to 2 mm.
6. Tighten the compression fitting to prevent the PT100 resistance thermometer
from loosening and rotating.

1.6 Connections
M16x1,5
SW17
SW19 (G 1/4)
SW27 (G 1/2)
Fig. 1: PT100 resistance thermometer (TR 55) connections
Fig. 2: Connections on MegaCPK
Fig. 3: Connections on CPKN, HPK: UP02/ P02as bearing bracket
Fig. 4: Connections on CPKN, HPK: UP03-UP06/P03s-P06s bearing bracket
6 of 8 Resistance Thermometer PT100

Fig. 5: Connections on HPK-L
Fig. 6: Connections on RPH

Table 5: Technical data, connections
Part No. Application Measuring point Connection
CPKN HPK, RPH
MegaCPK HPK-L
692.01 Temperature Bearing, pump end G 1/4 G 1/4 G1/2
measurement, PT100
resistance thermometer
692.02 Temperature Bearing, drive end G 1/4 G 1/4 G1/2
measurement, PT100
692.03 Temperature Mechanical seal chamber G 1/4 G 1/4 G1/2
measurement, PT100 (water temperature sensor)
1.7 Electrical connection

When temperature is measured by a resistance thermometer, the measurement result
is affected by the connection lead resistance.
Four-wire system A four-wire system provides the most accurate measurement because temperature
and connection lead resistance effects are eliminated.
Red
Red
Red
ϑ
ϑ
White
White
White
Fig. 7: Terminal assignment of four-wire system

1070.806/04-EN (01325177)
P.O. Box 1361 • 91253 Pegnitz • Bahnhofplatz 1, 91257 Pegnitz (Germany)
Tel. +49 9241 71-0 • Fax +49 9241 71-1793
www.ksb.com
Shock Pulse Measurement
CPKN, CPKNO, CPKN-CHs
HPK, HPK-L
KWP
MegaCPK
RPH
Supplementary Operating
Manual
9973172559/000100
P-1001/1002
Supplementary Operating Manual Shock Pulse Measurement

Contents
Contents
1 Supplementary Operating Manual ......................................................4

1.1 General .............................................................................................................. 4
1.2 Function ............................................................................................................ 4
1.3 Fitting measuring nipples ................................................................................ 4
1.4 Mounting the shock pulse meter .................................................................... 4
1.5 Connections ...................................................................................................... 5
1.6 Measuring nipple .............................................................................................. 6
Shock Pulse Measurement 3 of 8

1.1 General
This supplementary operating manual accompanies the installation/ operating
manual. All information contained in the installation/ operating manual must be
observed.
Table 1: Relevant operating manuals
Type series Reference number of the installation/operating
manual
CPKN 2730.8, 2713.813, 2730.89
CPKN-CHs 2730.84
CPKNO 2730.88
HPK 1121.8, 1121.817
HPK-L 1136.8
KWP 2361.8, 2361.81
MegaCPK 2731.8
RPH 1316.8014
1.2 Function
Principle The shock pulse method is based on the knowledge that a shock, i.e. a mechanical
impact, causes particles to accelerate at the point of impact. In turn, the accelerated
particles give rise to a pressure wave whose propagation during the initial stages is
only defined by the impact speed.
Starting from the point of impact, the pressure wave spreads through the material to
the transducer where it produces a dampened oscillation at the transducer’s resonant
frequency. The signal processed in the transducer is transformed within the
measuring circuit in such a way that the result is an indirect impact speed.
Use and purpose Shock pulse measurement primarily serves the purpose of preventive maintenance of
rolling element bearings. Regular measurements are used to monitor the installation,
operating conditions (lubrication, loads, etc.) and the development of the lifetime
expectancy (wear rate) of the bearings. These aim at making the best possible use of
the actual service life of the bearings and at determining when it is time to replace
the bearings to prevent an untimely breakdown.
A reduction in the number of bearing failures as well as in the costs and downtimes
caused by such failures are the beneficial effects of regular monitoring.
1.3 Fitting measuring nipples

Unless expressly ordered otherwise, only the two threaded holes, through which the
measuring nipples pass, are drilled in the bearing bracket. Each threaded hole is
drilled as close as possible to the rolling element bearing to be measured and, if
possible, in one plane with the raceway.
If the measuring nipples are not screwed into the provided holes, proceed as follows:
1. Remove the plug of the drilled hole.
2. Screw the measuring nipples into the respective holes.
3. Put the protective caps on the measuring nipples.
1.4 Mounting the shock pulse meter

1. Remove the protective caps from the measuring nipples.
2. Connect the shock pulse meter.
Make sure that the distance between the coupling and the meter is sufficient
during measuring.
3. Put the protective caps on the measuring nipples if necessary.
4 of 8 Shock Pulse Measurement

1.5 Connections
Fig. 1: Connections on MegaCPK
720.49
720.48
720.48 720.49
Fig. 2: Connections on CPKN, HPK
Fig. 3: Connections on HPK-L
Fig. 4: Connections on RPH

Fig. 5: Connections on KWP, bearing brackets P03ax to P12sx
Fig. 6: Connections on KWP, bearing brackets P16ax to P20sx

Table 2: Technical data, connections
Part No. Use Measuring point Connection
CPKN, HPK, HPK-L, RPH
KWP, MegaCPK
720.48 Shock pulse Pump-end bearing M8 -
measurement
720.49 Shock pulse Drive-end bearing M8 M8 for countersinking Ø
measurement 30 mm
1.6 Measuring nipple

Suitable measuring nipples can be delivered on request.
Table 3: Technical data, measuring nipple1)
Feature Value
Thread M8
Material Steel, zinc-electroplated (ST GAL ZN)
Length 24 mm
1) Measuring nipple to KSB works standard ZN407
6 of 8 Shock Pulse Measurement

60°
SW 17
4,2
8,5
O16
11
M8
O11
Fig. 7: Measuring nipple dimensions
90°
O 12
3max.
13min.
a) b)
M8
Fig. 8: Threaded hole for a) measuring nipple, b) vibration sensor to API 610

1070.807/05-EN (01325148)
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.com

Binder 1001-1002

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Process Pump

Original operating manual

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft, Frankenthal 20.01.2014

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

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

5 Installation at Site ...............................................................................20

5.5 Enclosure/insulation .......................................................................................24

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

10 EC Declaration of Conformity ............................................................72

11 Certificate of Decontamination .........................................................73

Back pull-out design Hydraulic system

Discharge line Suction lift line/suction head line

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.

2.4 Personnel qualification and training

2.5 Consequences and risks caused by non-compliance with this manual

2.6 Safety awareness

2.7 Safety information for the operator/user

2.8 Safety information for maintenance, inspection and installation work

2.9 Unauthorised modes of operation

2.10 Explosion protection

2.10.2 Temperature limits

2.10.3 Monitoring equipment

2) Depending on the material variant

Contact KSB for further information on monitoring equipment.

2.10.4 Operating limits

3.1 Checking the condition upon delivery

Fig. 1: Transporting the back pull-out unit

Fig. 2: Transporting the pump

Fig. 3: Transporting the complete pump set

Fig. 4: Transporting the pump on the baseplate

3.4 Return to supplier

4 Description of the Pump (Set)

4.1 General description

4.3 Name plate

4.4 Design details

Bearings used Table 7: Bearing design

4.5 Configuration and function

1 Clearance gap 2 Discharge nozzle

4.6 Noise characteristics

Rated Pump Pump set

4.7 Scope of supply

4.8 Dimensions and weights

5.1 Safety regulations

5.2 Checks to be carried out prior to installation

5.3 Installing the pump set

5.3.1 Installation on a foundation

5.4.1 Connecting the piping

5.4.2 Permissible forces and moments at the pump nozzles

Fig. 8: Coordinate system of forces and moments

Fx Fy Fz Fres Mx My Mz Mres Fx Fy Fz Fres Mx My Mz Mres

Suction nozzle Discharge nozzle

Fx Fy Fz Fres Mx My Mz Mres Fx Fy Fz Fres Mx My Mz Mres

5.4.3 Auxiliary connections