C147 - POLISH WATER PUMP, BOILER BLOWDOWN PUMP, LP FEED PUMP - O&M Manual

Standardised Chemical Pump
MegaCPK
Installation/Operating
Manual
Legal information/Copyright
Installation/Operating Manual MegaCPK
Original operating manual
KSB Aktiengesellschaft
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
KSB's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 02.08.2012

Contents
Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ........................................................................................................... 6
1.2 Installation of partly completed machinery .................................................... 6
1.3 Target group ..................................................................................................... 6
1.4 Other applicable documents ............................................................................ 6
1.5 Symbols ............................................................................................................. 6
2 Safety .....................................................................................................8
2.1 Key to safety symbols/markings ....................................................................... 8
2.2 General .............................................................................................................. 8
2.3 Intended use ..................................................................................................... 8
2.4 Personnel qualification and training ............................................................... 9
2.5 Consequences and risks caused by non-compliance with these operating
instructions ........................................................................................................ 9
2.6 Safety awareness .............................................................................................. 9
2.7 Safety 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 .............................................................................................................. 22
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Contents
5.5 Enclosure/insulation ....................................................................................... 26

5.6 Checking the coupling alignment ................................................................. 26
5.7 Aligning the pump and motor ...................................................................... 27
5.8 Electrical connection ...................................................................................... 29
5.9 Checking the direction of rotation ................................................................ 30
6 Commissioning/Start-up/Shutdown ...................................................32
6.1 Commissioning/start-up ................................................................................. 32
6.2 Operating limits .............................................................................................. 38
6.3 Shutdown/storage/preservation .................................................................... 40
6.4 Returning to service ....................................................................................... 41
7 Servicing/Maintenance .......................................................................42
7.1 Safety regulations ........................................................................................... 42
7.2 Maintenance/inspection ................................................................................. 43
7.3 Drainage/cleaning .......................................................................................... 47
7.4 Dismantling the pump set .............................................................................. 48
7.5 Reassembling the pump set ........................................................................... 51
7.6 Tightening torques ......................................................................................... 57
7.7 Spare parts stock ............................................................................................. 59
8 Trouble-shooting ................................................................................62
9 Related Documents ............................................................................64

9.1 General assembly drawing with list of components .................................... 64
10 EC Declaration of Conformity ............................................................68
11 Certificate of Decontamination .........................................................69
Index ....................................................................................................70
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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
MegaCPK 5 of 74
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, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
Noise characteristics. (⇨ 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 56)
1.3 Target group

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

Table 1: Overview of other applicable documents
Document 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 Description of auxiliary connections
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
1) If agreed to be included in the scope of supply
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1 General
Symbol Description
⇨ Result of an action
⇨ Cross-references
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
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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.
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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 these operating

instructions
▪ Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪ Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards and laws
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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 6.1.12 Page 37) (⇨ Section 6.3 Page 40)
▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3
Page 47)
▪ As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning.(⇨ Section 6.1 Page 32)
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) (⇨
Section 2.10.3 Page 11).
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
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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.
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 at 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, the operator of the system is responsible for
observing the specified temperature class 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 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 ℃2)
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.
If grease lubrication is used, compliance with temperature class T5 is not possible.
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,
2) Depending on the material variant
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2 Safety
appropriate monitoring devices must be used.

Check whether monitoring equipment is required to ensure that the pump set
functions properly.
Contact KSB for further information on monitoring equipment.
2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.2.3.1 Page 39) 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 are different from
water, it is essential to check whether an 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 39) can be used to check whether an additional heat build-up
may lead to a hazardous temperature increase at the pump surface.
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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 below.
Fig. 1: Transporting the back pull-out unit
Fig. 2: Transporting the pump
MegaCPK 13 of 74
≤ 90 °
Fig. 3: Transporting the complete pump set
≤ 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 40) .
3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 47)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
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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 69)
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 and supplies posing a health hazard and/or hot fluids and supplies
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing medium 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.
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4 Description of the Pump (Set)
4.1 General description

▪ Standardised chemical pump with shaft seal
Pump for handling aggressive liquids in the chemical and petrochemical industries.
4.2 Designation
Example: MCPK 50-32-160 CDhix
Table 5: Key to the designation
Code Description
MCPK Type series (full name: MegaCPK)
50 Nominal suction nozzle diameter [mm]
32 Nominal discharge nozzle diameter [mm]
160 Nominal impeller diameter [mm]
C Casing material, e.g. C = stainless steel
D Impeller material if different from casing material, e.g. D
= duplex
hix Additional description, e.g. h = heatable, i = inducer, x =
special version
4.3 Name plate

6
1 67227 Frankenthal 7
MCPK 50-32-160 CD 2011
2
0520-5-P-10000-31
3
P-No. 997125086300550001 8
4
Q 20 m3/h H 25 m
5
n 2955 1/min
Mat-No. 01 109 223 ZN 3804 - D 52 x 74
Fig. 5: Name plate (example)

1 Type series, size, material 2 Customer-specific information
(optional)
3 KSB order and order item number 4 Flow rate
5 Speed 6 Manufacturer's name and address
7 Year of construction 8 Head
4.4 Design details

Design
▪ Volute casing pump
▪ Horizontal installation
▪ Back pull-out design
▪ Single-stage
▪ Meets the technical requirements to ISO 5199
▪ Dimensions and ratings to EN 22858/ISO 2858,
complemented by pumps of nominal diameters DN 25, DN 200 and above
Pump casing
▪ Single or double volute, depending on the pump size
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▪ Radially split volute casing

▪ Volute casing with integrally cast pump feet
▪ Replaceable casing wear rings (as required)
Impeller type
▪ Closed radial impeller with multiply curved vanes
Shaft seal
▪ Gland packing
▪ Commercial single and double mechanical seals
▪ Commercial cartridge seals
▪ Shaft fitted with a replaceable shaft protecting sleeve in the shaft seal area
Alternative:
▪ Version without shaft protecting sleeve, with "wet" shaft (Europe only)
Bearing assembly
Bearings:
▪ Medium-duty
– Radial bearing: cylindrical roller bearing
– Fixed bearing: paired angular contact ball bearings / double-row angular
contact ball bearing
▪ Economy
– Floating bearing assembly: deep-groove ball bearings
Lubrication:
▪ Oil lubrication
▪ Grease lubrication
Bearing bracket Example: CS50E
designation Table 6: Bearing bracket designation
Designation Description
CS Bearing bracket MegaCPK
50 Size code (based on dimensions of seal chamber and shaft
end)
E Bearing design
E = Economy
-3) = Medium Duty
Bearings used Table 7: Standard bearing assembly
Version Bearing bracket Rolling element bearings
Pump end Drive end
Medium-duty (oil and CS40 NU208-E 3208
grease lubrication) CS50 NU310-E 2 x 73104)
CS60 NU312-E 2 x 73124)
CS80 NU216-E 2 x 72164)
Economy (oil CS40E 6208 C3 6208 C3
lubrication) CS50E 6310 C3 6310 C3
CS60E 6312 C3 6312 C3
CS80E 6216 C3 6216 C3
Economy (grease CS40E 6208-2Z C3 6208-2Z C3
lubrication) CS50E 6310-2Z C3 6310-2Z C3
3) Blank
4) FAG designation: B-TVP-UA; SKF designation: BECBP
MegaCPK 17 of 74
Version Bearing bracket Rolling element bearings

Pump end Drive end
CS60E 6312-2Z C3 6312-2Z C3
CS80E 6216-2Z C3 6216-2Z C3
4.5 Configuration and function

1 2 3 4 5
6 7 8 9 10
Fig. 6: Sectional drawing
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, drive 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.
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 casing to the suction nozzle. At the rear side of
the impeller, the shaft (4) enters the casing via the casing cover (3). The shaft passage
through the cover is sealed towards the atmosphere with a shaft seal (8). The shaft
runs in rolling element bearings (9 and 10), which are supported by a bearing bracket
(5) linked with the pump casing and/or casing cover.
Sealing The pump is sealed by a shaft seal (standardised mechanical seal or gland packing).
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4.6 Noise characteristics

Table 8: Surface sound pressure level LpA5)6)
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
Drive ▪ Surface-cooled IEC three-phase squirrel-cage motor
Shaft coupling ▪ Flexible coupling with or without spacer
Contact guard ▪ Coupling guard
Baseplate ▪ Cast or welded baseplate for the complete unit (pump and motor), in torsion-
resistant design
▪ Channel section steel or folded steel plate
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.
5) 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.
6) Increase for 60 Hz operation: 3500 rpm+3 dB; 1750 rpm +1 dB; 1160 rpm:±0 dB
MegaCPK 19 of 74
5 Installation at Site
5.1 Safety regulations
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
Damage to the pump set!
▷ Comply with the applicable local explosion protection regulations.
▷ Observe the information in the data sheet and on the name plates of pump and
motor.
5.2 Checks to be carried out prior to installation

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

Always install the pump set in horizontal position.
DANGER
Excessive temperatures due to improper installation
Explosion hazard!
▷ Install the pump in horizontal position to ensure self-venting of the pump.
5.3.1 Installation on the foundation
1
L
2 3
Fig. 7: 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.
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✓ The foundation has been prepared in accordance with the dimensions given in
the outline drawing/general arrangement drawing.
1. Position the pump set on the foundation and level it with the help of a spirit
level placed on the shaft and discharge nozzle.
Permissible deviation: 0.2 mm/m.
2. Use shims (1) for height compensation, if necessary.
Always fit shims, if any, immediately to the left and right of the foundation
bolts (3) between the baseplate/foundation frame and the foundation.
For a bolt-to-bolt distance (L) > 800 mm fit additional shims (2) halfway
between the bolt holes.
All shims must lie perfectly flush.
3. Insert the foundation bolts (3) into the holes provided.
4. Use concrete to set the foundation bolts (3) into the foundation.
5. Wait until the concrete has set firmly, then level the baseplate.
6. Tighten the foundation bolts (3) evenly and firmly.
7. Grout the baseplate using low-shrinkage concrete with a standard particle size
and a water/cement ratio of ≤ 0.5.
Produce flowability with the help of a solvent.
Perform secondary treatment of the concrete to DIN 1045.
NOTE
For low-noise operation contact KSB to check whether the pump set can be
installed on anti-vibration mounts.
NOTE
Expansion joints can be fitted between pump and suction/discharge line.
5.3.2 Installation without foundation (European version)
4
Fig. 8: Adjusting the levelling elements
1, 3 Locknut 2 Levelling nut
4 Levelling element
✓ The installation surface has the required strength and characteristics.
1. Position the pump set on the levelling elements (4) and level it with the help of
a spirit level (on the shaft/discharge nozzle).
2. To adjust any differences in height, loosen the bolts and locknuts (1, 3) of the
levelling elements (4).
3. Turn the levelling nut (2) until any differences in height have been
compensated.
MegaCPK 21 of 74
4. Re-tighten the locknuts (1, 3) at the levelling elements (4).
5.4 Piping
5.4.1 Connecting the piping
DANGER
Impermissible loads acting on the pump nozzles
Danger to life from leakage of hot, toxic, corrosive or flammable fluids!
▷ Do not use the pump as an anchorage point for the piping.
▷ Anchor the pipelines in close proximity to the pump and connect them without
transmitting any stresses or strains.
▷ Observe the permissible forces and moments at the pump nozzles.
▷ Take appropriate measures to compensate thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.
NOTE
It is recommended to install check and shut-off elements in the system, depending
on the type of plant 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 45) .
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).
22 of 74 MegaCPK
2
Fig. 9: 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.
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

[+]
Fz Fz The data on forces and moments apply to static piping loads only. If the limits are
exceeded, they must be checked and verified.
Fy Fy Mz
If a computerised strength analysis is required, values are available on request only.
My
The values are only applicable if the pump is installed on a completely grouted
Fx Mx
Fx baseplate and bolted to a rigid and level foundation.
Fz
Fy
Fx
Fig. 10: Forces and

moments at the pump
nozzles
Table 9: Forces and moments at the pump nozzles for "C" variant (1.4408/ A743 GR CF8M)
Size Suction nozzle Discharge nozzle
DN Fx Fy Fz ∑F Mx My Mz DN Fx Fy Fz ∑F Mx My Mz
[N] [N] [N] [N] [Nm] [Nm] [Nm] [N] [N] [N] [N] [Nm] [Nm] [Nm]
040-25-160 40 970 780 650 1404 500 280 410 25 460 410 600 860 370 185 280
040-25-200 40 970 780 650 1404 500 280 410 25 460 410 600 860 370 185 280
050-32-250.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-125 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-125.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-160 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-160.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-200 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-200.1 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
050-32-250 50 1240 1010 830 1802 650 320 500 32 650 500 780 1132 415 230 320
065-40-125 65 1600 1300 1050 2314 1050 550 780 40 780 640 1000 1421 500 280 415
065-40-160 65 1600 1300 1050 2314 1050 550 780 40 780 640 1000 1421 500 280 415
065-40-200 65 1600 1300 1050 2314 1050 550 780 40 780 640 1000 1421 500 280 415
065-40-250 65 1600 1300 1050 2314 1050 550 780 40 780 640 1000 1421 500 280 415
MegaCPK 23 of 74

065-40-315 65 1600 1300 1050 2314 1050 550 780 40 780 640 1000 1421 500 280 415
080-50-125 80 2000 1550 1300 2845 1330 690 1010 50 1000 830 1250 1803 650 320 500
080-50-160 80 2000 1550 1300 2845 1330 690 1010 50 1000 830 1250 1803 650 320 500
080-50-200 80 2000 1550 1300 2845 1330 690 1010 50 1000 830 1250 1803 650 320 500
080-50-250 80 2000 1550 1300 2845 1330 690 1010 50 1000 830 1250 1803 650 320 500
080-50-315 80 2000 1550 1300 2845 1330 690 1010 50 1000 830 1250 1803 650 320 500
100-65-125 100 2500 1950 1600 3551 1850 900 1400 65 1300 1050 1600 2314 1050 550 790
100-65-160 100 2500 1950 1600 3551 1850 900 1400 65 1300 1050 1600 2314 1050 550 790
100-65-200 100 2500 1950 1600 3551 1850 900 1400 65 1300 1050 1600 2314 1050 550 790
100-65-250 100 2500 1950 1600 3551 1850 900 1400 65 1300 1050 1600 2314 1050 550 790
100-65-315 100 2500 1950 1600 3551 1850 900 1400 65 1300 1050 1600 2314 1050 550 790
125-80-160 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1300 1950 2810 1350 690 1000
125-80-200 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1300 1950 2810 1350 690 1000
125-80-250 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1300 1950 2810 1350 690 1000
125-80-315 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1300 1950 2810 1350 690 1000
125-80-400 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1300 1950 2810 1350 690 1000
125-100-160 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1600 2500 3579 1850 900 1400
125-100-200 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1600 2500 3579 1850 900 1400
125-100-250 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1600 2500 3579 1850 900 1400
125-100-315 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1600 2500 3579 1850 900 1400
125-100-400 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1600 2500 3579 1850 900 1400
150-125-200 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900
150-125-250 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900
150-125-315 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900
150-125-400 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900
200-150-200 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450
200-150-250 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450
200-150-315 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450
200-150-400 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450
200-150-500 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450
200-200-250 200 6750 5250 4300 9572 4850 2450 3550 200 5250 4300 6750 9572 4850 2450 3550
250-200-315 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550
250-200-400 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550
250-200-500 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550
300-250-315 300 11000 9200 7350 16114 8400 4150 6350 250 7350 6150 9150 13250 6900 3350 5250
Correction coefficients depending on material and temperature (see diagram below).

Correction coefficient
1.2
1.1
1 E, D
0.9
C, V
0.8
0.7
0.6 °C
0 50 100 150 200 250 300 350 400
Fig. 11: Temperature correction diagram for "E, D, C, V" variant (1.4408/
A743 GR CF8M)
Table 10: Forces and moments at the pump nozzles for "G" variant (JL1040/ A48CL35B)
040-25-160 40 450 400 350 696 450 320 370 25 265 250 300 472 315 210 245
040-25-200 40 450 400 350 696 450 320 370 25 265 250 300 472 315 210 245
050-32-250.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-32-125 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-32-125.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-32-160 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-32-160.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-32-200 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-32-200.1 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
050-32-250 50 580 530 470 916 500 350 400 32 320 300 370 574 390 265 300
065-40-125 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
24 of 74 MegaCPK

065-40-160 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-40-200 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-40-250 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
065-40-315 65 740 650 600 1153 530 390 420 40 400 350 450 696 450 320 370
080-50-125 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400
080-50-160 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400
080-50-200 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400
080-50-250 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400
080-50-315 80 880 790 720 1385 560 400 460 50 530 470 580 916 500 350 400
100-65-125 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420
100-65-160 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420
100-65-200 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420
100-65-250 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420
100-65-315 100 1180 1050 950 1843 620 440 510 65 650 600 740 1153 530 390 420
125-80-160 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460
125-80-200 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460
125-80-250 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460
125-80-315 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460
125-80-400 125 1400 1250 1120 2186 740 530 670 80 790 720 880 1385 560 400 460
125-100-160 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510
125-100-200 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510
125-100-250 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510
125-100-315 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510
125-100-400 125 1400 1250 1120 2186 740 530 670 100 1050 950 1180 1843 620 440 510
150-125-200 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670
150-125-250 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670
150-125-315 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670
150-125-400 150 1750 1600 1400 2754 880 610 720 125 1250 1120 1400 2186 740 530 670
200-150-200 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720
200-150-250 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720
200-150-315 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720
200-150-400 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720
200-150-500 200 2350 2100 1900 3680 1150 800 930 150 1600 1400 1750 2754 880 610 720
200-200-250 200 2350 2100 1900 3680 1150 800 930 200 2100 1900 2350 3680 1150 800 930
250-200-315 250 2950 2600 2350 4581 1550 1100 1300 200 2100 1900 2350 3680 1150 800 930
250-200-400 250 2950 2600 2350 4581 1550 1100 1300 200 2100 1900 2350 3680 1150 800 930
250-200-500 250 2950 2600 2350 4581 1550 1100 1300 200 2100 1900 2350 3680 1150 800 930
300-250-315 300 3500 3150 2850 5504 2100 1500 1750 250 2600 2350 2950 4581 1550 1100 1300
Correction coefficients depending on material and temperature (see diagram below).
Correction coefficient
1
0,98
G
0,96
0,94
0,92
0,9
0 20 40 60 80 100 120 140 160 °C
Fig. 12: Temperature correction diagram for "G" variant (JL1040/ A48CL35B)
5.4.3 Auxiliary connections
DANGER
Risk of potentially explosive atmosphere as a result of incompatible liquids mixing
in auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure barrier/quench liquid is compatible with the fluid handled.
MegaCPK 25 of 74
WARNING
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing
liquid, etc.)
Risk of injury from escaping fluid!
Risk of burns!
Malfunction of the pump!
▷ Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the quantity, dimensions and locations of auxiliary
connections.
▷ Use the auxiliary connections provided.
5.5 Enclosure/insulation
DANGER
Risk of potentially explosive atmosphere due to insufficient venting
Explosion hazard!
▷ Make sure the space between the casing cover/discharge cover and the bearing
cover is sufficiently vented.
▷ Never close or cover the perforation of the bearing bracket guards (e.g. by
insulation).
WARNING
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.
26 of 74 MegaCPK
a) 1 b) 1
A B A B
A B A B
1 2 1 2
Fig. 13: Checking the coupling alignment: a) Coupling, b) Spacer-type coupling
1 Straight-edge 2 Wedge gauge
✓ The coupling guard and the footboard for the coupling guard, if any, have been
removed.
1. Loosen the support foot and re-tighten it without transmitting any stresses and
strains.
2. Place the straight-edge axially on both coupling halves.
3. Leave the straight-edge in this position and turn the coupling by hand.
The coupling is aligned correctly if the distances A) and B) to the respective
shafts are the same at all points around the circumference.
The radial and axial deviation between the two coupling halves must not
exceed 0.1 mm during standstill as well as at operating temperature and under
inlet pressure.
4. Check the distance (dimension see general arrangement drawing) between the
two coupling halves around the circumference.
The coupling is aligned correctly if the distance between the two coupling
halves is the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed 0.1 mm
during standstill as well as at operating temperature and under inlet pressure.
5. If alignment is correct, re-install the coupling guard and the footboard for the
coupling guard, if any.
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 (at the motor).
5.7.1 Motors with levelling screw
1
2
3
Fig. 14: Motor with levelling screw
MegaCPK 27 of 74
1 Hexagon head bolt 2 Levelling screw

3 Locknut
removed.
1. Check the coupling alignment.
2. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at the
baseplate.
3. Turn the levelling screws (2) by hand or by means of an open-jawed wrench
until the coupling alignment is correct and all motor feet rest squarely on the
baseplate.
4. Re-tighten the hexagon head bolts (1) at the motor and the locknuts (3) at the
baseplate.
5. Check that the coupling and shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
6. Re-install the coupling guard and the footboard for the coupling guard, if any.
7. Check the distance between coupling and coupling guard.
The coupling and coupling guard must not come into contact.
5.7.2 Motors without levelling screw

Any differences in the centreline heights of the pump and motor shafts are
compensated by means of shims.
1
Fig. 15: Pump set with shim
1 Shim
removed.
1. Check the coupling alignment.
2. Unscrew 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.
28 of 74 MegaCPK
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
7. Check the distance between coupling and coupling guard.
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
It is recommended to fit a motor protection device.
MegaCPK 29 of 74
5.8.1 Setting the time relay
CAUTION
Switchover between star and delta on three-phase motors with star-delta starting
takes too long.
Damage to the pump (set)!
▷ Keep switch-over intervals between star and delta as short as possible.
Table 11: Time relay settings for star-delta starting:
Motor rating Y time to be set
≤ 30 kW <3s
> 30 kW <5s
5.8.2 Earthing
DANGER
Electrostatic charging
Explosion hazard!
▷ Connect the PE conductor to the earthing terminal provided.
▷ Provide for potential equalisation between the pump set and foundation.
5.8.3 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.
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.
30 of 74 MegaCPK
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
▷ Separate the pump from the motor to check the direction of rotation.
CAUTION
Drive and pump running in the wrong direction of rotation
Damage to the pump!
▷ Refer to the arrow indicating the direction of rotation on the pump.
▷ Check the direction of rotation. If required, check the electrical connection and
correct the direction of rotation.
The correct direction of rotation of the motor and pump is clockwise (seen from the
drive end).
1. Start the motor and stop it again immediately to determine the motor's
direction of rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction
of rotation on the pump.
3. If the motor is running in the wrong direction of rotation, check the electrical
connection of the motor and switchgear, if any.
MegaCPK 31 of 74
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
33)
▪ The direction of rotation has been checked.(⇨ Section 5.9 Page 30)
▪ 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 41) have been carried out.
6.1.2 Filling in lubricants

Grease-lubricated bearings Grease-lubricated bearings have been packed with grease at the factory.
Oil-lubricated bearings Fill the bearing bracket with lubricating oil.
Oil quality see (⇨ Section 7.2.3.1.2 Page 45)
Oil quantity see (⇨ Section 7.2.3.1.3 Page 45)
Filling the constant-level oiler with lubricating oil (oil-lubricated bearings only)
✓ The constant-level oiler is screwed into the upper tapping hole of the bearing
bracket.
NOTE
If no constant-level oiler is provided on the bearing bracket, the oil level can be
read in the middle of the oil level sight glass arranged at the side of the bearing
bracket.
CAUTION
Insufficient lubricating oil in the reservoir of the constant-level oiler
Damage to the bearings!
▷ Regularly check the oil level.
▷ Always fill the oil reservoir completely.
▷ Keep the oil reservoir properly filled at all times.
1 2
3 4 5
Fig. 16: Bearing bracket with constant-level oiler
32 of 74 MegaCPK
1 Constant-level oiler 2 Vent plug

3 Connection elbow of the constant- 4 Screw plug
level oiler
5 Bearing bracket
1. Pull out the vent plug (2).
2. Hinge down the reservoir of the constant-level oiler (1) from the bearing
bracket (5) and hold it in this position.
3. Fill in oil through the hole for the vent plug until the oil reaches the connection
elbow of the constant-level oiler (3).
4. Completely fill the reservoir of the constant-level oiler (1).
5. Snap the constant-level oiler (1) back into its operating position.
6. Fit the vent plug (2) again.
7. After approximately 5 minutes, check the oil level in the glass reservoir of the
constant-level oiler (1).
The oil reservoir must be properly filled at all times to ensure that the correct oil
level is maintained. Repeat steps 1 - 6, if necessary.
8. To check the function of the constant-level oiler (1), slowly drain some oil via
the screw plug (4) until air bubbles can be seen in the oil reservoir.
NOTE
An excessively high oil level can lead to a temperature rise and to leakage of the
fluid handled or oil.
6.1.3 Shaft seal

Shaft seals are fitted prior to delivery.
Observe the instructions on dismantling(⇨ Section 7.4.6 Page 49) or reassembly(⇨
Section 7.5.3 Page 54) .
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 as a result of incompatible liquids mixing
in auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure barrier/quench liquid is compatible with the fluid handled.
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.
MegaCPK 33 of 74
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.(⇨ Section 5.6
Page 26)
5. Check the distance between the coupling and coupling guard.
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 tin=10 to 30 °C
Outlet temperature tout= 45 °C (max.)
6.1.7 Cooling of the bearing bracket (special design)

If the pump is permanently heated during standstill (above 185 °C), the bearing
bracket has to be cooled.
The following values are required for cooling the bearing bracket:
▪ Cooling liquid pressure: 6 bar max.
▪ Cooling liquid quantities: see table below
Table 12: Cooling liquid quantities for cooling the bearing bracket
Bearing bracket Cooling liquid quantity [l/min]
CS40 5
CS50 6
CS60 8
CS80 10
34 of 74 MegaCPK
6.1.8 Heating (version "h")

The pump can also be heated, if necessary. The volute casing and the casing cover
have heating chambers. The heating chambers can be heated with hot water, steam
or thermal oil.
DANGER
Excessive surface temperature
Explosion hazard!
Risk of burns!
▷ Observe the permissible temperature classes.
CAUTION
Lack of heating medium
Damage to the pump!
▷ Provide sufficient quantities of a suitable heating medium.
CAUTION
Time for warming up the pump too short
Damage to the pump!
▷ Check that the pump is sufficiently warmed up throughout.
CAUTION
Impermissibly high temperature of the heating medium
Fluid or heating medium could escape!
▷ Observe the application limits of the heating media.
Table 13: Temperature limits for heating with hot water or thermal oil
Heating medium t max [°C] pmax[bar]
Hot water / saturated steam 300 20
Thermal oil 300 6
6.1.9 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 the temperature is increased continuously.
▪ Max. heating speed: 10 °C/min (10 K/min)
Fluid temperatures above If the pump is used for handling fluids with fluid temperatures exceeding 150 °C,
150 °C make sure that the pump has been sufficiently 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.
MegaCPK 35 of 74
6.1.10 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 33)
▷ Always operate the pump within the permissible operating range.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
✓ The system piping has been cleaned.
✓ The pump, suction line and, if applicable, inlet tank have been vented and
primed with the fluid to be handled.
✓ 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 full rotational speed, slowly open the
shut-off element in the discharge line and adjust it to comply with the duty
point.
CAUTION
Misalignment of pump and coupling
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.
36 of 74 MegaCPK
6.1.11 Checking the shaft seal

Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
Gland packing The gland packing must drip slightly during operation.
DANGER
Impermissibly high temperatures at gland packings
Explosion hazard!
▷ Always use suitable temperature monitoring for gland packings.
▷ Gland packing must be tightened correctly.
Pure graphite packing If a pure graphite packing is used, there must always be some leakage.
Table 14: Leakage rate of the pure graphite packing
Quantity Values
Minimum 10 cm³/min
Maximum 20 cm³/min
Adjusting the leakage
Prior to commissioning 1. Only lightly tighten the nuts of the gland follower by hand.
2. Use a feeler gauge to verify that the gland follower is mounted centred and at
a right angle to the shaft.
⇨ The gland must leak after the pump has been primed.
After five minutes of
operation
WARNING
Unprotected rotating parts
Risk of personal injury!
▷ Do not touch rotating parts.
▷ When the pump is running, perform any work with utmost caution.
The leakage can be reduced.
1. Tighten the nuts on the gland follower by 1/6 turn.
2. Monitor the leakage for another five minutes.
Excessive leakage:
Repeat steps 1 and 2 until the minimum value has been reached.
Not enough leakage:
Slightly loosen the nuts at the gland follower.
No leakage:
Immediately switch off pump set!
Loosen gland follower and repeat commissioning.
Checking the leakage

After the leakage has been adjusted, monitor the leakage for about two hours at
maximum fluid temperature.
Check that enough leakage occurs at the gland packing at minimum fluid pressure.
6.1.12 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.
MegaCPK 37 of 74
2. Switch off the motor and make sure the pump set runs down smoothly to a
standstill.
NOTE
If the discharge line is equipped with a non-return or check valve, the shut-off
element in the discharge line may remain open, provided the site's requirements
and regulations are taken into account and observed.
NOTE
If shut-off is not possible, the pump will run in reverse direction.
The reverse runaway speed must be lower than the rated speed.
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
CAUTION
Operation outside the permissible ambient temperature
▷ Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
Table 15: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 50 °C
40 °C7)
Minimum See data sheet
38 of 74 MegaCPK
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
can be used for orientation for start-up with the discharge-side gate valve slightly
open:
Table 16: 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
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
6.2.3 Fluid handled
6.2.3.1 Flow rate

Unless specified otherwise in the characteristic curves or in the data sheets, the
following applies:
▪ Short-time operation: Qmin8) = 0.15 × Qopt 9)
▪ Continuous operation: Qmin8) = 0.3 × Qopt 9)
▪ 2-pole operation: Qmax10) = 1.1 × Qopt 9)
▪ 4-pole operation: Qmax10) = 1.25 × Qopt9)
▪ 6-pole operation: Qmax10) = 1.25 × Qopt9)
The data refer to water and water-like fluids. Longer operating periods with these
fluids and at the flow rates indicated will not cause an additional increase in the
temperatures on the pump surface. However, if the physical properties of the fluids
handled are different from water, the calculation formula below must be used to
check if an additional heat build-up may lead to a dangerous temperature increase at
the pump surface. If necessary, the minimum flow must be increased.
7) If compliance with 94/9/EC is required (ATEX-compliant products)

8) Minimum permissible flow rate
9) Flow rate at best efficiency point
10) Maximum permissible flow rate
MegaCPK 39 of 74
×
×
×
Table 17: Key

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

The power input of the pump increases in proportion to the density of the fluid
handled.
CAUTION
Impermissibly high density of the fluid handled
Motor overload!
▷ Observe the information on fluid density indicated in the data sheet.
▷ Make sure the motor has sufficient power reserves.
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 and stored
✓ The pump has been properly drained (⇨ Section 7.3 Page 47) and the safety
instructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page
48)
1. Spray-coat the inside wall of the pump casing, and in particular the impeller
clearance areas, with a preservative.
2. Spray the preservative through the suction and discharge nozzles.
It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).
3. Oil or grease all exposed machined parts and surfaces of the pump (with
silicone-free oil or grease, food-approved, if required) to protect them against
corrosion.
Observe the additional instructions.(⇨ Section 3.3 Page 14)
40 of 74 MegaCPK
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 32) and the operating limits.(⇨ Section 6.2 Page 38)
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service.(⇨ Section 7 Page 42)
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.
MegaCPK 41 of 74
7 Servicing/Maintenance
7.1 Safety regulations
DANGER
Sparks produced during servicing work
Explosion hazard!
▷ Observe the safety regulations in force at the place of installation!
▷ Always perform maintenance work on explosion-proof pump sets outside
potentially explosive atmospheres.
DANGER
Improperly serviced pump set
Explosion hazard!
▷ Service the pump set regularly.
▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.
The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly familiar
with the manual.
WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
WARNING
Fluids and supplies posing a health hazard and/or hot fluids or supplies
Risk of injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps which handle fluids posing a health hazard.
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tipping or falling over.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump (set) with a minimum of maintenance
expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".
Never use force when dismantling and reassembling the pump set.
42 of 74 MegaCPK
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!
Hot and/or toxic fluids could escape!
▷ Service the barrier fluid system regularly.
▷ Monitor the barrier fluid pressure.
CAUTION
Increased wear due to dry running
▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during
pump operation.
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 38)
While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.
▪ In case of oil lubrication, ensure the oil level is correct.(⇨ Section 6.1.2 Page 32)
▪ Check the shaft seal. (⇨ Section 6.1.11 Page 37)
▪ Check the static seals for leakage.
MegaCPK 43 of 74
▪ 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 stand-by pumps are ready for operation, start them up once a
week.
▪ Monitor the bearing temperature.
The bearing temperature must not exceed 90 °C (measured on the outside of the
bearing bracket).
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured
on the outside of the bearing bracket).
NOTE
After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is
only reached after a certain period of operation (up to 48 hours depending on the
conditions).
7.2.2 Inspection work
DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
▷ Regularly check the coupling guard, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.
7.2.2.1 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

The back pull-out unit must be removed to check the clearances.
If the clearance is larger than permitted (see the following table), fit a new casing
wear ring 502.01 and/or 502.2.
The clearances specified refer to the diameter.
Table 18: Clearances between impeller and casing/between impeller and casing wear
ring
Casing material Clearances
New Maximum permissible
enlargement
G, D, E 0.3 mm 0.9 mm
C, V 0.5 mm 1.5 mm
44 of 74 MegaCPK
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 19: Oil change intervals
Temperature at the First oil change All subsequent oil
bearing changes11)
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 20: Oil quality
Description Characteristics
Lubricating oil CL46 or Kinematic viscosity at 40 °C 46±4 mm²/s
CLP46 according to DIN Flash point (to Cleveland) +175 °C
51517 Solidification point (pour point) -15 °C
Application temperature12) Higher than permissible
bearing temperature
7.2.3.1.3 Oil quantity

Table 21: Oil quantity
Bearing bracket Oil quantity [l]
CS40 0.2
CS50 0.4
11) At least once a year

12) For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.
MegaCPK 45 of 74
Bearing bracket Oil quantity [l]

CS60 0.4
CS80 0.7
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. 17: 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. (⇨ Section 6.1.2 Page 32)
7.2.3.2 Grease lubrication

The bearings are supplied packed with high-quality lithium-soap grease.
7.2.3.2.1 Intervals
▪ Under normal operating conditions the grease-lubricated bearings will run for
25,000 operating hours.
▪ Under unfavourable operating conditions (e.g. high room temperature, high
atmospheric humidity, dust-laden air, aggressive industrial atmosphere, etc.)
check the bearings earlier and clean and re-lubricate them, if required.
▪ Replace the rolling element bearings after 25,000 operating hours or 2 years of
continuous operation.
46 of 74 MegaCPK
7.2.3.2.2 Grease quality

Table 22: Grease quality to DIN 51825
Soap basis NLGI grade Worked penetration Drop point Temperature range
at 25 °C in mm/10
Lithium 2 to 3 220-295 ≥ 175 °C -30 °C to 120 °C
7.2.3.2.3 Grease quantities

Medium-duty Table 23: Grease quantities for new grease fill
Bearing bracket Bearing + cover, Bearing+ cover,
pump-end drive-end
[g] [g]
CS40 13 66
CS50 50 135
CS60 72 196
CS80 64 276
Economy Economy bearing assemblies are greased for life; the grease fill cannot be renewed. If
necessary, replace the complete bearing.
7.2.3.2.4 Changing the grease
CAUTION
Mixing greases of differing soap bases
Changed lubricating qualities!
▷ Thoroughly clean the bearings.
▷ Adjust the re-lubrication intervals to the grease used.
✓ The pump has been dismantled for changing the grease.(⇨ Section 7.4 Page 48)
1. Only half-fill the bearing cavities with grease.
2. Fill the cavities in the bearing cover until they are about 1/3 full.
7.3 Drainage/cleaning
WARNING
Fluids and supplies posing a health hazard and/or hot fluids and supplies
▷ Collect and properly dispose of flushing medium and any residues of the fluid
handled.
If the fluids handled by the pump (set) leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might ignite
when coming into contact with oxygen, the pump set must be flushed through,
neutralised, and anhydrous inert gas must be blown through the pump for drying
purposes.
Use connection 6B to drain the fluid handled (see auxiliary connections).
MegaCPK 47 of 74
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 42)
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 6.1.12 Page 37)
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 47)
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
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. (⇨ Section 7.2.3.1.4 Page 46)
7.4.3 Dismantling 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.
48 of 74 MegaCPK
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

✓ The notes and steps stated in(⇨ Section 7.4.1 Page 48) to(⇨ Section 7.4.3 Page 48)
have been observed/carried out.
✓ On 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. Unbolt support foot 183 from the baseplate.
3. Undo hexagon nut 920.01 at the volute casing.
4. Pull the back pull-out unit out of the volute casing.
5. Remove and dispose of joint ring 411.10.
6. Place the back pull-out unit on a clean and level surface.
7.4.5 Removing the impeller

✓ The notes and steps stated in(⇨ Section 7.4.1 Page 48) to (⇨ Section 7.4.4 Page
49) have been observed/carried out.
✓ The back pull-out unit is kept in a clean and level assembly area.
1. Undo impeller nut 922 (right-hand thread).
2. Remove impeller 230 with an impeller removal device.
3. Place impeller 230 on a clean and level surface.
4. Remove keys 940.01 from shaft 210.
5. Remove and dispose of joint rings 411.31/411.32.
7.4.6 Removing the shaft seal
7.4.6.1 Removing the mechanical seal - cylindrical casing cover

1. Unscrew hexagon nuts 920.02 and push back seal cover 471 (if fitted).
2. Unscrew hexagon nuts 920.04, if any.
3. Remove casing cover 161 from bearing bracket 330.
4. Pull complete mechanical seal 433 with shaft protecting sleeve 524.01, seal
cover 471 and thrower 507.01 off shaft 210.
MegaCPK 49 of 74
7.4.6.2 Removing the mechanical seal - conical casing cover

1. Pull shaft sleeve 524.01 with the rotating assembly of mechanical seal 433 off
the shaft.
3. Dismantle casing cover 161 with the stationary ring of mechanical seal 433.
4. Remove thrower 507.01.
5. Press the stationary ring of mechanical seal 433 out of casing cover 161.
7.4.6.3 Removing the gland packing

1. Undo hexagon nuts 920.02 at gland follower 452 and remove the gland
follower.
3. Remove casing cover 161 from bearing bracket 330.
4. Remove stuffing box ring 454.01 and drip plate 463.01.
5. Remove packing rings 461.01 and lantern ring 458.01, if any, from the packing
chamber.
6. Pull shaft protecting sleeve 524.01 and thrower 507.01 off shaft 210.
7.4.7 Dismantling the bearings

✓ The bearing bracket is kept in a clean and level assembly area.
1. Unscrew 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. Undo screws 914.02 and remove drive-end bearing cover 360.02 and joint ring
400.02.
5. Undo screws 914.01 and remove pump-end bearing cover 360.01 and joint ring
400.01.
7.4.7.1 Dismantling the medium-duty bearing assembly

1. Carefully drive shaft 210 together with angular contact ball bearing 320.02 and
the inner ring of cylindrical roller bearing 322.01 out of the bearing bracket
towards the drive end.
2. Remove support disc 550.23 of angular contact ball bearing 320.02 from
bearing bracket 330.
3. In case of grease lubrication, remove disc 550.25.
4. Remove cylindrical roller bearing 322.01 (roller cage) from bearing bracket 330.
5. In case of grease lubrication, remove disc 550.24.
6. Bend open lockwasher 931.01 behind keywayed nut 920.21 on shaft 210.
7. Unscrew keywayed nut 920.21 (right-hand thread) and remove lockwasher
931.01.
50 of 74 MegaCPK
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.
8. 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.
9. Dispose of joint rings 400.01/.02.
7.4.7.2 Dismantling the economy bearing assembly

1. Carefully push shaft 210 with deep-groove ball bearing 321.01/.02 out of the
bearing bracket.
2. Heat up the deep-groove ball bearing to 80°C and pull it off shaft 210.
On grease-lubricated models, pull deep-groove ball bearing 321.01/.02 off the
shaft in cold condition.
3. Dispose of joint rings 400.01/.02.
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.
MegaCPK 51 of 74
CAUTION
Contact of O-ring with graphite or similar material
Fluid could escape!
▷ Do not coat O-ring with graphite or similar material.
▷ Use animal fats or lubricants based on silicone or PTFE.
▪ Assembly adhesives
– For gaskets, avoid the use of assembly adhesives, if possible.
– If assembly adhesives are required, use a commercially available contact
adhesive (e.g. "Pattex").
– Only apply adhesive at selected points and in thin layers.
– Never use quick-setting adhesives (cyanoacrylate adhesives).
– Coat the locating surfaces of the individual components and screwed
connections with graphite or similar before reassembly.
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.(⇨ Section 7.6
Page 57)
7.5.2 Reassambling the bearing assembly
7.5.2.1 Reassembling the medium-duty bearing assembly

✓ The individual parts are kept 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
Risk of burns!
1. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical
roller bearing 322.01 to approx. 80 ℃ in an oil bath.
2. Push angular contact ball bearing 320.02 and the inner ring of cylindrical roller
bearing 322.01 onto shaft 210 until they will not go any further.
NOTE
Angular contact ball bearings must be installed in "O" arrangement. Angular

contact ball bearings installed in pairs must always be from the same manufacturer.
3. Use a C-spanner to tighten keywayed nut 920.21 without lockwasher 931.01.
4. Let angular contact ball bearing 320.01 cool down to approximately 5 °C above
ambient temperature.
5. Re-tighten keywayed nut 920.21, then unscrew it again.
6. Apply a few spots of a suitable lubricant (e.g. Molykote) to the contact faces of
lockwasher 931.01 and keywayed nut 920.21.
7. Fit lockwasher 931.01.
8. Tighten keywayed nut 920.21.
9. Bend back lockwasher 931.01.
10. Insert circlip 932.01/932.02 into the bearing bracket.
11. In case of grease lubrication, insert disc 550.24.
52 of 74 MegaCPK
12. Fit cylindrical roller bearing 322.01 (roller cage) in the bearing bracket.
Fig. 18: Reassembling the medium-duty bearing assembly

13. In case of grease lubrication, insert disc 550.25.
14. Insert support disc 550.23 of angular contact ball bearing 320.02 into bearing
bracket 330.
15. Carefully push pre-assembled shaft 210 with angular contact ball bearing 320.02
and the inner ring of cylindrical roller bearing 322.01 from the drive end into
bearing bracket 330.
16. In case of grease lubrication, fill the bearings and bearing covers with grease.
Grease lubrication(⇨ Section 7.2.3.2 Page 46)
17. Fit pump-end bearing cover 360.01 with joint ring 400.01; take care not to
damage lip seal 421.01.
18. Fit drive-end bearing cover 360.02 with joint ring 400.02; take care not to
19. Fit throwers 507.01 and 507.02, if any, and align flush with the shaft shoulder.
20. Fit keys 940.02.
21. Pull the coupling hub onto the shaft end.
22. Secure the coupling hub with a set screw.
7.5.2.2 Reassembling the economy bearing assembly

✓ The individual parts are kept in a clean and level assembly area.
WARNING
Risk of burns!
1. Oil-lubricated models: Heat up deep-groove ball bearing 321.01/.02 in an oil
bath to approx. 80°C and slide it onto shaft 210 until it will not go any further.
Grease-lubricated models: Press deep-groove ball bearing 321.01/.02 onto shaft
210 in cold condition until it will not go any further. Only apply force via the
inner ring of the deep-groove ball bearings.
2. Carefully slide pre-assembled shaft 210 with deep-groove ball bearing
321.01/.02 into bearing bracket 330.
3. Fit pump-end bearing cover 360.01 with joint ring 400.01; take care not to
4. Fit drive-end bearing cover 360.02 with joint ring 400.02; take care not to
MegaCPK 53 of 74
5. Fit throwers 507.01 and 507.02, if any, and align flush with the shaft shoulder.
6. Fit keys 940.02.
7. Pull the coupling hub onto the shaft end.
8. Secure the coupling hub with a set screw.
7.5.3 Fitting the shaft seal
7.5.3.1 Fitting the mechanical seal

The following rules must be observed when installing the mechanical seal:
▪ For installing the mechanical seal, proceed as shown in the seal installation
drawing.
▪ Work cleanly and accurately.
▪ Only remove the protective wrapping of the contact faces immediately before
installation takes place.
▪ Prevent any damage to the sealing surfaces or O-rings.
▪ After inserting the stationary ring, check that it is plane-parallel in relation to the
casing part.
▪ The surface of the shaft protecting sleeve must be absolutely clean and smooth,
and the sleeve's mounting edge must be chamfered.
▪ When sliding the rotating assembly onto the shaft protecting sleeve, take
appropriate steps to protect the surface of the shaft protecting sleeve from
damage.
7.5.3.1.1 Fitting the single mechanical seal – cylindrical casing cover

✓ The bearing assembly and the individual parts of mechanical seal 433 are kept in
a clean and level assembly area.
1. Fit thrower 507.01, if any, and align flush with the shaft shoulder.
2. Fasten seal cover 471 with inserted O-ring, the stationary ring of the mechanical
seal and gasket 411.05 to casing cover 161 with hexagon nut 920.02.
3. Place casing cover 161 into the locating fit of bearing bracket 330.
4. Fit and tighten hexagon nuts 920.04, if any.
5. Fit the rotating assembly of mechanical seal 433 on shaft protecting sleeve
524.01 (observe distance B - see Supplementary Sheet of the mechanical seal).
6. Slide pre-assembled mechanical seal 433 and shaft protecting sleeve 524.01
onto shaft 210.
7.5.3.1.2 Fitting the double mechanical seal – cylindrical casing cover

54 of 74 MegaCPK
2. Fit the rotating assembly of mechanical seals 433.01 and 433.02 on shaft
protecting sleeve 524.01 (observe distance B - see Supplementary Sheet for the
mechanical seal).
3. Position the stationary ring of mechanical seal 433.01 with the O-ring in casing
cover 161. Fit ring and circlip, if any.
4. Position the stationary ring of mechanical seal 433.02 with the O-ring in casing
cover 471.01.
5. Insert pre-assembled mechanical seals 433.01 and 433.02 and shaft protecting
sleeve 524.01 in the casing cover.
6. Fit seal cover 471.01 with gasket 411.15 on the casing cover. Make sure the
connection bores are positioned correctly.
7.5.3.1.3 Fitting the mechanical seal – conical casing cover

2. Carefully press the stationary ring of mechanical seal 433 with O-ring into
casing cover 161.
3. Fit casing cover 161 with inserted stationary ring into bearing bracket 330.
5. Fit the rotating assembly of mechanical seal 433 and spacer ring, if any, on shaft
protecting sleeve 524.01 (observe distance B - see Supplementary Sheet for the
mechanical seal).
6. Slide pre-assembled mechanical seal 433 and shaft protecting sleeve 524.01
onto shaft 210.
7.5.3.2 Fitting the gland packing
a) b)
Fig. 19: Gland packing chamber a) with lantern ring and b) without lantern ring
Table 24: Gland packing chamber
Bearing Gland packing chamber Packing cross- Packing rings
bracket Ø di Ø da l section
CS40 35 51 53 8x8 4 rings and
CS50 45 65 64 10 x 10 1 lantern ring
CS60 55 75 64 10 x 10 or
CS80 70 95 79 12.5 x 12.5
6 rings
Pure graphite packings see supplementary operating instructions.
Always use pre-compressed packing rings.
MegaCPK 55 of 74
✓ The bearing assembly as well as the individual parts are kept in a clean and level
assembly area.
1. Clamp casing cover 161 into a vice.
2. Insert the first packing ring, ensuring that its cut edge is in horizontal position.
3. Hold the packing ring in place and slide shaft protecting sleeve 524 (chamfered
side first) into the gland packing chamber from the pump end.
4. Slightly expand the inside diameter of the packing ring by moving shaft
protecting sleeve 524 back and forth. Then pull out the shaft protecting sleeve.
Insert lantern ring 458, if any (see illustration above).
Insert each subsequent packing ring separately with its joint offset by approx.
90° in relation to the previous one. Repeat the expansion procedure.
When the last packing ring has been inserted, shaft protecting sleeve 524
remains in the packing chamber.
5. Insert stuffing box ring 454.01 with the drilled hole down.
6. Fit gland follower 452 and lightly fasten it by hand with the two hexagon nuts
920.02; watch discs 550.01.
7. Place the entire casing cover 161 with shaft protecting sleeve 524 into the
locating fit of bearing bracket 330.
7.5.4 Fitting the impeller

✓ The bearing assembly/mechanical seal as well as the individual parts are kept in a
clean and level assembly area.
✓ Impeller bore, shaft and keyways are clean and free from burrs.
1. Insert keys 940.01 into the shaft keyway.
2. Insert joint ring 411.08 into shaft protecting sleeve 524.01.
3. Coat the impeller seat with a suitable lubricant.
4. Slide impeller 230 onto shaft 210.
5. Thread impeller nut 922 with inserted joint ring 411.31 onto shaft 210 and
tighten(⇨ Section 7.6.2 Page 58).
7.5.5 Fitting the back pull-out unit
WARNING
Back pull-out unit tipping over
▷ Suspend or support the bearing bracket at the pump end.
✓ The notes and steps stated in (⇨ Section 7.5.1 Page 51) to (⇨ Section 7.5.4 Page
56) have been observed/carried out.
56 of 74 MegaCPK
✓ For back pull-out units supplied 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 the volute casing.
3. Bolt support foot 183 to the baseplate.
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.(⇨ Section 5.7 Page 27)
4. Connect the motor to the power supply (refer to manufacturer's product
literature).
7.6 Tightening torques
7.6.1 Tightening torques for the pump
X X
A
A C C
B
A
X
D
a) b)
Fig. 20: a) Tightening points at the pump, b) Version with clamped discharge cover
Use a torque wrench to tighten the bolted connections (902.01/920.01) between the
volute casing and the bearing bracket.
MegaCPK 57 of 74
Table 25: Tightening torques

Position Thread size Nominal value [Nm]
PN16 (G, C, PN25 (E, D)13)
V)13)
A M12 50 65
M16 125 165
B M14x1.5 SW21 (CS40) 60
M16x1.5 SW24 (CS50) 125
M20x1.5 SW30 (CS60) 200
M24x1.5 SW36 (CS80) 300
C M8 20
M10 38
M12 55
D M12 90
X 1/8 25
1/4 55
3/8 80
1/2 130
3/4 220
7.6.2 Tightening torques for the pump set
1 2 3 4
Fig. 21: Tightening points at the pump set

Table 26: Tightening torques
Position Thread size Nominal value Comment
[Nm]
1 M12 30 Pump on baseplate
M16 75
M20 75
M24 140
2 M12 30
3 M24x1.5 140 Levelling screws in baseplate
M36x1.5 140
13) Casing material: G=cast iron; C,V=stainless steel; E=unalloyed steel; D=duplex steel
58 of 74 MegaCPK
Position Thread size Nominal value Comment

[Nm]
4 M6 10 Motor on levelling screws or bases
M8 10
M10 15
M12 30
M16 75
M20 140
M24 140
5 M6 13 Coupling (only for spacer-type
M8 18 coupling made by Flender)
M10 44
6 M6 10 Coupling guard
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 supply 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 64)
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 27: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
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 %
320.02 Rolling element bearing (set) 1 1 2 2 2 3 25 %
321.01 Radial ball bearing 1 1 2 2 2 3 25%
321.02 Radial ball bearing 1 1 2 2 2 3 25%
322.01 Radial roller bearing 1 1 2 2 2 3 25 %
502.01/.02 Casing wear ring 2 2 2 3 3 4 50 %
503.01/.02 Impeller wear ring 2 2 2 3 3 4 50 %
524.01 Shaft protecting sleeve 2 2 2 3 3 4 50 %
- Sealing elements for pump 4 6 8 8 9 12 150 %
casing (set)
- Torque-transmitting coupling 1 1 2 2 3 4 30 %
elements (set)
MegaCPK 59 of 74
Part No. Description Number of pumps (including stand-by pumps)

2 3 4 5 6 and 7 8 and 9 10 and
more
Versions with mechanical seal:
433 Mechanical seal, complete 1 1 2 2 2 3 25 %
Versions with gland packing:
461.01 Gland packing (set) 4 4 6 6 6 8 100 %
7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.
Table 28: Interchangeability of pump components
Description
Shaft protecting sleeve14)

Rolling element bearing
Radial roller bearing

Shaft, medium-duty
Radial ball bearing
Radial ball bearing
Stuffing box ring

Casing wear ring
Casing wear ring

Bearing bracket
Mechanical seal
Shaft, economy
Gland follower
Gland packing
Support foot
Casing cover
Lantern ring
Impeller nut
Seal cover
Thrower
Bearing bracket
Part No.
320.01
321.01
321.02
322.01
502.01
502.02
507.01
524.01
471.07
452.01
454.01
458.01
461.01
Size
161
183
210
210
330
922
433
40-25-160 CS40 1 1 1 1 1 1 1 1 1 1 - 1 1 1 1 1 1 1 1 1
40-25-200 CS40 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
50-32-125 CS40 1 3 1 1 1 1 1 1 1 3 - 1 1 1 1 1 1 1 1 1
50-32-125.1 CS40 1 3 1 1 1 1 1 1 1 2 - 1 1 1 1 1 1 1 1 1
50-32-160 CS40 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1
50-32-160.1 CS40 1 1 1 1 1 1 1 1 1 2 - 1 1 1 1 1 1 1 1 1
50-32-200 CS40 2 2 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1
50-32-200.1 CS40 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1
65-40-125 CS40 1 3 1 1 1 1 1 1 1 4 - 1 1 1 1 1 1 1 1 1
65-40-160 CS40 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1
65-40-200 CS40 2 2 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1
80-50-125 CS40 1 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1
80-50-160 CS40 1 2 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1
80-50-200 CS40 2 2 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1
100-65-125 CS40 1 2 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1
50-32-250 CS50 3 4 2 2 2 2 2 2 2 3 2 2 2 2 2 2 2 2 2 2
50-32-250.1 CS50 3 4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
65-40-250 CS50 3 4 2 2 2 2 2 2 2 7 2 2 2 2 2 2 2 2 2 2
65-40-315 CS50 4 5 2 2 2 2 2 2 2 7 3 2 2 2 2 2 2 2 2 2
80-50-250 CS50 3 4 2 2 2 2 2 2 2 5 2 2 2 2 2 2 2 2 2 2
80-50-315 CS50 4 6 2 2 2 2 2 2 2 8 3 2 2 2 2 2 2 2 2 2
100-65-160 CS50 5 7 2 2 2 2 2 2 2 8 4 2 2 2 2 2 2 2 2 2
100-65-200 CS50 6 4 2 2 2 2 2 2 2 8 4 2 2 2 2 2 2 2 2 2
100-65-250 CS50 7 5 2 2 2 2 2 2 2 6 3 2 2 2 2 2 2 2 2 2
125-80-160 CS50 5 4 2 2 2 2 2 2 2 9 4 2 2 2 2 2 2 2 2 2
125-80-200 CS50 8 4 2 2 2 2 2 2 2 9 3 2 2 2 2 2 2 2 2 2
125-80-250 CS50 7 6 2 2 2 2 2 2 2 9 3 2 2 2 2 2 2 2 2 2
125-100-160 CS50 8 5 2 2 2 2 2 2 2 10 3 2 2 2 2 2 2 2 2 2
125-100-200 CS50 8 5 2 2 2 2 2 2 2 10 3 2 2 2 2 2 2 2 2 2
100-65-315 CS60 9 6 3 3 3 3 3 3 3 9 3 3 3 3 3 3 3 3 3 3
14) Depending on mechanical seal type
60 of 74 MegaCPK
Description
Shaft protecting sleeve14)

Rolling element bearing
Radial roller bearing

Shaft, medium-duty
Radial ball bearing
Radial ball bearing
Stuffing box ring

Casing wear ring
Casing wear ring

Bearing bracket
Mechanical seal
Shaft, economy
Gland follower
Gland packing
Support foot
Casing cover
Lantern ring
Impeller nut
Seal cover
Thrower
Bearing bracket
Part No.
320.01
321.01
321.02
322.01
502.01
502.02
507.01
524.01
471.07
452.01
454.01
458.01
461.01
Size
161
183
210
210
330
922
433
125-80-315 CS60 9 8 3 3 3 3 3 3 3 9 3 3 3 3 3 3 3 3 3 3
125-80-400 CS60 10 9 3 3 3 3 3 3 3 10 5 3 3 3 3 3 3 3 3 3
125-100-250 CS60 11 6 3 3 3 3 3 3 3 10 3 3 3 3 3 3 3 3 3 3
125-100-315 CS60 9 8 3 3 3 3 3 3 3 10 3 3 3 3 3 3 3 3 3 3
125-100-400 CS60 10 9 3 3 3 3 3 3 3 11 5 3 3 3 3 3 3 3 3 3
150-125-200 CS60 12 8 3 3 3 3 3 3 3 11 6 3 3 3 3 3 3 3 3 3
150-125-250 CS60 13 8 3 3 3 3 3 3 3 11 6 3 3 3 3 3 3 3 3 3
150-125-315 CS60 14 9 3 3 3 3 3 3 3 11 5 3 3 3 3 3 3 3 3 3
150-125-400 CS60 10 10 3 3 3 3 3 3 3 11 5 3 3 3 3 3 3 3 3 3
200-150-200 CS60 12 9 3 3 3 3 3 3 3 12 6 3 3 3 3 3 3 3 3 3
200-150-250 CS60 13 9 3 3 3 3 3 3 3 13 6 3 3 3 3 3 3 3 3 3
200-150-315 CS80 15 11 4 4 4 4 4 4 4 13 5 4 4 4 4 4 4 4 4 4
200-150-400 CS80 16 11 4 4 4 4 4 4 4 13 5 4 4 4 4 4 4 4 4 4
200-150-500 CS80 17 12 4 4 4 4 4 4 4 14 7 4 4 4 4 4 4 4 4 4
200-200-250 CS80 18 13 4 4 4 4 4 4 4 13 8 4 4 4 4 4 4 4 4 4
250-200-315 CS80 19 13 4 4 4 4 4 4 4 15 9 4 4 4 4 4 4 4 4 4
250-200-400 CS80 20 13 4 4 4 4 4 4 4 16 9 4 4 4 4 4 4 4 4 4
250-200-500 CS80 17 14 4 4 4 4 4 4 4 17 7 4 4 4 4 4 4 4 4 4
300-250-315 CS80 19 15 5 5 4 4 4 4 4 18 9 4 4 4 4 4 4 4 4 4
14) Depending on mechanical seal type
MegaCPK 61 of 74
8 Trouble-shooting
8 Trouble-shooting
WARNING
Improper remedial work on the pump (set)
Risk of injury!
▷ For any work performed in order to remedy faults on the pump (set) observe
the relevant information given in this operating manual or the product
literature provided by the accessories manufacturers.
If problems occur that are not described in the following table, consultation with
KSB’s customer service is required.
A Pump delivers insufficient flow rate
B Motor is overloaded
C Excessive pump discharge pressure
D Increased bearing temperature
E Leakage at the pump
F Excessive leakage at the shaft seal
G Vibrations during pump operation
H Impermissible rise of temperature inside the pump
Table 29: Trouble-shooting
A B C D E F G H Possible cause Remedy 15)
✘ Pump delivers against an excessively Re-adjust to duty point.
high pressure. Check system for impurities.
Fit a larger impeller. 16)
Increase speed (turbine, I.C. engine).
✘ ✘ ✘ Pump or piping are not completely Vent and/or prime.
vented or primed.
✘ Supply line or impeller clogged Remove deposits in the pump and/or piping.
✘ Formation of air pockets in the piping Alter piping layout.
Fit vent valve.
✘ ✘ ✘ Suction lift is too high/NPSH available 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 switchgear, if any.
✘ Speed is too low. 16)
- Operation with frequency inverter - Increase voltage/frequency at the frequency
- Operation without frequency inverter in the permissible range.
inverter - Check voltage.
✘ ✘ Impeller Replace worn parts by new ones.
✘ ✘ Pump back pressure is lower than Adjust duty point accurately.
specified in the purchase order. In the case of persistent overloading, turn
down impeller. 16)
✘ Density or viscosity of fluid handled Contact KSB.
higher than stated in purchase order
15) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
16) Contact KSB.
62 of 74 MegaCPK
8 Trouble-shooting
A B C D E F G H Possible cause Remedy 15)

✘ ✘ Gland follower over-tightened or Correct.
cocked
✘ ✘ Speed is too high. Reduce speed. 16)
✘ Defective gasket Fit new gasket between volute casing and
discharge cover.
✘ Worn shaft seal Fit new shaft seal.
Check flushing liquid/barrier fluid.
✘ ✘ Score marks or roughness on shaft Replace shaft protecting sleeve/shaft sleeve.
protecting sleeve / shaft sleeve Fit new shaft seal.
✘ 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 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 Replace.
✘ ✘ Flow rate is too low. Increase minimum flow rate.
✘ Incorrect inflow of circulation liquid Increase the free cross-section.
15) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
MegaCPK 63 of 74
9 Related Documents
9 Related Documents
9.1 General assembly drawing with list of components
Fig. 22: General assembly drawing of standard version (oil-lubricated)
901.22
Version with bearing bracket CS40 Version with clamped discharge cover Heatable version ("h" version)
64 of 74 MegaCPK
9 Related Documents
Version with gland packing Mechanical seal with conical casing cover
Mechanical seal with cylindrical casing cover Mechanical seal with cylindrical casing
cover (heatable version "h")
Grease-lubricated version (medium-duty bearing Oil-lubricated version (economy bearing assembly)

assembly)
MegaCPK 65 of 74
9 Related Documents
Version with coolable bearing bracket

Table 30: List of components
Part No. Comprising: Description
102 102 Volute casing
411.01/.0217)/0317)/.0417)/.1018) Joint ring
502.0117) Casing wear ring
902.01 Stud
903.01/.0217)/.0317)/.0417) Screw plug
920.01 Hexagon nut
161 161 Casing cover
502.0217) Casing wear ring
901.22 19)/31 Hexagon head bolt
902.02 Stud
920.02 Hexagon nut
183 183 Support foot
210 210 Shaft
920.2120) Keywayed nut
931.0120) Lockwasher
940.01/.02/.0921) Key
230 230 Impeller
503.01/.0217) Impeller wear ring
320.0220) 320.02 Angular contact ball bearing (double-row in CS40)
321.01 22) 321.01 Deep-groove ball bearing
321.0222) 321.02 Deep-groove ball bearing
322.01 20) 322.01 Cylindrical roller bearing
330 330 Bearing bracket
360.01 360.01 Bearing cover
360.02 360.02 Bearing cover
400.01 400.01 Gasket
400.02 400.02 Gasket
411.1518) 411.15 Joint ring
411.31 411.31 Joint ring
411.32 411.32 Joint ring
421.01 421.01 Lip seal
421.02 421.02 Lip seal
17) Not fitted on all models

18) Joint ring 411.10 (and 411.15 for versions with mechanical seal with seal cover only) depending on the operating
temperature. Order separately in spare parts order.
19) Only for clamped cover
20) Not fitted on versions with economy bearing assembly
21) From CS 60
22) On versions with economy bearing assembly only
66 of 74 MegaCPK
9 Related Documents
Part No. Comprising: Description

433.02 433.02 Mechanical seal (complete)
452.01 452.01 Gland follower
454.01 454.01 Stuffing box ring
458.01 458.01 Lantern ring
461.01 461.01 Gland packing
463.01 463.01 Drip plate
471.01 471.01 Seal cover
502.0117) 502.01 Casing wear ring
502.0217) 502.02 Casing wear ring
503.0117) 503.01 Impeller wear ring
503.0217) 503.02 Impeller wear ring
507.01 507.01 Thrower
524.01 524.01 Shaft protecting sleeve
550.01 550.01 Disc
550.23 550.23 Disc
550.2423) 550.24 Disc
550.2523) 550.25 Disc
550.74 550.74 Disc
554.98 554.98 Washer
561.03 561.03 Grooved pin
636.0223) 636.02 Lubricating nipple
636.0323) 636.03 Lubricating nipple
63824) 638 Constant-level oiler
64224) 642 Oil level sight glass
67224) 672 Vent plug
81-92 81-92 Cover plate
99-9 411.01/.02/.03/.04/.10/.15/31/.32/.46 Joint ring
400.01/02 Gasket
901.04 901.04 Hexagon head bolt
902.15 902.15 Stud
903.46 903.46 Screw plug
914.01 914.01 Hexagon socket head cap screw
914.02 914.02 Hexagon socket head cap screw
920.15 920.15 Hexagon nut
922 922 Impeller nut
932.01 932.01 Circlip
932.02 932.02 Circlip
The relevant version is indicated in the documentation supplied.
23) On grease-lubricated versions only

24) Not applicable for grease-lubricated versions
MegaCPK 67 of 74
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:
MegaCPK (MCPK)
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100,
– EN 809/A1
▪ Applied national technical standards and specifications, in particular:
– DIN EN ISO 5199
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
..............................25).............................
Name
Function
Company
Address
Address
25) A signed, legally binding declaration of conformity is supplied with the product.
68 of 74 MegaCPK
11 Certificate of Decontamination
11 Certificate of Decontamination
Type ................................................................................................................................
Order number/
Order item number26) ................................................................................................................................
Delivery date ................................................................................................................................
Field of application: ................................................................................................................................
Fluid pumped26): ................................................................................................................................
Please tick where applicable26):
⃞ ⃞ ⃞ ⃞
Radioactive Explosive Corrosive Toxic
⃞ ⃞ ⃞ ⃞
Harmful Bio-hazardous Highly flammable Safe
Reason for return26): ................................................................................................................................
Comments: ................................................................................................................................
................................................................................................................................
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We hereby declare that this product is free from hazardous chemicals, biological or radioactive substances.
On seal-less pumps, the rotor has been removed from the pump for cleaning.
⃞ No special safety precautions are required for further handling.

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

.
Place, date and signature Address Company stamp
26) Required fields
MegaCPK 69 of 74
Index
Index
A Interchangeability of pump components 60
Abrasive fluids 40
Auxiliary connections 26 K
Keeping the pump warm 35
B
Bearing assembly 17 L
Bearing temperature 44 Leakage rate 37
Lubrication 17
C
Certificate of decontamination 69 M
Clearances 44, 44 Mechanical seal 37
Commissioning/start-up 32 Misuse 9
Constant-level oiler 32 Monitoring equipment 12
Coupling 44
Coupling alignment 27
N
D Name plate 16
Noise characteristics 19
Design 16, 18
Designation 16
Direction of rotation 31 O
Disassembly 48
Oil lubrication
Disposal 15
Intervals 45
Oil quality 45
E Oil quantity 45
Operating limits 8, 38
Explosion protection 10, 20, 20, 26, 26, 28, 29, 29, 30, Order number 6
30, 33, 35, 36, 36, 37, 38, 39, 42, 42, 43, 43, 43, 44, 45 Ordering spare parts 59
Other applicable documents 6
F
Filter 22, 45 P
Final check 34 Partly completed machinery 6
Flow rate 39 Permissible forces and moments at the pump nozzles
Frequency of starts 39, 39 23
Function 18 Piping 22
Preservation 14, 41
G Priming and venting 34
Product description 16
General assembly drawing 64 Pump casing 16
Gland packing 37 Pure graphite packing 37
Grease lubrication
Grease quality 47
R
H Return to supplier 14
Returning to service 41
Heating 35, 35 Running noises 43, 44
Heating speed 35
Heating up 35
S
I Safety 8
Safety awareness 9
Impeller type 17 Scope of supply 19, 19
Installation Servicing/maintenance 42
Installation on a foundation 20 Shaft seal 17
Installation without foundation 21 Shutdown 37, 41
Installation at site 20 Spare parts stock 59
Intended use 8 Start-up 36
70 of 74 MegaCPK
Index
Storage 14, 41 Transport 13

Trouble-shooting 62
T
Temperature difference 35 W
Temperature limits 11 Water cooling 34
Tightening torques 57, 58
MegaCPK 71 of 74
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Deutschland)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.de
2731.8/05-EN (01362313)
KSB Bombas Hidráulicas SA

Rua José Rabello Portella, 638
13220-540 - Várzea Paulista - SP - Brasil
Tel.: +55 11 4596 8500 • Fax: +55 11 4596 8580
www.ksb.com.br
KSB Pumps Limited

Plot no. E3 & E4, MIDC, Sinnar, (Malegaon) • Nashik 422 113
Tel. +91 2551 230252
Tel. +91 2551 230253
Tel. +91 2551 229700
Fax +91 2551 230254 • www.ksbindia.co.in
india.co

C147 - POLISH WATER PUMP, BOILER BLOWDOWN PUMP, LP FEED PUMP - O&M Manual

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Standardised Chemical Pump

Original operating manual

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft Frankenthal 02.08.2012

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

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

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

5.5 Enclosure/insulation ....................................................................................... 26

9 Related Documents ............................................................................64

10 EC Declaration of Conformity ............................................................68

11 Certificate of Decontamination .........................................................69

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 these operating

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

appropriate monitoring devices must be used.

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

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

Fig. 5: Name plate (example)

4.4 Design details

▪ Radially split volute casing

Version Bearing bracket Rolling element bearings

4.5 Configuration and function

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 the foundation

5.3.2 Installation without foundation (European version)

4. Re-tighten the locknuts (1, 3) at the levelling elements (4).

5.4.1 Connecting the piping

5.4.2 Permissible forces and moments at the pump nozzles

Fig. 10: Forces and