Etanorm Syt1

Thermal Oil / Hot Water Pump
Etanorm SYT
Installation/Operating
Manual
Order number:
Installation/Operating Manual Etanorm SYT
Original operating manual
KSB Aktiengesellschaft Pegnitz
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced,
processed for any other purpose, nor otherwise transmitted to a third party without KSB´s express
written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 17.03.2010

Contents
Contents
Glossary ................................................................................................ 5
1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Installation of partly completed machinery .................................................. 6
1.3 Target group ................................................................................................... 6
1.4 Other applicable documents .......................................................................... 6
1.5 Symbols ............................................................................................................ 6
2 Safety ................................................................................................... 8
2.1 Key to safety symbols/markings ..................................................................... 8
2.2 General ............................................................................................................ 8
2.3 Intended use .................................................................................................... 8
2.4 Personnel qualification and training ............................................................. 9
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 9
2.6 Safety awareness ............................................................................................. 9
2.7 Safety 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 Transport ....................................................................................................... 13
3.2 Storage and preservation ............................................................................. 13
3.3 Return to supplier ......................................................................................... 14
3.4 Disposal .......................................................................................................... 14
4 Description of the Pump (Set) .......................................................... 15

4.1 General description ....................................................................................... 15
4.2 Designation ................................................................................................... 15
4.3 Name plate .................................................................................................... 15
4.4 Design details ................................................................................................ 15
4.5 Configuration and function ......................................................................... 16
4.6 Noise characteristics ...................................................................................... 17
4.7 Scope of supply ............................................................................................. 18
4.8 Dimensions and weights ............................................................................... 18
5 Installation at Site ............................................................................. 19

5.1 Safety regulations ......................................................................................... 19
5.2 Checking the site before installation ........................................................... 19
5.3 Installing the pump set ................................................................................. 19
5.4 Piping ............................................................................................................. 21
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Contents
5.5 Protective equipment ................................................................................... 25

5.6 Checking the coupling alignment ................................................................ 25
5.7 Aligning the pump and motor ..................................................................... 26
5.8 Electrical connection ..................................................................................... 28
5.9 Checking the direction of rotation .............................................................. 28
6 Commissioning/Start-up/Shutdown ................................................. 30
6.1 Commissioning/start-up ................................................................................ 30
6.2 Operating limits ............................................................................................ 33
6.3 Shutdown/storage/preservation ................................................................... 35
6.4 Returning to service after storage ............................................................... 35
7 Servicing/Maintenance ...................................................................... 37
7.1 Safety regulations ......................................................................................... 37
7.2 Servicing/inspection ...................................................................................... 37
7.3 Drainage/disposal .......................................................................................... 40
7.4 Dismantling the pump set ............................................................................ 41
7.5 Reassembling the pump set .......................................................................... 44
7.6 Tightening torques ....................................................................................... 48
7.7 Spare parts stock ........................................................................................... 49
8 Trouble-shooting ............................................................................... 53
9 Related Documents ........................................................................... 55

9.1 Exploded views and lists of components ..................................................... 55
9.2 Wiring diagrams for double-acting mechanical seal .................................. 61
10 EC Declaration of Conformity ......................................................... 62
11 Certificate of Decontamination ....................................................... 63
Index .................................................................................................. 64
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Glossary
Glossary
Back pull-out design Pool of pumps

The complete back pull-out unit can be pulled Pumps which are purchased and stored
out without having to remove the pump casing independently of their later use
from the piping.
Pump
Back pull-out unit Machine without drive, additional components
Pump without pump casing; partly completed or accessories
machinery
Pump set
Certificate of decontamination Complete pump set consisting of pump, drive,
A certificate of decontamination certifies that additional components and accessories
the pump (set) has been properly drained to
eliminate any environmental and health
Suction lift line/suction head line
hazards arising from components in contact
with the fluid handled. The line which is connected to the suction
nozzle
Discharge line
The line which is connected to the discharge
nozzle
Hydraulic system
The part of the pump in which the kinetic
energy is converted into pressure energy
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1 General
1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. It describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
Noise characteristics (⇨ Section 4.6 Page 17)
1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, please refer to the sub-
sections under Servicing/Maintenance. (⇨ Section 7.5.5 Page 47)
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)
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
of 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
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1) If agreed to be included in the scope of supply
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1 General
Symbol Description
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 responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for meeting all local regulations which are not taken into
account in this manual.
2.3 Intended use

The pump (set) must only be operated within the operating limits which are
described in the other applicable documents.
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate partially assembled pumps/pump sets.
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2 Safety
▪ Only use the pump to handle the fluids specified in the data sheet or product
literature of the respective design variant.
▪ Never operate the pump without the fluid to be handled.
▪ Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪ Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪ Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪ Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse

▪ Never open discharge-side shut-off elements further than permitted.
– The maximum flow rate specified in the data sheet or product literature
would be exceeded.
– Risk of cavitation damage
▪ Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪ Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in

installation, operation, maintenance and inspection must be clearly defined by the
operator.
Deficits in knowledge must be rectified by sufficiently trained specialist personnel

training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.
Training on the pump (set) must always be supervised by technical specialist

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

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

In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
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2 Safety
▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws
2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold or moving parts and check that
the guards function properly.
▪ Do not remove the contact guard while the pump is running.
▪ Connect an earth conductor to the metal jacket if the fluid handled is
electrostatically charged.
▪ 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.)
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 consequential
damage.
▪ The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪ Carry out work on the pump (set) during standstill only.
▪ The pump casing must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pump set out of service always adhere to the procedure
described in the manual. (⇨ Section 6.1.7 Page 32)
▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3
Page 40)
▪ 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 30)
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.
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2 Safety
Only pumps/pump sets marked as explosion-proof and identified as such in the data
sheet may be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof pump sets to EC

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

In normal pump operation, the highest temperatures are to be expected on the
surface of the pump casing, at the shaft seal and in the bearing areas.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated, the operator of the system is responsible for
observing the specified temperature classes and fluid temperature (operating
temperature).
The table below lists the temperature classes and the resulting theoretical
temperature limits of the fluid handled. (A possible temperature rise in the shaft seal
area has already been taken into account).
The temperature class specifies the maximum permissible temperature at the surface
of the pump set during operation. For the permissible operating temperature of the
pump in question refer to the data sheet.
Table 4: Temperature limits
Temperature class as per EN 13463-1 Maximum permissible fluid
temperature
T1 Temperature limit of the pump
T2 280 ℃
T3 185 ℃
T4 120 ℃
T5 85 ℃
T6 Only after consultation
with the manufacturer
In the following cases, and if ambient temperatures are higher, contact the
manufacturer.
Temperature class T5 Compliance with temperature class T5 is warranted for the area of the rolling
element bearings based on an ambient temperature of 40°C, assuming that the
pump set is properly serviced and operated and that the surfaces in the bearing area
are freely exposed to the atmosphere.
Temperature class T6 If temperature class T6 has to be complied with, special measures may have to be
taken with regard to the bearing temperatures.
Misuse, malfunctions or non-compliance with the instructions may result in

substantially higher temperatures.
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2 Safety
If the pump is to be operated at a higher temperature, the data sheet is missing or if

the pump is part of a pool of pumps, contact KSB for the maximum permissible
operating temperature.
2.10.3 Monitoring equipment

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

The minimum flows indicated in (⇨ Section 6.2.3 Page 34) refer to water and water-
like liquids. 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, it is essential to check if 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 Page 34) can be used to check if an additional heat build-up may lead
to a hazardous temperature increase at the pump surface.
3 Transport/Temporary Storage/Disposal
3.1 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in horizontal position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Refer to the weights given in the general arrangement drawing.
▷ Observe the local accident prevention regulations.
▷ Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.
To transport the pump/pump set suspend it from the lifting tackle as shown below.
Fig. 1: Transporting the pump
max. 90 °
Fig. 2: Transporting the complete pump set
max. 90 °
Fig. 3: Transporting the pump on the baseplate
3.2 Storage and preservation

If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the pump (set) or the packaged pump (set) and
accessories with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
▷ Only remove caps/covers from the openings of the pump set at the time of
installation.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, observe the relevant
instructions. (⇨ Section 6.3.1 Page 35)
3.3 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 40)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the fluids handled by the pump leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might
ignite when coming into contact with oxygen, the pump set must also be
neutralised, and anhydrous inert gas must be blown through the pump for
drying purposes.
4. Always complete and enclose a certificate of decontamination when returning
the pump set. (⇨ Section 11 Page 63)
It is imperative to indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the KSB web
site at: www.ksb.com/certificate_of_decontamination
3.4 Disposal
WARNING
Fluids posing a health hazard
Hazardous to persons and the environment!
▷ Collect and properly dispose of flushing liquid and any fluid residues.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set).

Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another controlled
manner.
4 Description of the Pump (Set)
4.1 General description

Pump for handling fluids in heat transfer systems (DIN 4754) or for hot water
circulation
4.2 Designation
Example: EN 80 - 160 S Y T 8
Table 5: Key to the designation
Code Description
Etanorm Type series
80 Nominal discharge nozzle diameter [mm]
160 Nominal impeller diameter [mm]
S Casing made of nodular cast iron
YT Thermal oil/hot water variant
8 Shaft seal, mechanical seal AQ1VGG
4.3 Name plate
Aktiengesellschaft
D-67227 Frankenthal
1 6
Etanorm SYT 80-250 SYT8 7
2
3
9970857065 000100 / 01 8
Q 160 m3/h l H 77 m 9
4
n 2970 1/min l 2009
5
16.5 mm2/s
Id-No. 00 117 385 ZN 3804 - C 37 x 52
Fig. 4: Name plate Etanorm SYT
1 Type series, size and version 2 KSB order number

(ten digits)
3 Flow rate 4 Speed
5 Kinematic viscosity of the fluid 6 Order item number
handled (six digits)
7 Consecutive number 8 Head
(two digits)
9 Year of construction
4.4 Design details

Design
▪ Volute casing pump
▪ Back pull-out design
▪ Horizontal installation
▪ Single-stage
▪ Dimensions and ratings to EN 733
Pump casing
▪ Radially split volute casing
▪ Replaceable casing wear rings

▪ Volute casing with integrally cast pump feet
Impeller type
▪ Closed radial impeller with multiply curved vanes
Bearings
Motor-end bearing:
▪ Radial ball bearing
▪ Grease lubrication
Table 6: Rolling element bearing
Shaft unit Code
25 6306-2RS/C3 PCP-LLG
▪ Grease-packed for life (high melting point grease), with sealing washers on both
sides
Pump-end bearing:
▪ Plain bearing
▪ Product-lubricated
Shaft seal
▪ Standardised mechanical seal to EN 12756
Optional:
▪ Double-acting mechanical seal
4.5 Configuration and function

1 2 3 4 5
6 7 8 9 10
Fig. 5: Sectional drawing
1 Clearance gap 2 Discharge nozzle

3 Casing cover 4 Shaft
5 Bearing bracket 6 Suction nozzle
7 Impeller 8 Plain bearing
9 Shaft seal 10 Rolling element bearing, motor
end
Design The pump is designed with an axial fluid inlet and a radial 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 a suction nozzle (6) and is accelerated outward
in a cylindrical flow by the rotating impeller (7). The flow profile of the pump casing
converts the kinetic energy of the fluid into pressure energy. The fluid is pumped to
the discharge nozzle (2), where it leaves the pump. The clearance gap (1) prevents
any fluid from flowing back from the casing into the suction nozzle. The hydraulic
system is closed with a casing cover (3) at the rear side of the impeller; the shaft (4)
enters the casing via the casing cover. The shaft passage through the bearing bracket
is sealed towards the atmosphere with a shaft seal (9). The shaft runs in a plain
bearing and a rolling element bearing (8 and 10); the bearings are supported by a
bearing bracket (5) linked with the pump casing and/or casing cover.
Sealing The pump is sealed by a standardised mechanical seal.

If the pump is fitted with a double-acting mechanical seal, the pump is connected to
a quench pot. The unpressurised quench liquid supply serves to prevent any leakage
of the fluid handled towards the atmosphere. It also prevents any contact between
the fluid and the lubricating grease of the rolling element bearing, especially for
fluids which have a tendency to creep.
4.6 Noise characteristics

Table 7: Sound pressure level measured at surfaces LpA2) 3)
Rated power Pump Pump set
input 1450 rpm 2900 rpm 1450 rpm 2900 rpm
PN [dB] [dB] [dB] [dB]
[kW]
0.55 47 48 55 64
0.75 48 50 56 66
1.1 50 52 57 66
1.5 52 54 58 67
2.2 54 56 59 67
3 55 57 60 68
4 57 59 61 68
5.5 59 61 62 70
7.5 60 62 64 71
11 62 64 65 73
15 64 66 67 74
18.5 65 67 68 75
22 66 68 69 76
30 67 70 70 77
37 68 71 71 78
45 69 72 73 78
55 70 73 74 79
75 72 75 75 80
90 73 76 76 81
110 74 77 77 81
2) Spatial average to ISO 3744 and EN 12639. Applies to non-cavitating pump operation in the range Q/Qopt = 0.8 - 1.1. If
noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.
3) Increase for 60 Hz operation: 3500 rpm, +3 dB; 1750 rpm +1 dB
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 current squirrel-cage motor
CAUTION
Excessive temperature due to insufficient cooling
Damage to the pump set!
▷ Only use electric motors whose cooling air flows in axial direction towards the
pump end.
▷ Ensure an air velocity ≥ 3 m/s measured in the area of the bearing end plate on
the drive side.
▷ If the pump is driven by a combustion engine, only use engines whose cooling
air is sucked in or blown out via the coupling/flywheel.
Shaft coupling ▪ Flexible coupling with or without spacer
Contact guard ▪ Coupling guard to EN 294
DANGER
Risk of ignition by frictional sparks
Risk of explosion!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
▷ If any coupling parts are made of aluminium, a brass coupling guard must be
used.
Baseplate ▪ Channel section steel or folded steel plate
Optional:
▪ Cast baseplate (to ISO 3661)
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 (set).
5 Installation at Site
5.1 Safety regulations
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
▷ 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 Checking the site before installation

Place of installation
WARNING
Installation on foundations which are unsecured and cannot support the load
Personal injury and damage to property!
▷ Make sure the foundation concrete is of sufficient strength (min. X0 to
DIN 1045).
▷ Only place the pump set on a foundation whose concrete has set firmly.
▷ Only place the pump set on a horizontal and level surface.
▷ Refer to the weights given in the general arrangement drawing.
1. Check the structural requirements.

All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.3 Installing the pump set

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

2
1
3 4
Fig. 6: Fitting the shims
1 Bolt-to-bolt clearance 2 Shim

3 Shim for bolt-to-bolt clearance > 4 Foundation bolt
800 mm
✓ The foundation has the required strength and characteristics.
✓ 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 use a spirit level to align shaft and
discharge nozzle.
Permissible deviation: 0.2 mm/m
2. If required, use shims (2) to adjust the height.
Always fit shims immediately to the left and right of the foundation bolts (4)
between the baseplate/foundation frame and the foundation itself.
For a bolt-to-bolt clearance > 800 mm, fit additional shims (3) halfway between
the adjoining holes.
All shims must lie perfectly flush.
3. Insert the foundation bolts (4) into the holes provided.
4. Use concrete to set the foundation bolts (4) into the foundation.
5. Wait until the concrete has set firmly, then align the baseplate.
6. Tighten the foundation bolts (4) evenly and firmly.
NOTE
For baseplates more than 400 mm wide it is recommended to grout the baseplate with
low-shrinkage concrete.
NOTE
For baseplates made of grey cast iron it is recommended to grout the baseplate with low-
shrinkage concrete.
NOTE
For low-noise operation contact KSB to check whether the pump set can be installed on
anti-vibration mounts.
5.3.2 Installation without foundation

1
4
Fig. 7: 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 align 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.
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. (⇨ Section
5.4.2 Page 22)
▷ Take appropriate measures to compensate thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.
NOTE
It is recommended to install check and shut-off elements in the system, depending on the
type of plant and pump. However, such elements must not obstruct proper drainage or
hinder disassembly of the pump.
✓ The suction lift line/suction head line has been laid with a rising/downward slope
towards the pump.
✓ The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
✓ To prevent excessive pressure losses, adapters to larger diameters have a diffuser
angle of approximately 8°.
✓ The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the suction
and discharge nozzles of the pump.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Free the piping from any impurities.
▷ If necessary, install a filter.
▷ Observe the instructions in (⇨ Section 7.2.2.3 Page 40).
3. If required, install a filter in the piping (see drawing: Filter in the piping).
2
Fig. 8: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of
corrosion-resistant material.
Use a filter three times the diameter of the piping.
Conical filters have proved suitable.
4. Connect the pump nozzles with 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

FV
FH
FH
FV
FH 2 2 2
FV FH Mt
+ + -1
FVmax FHmax Mtmax
FH
Fig. 9: Forces and moments at the pump nozzles
The following condition must be met:
∑IFVI, ∑IFHI, and ∑IMtI are the sums of the absolute values of the respective loads
acting on the nozzles. Neither the load direction nor the load distribution among the
nozzles are taken into account in these sums.
Table 8: Forces and moments at the pump nozzles4)

Size t = 20 °C t = 300 °C
F Vmax FHmax Mtmax FVmax FHmax Mtmax
[kN] [kN] [kNm] [kN] [kN] [kNm]
32-125.1 3.65 2.59 0.58 3.15 2.24 0.5
32-160.1 3.56 2.51 0.51 3.08 2.17 0.44
4) The values indicated apply to nodular cast iron JS1025.
Size t = 20 °C t = 300 °C
F Vmax FHmax Mtmax FVmax FHmax Mtmax
[kN] [kN] [kNm] [kN] [kN] [kNm]
32-200.1 3.6 2.43 0.51 3.11 2.10 0.44
32-160 3.56 2.51 0.51 3.08 2.17 0.44
32-200 3.65 2.43 0.51 3.11 2.10 0.44
32-250 3.65 2.43 0.51 3.11 2.10 0.44
40-160 3.81 2.67 0.81 3.29 2.31 0.7
40-200 3.81 2.67 0.81 3.29 2.31 0.7
40-250 4.21 2.92 0.58 3.64 2.52 0.5
40-315 4.09 2.84 0.55 3.54 2.46 0.48
50-160 3.97 2.67 1.11 3.43 2.31 0.96
50-200 4.21 2.92 1.11 3.64 2.52 0.96
50-250 4.58 3.32 0.87 3.96 2.87 0.75
50-315 4.54 3.24 0.84 3.92 2.80 0.73
65-160 4.42 3.04 1.16 3.82 2.63 1
65-200 5.27 3.89 1.79 4.55 3.36 1.55
65-250 5.27 3.89 1.79 4.55 3.36 1.55
65-315 5.43 4.05 1.62 4.69 3.5 1.4
80-160 5.43 4.05 1.91 4.69 3.5 1.65
80-200 6.08 4.74 2.44 5.25 4.1 2.1
80-250 6.16 4.78 2.44 5.32 4.13 2.1
80-315 6.28 4.86 2.78 5.43 4.20 2.4
100-160 7.7 6.28 3.6 6.65 5.43 3.1
100-200 7.7 6.28 3.6 6.65 5.43 3.1
100-250 7.86 6.48 3.47 6.79 5.6 3
100-315 7.57 6.16 3.18 6.54 5.32 2.75
125-200 9.5 8.5 5.1 8.21 7.34 4.4
125-250 9.84 8.71 5.1 8.5 7.53 4.4
125-315 9.32 8.1 4.75 8.05 7 4.1
125-400 9.32 7.9 4.63 7.97 6.83 4
150-315 10.53 9.72 5.67 9.1 8.4 4.9
150-400 10.53 9.72 5.67 9.1 8.4 4.9
5.4.3 Vacuum balance line
NOTE
Where fluid has to be pumped out of a vessel under vacuum, it is recommended to install
a vacuum balance line.
The following rules apply to vacuum balance lines:

▪ Minimum nominal line diameter 25 mm.
▪ The line extends above the highest permissible fluid level in the vessel.
1 2 3 4
5 6
Fig. 10: Vacuum balance system
1 Vessel under vacuum 2 Vacuum balance line

3 Shut-off valve 4 Swing check valve
5 Main shut-off valve 6 Vacuum-tight shut-off valve
NOTE
An additional line fitted with a shut-off valve – from the pump discharge nozzle to the
balance line – facilitates venting of the pump before start-up.
5.4.4 Auxiliary connections

CAUTION
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing liquid,
etc.)
Malfunction of the pump!
▷ Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the dimensions and locations of auxiliary connections.
▷ Use the auxiliary connections provided.
Double-acting mechanical
seal
Fig. 11: Connections 24E and 24A
24 A Outlet quench liquid 24 E Inlet quench liquid
For designs with double-acting mechanical seal, use connections 24A and 24E to
connect the pump set to the quench system.
Connect the quench pot in accordance with the manufacturer's instructions.
5.5 Protective equipment
DANGER
An explosive atmosphere forms due to insufficient venting
Explosion hazard!
▷ Make sure the space between the casing cover/discharge cover and the bearing
cover is sufficiently vented.
WARNING
The volute casing and casing/discharge cover take on the same temperature as the fluid
handled
Risk of burns!
▷ Insulate the volute casing.
▷ Fit protective equipment.
CAUTION
Heat build-up in the bearing bracket
Damage to the bearing!
▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover.
5.6 Checking the coupling alignment
DANGER
Impermissible temperatures at the coupling or bearings caused by misalignment of the
coupling
Explosion hazard!
▷ Make sure that the coupling is correctly aligned at all times.
CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷ Always check the coupling after the pump has been installed and connected to
the piping.
▷ Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
a) 1 b) 1
A B A B
A B A B
1 2 1 2
Fig. 12: a) Checking the coupling alignment and b) Aligning a spacer-type coupling
1 Straight-edge 2 Wedge gauge

✓ The coupling guard and step guard, if any, have been removed.
1. 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 correctly aligned if the distances A) and B) to the respective shafts
are the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed 0.1 mm
during standstill as well as at operating temperature and under inlet pressure.
4. Check the distance between the two coupling halves around the circumference.
The coupling is correctly aligned if the distance between the two coupling halves
is the same at all points around the circumference.
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.
5.7 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. 13: Motor with levelling screw
1 Hexagon head bolt 2 Levelling screw

3 Locknut
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.
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
Explosion hazard!
6. Re-install the coupling guard and step guard, if any.
7. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
5.7.2 Motors without levelling screw
Any differences in the centre heights of the pump and motor shafts are compensated
by means of shims.
1
Fig. 14: Pump set with shim
1 Shim
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 centre height
has been compensated.
4. Re-tighten the hexagon head bolts.
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
Explosion hazard!
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 electrician.
▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pump
sets, IEC 60079 (DIN VDE 0165).
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method.
NOTE
It is recommended to fit a motor protection device.
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 or objects inside the pump casing
Risk of injuries, damage to the pump!
▷ Never insert your hands or any other objects into the pump.
▷ Check that the inside of the pump is free from any foreign objects.
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
▷ Separate the pump from the motor to check the direction of rotation.
CAUTION
Motor and pump running in the wrong direction of rotation
Damage to the pump!
▷ Refer to the arrow indicating the direction of rotation on the pump.
▷ Check the direction of rotation. If required, interchange any two phases to
correct the direction of rotation.
The correct direction of rotation of motor and pump is clockwise (seen from the
motor 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 the control system, if necessary.
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/start-up
6.1.1 Prerequisites for commissioning/start-up

Before starting up the pump set make sure that the following requirements are met:
▪ The pump set has been properly connected to the electric power supply and is
equipped with all protection devices.
▪ The pump and the bearing bracket have been primed with the fluid to be
handled. (⇨ Section 6.1.3 Page 30)
▪ The quench system, if any, has been filled with the quench liquid. (⇨ Section 6.1.2
Page 30)
▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 28)
▪ All auxiliary connections required are connected and operational.
▪ The lubricants have been checked. (⇨ Section 7.2.3 Page 40)
▪ After prolonged shutdown of the pump (set), the activities described in (⇨
Section 6.4 Page 35) have been carried out.
6.1.2 Quench liquid supply

Permissible quench liquids The quench liquid has to be compatible with and suitable for mixing with the fluid
handled.
For synthetic heat transfer oils, it is advisable to use a mineral oil based thermal fluid
or a different mineral oil as the quench liquid.
Heat transfer oils of the diphyl group are not suitable as quench liquids.
6.1.3 Priming and venting the pump
DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ Before starting up the pump, vent the suction line and the pump and prime
them with the fluid to be handled.
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.
1. Remove screwed plug 903.1 (connection 6D) to prime and vent the bearing
housing.
2. Vent the pump and suction line and prime both with the fluid to be handled.
Via the inlet line the pump can be primed with fluid to be handled from the
system.
3. Fully open the shut-off element in the suction line.
4. Fully open all auxiliary feed lines (barrier fluid, flushing liquid, etc), if applicable.
5. Open the shut-off element, if any, in the vacuum balance line and close the
vacuum-tight shut-off element, if any. (⇨ Section 5.4.3 Page 23)
WARNING
Hot water escaping under pressure when the vent plug is opened
Risk of electric shock.
Risk of scalding!
▷ Protect the electric components against escaping fluid.
▷ Wear protective clothing (e.g. gloves).
NOTE
For design-inherent reasons a remaining gas volume in the hydraulic system cannot be
excluded after the pump has been primed for commissioning/start-up. However, once the
motor is started up the pumping effect will immediately fill this volume with the fluid
handled.
6. Close the vent hole (connection 6D) with screwed plug 903.1.
6.1.4 Final check
1. Remove the coupling guard and step guard, if any.

2. Check the coupling alignment; re-align the coupling, if required. (⇨ Section 5.6
Page 25)
NOTE
The coupling alignment check must be repeated after the pump has reached operating
temperature.
6.1.5 Start-up
DANGER
The permissible pressure and temperature limits will be exceeded if the pump is
operated with the suction and discharge lines closed.
Explosion hazard!
Leakage of hot or toxic fluids!
▷ Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷ Only start up the pump set with the discharge side gate valve slightly or fully
open.
DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid handled
Explosion hazard!
▷ Prime the pump as specified.
▷ Always operate the pump within the permissible operating range.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
✓ The system piping has been cleaned.

✓ The pump, suction line and inlet tank, if any, have been vented and primed with
the fluid to be handled.
✓ The filling and venting lines have been closed.
CAUTION
Start-up against open discharge line
Motor overload!
▷ Make sure the power reserve of the motor is sufficient.
▷ Use a soft starter.
▷ Use speed control.
1. Fully open the shut-off element in the suction head/suction lift line.
2. Close or slightly open the shut-off element in the discharge line.
3. Start up the motor.
4. Immediately after the pump has reached full rotational speed, slowly open the
shut-off element in the discharge line and adjust it to the duty point.
CAUTION
Misalignment of pump and coupling
Damage to pump, motor and coupling!
▷ When the operating temperature has been reached, switch off the pump set
and check the coupling alignment.
5. Check the coupling alignment and re-align the coupling, if required.
6.1.6 Checking the shaft seal

Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
NOTE
Mechanical seal failure may result in the fluid handled penetrating into the rolling element
bearing, where it may damage the grease fill. Whenever fluid leakage occurs, the rolling
element bearing should therefore also be replaced as a precaution. This is particularly
important when the pump is handling synthetic heat transfer fluids.
6.1.7 Shutdown
CAUTION
Heat build-up inside the pump
Damage to the shaft seal!
▷ Depending on the type of installation, the pump set requires sufficient after-run
time – with the heat source switched off – until the fluid handled has cooled
down.
✓ The shut-off element in the suction line is and remains open.

1. Close the shut-off element in the discharge line.
2. Switch off the motor and make sure the pump set runs down smoothly to a
standstill.
NOTE
If the discharge line is equipped with a non-return or check valve, the shut-off element
may remain open as long as there is back pressure.
For prolonged shutdown periods:

1. Close the shut-off element in the suction line.
2. Close the auxiliary connections.
If the fluid handled is fed in under vacuum, also supply the shaft seal with barrier
fluid during standstill.
CAUTION
Risk of freezing during prolonged pump shutdown periods
Damage to the pump!
▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect
them against freezing.
6.2 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature and speed
Explosion hazard!
Hot or toxic fluid may escape!
▷ Comply with the operating data indicated in the data sheet.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures exceeding those specified in the data
sheet or on the name plate unless the written consent of the manufacturer has
been obtained.
6.2.1 Ambient temperature
Observe the following parameters and values during operation:

Table 9: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 40 °C
Minimum See data sheet.
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
▷ Observe the specified limits for permissible ambient temperatures.
NOTE
After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is only
reached after a certain period of operation (up to 48 h depending on the conditions).
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 (d.o.l., star-delta, moments of inertia,
etc). Provided that the start-ups are evenly spaced over the period indicated, the
pump set can be started not more than 15 times per hour with the discharge-side
gate valve slightly open.
CAUTION
Re-start while motor is still running down
Damage to the pump (set)!
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
6.2.3 Flow rate

Table 10: Flow rate
Temperature range (t) Minimum flow rate Maximum flow rate
-30 to +350 °C ≈ 25 % of QOpt See hydraulic characteristic
curves
The calculation formula below can be used to check if an additional heat build-up
could lead to a dangerous temperature increase at the pump surface.
Table 11: 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 °C
6.2.4 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 power reserve of the motor is sufficient.
6.2.5 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, plain bearing and shaft seal are to be expected. In this case, reduce
the intervals commonly recommended for servicing and maintenance.
6.2.6 Permissible speed

Table 12: Permissible speed for pump control systems with continuously variable
speed adjustment
n min nmax
[rpm] [rpm]
800 -
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 once a month or once every three months for
approximately five minutes during prolonged shutdown periods.
This will prevent the formation of deposits within the pump and the pump
intake area.
The pump (set) is removed from the pipe and stored

✓ The pump has been properly drained (⇨ Section 7.3 Page 40) and the safety
instructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page
41)
1. Spray-coat the inside wall of the pump casing, and in particular the impeller
clearance areas, with a preservative.
2. Spray the preservative through the suction and discharge nozzles.
It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).
3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil and
grease, food-approved if required) to protect them against corrosion.
Observe the additional instructions. (⇨ Section 3.2 Page 13)
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 after storage

For returning the pump to service observe the sections on commissioning/start-up (⇨
Section 6.1 Page 30) and the operating limits. (⇨ Section 6.2 Page 33)
In addition, carry out all servicing/maintenance operations before returning the

pump (set) to service. (⇨ Section 7 Page 37)
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
▷ As soon as the work is completed, re-install and/or re-activate any safety-
relevant and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer seals.
7 Servicing/Maintenance
7.1 Safety regulations

DANGER
Improperly serviced pump set
Explosion hazard!
▷ Service the pump set regularly.
▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.
The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly familiar
with the manual.
WARNING
Pump set started up inadvertently
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up accidentally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
WARNING
Fluids posing a health hazard or hot fluids
Risk of personal injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps handling fluids posing a health hazard.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump (set) with a minimum of maintenance
expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service. Find
your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/
contact".
Never use force when dismantling and reassembling a pump set.
7.2 Servicing/inspection
7.2.1 Supervision of operation
DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
Fire hazard!
▷ Regularly check the rolling element bearings for running noises.
CAUTION
Increased wear due to dry running
▷ 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 33)
While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.
▪ Check the shaft seal.
▪ Check the static seals for leakages.
▪ Check the bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
▪ Monitor the correct functioning of any auxiliary connections.
▪ Monitor the stand-by pump.
To make sure that the stand-by pumps are ready for operation, start them up
once a week.
▪ Check the quench liquid level.
Make sure the quench pot always contains sufficient quench liquid.
NOTE
If the liquid level in the quench pot rises, fluid from the pump has mixed with the quench
liquid, which indicates leakage at the pump-end mechanical seal. During start-up it is
normal for the liquid level in the quench pot to rise until the operating temperature has
been reached.
NOTE
If the liquid level in the quench pot drops rapidly, this indicates leakage at the drive-end
mechanical seal. In this case, the quench liquid could mix with the grease of rolling
element bearing 321 and affect the lubrication. Check the rolling element bearing and
replace it, if required.
▪ Monitor the temperature of the rolling element bearing.
The bearing temperature must not exceed 90 °C (measured outside on the
bearing bracket).
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The rolling element bearing temperature of the pump (set) must never exceed
90 °C (measured on the outside of the bearing bracket).
NOTE
After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is only
reached after a certain period of operation (up to 48 h depending on the conditions).
7.2.2 Inspection work
DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
▷ Regularly check the coupling guard, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.
7.2.2.1 Checking the coupling

Check the flexible elements of the coupling. Replace these parts in due time if there
is any sign of wear.
7.2.2.2 Checking the clearance gaps

Clearance gaps between impeller and casing
For checking the clearance gaps remove the impeller, if required. (⇨ Section 7.4.5
Page 42)
If the clearance gap is larger than permitted (see the following table), replace casing
wear rings 502.1 and/or 502.2 with new ones.
The clearance gaps given refer to the diameter.
Table 13: Clearance gaps between impeller and casing / between impeller and casing
cover
Permissible clearance gap in
[mm]
New 0.3
Maximum permissible enlargement 0.9
NOTE
If the clearances given are exceeded by more than 1 mm (referring to the diameter)
replace the affected components or restore the original clearance by means of a casing
wear ring.
Contact KSB.
Plain bearing clearances

Table 14: Plain bearing clearances in mm
Shaft unit Permissible clearance
[mm]
New Maximum permissible
enlargement
25 0.08 - 0.13 0.35
35 0.08 - 0.13 0.4
55 0.08 - 0.13 0.4
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 in appropriate intervals.
7.2.3 Lubricating the rolling element bearing
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
Fire hazard!
▷ Regularly check the bearing seal.
The bearings are delivered packed for life with a special high-temperature grease.
7.2.3.1 Intervals
Under normal operating conditions the grease-packed rolling element bearing will
run for 15,000 operating hours. Under unfavourable operating conditions (e.g. high
room temperature, high atmospheric humidity, dust-laden air, aggressive industrial
atmosphere etc.), check the rolling element bearing earlier and replace it, if required.
7.2.4 Lubricating the plain bearing

The pump-end plain bearing is lubricated by the fluid handled. It is maintenance-
free.
7.3 Drainage/disposal
WARNING
Fluids posing a health hazard
Hazardous to persons and the environment!
▷ Collect and properly dispose of flushing liquid and any fluid residues.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. For draining the fluid handled use connection 6B (see drawing of auxiliary
connections).
2. If noxious, explosive, hot or other hazardous fluids have been handled, flush the
pump.
Always flush and clean the pump before transporting it to the workshop. Provide
a cleaning record for the pump.
7.4 Dismantling the pump set
7.4.1 General notes/Safety regulations
WARNING
Unqualified personnel performing work on the pump (set)
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
WARNING
Hot surface
▷ Allow the pump set to cool down to ambient temperature.
Observe the general safety instructions and information. (⇨ Section 7.1 Page 37)
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly observe the exploded views and the general
assembly drawing.
NOTE
All maintenance, service and installation work can be carried out by KSB Service. Find
your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/
contact".
DANGER
Insufficient preparation of work on the pump (set)
▷ Properly shut down the pump set. (⇨ Section 6.1.7 Page 32)
▷ Close the shut-off elements in the suction and discharge line.
▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 40)
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
NOTE
After a prolonged period of operation the individual parts may be hard to pull off the
shaft. If this is the case, use a brand name penetrating agent and/or - if possible - an
appropriate pull-off device.
7.4.2 Preparing the pump set

1. Disconnect the power supply (e.g. at the motor).
2. Disconnect and remove all auxiliary pipework.
3. Remove the coupling guard.
4. Remove the coupling spacer, if any.
7.4.3 Dismantling the motor

NOTE
For pump sets with spacer-type couplings, the back pull-out unit can be removed while
the motor remains bolted to the baseplate.
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.
WARNING
Motor tipping over
Risk of squashing hands and feet!
▷ Suspend or support the motor to prevent it from tipping over.
7.4.4 Removing the back pull-out unit

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.3 Page
42) 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 nuts 920.1 at the volute casing.
4. Pull the back pull-out unit out of the volute casing.
5. Remove and dispose of joint ring 411.4.
WARNING
Thin metal foil used as carrier material in joint rings
Risk of injury (cuts)!
▷ Wear protective clothing.
▷ Always use an appropriate tool to remove joint rings.
6. Place the back pull-out unit on a clean and level surface.
7.4.5 Removing the impeller

✓ The back pull-out unit is kept in a clean and level assembly area.
1. Undo impeller nut 920.3 (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 940.1 from shaft 210.
7.4.6 Dismantling the shaft seal
7.4.6.1 Removing the pump assembly from the bearing bracket — all shaft units
✓ The back pull-out unit is kept in a clean and level assembly area.
1. Undo nuts 920.2.
2. Pull bearing bracket 330 out of discharge cover 163.
WARNING
Thin metal foil used as carrier material in joint rings
Risk of injury (cuts)!
▷ Wear protective clothing.
▷ Always use an appropriate tool to remove joint rings.
3. Remove and dispose of joint ring 411.3.
4. Remove bearing cover 360.
5. Remove circlip 932.2.
6. Press shaft 210 out of bearing bracket 330.
7.4.6.1.1 Dismantling a single-acting mechanical seal — shaft units 25 and 35
✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.6.1 Page
1. Remove circlip 932.1 and support disc 550.2.
2. Pull bearing 321 off shaft 210.
3. Remove support disc 550.1 and seat ring holder 476.
4. Press the seat ring of mechanical seal 433 out of seat ring holder 476.
5. Remove the rotating assembly of mechanical seal 433 (spring-loaded ring) from
shaft 210.
7.4.6.1.2 Dismantling a single-acting mechanical seal — shaft unit 55
2. Remove the rotating assembly of mechanical seal 433 (spring-loaded ring) from
the shaft.
3. Remove seat ring holder 476.
4. Press the seat ring of mechanical seal 433 out of seat ring holder 476.
7.4.6.1.3 Dismantling a double-acting mechanical seal — shaft units 25 and 35

2. Pull bearing 321 off shaft 210.
3. Remove support disc 550.1 and seat ring holder 476.
4. Press the seat ring of mechanical seal 433.2 out of seat ring holder 476.
5. Remove spacer sleeve 525.
6. Remove the rotating assembly of mechanical seal 433.2 (spring-loaded ring) from
the shaft.
8. Remove seat ring holder 476.1.
9. Press the seat ring of mechanical seal 433.1 out of seat ring holder 476.1.
the shaft.
7.4.6.1.4 Dismantling a double-acting mechanical seal — shaft unit 55

the shaft.
3. Remove seat ring holder 476.1.
4. Press the seat ring of mechanical seal 433.1 out of seat ring holder 476.1.
5. Remove spacer sleeve 525.
the shaft.
8. Remove seat ring holder 476.
9. Press the seat ring of mechanical seal 433.2 out of seat ring holder 476.
7.4.7 Removing the plain bearing

Removing the carbon bearing
1. Push plain bearing 310 out of bearing bracket 330 from the drive end.
Removing the SiC bearing

2. Pull bearing sleeve 529 off shaft 210.
4. Push bush 540.1 and bearing bush 381 out of bearing bracket 330 from the drive
end.
7.5 Reassembling the pump set
7.5.1 General notes/Safety regulations

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 or exploded view.
Seal elements Check O-rings for any damage and replace by new O-rings, if required.
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).
Assembly adhesives Avoid the use of assembly adhesives, if possible.
Should an assembly adhesive be required after all, use a commercially available
contact adhesive (e.g. "Pattex") or sealant (e.g. HYLOMAR or Epple 33).
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 with graphite or similar
before reassembly.
Tightening torques For reassembly, tighten all screws/bolts as specified in this manual. (⇨ Section 7.6
Page 48)
7.5.2 Installing the plain bearing

Fitting the carbon bearing
✓ The individual parts are kept in a clean and level assembly area.
✓ All disassembled parts have been cleaned and checked for wear.
✓ Any damaged or worn parts have been replaced by original spare parts.
✓ The sealing surfaces have been cleaned.
1. Press plain bearing 310 carefully into bearing bracket 330 until it will not go any
further.
Fitting the SiC bearing
✓ The individual parts are kept in a clean and level assembly area.
1. Push bearing sleeve 529 onto shaft 210.
2. Fit circlip 932.7.
3. Fit O-rings 412.3 at both sides of bearing bush 381.
4. Carefully press bearing bush 381 into bearing bracket 330.
5. Fit bush 540.1.
7.5.3 Installing the shaft seal
Installing the mechanical Always observe the following rules when installing the mechanical seal:
seal ▪ Work cleanly and accurately.
▪ Only remove the protective wrapping of the contact faces immediately before
assembly takes place.
▪ Prevent any damage to the sealing surfaces or O-rings.
7.5.3.1 Installing a single-acting mechanical seal — shaft units 25 and 35

1. Clean the seat ring location in seat ring holder 476.
2. Carefully insert the seat ring of mechanical seal 433 into seat ring holder 476.
Press it in evenly.
3. Slide the rotating assembly of the mechanical seal (spring-loaded ring) onto shaft
210.
4. Fit seat ring holder 476 with O-Ring 412.1.

5. Fit support disc 550.1.
6. Press radial ball bearing 321 onto the shaft and secure it with support disc 550.2
and circlip 932.1.
7.5.3.2 Installing a single-acting mechanical seal — shaft unit 55
1. Clean the seat ring location in seat ring holder 476.

2. Carefully insert the seat ring of mechanical seal 433 into seat ring holder 476.
Make sure to apply pressure evenly.
4. Slide the rotating assembly of the mechanical seal (spring-loaded ring) onto shaft
210.
5. Fit support disc 550.5 and circlip 932.4.
7.5.3.3 Installing a double-acting mechanical seal — shaft units 25 and 35

1. Clean the seat ring location of seat ring holders 476 and 476.1.
2. Insert the seat rings of mechanical seals 433.1 and 433.2 into seat ring holders
476 and 476.1.
Press them in evenly.
3. Slide the rotating assembly of the mechanical seal 433.1 (spring-loaded ring)
onto shaft 210.
4. Fit seat ring holder 476.1 with O-Ring 412.2.
5. Fit circlip 932.5 and support disc 550.6.
6. Slide the rotating assembly of mechanical seal 433.2 (spring-loaded ring) onto
shaft 210.
7. Fit spacer sleeve 525.
9. Fit support disc 550.1.
10. Press radial ball bearing 321 onto the shaft and secure it with support disc 550.2
and circlip 932.1.
7.5.3.4 Installing a double-acting mechanical seal — shaft unit 55

1. Clean the seat ring location of seat ring holders 476 and 476.1.
2. Insert the seat rings of mechanical seals 433.1 and 433.2 into seat ring holders
476 and 476.1.
Press them in evenly.
shaft 210.
5. Fit spacer sleeve 525 with seat ring holder 476.1 and O-Ring 412.2.
shaft 210.
7.5.3.5 Installing the shaft assembly in the bearing bracket — all shaft units
1. Carefully press the shaft assembly into bearing bracket 330.

3. Fit bearing cover 360.
7.5.4 Fitting the impeller

✓ The assembled bearing bracket as well as the individual parts are kept in a clean
and level assembly area.
1. Insert key 940.1 and push impeller 230 onto shaft 210.
2. Fasten impeller nut 920.3, spring washer 930 and disc 550.3, if any (see table:
Tightening torques for screwed connections at the pump (⇨ Section 7.6 Page
48)).
7.5.5 Installing the back pull-out unit
WARNING
Back pull-out unit tipping over
▷ Suspend or support the bearing bracket at the pump end.
✓ For back pull-out units without coupling, install the coupling in accordance with
the manufacturer's instructions.
1. Insert new joint ring 411.4 into volute casing 102.
2. If required, prevent the back pull-out unit from tipping over, e.g. by suspending
or supporting it. Then push it into volute casing 102.
3. Tighten nut 920.1 at the volute casing. Observe the tightening torques.
4. Fasten support foot 183 to the baseplate with a foundation bolt.
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 the pump. (⇨ Section 5.7 Page 26)
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
Fig. 15: Tightening points at the pump

Table 15: Tightening torques for screwed connections at the pump
Position Thread size Rated torque5)
[Nm]
901.2 M12 50
902.1/920.1 M10 35
M12 50
902.2/920.2 M8 20
M10 35
920.3 M12 x1.5 55
M24 x 1.5 130
M30 x 1.5 170
7.6.2 Tightening torques for the pump set

5
1215:5/2
6
1 2 6 3 4
Fig. 16: Tightening points at the pump set
Table 16: Tightening torques for the pump set
Position Thread size Rated Description
torque
[Nm]
1 M12 30 Pump on baseplate
M16 75
M20 75
2 M12 30
3 M24 x 1.5 140 Levelling screws in baseplate
M36 x 1.5 140
5) Valid for unlubricated threads
Position Thread size Rated Description

torque
[Nm]
4 M6 10 Motor on baseplate or
M8 10 motor on levelling screws or shims
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
▪ Material variant
▪ Size
▪ Seal code
▪ KSB order number
▪ Order item number
▪ Consecutive number
▪ Year of construction
Refer to the name plate for all data. (⇨ Section 4.3 Page 15)
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 exploded view or general assembly drawing for part numbers and
descriptions. (⇨ Section 9.1 Page 55)
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 17: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 10 and
more
210 Shaft 1 1 1 2 2 2 20 %
230 Impeller6) 1 1 1 2 2 2 20 %
310 Plain bearing 2 3 4 5 7 9 100 %
321 Radial ball bearing 1 1 2 2 2 3 25 %
6) Including casing wear ring 502.2
Part No. Description Number of pumps (including stand-by pumps)

2 3 4 5 6 and 7 8 and 9 10 and
more
330 Bearing bracket7) - - - - - 1 2
433 Mechanical seal8) 1 1 2 2 3 3 25 %
502.1/.2 Casing wear ring 1 1 1 2 2 2 20 %
411.3/.4 Joint ring 4 6 8 8 9 12 150 %
412 O-ring9) 4 6 8 8 9 10 100 %
- Torque-transmitting 1 1 2 2 3 4 30 %
coupling elements (set)
7) Complete bearing bracket. Example of a pump set with single-acting mechanical seal and carbon plain bearing: shaft 210,
plain bearing 310, radial ball bearing 321, bearing bracket 330, bearing cover 360, joint ring 411.1, O-ring 412.1/.2,
mechanical seal 433, seat ring holder 476, disc 550.1/.2/.3, hexagon head bolt 901.1, screwed plug 903, plug 916, hexagon
nut 920.3, spring washer 930, circlip 932.1/.2
8) For double-acting mechanical seals double the quantity.
9) For double-acting mechanical seal: parts 412.1 and 412.2
7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.
Table 18: Interchangeability of pump components
Description
Casing wear ring, discharge side

Casing wear ring, suction side
Deep-groove ball bearing10)
Mechanical seal10) 12)

Bearing housing11)
Seat ring holder10)

Bearing bracket10)
Mechanical seal11)
Bearing cover10)
Discharge cover
Support foot10)
Plain bearing
Seal cover11)
Impeller
Shaft 10)
Etanorm SYT
Etabloc SYT
Etaline SYT
Shaft unit
Part No.
502.1
502.2
163
183
210
230
310
321
330
350
360
433
433
471
476
32-125.5 25 32-125.1/. - 1 1 1 O O 1 1 1 1 1 3 1 1 1 X
32-160.1 25 32-160.1/. 40-160/.. 1 2 1 1 O 1 1 1 1 1 3 1 1 1 3
32-200.1 25 32-200.1/. 40-200/.. 2 3 1 2 O 1 1 1 1 1 3 1 1 1 3
32-160 25 32-160/.. 50-160/.. 1 2 1 1 O 1 1 1 1 1 3 1 1 1 3
32-200 25 32-200/.. 50-200/.. 2 3 1 2 O 1 1 1 1 1 3 1 1 1 3
32-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 1 10
40-160 25 40-160/.. 65-160/.. 1 2 1 O O 1 1 1 1 1 3 1 1 2 3
40-200 25 40-200/.. 65-200/.. 2 3 1 O O 1 1 1 1 1 3 1 1 O 3
40-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 2 10
40-315 35 - - O 7 2 O 3 2 2 - 2 2 - - 2 2 13
50-160 25 50-160/.. 80-160/.. 1 3 1 O O 1 1 1 1 1 3 1 1 3 3
50-200 25 50-200/.. 80-200/.. 2 3 1 O O 1 1 1 1 1 3 1 1 3 3
50-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 3 10
50-315 35 - - 7 7 2 O 3 2 2 - 2 2 - - 2 4 11
65-160 25 65-160/.. 100-160/.. 4 3 1 O O 1 1 1 1 1 3 1 1 4 5
65-200 25 65-200/.. - O 4 1 O O 1 1 - 1 1 - - 1 4 5
65-250 35 - - O 5 2 O 3 2 2 - 2 2 - - 2 5 13
65-315 35 - - 7 7 2 O 3 2 2 - 2 2 - - 2 5 11
80-160 25 80-160/.. 100-170/.. 4 4 1 O O 1 1 - 1 1 - - 1 6 5
80-200 35 - - 5 O 2 O 3 2 2 - 2 2 - - 2 6 11
80-250 35 - - 6 5 2 O 3 2 2 - 2 2 - - 2 6 11
80-315 35 - - 7 6 2 O 3 2 2 - 2 2 - - 2 6 11
100-160 35 - - 5 5 2 O 3 2 2 - 2 2 - - 2 7 11
100-200 35 - - 5 5 2 O 3 2 2 - 2 2 - - 2 7 11
100-250 35 - - 6 7 2 O 3 2 2 - 2 2 - - 2 7 11
100-315 35 - - 7 6 2 O 3 2 2 - 2 2 - - 2 7 11
125-200 35 - - O 6 2 O 3 2 2 - 2 2 - - 2 8 O
125-250 35 - - O 6 2 O 3 2 2 - 2 2 - - 2 8 O
125-315 55 - - 8 9 3 O 3 3 3 - 3 2 - - 3 8 12
125-400 55 - - 9 8 3 O 3 3 3 - 3 2 - - 3 8 12
150-315 55 - - 8 9 3 O 3 3 3 - 3 2 - - 3 9 12
150-400.1 55 - - 10 8 3 O 3 3 3 - 3 2 - - 3 9 -
10) Etanorm SYT only

11) Etabloc SYT/Etaline SYT only
12) Single-acting mechanical seal 433 not interchangeable with double-acting mechanical seal 433.1/.2
Table 19: Key to the symbols

Symbol Description
X Components differ
O Component not fitted
8 Trouble-shooting
8 Trouble-shooting
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 20: Trouble-shooting
A B C D E F G H Possible cause Remedy13)
X Pump delivers against an excessively Re-adjust to duty point.
high discharge pressure. Check system for impurities.
Fit a larger impeller.14)
Increase the speed (turbine, I.C. engine).
X X X Pump or piping are not completely Vent and/or prime.
vented or primed. Clean vent hole.
X Supply line or impeller clogged Remove deposits in the pump and/or piping.
X Formation of air pockets in the piping Alter piping layout.
Fit vent valve.
X X X Suction head is too high, NPSHavailable Check/alter fluid level.
(positive suction head) is too low. Install pump at lower level.
Fully open shut-off element in suction/inlet
line.
Change suction line if friction losses in suction
line are too high.
Check any strainers installed/suction opening.
Observe permissible speed of pressure fall.
X Wrong direction of rotation Interchange two of the phases of the power
cable.
X Speed is too low.
- Operation with frequency inverter - Increase voltage/frequency at FI in

permissible range.
- Operation without frequency inverter - Check voltage.
X X Wear of internal parts Replace worn parts by new ones.
X X Pump back pressure is lower than Re-adjust to duty point.
specified in the purchase order. In the case of persistent overloading, turn
down impeller.14)
X Density or viscosity of the fluid handled Contact KSB.
is higher than stated in the purchase
order.
X X Speed is too high. Reduce speed.14)
X Defective seal Fit new seal between volute casing and
discharge cover or between discharge cover
and bearing bracket.
13) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
14) Contact KSB.
8 Trouble-shooting
A B C D E F G H Possible cause Remedy13)

X Joint ring not pre-loaded sufficiently Increase pre-loading of the joint ring at
operating temperature:
1. Close the valves on the discharge and
suction side.
2. Allow the pump set to cool down to a
temperature below the boiling point of
the fluid handled.
3. Re-tighten hexagon nuts 920.1 and 920.1
at the discharge cover.
4.
Start up the pump set. (⇨ Section 6 Page
30)
X Worn shaft seal Replace shaft seal.
Check flushing liquid/barrier fluid.
X Vibrations during pump operation Correct suction conditions.
Re-align pump set.
Re-balance impeller.
Increase pressure at pump suction nozzle.
X X X The pump set is misaligned. Re-align the pump set.
X X X Pump is warped or sympathetic Check pipeline connections and secure fixing
vibrations in the piping. of pump; if required, reduce distances
between pipe clamps.
Fix pipelines using anti-vibration material.
X Increased axial thrust14) Clean balancing holes in the impeller.
Replace the casing wear rings.
X Non-compliance with specified coupling Correct distance according to the general
distance arrangement drawing.
X X Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
X Rotor is out of balance. Clean impeller.
Re-balance impeller.
X Defective bearing Fit new bearing.
X X X Insufficient flow rate Increase the minimum flow rate.
13) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
9 Related Documents
9 Related Documents
9.1 Exploded views and lists of components
9.1.1 Etanorm SYT, SU 25
Fig. 17: Exploded view Etanorm SYT, SU 25

Table 21: List of components
Part No. Description Part No. Description Part No. Description
102 Volute casing 412.1 O-ring 930 Spring washer
163 Discharge cover 433 Mechanical seal 932.1/.2 Circlip
183 Support foot 476 Seat ring holder 940.1/.2 Key
210 Shaft 502.1/.215) Casing wear ring 99-20 Repair kit
230 Impeller 550.1/.2/.3 Disc
310 Plain bearing 901.2 Hexagon head bolt
321 Radial ball bearing 902.1/.2 Stud with reduced 1M Connection for
shank pressure gauge
330 Bearing bracket 903.1/.2 Screwed plug 6B Fluid drain
360 Bearing cover 914 Pan head screw 6D Fluid vent
411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 8B Leakage drain
15) 502.2 not for pump size 32-125.1
9 Related Documents
9.1.2 Etanorm SYT, SU 25 with double-acting mechanical seal
Fig. 18: Exploded view of Etanorm SYT, SU 25 with double-acting mechanical seal
102 Volute casing 433.1/.2 Mechanical seal 930 Spring washer
163 Discharge cover 476/476.1 Seat ring holder 932.1/.2/.5 Circlip
183 Support foot 940.1/.2 Key
230 Impeller 525 Spacer sleeve
310 Plain bearing 550.1/.2/.3/.6 Disc 24A Outlet of the quench
liquid
321 Radial ball bearing 901.2 Hexagon head bolt 24E Inlet of the quench
liquid
330 Bearing bracket 902.1/.2 Stud with reduced 1M Connection for
360 Bearing cover 903.1/.2 Screwed plug 6B Fluid drain
411.1/.3/.4/.5 Joint ring 914 Pan head screw 6D Fluid vent
412.1/.2 O-ring 920.1/.2/.3 Nut 8B Leakage drain
16) 502.2 not for pump size 32-125.1
9 Related Documents

163 Discharge cover 433 Mechanical seal 932.1/.2/.4 Circlip
210 Shaft 502.1/.2 Casing wear ring 99-20 Repair kit
9 Related Documents
102 Volute casing 433.1/.2 Mechanical seal 932.1/.2/.4/.5 Circlip
163 Discharge cover 476/476.1 Seat ring holder 940.1/.2 Key
183 Support foot 502.1/.2 Casing wear ring 99-20 Repair kit
210 Shaft 525 Spacer sleeve
230 Impeller 550.1/.2/.5/.6 Disc
310 Plain bearing 901.2 Hexagon head bolt 24A Outlet of the quench
liquid
321 Radial ball bearing 902.1/.2 Stud with reduced 24E Inlet of the quench
shank liquid
330 Bearing bracket 903.1/.2 Screwed plug 1M Connection for
pressure gauge
360 Bearing cover 914 Pan head screw 6B Fluid drain
411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 6D Fluid vent
412.1/.2 O-ring 930 Spring washer 8B Leakage drain
9 Related Documents
UG1289004

163 Discharge cover 433 Mechanical seal 932.1/.2/.4 Circlip
17) 502.2 not for pump size 150-400.1
9 Related Documents
UG1289009
102 Volute casing 433.1/.2 Mechanical seal 932.1/.2/.4/.5 Circlip
163 Discharge cover 476/476.1 Seat ring holder 940.1/.2 Key
183 Support foot 502.1/.218) Casing wear ring 99-20 Repair kit
210 Shaft 525 Spacer sleeve
230 Impeller 550.1/.2/.5/.6 Disc
310 Plain bearing 901.2 Hexagon head bolt 24A Outlet of the quench
liquid
321 Radial ball bearing 902.1/.2 Stud with reduced 24E Inlet of the quench
shank liquid
330 Bearing bracket 903.1/.2 Screwed plug 1M Connection for
pressure gauge
360 Bearing cover 914 Pan head screw 6B Fluid drain
411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 6D Fluid vent
412.1/.2 O-ring 930 Spring washer 8B Leakage drain
18) Not for pump size 150-400.1
9 Related Documents
9.1.7 Etanorm SYT with SiC plain bearing
Fig. 23: Exploded view of Etanorm SYT, SIC plain bearing

381 Bearing cartridge 412.3 O-ring 529 Bearing sleeve
540.1 Bush 561 Grooved pin 932.6/.7 Circlip
9.2 Wiring diagrams for double-acting mechanical seal
Fig. 24: Wiring diagram for double-acting mechanical seal
1M.1/.2 Connection for pressure gauge

6B Fluid drain
6D Fluid vent
8B Leakage drain
24A Outlet of the quench liquid
24E Inlet of the quench liquid
10 EC Declaration of Conformity
10 EC Declaration of Conformity
Manufacturer: KSB Aktiengesellschaft

Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the pump/pump set:
Etabloc, Etabloc SYT, Etaline, Etaline SYT, Etaline Z,

Etachrom NC, Etachrom BC, Etanorm, Etanorm SYT,
Etanorm GPV/CPV, Etaprime L, Etaprime B/BN, Vitachrom
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following directives as applicable in their current version:
– EC Machinery Directive 2006/42/EC
The manufacturer also declares that

▪ the following harmonised international standards have been applied:
– ISO 12100-1/A1, ISO 12100-2/A1,
– ISO 14121-1,
– EN 809/A1
Frankenthal, 29 December 2009

...........................................................
Name
Function
Responsible for compiling the technical documentation
KSB Aktiengesellschaft
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
11 Certificate of Decontamination
11 Certificate of Decontamination
Type ................................................................................................................................
Order number/
Order item number19) ................................................................................................................................
Delivery date ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled19) : ................................................................................................................................
Please tick where applicable19) :
⃞ ⃞ ⃞ ⃞
radioactive explosive corrosive toxic
⃞ ⃞ ⃞ ⃞
harmful bio-hazardous highly flammable safe
Reason for return19) : ................................................................................................................................
Comments: ................................................................................................................................
................................................................................................................................
The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing
at your disposal.
On sealless pumps, the rotor has been removed from the pump for cleaning.
⃞ 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
19) Required fields
Index
Index
A M
Abrasive fluids 35 Maintenance/repair 37
Mechanical seal 32
Misuse 9
B Monitoring equipment 12
Bearing temperature 38
Bearings 16
N
Name plate 15
C Noise characteristics 17
Certificate of decontamination 63
Clearance gaps 39
Commissioning/start-up 30 O
Coupling 39 Operating limits 8, 33
Coupling alignment 25 Order number 6
Ordering spare parts 49
Other applicable documents 6
D
Design 15, 16
Designation 15 P
Direction of rotation 29 Partly completed machinery 6
Dismantling 41 Permissible forces at the pump nozzles 22
Disposal 14 Piping 21
Preservation 14, 35
Pump casing 15
E
Explosion protection 11, 18, 19, 25, 27, 28, 30, 31, 33,
34, 37, 38, 39, 40 R
Reassembly 41, 44
Return to supplier 14
F Returning to service 35
Fault/malfunction 53
Filling and venting 30
Filter 21, 40 S
Final check 31 Safety 8
Frequency of starts 34 Safety awareness 9
Function 16 Scope of supply 18
Shaft seal 16
Shutdown 35
G Spare parts stock 49
Grease lubrication Start-up 32
Intervals 40 Storage 14, 35
I T
Impeller type 16 Temperature limits 11
Installation Tightening torques 48
Installation on the foundation 19 Transport 13
Installation without foundation 20
Installation at site 19
Intended use 8
Interchangeability of pump components 51
1226.8-10
KSB Aktiengesellschaft
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.com

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© KSB Aktiengesellschaft Frankenthal 17.03.2010

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

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

5 Installation at Site ............................................................................. 19

5.5 Protective equipment ................................................................................... 25

9 Related Documents ........................................................................... 55

10 EC Declaration of Conformity ......................................................... 62

11 Certificate of Decontamination ....................................................... 63

Back pull-out design Pool of pumps

Noise characteristics (⇨ Section 4.6 Page 17)

1.2 Installation of partly completed machinery

1.3 Target group

1.4 Other applicable documents

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

2.1 Key to safety symbols/markings

2.3 Intended use

Prevention of foreseeable misuse

2.4 Personnel qualification and training

The responsibilities, competence and supervision of all personnel involved in

Deficits in knowledge must be rectified by sufficiently trained specialist personnel

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

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

2.6 Safety awareness

▪ Safety regulations for handling hazardous substances

2.7 Safety 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

Special conditions apply to the operation of explosion-proof pump sets to EC

Motor The motor must be considered separately.

2.10.2 Temperature limits

Misuse, malfunctions or non-compliance with the instructions may result in

If the pump is to be operated at a higher temperature, the data sheet is missing or if

2.10.3 Monitoring equipment

2.10.4 Operating limits

Fig. 1: Transporting the pump

Fig. 2: Transporting the complete pump set

Fig. 3: Transporting the pump on the baseplate

3.2 Storage and preservation

3.3 Return to supplier

1. Dismantle the pump (set).

4 Description of the Pump (Set)

4.1 General description

4.3 Name plate

Fig. 4: Name plate Etanorm SYT

1 Type series, size and version 2 KSB order number

4.4 Design details

▪ Replaceable casing wear rings

4.5 Configuration and function

Fig. 5: Sectional drawing

1 Clearance gap 2 Discharge nozzle

Sealing The pump is sealed by a standardised mechanical seal.

4.6 Noise characteristics

4.7 Scope of supply

4.8 Dimensions and weights

5.1 Safety regulations