Multitec a Sx Operating Instructions

Sprinkler Pump

Multitec A SX

Installation/OperatingManual

Legal information/Copyright Installation/Operating Manual Multitec A SXOriginal operating manual KSB Aktiengesellschaft Frankenthal All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, editedor processed for any other purpose, nor otherwise transmitted, published or made available to a thirdparty without KSBs express written consent. Subject to technical modification without prior notice. KSB Aktiengesellschaft Frankenthal 07.10.2010

Contents Glossary ................................................................................................ 51 General ................................................................................................ 61.1 Principles .......................................................................................................... 61.2 Installation of partly completed machinery .................................................. 61.3 Target group ................................................................................................... 61.4 Other applicable documents .......................................................................... 61.5 Symbols ............................................................................................................ 6

2 Safety ................................................................................................... 82.1 Key to safety symbols/markings ..................................................................... 82.2 General ............................................................................................................ 82.3 Intended use .................................................................................................... 82.4 Personnel qualification and training ............................................................. 92.5 Consequences and risks caused by non-compliance with these operating

instructions ...................................................................................................... 92.6 Safety awareness ............................................................................................. 92.7 Safety information for the operator/user .................................................... 102.8 Safety information for maintenance, inspection and installation work ... 102.9 Unauthorised modes of operation ............................................................... 102.10 Explosion protection ..................................................................................... 10

3 Transport/Temporary Storage/Disposal ........................................... 133.1 Transport ....................................................................................................... 133.2 Storage/preservation ..................................................................................... 133.3 Return to supplier ......................................................................................... 143.4 Disposal .......................................................................................................... 14

4 Description of the Pump (Set) .......................................................... 154.1 General description ....................................................................................... 154.2 Designation ................................................................................................... 154.3 Name plate .................................................................................................... 154.4 Design details ................................................................................................ 164.5 Configuration and function ......................................................................... 174.6 Noise characteristics ...................................................................................... 184.7 Scope of supply ............................................................................................. 184.8 Dimensions and weights ............................................................................... 19

5 Installation at Site ............................................................................. 205.1 Safety regulations ......................................................................................... 205.2 Checks to be carried out prior to installation ............................................. 205.3 Installing the pump set ................................................................................. 205.4 Piping ............................................................................................................. 22

Contents

Multitec A SX 3 of 64

5.5 Checking the coupling alignment ................................................................ 245.6 Aligning the pump and motor ..................................................................... 255.7 Electrical connection ..................................................................................... 265.8 Checking the direction of rotation .............................................................. 28

6 Commissioning/Start-up/Shutdown ................................................. 296.1 Commissioning/start-up ................................................................................ 296.2 Operating limits ............................................................................................ 336.3 Shutdown/storage/preservation ................................................................... 356.4 Returning to service ...................................................................................... 36

7 Servicing/Maintenance ...................................................................... 377.1 Safety regulations ......................................................................................... 377.2 Maintenance/inspection ............................................................................... 377.3 Drainage/disposal .......................................................................................... 427.4 Dismantling the pump set ............................................................................ 437.5 Reassembling the pump set .......................................................................... 487.6 Tightening torques ....................................................................................... 547.7 Spare parts stock ........................................................................................... 55

8 Trouble-shooting ............................................................................... 579 Related Documents ........................................................................... 599.1 General assembly drawing with list of components ................................... 59

10 EC Declaration of Conformity .......................................................... 6111 Certificate of Decontamination ....................................................... 62 Index .................................................................................................. 63

Contents

4 of 64 Multitec A SX

GlossaryCertificate of decontamination

A certificate of decontamination certifies thatthe pump (set) has been properly drained toeliminate any environmental and healthhazards arising from components in contactwith the fluid handled.

Discharge lineThe line which is connected to the dischargenozzle

DriveElectric / hydraulic drive, Diesel engine orturbine up to max. 4000 rpm.

Hydraulic systemThe part of the pump in which the kineticenergy is converted into pressure energy

Pool of pumpsPumps which are purchased and storedindependently of their later use

PumpMachine without drive, additional componentsor accessories

Pump setComplete pump set consisting of pump, drive,additional components and accessories

RotorFully assembled unit of all rotating parts,without mechanical seal, rolling elementbearings or plain bearings

Suction lift line/suction head lineThe line which is connected to the suctionnozzle

Glossary


1 General

1.1 PrinciplesThis manual is supplied as an integral part of the type series and variants indicatedon the front cover. It describes the proper and safe use of this equipment in allphases of operation.

The name plate indicates the type series and size, the main operating data, the ordernumber and the order item number. The order number and order item numberclearly identify the pump (set) and serve as identification for all further businessprocesses.

In the event of damage, contact your nearest KSB service centre immediately tomaintain the right to claim under warranty.

Noise characteristics ( Section 4.6 Page 18)

1.2 Installation of partly completed machineryTo install partly completed machinery supplied by KSB, refer to the sub-sectionsunder Servicing/Maintenance.

1.3 Target groupThis manual is aimed at the target group of trained and qualified specialist technicalpersonnel. ( Section 2.4 Page 9)

1.4 Other applicable documentsTable 1: Overview of other applicable documentsDocument ContentsData sheet Description of the technical data of the pump

(set)General arrangement drawing/Outline drawing

Description of mating and installation dimensionsfor the pump (set)

Drawing of auxiliary connections Description of auxiliary connectionsHydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power inputGeneral assembly drawing1) Sectional drawing of the pumpSub-supplier product literature1) Operating manuals and other product literature

of accessories and integrated machinerycomponents

Spare parts lists1) Description of spare partsPiping layout1) Description of auxiliary pipingList of components1) Description of all pump components

1.5 SymbolsTable 2: Symbols used in this manual

Symbol Description Conditions which need to be fulfilled before proceeding with the

step-by-step instructions Safety instructions Result of an action Cross-references

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

1 General


Symbol Description1.2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General


2 SafetyAll the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markingsTable 3: Definition of safety symbols/markings

Symbol Description! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,

will result in death or serious injury.! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if not

avoided, could result in death or serious injury.CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, could

result in damage to the machine and its functions.Explosion protectionThis symbol identifies information about avoiding explosions inpotentially explosive atmospheres in accordance with EC Directive94/9/EC (ATEX).General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies informationabout protection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 GeneralThis manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent personal injuryand 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 specialistpersonnel/operators prior to installation and commissioning.The contents of this manual must be available to the specialist personnel at the siteat all times.Information attached directly to the pump must always be complied with and bekept in a perfectly legible condition at all times. This applies to, for example:

Arrow indicating the direction of rotation Markings for connections Name plate

The operator is responsible for ensuring compliance with all local regulations whichare not taken into account in this manual.

2.3 Intended useThe pump (set) must only be operated within the operating limits which aredescribed in the other applicable documents.

Only operate pumps/pump sets which are in perfect technical condition. Do not operate partially assembled pumps/pump sets.

! DANGER

2 Safety


Only use the pump to handle the fluids specified in the data sheet or productliterature 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 preventcavitation damage).

Consult the manufacturer about any use or mode of operation not described inthe 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 literaturewould 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 trainingAll personnel involved must be fully qualified to install, operate, maintain andinspect the machinery this manual refers to.The responsibilities, competence and supervision of all personnel involved ininstallation, operation, maintenance and inspection must be clearly defined by theoperator.Deficits in knowledge must be rectified by sufficiently trained specialist personneltraining and instructing the personnel who will carry out the respective tasks. Ifrequired, the operator can commission the manufacturer/supplier to train thepersonnel.Training on the pump (set) must always be supervised by technical specialistpersonnel.

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

Non-compliance with these operating instructions will lead to forfeiture ofwarranty 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 awarenessIn addition to the safety information contained in this manual and the intended use,the following safety regulations shall be complied with:

Accident prevention, health and safety regulations Explosion protection regulations

2 Safety


Safety regulations for handling hazardous substances Applicable standards and laws

2.7 Safety 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 any contact guards 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 nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

2.8 Safety information for maintenance, inspection and installation work Modifications or alterations of the pump are only permitted with the

manufacturer's prior consent. Use only original spare parts or parts authorised by the manufacturer. The use of

other parts can invalidate any liability of the manufacturer for resulting damage. The operator ensures that all maintenance, inspection and installation work is

performed by authorised, qualified specialist personnel who are thoroughlyfamiliar 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 33) Decontaminate pumps which handle fluids posing a health hazard. 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 allinstructions on commissioning. ( Section 6.1 Page 29)

2.9 Unauthorised modes of operationNever operate the pump (set) outside the limits stated in the data sheet and in thismanual.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 protectionAlways observe the information on explosion protection given in this section whenoperating the pump in potentially explosive atmospheres.Only pumps/pump sets marked as explosion-proof and identified as such in the datasheet may be used in potentially explosive atmospheres.Special conditions apply to the operation of explosion-proof pump sets to ECDirective 94/9/EC (ATEX). Especially adhere to the sections in this manual marked with the Ex symbol and thefollowing sections. ( Section 2.10.1 Page 11) to ( Section 2.10.4 Page 12) (Section 2.10.4 Page 12)

! DANGER

2 Safety


The explosion-proof status of the pump set is only assured if the pump set is used inaccordance with its intended use. Never operate the pump (set) outside the limits stated in the data sheet and on thename plate.Prevent impermissible modes of operation at all times.

2.10.1 MarkingThe marking on the pump refers to the pump part only. Example of such marking: II 2 G c TX Refer to the Temperature limits table for the temperatures permitted for theindividual pump variants. An EC manufacturer's declaration is required for the shaft coupling; the shaftcoupling must be marked accordingly.The motor must be considered separately.

2.10.2 Temperature limitsIn normal pump operation, the highest temperatures are to be expected on thesurface of the pump casing, at the shaft seal and in the bearing areas. The surfacetemperature at the pump casing corresponds to the temperature of the fluidhandled. If the pump is heated, the operator of the system is responsible forobserving the specified temperature classes and fluid temperature (operatingtemperature). The table below lists the temperature classes and the resultingtheoretical temperature limits of the fluid handled. (A possible temperature rise inthe shaft seal area has already been taken into account). The temperature class specifies the maximum permissible temperature at the surfaceof the pump set during operation. For the permissible operating temperature of the pump in question refer to the datasheet.Table 4: Temperature limits

Temperature class as per EN 13463-1 Max. permissible fluidtemperature

T1 200 CT2 200 CT3 185 CT4 120 CT5 85 CT6 on request only

Based on an ambient temperature of 40C, grease lubrication and propermaintenance and operation, compliance with temperature class T4 is warranted inthe area of the rolling element bearings.In the cases listed below, and if ambient temperatures exceed 40 C, contact themanufacturer.If temperature classes T5 and T6 have to be complied with, special measures mayhave to be taken with regard to bearing temperature.Misuse, malfunctions or non-compliance with the instructions may result insubstantially higher temperatures.A special design is required for compliance with temperature class T6.If the pump is to be operated at a higher temperature, if there is no data sheet, or ifthe pump is part of a pool of pumps, contact KSB for the maximum permissibleoperating temperature.

2.10.3 Monitoring equipmentThe pump (set) must only be operated within the limits specified in the data sheetand on the name plate. If the system operator cannot warrant compliance with these operating limits,

Pump

Shaft coupling

Motor

Temperature class T4

Temperature classes T5and T6

2 Safety


appropriate monitoring devices must be used. Check whether monitoring equipment is required to ensure that the pump setfunctions properly.Contact KSB for further information on monitoring equipment.

2.10.4 Operating limitsThe minimum flows indicated in ( Section 6.2.3 Page 34) refer to water and water-like fluids. Longer operating periods with these fluids and at the flow rates indicatedwill not cause an additional increase in the temperatures at the pump surface.However, if the physical properties of the fluids handled are different from water, itis essential to check whether an additional heat build-up may occur and if theminimum flow rate must therefore be increased. The calculation formula in (Section 6.2.3 Page 34) can be used to check whether an additional heat build-upmay lead to a hazardous temperature increase at the pump surface.

2 Safety


3 Transport/Temporary Storage/Disposal

3.1 TransportDANGER

The pump (set) could slip out of the suspension arrangementDanger 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.

Fig. 1: Transporting the pump

Fig. 2: Transporting the complete pump set

3.2 Storage/preservationIf commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for pump (set) storage.CAUTIONDamage during storage by humidity, dirt, or verminCorrosion/contamination of the pump (set)! For outdoor storage cover the packed or unpacked pump (set) and accessories

with waterproof material.

CAUTIONWet, contaminated or damaged openings and connectionsLeakage 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 asconstant 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 three months (please referto order or order confirmation).New pumps/pump sets are supplied by our factory duly prepared for storage.



For storage periods exceeding three months, the pump set is preserved as specified inthe purchase order (please refer to order or order confirmation).

3.3 Return to supplier1. Drain the pump as per operating instructions. 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 mightignite when coming into contact with oxygen, the pump set must also beneutralised, and anhydrous inert gas must be blown through the pump fordrying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set). ( Section 11 Page 62)Always indicate any safety and decontamination measures taken.

NOTEIf required, a blank certificate of decontamination can be downloaded from the KSB website at: www.ksb.com/certificate_of_decontamination

Also see Certificate of decontamination [ 62]

3.4 DisposalWARNING

Fluids posing a health hazard and/or hot fluidsHazard to persons and the environment! Collect and properly dispose of flushing liquid and any liquid 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 controlledmanner.



4 Description of the Pump (Set)

4.1 General description Sprinkler pump Multistage centrifugal pump in ring-section design with suction impeller for low

NPSH value.Type of installation Drawing Description

A Horizontal design, baseplate mounted,one casing entry (drive end), rolling element bearings (drive end) andplain bearing (suction end), axial suction nozzlefor the entire H/Q range

4.2 DesignationExample: Mult i tec A SX 100/3 - 8 .1 25.65Table 5: Key to the designation Code DescriptionMultitec Type seriesA Type of installationSX Variant (SX = sprinkler pump)100 Nominal discharge nozzle diameter [mm]3 No. of stages / impeller combination8.1 Hydraulic system25 Material code65 Seal code

4.3 Name plate

Aktiengesellschaft 67227 Frankenthal

SprinklerpumpeTypFabrikations-Nr.VdS-Anerkennungs-Nr.Q zulnnLaufraddurchmessermax. Anlaufstrom

l/min1/min

Jahr

HPm kW

m

mmA

Ident-No. 00 107 606 ZN 3814 - D 31

MULTITEC A SX 100/3 - 8.1 25.659971581385 000100 01

P 48404163.164,002930

269

Pn 12,00 bar

2010

94,7090,00

1

23

4

56789101112

Fig. 3: Name plate1 Year of construction 2 VdS approved head3 Required motor rating at 15 m

NPSH4 Nominal pressure



5 Maximum starting current (onlyrelevant for submersible boreholepumps)

6 Impeller diameter [mm]

7 Rated speed 8 VdS approved flow rate9 VdS approval number 10 KSB order and order item number11 Type series, size 12 Application

4.4 Design detailsDesign

Sprinkler pump High-pressure centrifugal pump Long-coupled (baseplate mounted) design Axial suction nozzle Radial discharge nozzle can be turned by 90. Horizontal/vertical installation

Pump cas ing Radially split volute casing Casing in ring-section design

Impel ler type Closed radial impeller with multiply curved vanes

Bearings Radial bearings are silicon carbide plain bearings. Self-aligning Plain bearing lubricated by fluid handled Fixed bearings are rolling element bearings. Grease or oil lubrication

Shaft seal Gland packing

DANGERExcessive temperatures in the shaft seal areaRisk of explosion! Never operate a pump (set) with gland packing in potentially explosive

atmospheres. Standardised mechanical seal to EN 12756



4.5 Configuration and function1 432 5

6 87 1413121110 159Fig. 4: Sectional drawing1 Clearance gap 2 Discharge nozzle3 Discharge casing 4 Shaft5 Bearing housing 6 Suction casing7 Plain bearing 8 (Suction) impeller9 Diffuser 10 Stage casing11 Impeller 12 Balance drum13 Shaft seal housing 14 Shaft seal15 Rolling element bearings The pump is designed with an axial fluid inlet and a radial outlet. The hydraulicsystem runs in its own bearings and is connected to the motor via a shaft coupling.The fluid enters the pump via the suction casing (6) and is accelerated outward in acylindrical flow by the rotating (suction) impeller (8). In the flow passage of the stagecasing (10) the kinetic energy of the fluid is converted into pressure energy and thefluid is routed to the next impeller (11) via the diffuser (9). This process is repeated inall stages until the fluid has passed the last impeller (11). It then passes through thedischarge casing (3) to the discharge nozzle (2), from where it leaves the pump. Theclearance gap (1) prevents any fluid from flowing back from the stage casing (10)into the suction range of the previous impeller. If required, a balance drum (12) isfitted behind the last impeller, providing axial thrust balancing by means of hydraulicforces. Behind the last impeller (11) and the balancing drum (12), the hydraulicsystem is closed off by a seal housing (13) through which the drive shaft (4) passes.The shaft passage through the seal housing (13) is sealed towards the atmosphere bya dynamic shaft seal (14). The drive shaft (4) is supported by rolling element bearings(15) and plain bearings (7) located in a bearing housing (5) and the suction casing (6),respectively. The bearing housing (5) is connected with the suction casing (6) and/ordischarge casing (3).The pump is sealed by a shaft seal.Standardised mechanical seal or gland packing

Design

Function

Sealing



4.6 Noise characteristicsTable 6: Surface sound pressure level LpA2) 3)

Rated powerinput PN

[kW]

Pump Pump set2900 rpm

[dB]2900 rpm

[dB]2.2 57 653.0 60 674.0 61 685.5 63 707.5 65 719 66 7311 67 7315 68 75

18.5 69 7622 70 7730 71 7837 72 7945 73 7955 74 8075 74 8290 75 82110 75 83132 76 83160 76 84200 77 85250 78 --315 78 --

Noise characteristics for higher power ratings on request.

4.7 Scope of supplyDepending on the model, the following items are included in the scope of supply:

Pump Electric / hydraulic drives, Diesel engines or turbines up to max. 4000 rpm Flexible coupling with or without spacer Coupling guard to EN 294

DANGERRisk of ignition by frictional sparksRisk 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. Channel section steel, welded U-rail As required

DriveShaft couplingContact guard

Baseplate

Special accessories

2) Measured at a distance of 1 m from the pump outline (as per DIN 45635 Parts 1 and 24)3) Increase for 60 Hz operation: 3500 rpm +3dB; 1750 rpm 1dB



4.8 Dimensions and weightsFor dimensions and weights please refer to the general arrangement drawing/outlinedrawing of the pump/pump set.



5 Installation at Site

5.1 Safety regulationsDANGER

Improper installation in potentially explosive atmospheresExplosion hazard!Damage to the pump set! Comply with the applicable local explosion protection regulations. Observe the information in the data sheet and on the name plates of pump and

motor.For positioning, installing and operating sprinkler pumps, generally comply with thefollowing fire protection standards and directives:

VDS CEA 4001 CEA 4001 EN 12845 NFPA 20 FM GLOBAL

5.2 Checks to be carried out prior to installationPlace of instal lat ion

WARNINGInstallation on foundations which are unsecured and cannot support the loadPersonal injury and damage to property! Make sure the foundation concrete is of sufficient strength (min. C12/15 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 thedimensions stated in the outline drawing/general arrangement drawing.

5.3 Installing the pump setCAUTIONWarped baseplate or pumpDamage to the pump! Align the baseplate and the pump accurately and carefully when setting up the

pump set.



5.3.1 Installation on the foundation

12

43Fig. 5: Fitting the shims

1 Bolt-to-bolt clearance 2 Shim3 Shim for bolt-to-bolt clearance >

800 mm4 Foundation bolt

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 align it with the help of a spirit

level placed on the shaft and discharge nozzle.Permissible deviation: 0.2 mm/m

2. Use shims (2) for height compensation, if necessary. Always fit shims between the baseplate/foundation frame and the foundationitself; always insert them to the left and right of the foundation bolts (4) and inclose proximity to these bolts.For a bolt-to-bolt clearance > 800 mm, fit additional shims (3) halfway betweenthe 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.7. Grout baseplates > 400 mm using low-shrinkage concrete with a standard particle

size and a water/cement ratio 0.5. Produce flowability with the help of a solvent. Perform secondary treatment of the concrete to DIN 1045.

NOTEFor low-noise operation contact KSB to check whether the pump set can be installed onanti-vibration mounts.

NOTEExpansion joints can be fitted between pump and suction/discharge line.



5.4 Piping

5.4.1 Connecting the pipingDANGER

Impermissible loads acting on the pump nozzlesDanger to life from leakage of hot, toxic, corrosive or flammable fluids! Do not use the pump as an anchorage point for the piping. Anchor the pipelines in close proximity to the pump and connect them without

transmitting any stresses or strains. Observe the permissible forces and moments at the pump nozzles. Take appropriate measures to compensate thermal expansion of the piping.CAUTIONIncorrect earthing during welding work at the pipingDestruction 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.NOTEIt is recommended to install check and shut-off elements in the system, depending on thetype of plant and pump. However, such elements must not obstruct proper drainage orhinder disassembly of the pump. The suction lift line/suction head line has been laid with a rising/downward slope

towards the pump. The nominal diameters of the pipelines are at least equal to the nominal

diameters of the pump nozzles. To prevent excessive pressure losses, adapters to larger diameters have a diffuser

angle of approx. 8. The pipelines have been anchored in close proximity to the pump and connected

without transmitting any stresses or strains.1. Thoroughly clean, flush and blow through all vessels, pipelines and connections

(especially of new installations).2. Before installing the pump in the piping, remove the flange covers on the suction

and discharge nozzles of the pump.Multitec A: Do not close the hole provided in the plain bearing cover.

CAUTIONWelding beads, scale and other impurities in the pipingDamage to the pump! Free the piping from any impurities. If necessary, install a filter. Comply with the instructions set out in ( Section 7.2.2.3 Page 40) .3. If required, install a filter in the piping (see illustration: Filter in the piping).



12Fig. 6: Filter in the piping

1 Differential pressure gauge 2 FilterNOTEUse a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) ofcorrosion-resistant material.Use a filter with a filter area three times the cross-section of the piping.Conical filters have proved suitable.4. Connect the pump nozzles with the piping.CAUTIONAggressive flushing and pickling agentsDamage 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

Fx

Fz

FyMy

Mz

Mx DN

Fig. 7: Forces and moments at the pump nozzlesDirection of forcesFX horizontal, parallel to the pump axisFY vertical to the pump axisFZ horizontal, at a right angle to the pump axisDirection of momentsMX around the horizontal axis, parallel to the pump axisMY around the vertical nozzle axisMZ around the horizontal axis, at a right angle to the pump axisSuction and discharge nozzles must be regarded separately. Refer to the data sheetfor the relevant suction and discharge nozzle diameters.



Forces and moments at the pump nozzlesTable 7: Forces and moments at the pump nozzles (cast iron suction and discharge nozzles)

DN Vertical nozzleat a right angle to the

shaft

Horizontal nozzleat a right angle to the

shaft

Axial nozzleparallel to the shaft

Moments for allnozzles

F x[N]

Fy[N]

Fz[N]

F x[N]

Fy[N]

Fz[N]

F x[N]

Fy[N]

Fz[N]

M x[Nm]

My[Nm]

Mz[Nm]

100 1421 1778 1162 1421 1162 1778 - - - 1360 1000 686150 1780 2220 1465 1780 1465 2220 2220 1465 1780 1640 1260 840

5.5 Checking the coupling alignmentDANGER

Impermissible temperatures at the coupling or bearings caused by misalignment of thecouplingExplosion hazard! Make sure that the coupling is correctly aligned at all times.CAUTIONMisalignment of pump and motor shaftsDamage 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.

BA

A B

a) b)

B

B

A

A

1

1 2 21

1

Fig. 8: a) Checking the coupling alignment and b) Aligning a spacer-type coupling1 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 shaftsare the same at all points around the circumference.The radial and axial deviation of both coupling halves must not exceed 0.1 mmduring 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 halvesis the same at all points around the circumference.



The radial and axial deviation of both coupling halves must not exceed 0.1 mmduring standstill as well as at operating temperature and under inlet pressure.

5.6 Aligning the pump and motorAfter having installed the pump set and connected the piping, check the couplingalignment and, if required, re-align the pump set (at the motor).

5.6.1 Motor with levelling screw

1

32

Fig. 9: Motor with levelling screw1 Hexagon head bolt 2 Levelling screw3 Lock nut The coupling guard and step guard, if any, have been removed.1. Check the coupling alignment.2. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at the

baseplate.3. Turn the levelling screws (2) by hand or by means of an open-jawed wrench until

the coupling alignment is correct.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.

WARNINGUnprotected rotating couplingRisk 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'sdelivery, then the operator must supply one!

Observe all relevant regulations for selecting a coupling guard.

DANGERRisk of ignition by frictional sparksExplosion hazard! Choose a coupling guard material that is non-sparking in the event of

mechanical contact (see DIN EN 13463-1).6. Re-install the coupling guard and step guard, if any.7. Check the distance between coupling and coupling guard.

The coupling guard must not touch the coupling.



5.6.2 Motor without levelling screwAny differences in shaft centre height between the pump and the motor arecompensated by means of shims.

1Fig. 10: Pump set with shims1 Shim The coupling guard and step guard, if any, have been removed.1. Check the coupling alignment.2. Unscrew the hexagon head bolts at the motor.3. Insert shims underneath the motor feet until the difference in shaft centre height

has been compensated.4. Re-tighten the hexagon head bolts.5. Check that the coupling and shaft can easily be rotated by hand.

WARNINGUnprotected rotating couplingRisk 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'sdelivery, then the operator must supply one!

Observe all relevant regulations for selecting a coupling guard.

DANGERRisk of ignition by frictional sparksExplosion hazard! Choose a coupling guard material that is non-sparking in the event of

mechanical contact (see DIN EN 13463-1).6. Re-install the coupling guard and step guard, if any.7. Check the distance between coupling and coupling guard.


5.7 Electrical connectionDANGER

Incorrect electrical installationExplosion hazard! For electrical installation, also observe the requirements of IEC 60079-14. Always connect explosion-proof motors via a motor protection switch.



DANGERWork on the pump set by unqualified personnelDanger 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, EN 60079.

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit! Observe the technical specifications of the local energy supply companies.NOTEIt is recommended to fit a motor protection device.However, this device must not switch off the pump set; it must serve as an indicator only.

5.7.1 Setting the time relayCAUTIONSwitchover between star and delta on three-phase motors with star-delta starting takestoo long.Damage to the pump (set)! Keep switch-over intervals between star and delta as short as possible.

Time relay settings for star-delta starting: 3 seconds 30 %.

5.7.2 Earthing

DANGERElectrostatic chargingExplosion hazard!Fire hazard!Damage to the pump set! Connect the PE conductor to the earthing terminal provided.

5.7.3 Connecting the motorNOTEIn compliance with DIN VDE 0530 - Part 8, three-phase motors are always wired forclockwise rotation (looking at the motor shaft stub).The pump's direction of rotation is indicated by an arrow on the pump.1. Change the motor's direction of rotation to match that of the pump.2. Observe the manufacturer's product literature supplied with the motor.



5.8 Checking the direction of rotationDANGER

Temperature increase resulting from contact between rotating and stationarycomponentsExplosion hazard!Damage to the pump set! 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.

WARNINGHands or objects inside the pump casingRisk 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.CAUTIONIncorrect direction of rotation with non-reversible mechanical sealDamage to the mechanical seal and leakage! Separate the pump from the motor to check the direction of rotation.CAUTIONMotor and pump running in the wrong direction of rotationDamage to the pump! Refer to the arrow indicating the direction of rotation on the pump. Check the direction of rotation. If required, check the electrical connection and

correct the direction of rotation.The correct direction of rotation of motor and pump is clockwise (seen from themotor 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 directionof rotation on the pump.

3. If the motor is running in the wrong direction of rotation, check the electricalconnection 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-upBefore commissioning/starting up the pump set, make sure that the followingconditions are met:

The pump set has been properly connected to the electric power supply and isequipped with all protection devices.

The pump has been primed with the fluid to be handled. The direction of rotation has been checked. ( Section 5.8 Page 28) All auxiliary connections required are connected and operational. The lubricants have been checked. After prolonged shutdown of the pump (set), the activities described in (

Section 6.4 Page 36) have been carried out. The quality of the concrete foundation complies with the regulations. The pump set has been installed and aligned in accordance with the tolerances

specified. The pipelines have been connected without warping the pump nozzles.

6.1.2 Filling in lubricantsGrease- lubricated bearingsGrease-lubricated bearings have been packed with grease at the factory.Oi l - lubricated bearingsFill the bearing bracket with lubricating oil.Oil quality see ( Section 7.2.3.1.2 Page 40)Oil quantity see ( Section 7.2.3.1.3 Page 41)Fi l l ing the constant- level oi ler with lubricat ing oi l (oi l - lubr icatedbearings only)NOTEIf no constant-level oiler is provided on the bearing bracket, the oil level can be read inthe middle of the oil level sight glass arranged at the side of the bearing bracket.

CAUTIONInsufficient lubricating oil in the reservoir of the constant-level oilerDamage to the bearings! Regularly check the oil level. Always fill the oil reservoir completely. Keep the oil reservoir properly filled at all times.



1a) b)

2

4

3

5 6 8

7

Fig. 11: a) Bearing bracket with constant-level oiler - b) Bearing bracket with oil levelsight glass1 Constant-level oiler 2 Vent plug3 Oil level

Constant-level oiler4 Connection elbow of the constant-level

oiler5 Screw plug 6 Bearing cover7 Oil level

Oil level sight glass8 Oil level sight glass

NOTEAn excessively high oil level can lead to a temperature rise and to leakage of the fluidhandled or oil. The constant-level oiler has been fitted. The screw plug has been fitted.1. Pull out the vent plug (2).2. Pull the constant-level oiler (1) down away from the bearing cover (6) and hold it

in this position.3. Fill in oil through the hole for the vent plug until the oil reaches the connection

elbow of the constant-level oiler (4).4. Completely fill the reservoir of the constant-level oiler (1).5. Snap the constant-level oiler (1) back into its operating position.6. Fit the vent plug (2) again.7. After approximately 5 minutes, check the oil level in the glass reservoir of

constant-level oiler (1). The oil reservoir must be properly filled at all times to provide an optimum oillevel. Repeat steps 1 - 6, if necessary.

8. To check the function of the constant-level oiler (1), slowly drain some oil via thescrew plug (5) until air bubbles can be seen in the oil reservoir.

Oil-lubricated pumps are standard supplied with a constant-level oiler mounted atthe bearing cover. Alternatively, an oil level sight glass can be connected to the lowerconnection hole in the bearing cover.On pumps with oil level sight glass the oil level must be visible between the two redmarks on the oil level sight glass. Remove the vent plug and top up oil, if necessary.

Bearing bracket withconstant-level oiler

Bearing bracket with oillevel sight glass



6.1.3 Priming and venting the pumpCAUTIONShaft seal failure caused by dry runningDamage to the pump! Before starting up the pump set, vent the pump and suction line and prime

both with the fluid to be handled.1. Vent the pump and suction line and prime both with the fluid to be handled.2. Fully open the shut-off element in the suction line.

6.1.4 Final check1. Remove the coupling guard and step guard, if any.2. Check the coupling alignment; re-align the coupling, if required. ( Section 5.5

Page 24) 3. Check that the coupling and shaft can easily be rotated by hand.4. Re-install the coupling guard and step guard, if any.5. Check the distance between coupling and coupling guard.


6.1.5 Start-upDANGER

The permissible pressure and temperature limits will be exceeded if the pump isoperated 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.

DANGERExcessive temperatures due to dry running or excessive gas content in the fluid handledExplosion hazard!Damage to the pump set! Never operate the pump set without liquid fill. Prime the pump as specified. Always operate the pump within the permissible operating range.CAUTIONAbnormal noises, vibrations, temperatures or leakageDamage to the pump! Switch off the pump (set) immediately. Eliminate the causes before returning the pump set to service. The system piping has been cleaned. Pump, suction line and inlet tank, if any, have been vented and primed with the

fluid handled. The lines for priming and venting have been closed.



CAUTIONStart-up against open discharge lineMotor overload! Make sure the motor has sufficient power reserves. Use a soft starter. Use speed control.1. Fully open the shut-off element in the suction head/suction lift line.2. Close or slightly open the shut-off element in the discharge line.3. Switch on the motor.

Start-up must proceed without abnormal vibrations or noises.4. Immediately after the pump has reached full rotational speed, slowly open the

shut-off element in the discharge line and adjust it to comply with the dutypoint.An automatic check valve installed must open steadily when the operating speedhas been reached, without abnormal noise, vibrations or increased powerconsumption of the pump set.

5. After the duty point has been reached, check motor input power and bearingtemperature.

6. After the operating temperature has been reached and/or in the event ofleakage, switch off the pump set and re-tighten the bolts between lantern andcasing.

7. Check the coupling alignment. Re-align the coupling if required.

6.1.6 Checking the shaft sealThe mechanical seal only leaks slightly or invisibly (as vapour) during operation.Mechanical seals are maintenance-free. The packed gland must leak slightly during operation.(approx. 20 drops per minute)NOTEOn variable-speed pumps, the necessary gland packing leakage must be set for theminimum fluid pressure; higher leakage rates are to be expected for other operatingconditions.Adjust ing the leakage1. Only lightly tighten the nuts of the gland follower by hand.2. Use a feeler gauge to verify that the gland follower is mounted centred and at a

right angle to the shaft. The gland must leak after the pump has been primed.

The leakage can be reduced.1. Tighten the nuts of the gland follower by 1/6 turn.2. Monitor the leakage for another five minutes.

Excessive leakage:Repeat steps 1 and 2 until the minimum value has been reached.Not enough leakage:Slightly loosen the nuts at the gland follower.No leakage:Switch off the pump set immediately!Loosen the gland follower and repeat start-up.Checking the leakageAfter the leakage has been adjusted, monitor the leakage for about two hours atmaximum fluid temperature. Check that enough leakage occurs at the gland at minimum fluid pressure.

Mechanical seal

Gland packing

Prior to commissioning

After five minutes ofoperation



6.1.7 ShutdownCAUTIONHeat build-up inside the pumpDamage 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 cooleddown.

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.NOTEIf the discharge line is equipped with a non-return or check valve, the shut-off elementmay remain open as long as there is some 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 barrierfluid during standstill.

CAUTIONRisk of freezing during prolonged pump shutdown periodsDamage to the pump! Drain the pump and the cooling/heating chambers (if any) or otherwise protect

them against freezing.

6.2 Operating limitsDANGER

Non-compliance with operating limits for pressure, temperature and speedExplosion 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 hasbeen obtained.

6.2.1 Ambient temperatureObserve the following parameters and values during operation:Table 8: Permissible ambient temperaturesPermissible ambient temperature ValueMaximum 40 Minimum on request



CAUTIONOperation outside the permissible ambient temperatureDamage to the pump (set)! Observe the specified limits for permissible ambient temperatures.

6.2.2 Frequency of startsDANGER

Excessive surface temperature of the motorExplosion hazard!Damage to the motor! In case of explosion-proof motors, observe the frequency of starts specified in

the manufacturer's product literature.

CAUTIONRe-starting while motor is still running downDamage to the pump (set)! Do not re-start the pump set before the pump rotor has come to a standstill.

The frequency of starts is usually determined by the maximum temperature increaseof the motor. This largely depends on the power reserves of the motor in steady-state operation and on the starting conditions (DOL., star-delta, moments of inertia,etc). If the start-ups are evenly spaced over the period indicated, the following limitscan be used for orientation for start-up with the discharge-side gate valve slightlyopen:Table 9: Frequency of starts

Motor rating [kW]

Maximum No. of start-ups [Start-ups/hour]

up to 45 10more than 45 5

Overloading of the motor may generally result in: an abnormal temperate increase leading to the motor temperature exceeding

the temperature limit of the winding or bearing grease premature coupling wear reduced service life of the pump components irregularities or malfunctions in the system

6.2.3 Flow rateThe minimum flow rates indicated below are for single-pump operation and willprevent thermal or mechanical overloading of the pump. In case of parallel operationwith pumps of identical or different design, higher flow rates may be required toguarantee a stable operating behaviour.Table 10: Flow rate

Size Temperature range (t) Minimum flow rate Maximum flowrate

100 independent oftemperature

35 % of Qopt.4) See hydrauliccharacteristic

curves.A temporary minimum flow rate of 25 % of QOpt4) has been defined. This temporaryflow rate shall be limited to one hour's uninterrupted operation and approx. 200hours/year.

4) Best efficiency point



The calculation formula below can be used to check if an additional heat build-upcould lead to a dangerous temperature increase at the pump surface.

Table 11: KeySymbol Description Unit

c Specific heat capacity J/kg Kg Gravitational constant m/sH Pump head mTf Temperature of the fluid handled CTo Temperature at the casing surface C

Pump efficiency at duty point -Temperature difference C

6.2.4 Density of the fluid handledThe power input of the pump increases in proportion to the density of the fluidhandled.CAUTIONImpermissibly high density of the fluid handledMotor overload! Observe the information on fluid density indicated in the data sheet. Make sure the motor has sufficient power reserves.

6.2.5 Abrasive fluidsDo not exceed the maximum permissible solids content specified in the data sheet.When the pump handles fluids containing abrasive substances, increased wear of thehydraulic system and the shaft seal are to be expected. In this case, reduce theintervals commonly recommended for servicing and maintenance.

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdownThe pump (set) remains instal led Sufficient fluid is supplied for the operation check run of the pump.1. Start up the pump (set) regularly between once a month and once every three

months for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pumpintake area.

NOTEProlonged shutdown periods should be avoided in the case of pumps in material variants10, 13, 17, 20, 21 and 27 (cast-iron hydraulics), particularly if the pumps are handlingaggressive water qualities (high oxygen content). In such cases, the pump should remainfilled, and the operation check run should be performed at least every other day.NOTEThe stage casings of horizontal pumps can only be drained completely through the drainplugs provided on the stage casings (optional). If this is not possible we recommend toproceed as described in the following section.



The pump (set) i s removed from the pipe and stored The pump has been properly drained and the safety instructions for dismantling

the pump have been observed .1. Fill the pump with a water-repellent preservative (e.g. RUSTELO DEWATERING

924, producer: CASTROL; OSYRIS DW, producer: TOTAL; or equivalent).2. Turn the pump rotor by hand several times, to ensure even distribution of the

preservative.CAUTIONGlycol-base preservatives (e.g. KLBERTOP K 01-601)Corrosion damage on surfaces not treated with preservative Do not drain the preservative if the pump is stored for a longer period. Completely fill the pump with preservative for storage. Do not drain the preservative until immediately before the pump is returned to

service.(The preservative can be re-used if water content < 20%.)

3. Drain the pump and close the suction and discharge nozzle, respectively.4. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil or

grease) to protect them against corrosion.Observe any additional instructions and information provided. ( Section 3.2Page 13)

6.4 Returning to serviceFor returning the pump to service observe the sections on commissioning/start-up (Section 6.1 Page 29) and the operating limits. ( Section 6.2 Page 33) In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. ( Section 7 Page 37)

WARNINGFailure to re-install or re-activate protective devicesRisk 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.

NOTEIf the pump has been out of service for more than one year, replace all elastomer seals.



7 Servicing/Maintenance

7.1 Safety regulationsDANGER

Improperly serviced pump setExplosion hazard!Damage to the pump set! 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 isperformed by authorised, qualified specialist personnel who are thoroughly familiarwith the manual.

WARNINGPump set started up inadvertentlyRisk 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.

WARNINGFluids posing a health hazard and/or hot fluidsRisk of personal injury! Observe all relevant laws. When draining the fluid take appropriate measures to protect persons and the

environment. Decontaminate pumps which handle fluids posing a health hazard.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the pump (set) with a minimum of maintenanceexpenditure and work.NOTEAll maintenance, service and installation work can be carried out by KSB Service. Findyour 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 Maintenance/inspection

7.2.1 Supervision of operationDANGER

Formation of an explosive atmosphere inside the pumpExplosion 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 alltimes.

Provide sufficient inlet pressure. Provide an appropriate monitoring system.



DANGERIncorrectly serviced shaft sealExplosion hazard!Fire hazard!Leakage of hot, toxic fluids!Damage to the pump set! Regularly service the shaft seal.

DANGERExcessive temperatures as a result of bearings running hot or defective bearing sealsExplosion hazard!Fire hazard!Damage to the pump set! Regularly check the lubricant level. Regularly check the rolling element bearings for running noises.CAUTIONIncreased wear due to dry runningDamage to the pump set! 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.

CAUTIONImpermissibly high temperature of fluid handledDamage 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. In case of oil lubrication, ensure the oil level is correct. ( Section 6.1.2 Page 29) Check the shaft seal. ( Section 6.1.6 Page 32) Check the static seals for any leakage. Check the rolling element bearings for running noises.

Vibrations, noise and an increase in current input occurring during unchangedoperating conditions indicate wear.

Check 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 uponce a week.

Monitor the bearing temperature.The bearing temperature must not exceed 90 C (measured on the outside of thebearing bracket).

On oil-lubricated models the bearing temperature can be measured in the oilsump. The alert limit is 100 C. Never exceed 110 C (pump trip).



CAUTIONOperation outside the permissible bearing temperatureDamage to the pump! The bearing temperature of the pump (set) must never exceed 90 C (measured

on the outside of the bearing bracket).

NOTEAfter commissioning, increased temperatures may occur at grease-lubricated rollingelement bearings due to the running-in process. The final bearing temperature is onlyreached after a certain period of operation (up to 48 hours depending on the conditions).Please note the following when checking the bearing temperature:

Manual temperature checks are not sufficient ! If the bearing temperature exceeds 100 C during start-up, switch off the pump

and check the following: Check the alignment of the pump set. Verify bearing type and arrangement. Remove the rolling element bearings. Check the grease quantity in the rolling element bearings (grease-lubricated

bearings only).Excessive amounts of grease will cause increased temperatures.

After reassembly, ensure a tight press fit of the outer bearing ring via thecover (fixed bearing).

A temperature rise may also occur after replacement of the bearings ordismantling of the hydraulic system.

7.2.2 Inspection work

DANGERExcessive temperatures caused by friction, impact or frictional sparksExplosion hazard!Fire hazard!Damage to the pump set! 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 couplingCheck the flexible elements of the coupling. Replace these parts in due time if thereis any sign of wear.

7.2.2.2 Checking the clearancesExcessive clearances will affect pump performance. Losses in efficiency and dischargehead will occur.Max. c learancesThe clearances given refer to the diameter.Table 12: Max. permissible clearancesDiameter Clearance

[mm]Impellers 230 and 231 Suction-side clearance 0.8Clearance at the hub 0.8Balance drum 59.4 0.8



NOTEIf 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 casingwear ring. Contact KSB.

7.2.2.3 Cleaning filters

CAUTIONInsufficient inlet pressure due to clogged filter in the suction lineDamage to the pump! Monitor contamination of filter with suitable means (e.g. differential pressure

gauge). Clean filter in appropriate intervals.

7.2.2.4 Checking the bearing seals

DANGERExcessive temperatures caused by mechanical contactRisk of explosion!Damage to the pump set! Check correct seating of axial sealing rings mounted on the shaft.

Only gentle contact of the sealing lip shall be established.

7.2.3 Lubrication and lubricant change of rolling element bearings

DANGERExcessive temperatures as a result of bearings running hot or defective bearing sealsExplosion hazard!Fire hazard!Damage to the pump set! Regularly check the condition of the lubricant.

7.2.3.1 Oil lubricationThe rolling element bearings are usually lubricated with mineral oil.

7.2.3.1.1 IntervalsTable 13: Oil change intervals

Temperature at thebearing

First oil change All subsequent oilchanges5)

up to 70 After 300 operating hours Every 8500 operating hours70 C - 80 C After 300 operating hours Every 4200 operating hours80 C - 90 C After 300 operating hours Every 2000 operating hours

7.2.3.1.2 Oil qualityQuality: ISO VG 46

5) At least once a year



7.2.3.1.3 Oil quantityTable 14: Oil quantity

Oil quantity (approx.)6) [ml]

Drive end Non-drive end880 920

7.2.3.1.4 Changing the oil

WARNINGLubricants posing a health hazard and/or hot lubricantsHazardous to persons and the environment! When draining the lubricant take appropriate measures to protect persons and

the environment. Wear safety clothing and a protective mask, if required. Collect and dispose of any lubricants. Observe all legal regulations on the disposal of fluids posing a health hazard.

1a) b)

2

4

3

5 6 8

7

Fig. 12: a) Bearing bracket with constant-level oiler - b) Bearing bracket with oil levelsight glass1 Constant-level oiler 2 Vent plug3 Oil level

Constant-level oiler4 Connection elbow of the constant-level

oiler5 Screw plug 6 Bearing cover7 Oil level

Oil level sight glass8 Oil level sight glass

A suitable container for the used oil is on hand.1. Place the container underneath the screw plug.2. Undo the screw plug (5) at the bearing cover (6) and drain the oil.3. Once the bearing housing (3) has been drained, re-insert and re-tighten the

screw plug (5).4. Re-fill with oil. ( Section 6.1.2 Page 29)

7.2.3.2 Grease lubricationThe bearings are supplied packed with high-quality lithium-soap grease.

6) Oil quantity without oil fill in the reservoir of the constant-level oiler



7.2.3.2.1 IntervalsSize Rotational speed in rpm

< 1800 2950 3550100 9000 h 5700 h 3900 h

NOTEIf re-lubrication intervals are short, we recommend to completely replace the grease oncea year.Otherwise, the grease fill must be replaced completely every two years. To do so,remove the rolling element bearings, clean and pack with new grease.

7.2.3.2.2 Grease qualityOptimum grease propert ies for rol l ing element bear ings

High melting point lithium soap base grease Free of resin and acid Not liable to crumble With good rust-preventive characteristics Penetration number between 2 and 3 (corresponding to a worked penetration of

220 to 295 mm/10) Drop point 175 C

If required, the bearings may be lubricated with greases of other soap bases.Make sure to remove any old grease and rinse the bearings thoroughly.

7.2.3.2.3 Grease quantityUse a grease quantity of 25 grams per bearing.

7.2.3.2.4 Changing the greaseCAUTIONMixing greases of differing soap basesChanged lubricating qualities! Thoroughly clean the bearings. Adjust the re-lubrication intervals to the grease used.1. Only half-fill the bearing cavities with grease.

7.3 Drainage/disposalWARNING

Fluids posing a health hazard and/or hot fluidsHazard to persons and the environment! Collect and properly dispose of flushing liquid and any liquid residues. Wear safety clothing and a protective mask, if required. Observe all legal regulations on the disposal of fluids posing a health hazard.

Horizontal pumpsRemove the drain plugs in the stage casing (optional), suction casing (if any) anddischarge casing.1. Use a crane to bring the pump into a vertical position, with the suction nozzle

pointing downwards.2. Turn the rotor by hand.3. Remove the drain plugs at the seal housing, suction casing and discharge casing.



If the pump cannot be drained completely, we recommend to dismantle it and drythe individual components.

7.4 Dismantling the pump set

7.4.1 General information/Safety regulationsWARNING

Unqualified personnel performing work on the pump (set)Risk of injury! Always have repair and servicing work performed by specially trained, qualified

personnel.

WARNINGHot surfaceRisk of injury! Allow the pump set to cool down to ambient temperature.CAUTIONProtruding plain bearingsDamage to plain bearings when dismantling the suction line! When separating the suction line from the suction nozzle, make sure to shift

the suction line axially away from the pump by at least 20 mm before removingit.

Observe the general safety instructions and information. ( Section 7.1 Page 37)For any work on the motor, observe the instructions of the relevant motormanufacturer.For dismantling and reassembly observe the exploded views and the generalassembly drawing. NOTEAll maintenance, service and installation work can be carried out by KSB Service. Findyour contact in the attached "Addresses" booklet or on the internet at www.ksb.com/contact".

DANGERInsufficient preparation of work on the pump (set)Risk of injury! Properly shut down the pump set. ( Section 6.1.7 Page 33) Close the shut-off elements in suction and discharge line. Drain the pump and release the pump pressure. Close any auxiliary connections. Allow the pump set to cool down to ambient temperature.NOTEAfter a prolonged period of operation the individual components may be hard to pull offthe shaft. If this is the case, use a brand name penetrating agent and/or - if possible - anappropriate pull-off device.

7.4.2 Preparing the pump set1. 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.5. Drain the oil fill of oil-lubricated bearings.

7.4.3 Dismantling the bearings

7.4.3.1 Dismantling the plain bearing (non-drive end)The plain bearing is removed without dismantling the hydraulic section of the pump.

901.2

550.7

412.2

106.2

160.2381

561.1932.1529

Fig. 13: Dismantling the plain bearing - axial suction nozzle1. Pull off cover 160.2 with a forcing screw (M12).2. Shaft in C45

Remove circlip 932.1.Shaft in 1.4021 Remove bolt 901.2 and disc 550.7.

3. Take out SiC bearing sleeve 529.4. Pull out bearing cartridge 381 with both O-rings 412.2.

Note:Half round head grooved pin 561.1 remains in position.

7.4.3.2 Dismantling the rolling element bearing (drive end)The drive-end rolling element bearing are removed without dismantling the plainbearing located at the opposite end of the shaft.Removing the coupl ing halfThe coupling half must be removed before the drive-end rolling element bearing canbe dismantled.1. Undo the grub screw in the coupling hub.2. Pull off the coupling half.3. Pull out key 940.3.

Preparat ions for dismantl ing the rol l ing element bearingGrease lubrication

Axial suction nozzle



920.6

320.1 520.1

551.1 360.1901.1920.2931411.7940.3

210

Fig. 14: Grease lubrication1. Remove joint ring (V-ring) 411.7.2. Undo hexagon head bolts 901.1.3. Remove bearing cover 360.1.

936525.1

412.10

423.1

551.1 901.1

423.2

920.6940.3

520.1

360.1320.1Fig. 15: Grease lubrication of labyrinth seal1. Remove labyrinth ring 423.2.2. Undo hexagon head bolt 901.1.3. Remove bearing cover 360.1.

Oil lubrication of lip seal

903.14525.1421.1

412.10

412.6 320.1 360.2520.1421.2

520.4500.1412.11

940.3

920.6

914.4550.10412.12

551.1

Fig. 16: Oil lubrication of lip seal For oil lubrication: The oil has been drained.1. Undo socket head cap screws 914.4 and remove them together with disc 550.10

and O-ring 412.12.2. Remove bearing cover 360.2.3. Pull off sleeve 520.4 with ring 500.1 (tolerance ring) and O-ring 412.11.

Oil lubrication of labyrinth seal



903.14525.1

412.10

423.1

412.6 320.1 360.2520.1

423.2

940.3920.6

914.4550.10412.12

551.1

Fig. 17: Oil lubrication of labyrinth seal For oil lubrication: The oil has been drained.1. Pull out labyrinth ring 423.2.2. Undo socket head cap screws 914.4 and remove them together with disc 550.10

and O-ring 412.12.3. Remove bearing cover 360.2.

Removing the rol l ing element bearingNOTEWhen dismantling keywayed nut 920.6, mark all relevant positions such as sequenceand orientation of the contact face to ensure identical reassembly.1. Undo nut 920.2 with lockwasher 931 or nuts 920.6, holding onto shaft 210.2. Pull off sleeve 520.1 with rolling element bearing(s) 320.1. (The shaft is centered

in the sleeve without locking device.)CAUTIONIncorrect axial adjustment of rotor After bearing or seal replacement, fit the same spacer discs on the bearing side. Always reproduce the original rotor adjustment.3. Take out spacer disc 551.1.

7.4.4 Dismantling the shaft seal

7.4.4.1 Removing the mechanical sealRemoving the standard mechanical seal

Fig. 18: Removing the mechanical seal



The pump has been drained. The bearings have been removed.

1. Remove O-ring 412.10.2. Dismantle any auxiliary piping (circulation, etc., depending on model).3. Loosen nut 920.3 on seal cover 471 until the spring of the mechanical seal is

relaxed.4. Undo nut 920.1 and remove bearing housing 350.1.5. Pull off spacer sleeve 525.1.6. Remove seal cover 471.1 with the mating ring and gasket 400.1.7. Remove primary ring (not in case of bellows-type seals).8. Remove key 940.2.9. Pull off shaft sleeve 523.1 with the rotating assembly of mechanical seal 433.1.

Two holes are provided in the shaft sleeve for engaging a puller.10. Take off seal housing 441.1.11. Remove O-ring 412.4.

7.4.4.2 Dismantling the gland packing

Fig. 19: Dismantling the gland packingRemoving the packing r ingsThe packing rings can be removed without dismantling the bearing section.1. Undo nuts 920.3.2. Pull gland follower 452 out of seal housing 441.1.3. Remove packing rings 461 and lantern ring, if any.

Removing the shaft protect ing s leeve The bearings have been removed. The packing rings 461 have been removed.1. Remove O-ring 412.10.2. Undo nut 920.1 and remove bearing housing 350.1.3. Pull off spacer sleeve 525.1.4. Pull out seal housing 441.1 with gland follower 452.5. Remove key 940.2.6. Use a puller to remove shaft protecting sleeve 524. Use the groove provided in

the shaft protecting sleeve for this purpose.7. Remove O-ring 412.4.

Note:



If shaft protecting sleeve 524 is hard to remove, the balance drum 59-4, if fitted, canbe used for leverage.1. The puller can engaged in the threaded holes provided in the balance drum.2. Pull out balance drum 59-4, disc 550.3 and shaft protecting sleeve 524.

7.4.5 Dismantling the hydraulic systemRemoving the discharge cas ing Rolling element bearings 320.1 have been removed. The shaft seal has been removed. The hydraulic system is in vertical position (if possible)

1. Remove the plain bearing. 2. Place the pump in a vertical position, with the bare shaft end pointing upwards.3. Support the opposite pump end (suction side).4. Start dismantling from the top (discharge side).5. Number and match-mark the casing faces to ensure identical reassembly.6. Remove balancing line (pipe) 710.1 (if fitted).7. Attach discharge casing 107 to lifting gear to hold it safely in position.8. Undo the four tie bolts 905.9. Lift discharge casing 107 slightly and separate it by gently tapping the last stage

of the suction casing with a mallet.10. Pull off discharge casing 107.11. Remove balance drum 59-4 (or spacer sleeve 525.4) and disc 550.3.12. Remove key 420.2.13. Pull off impeller 230.3 or 230.1 and remove the respective key.14. Remove and dispose of O-ring 412.1.

Dismantl ing the stage cas ing1. Remove disc 550.1.2. Pull off stage casing 108.1 and diffuser 171.1.

Use the raised areas at the outside diameter or the groove provided for thispurpose. If necessary, separate them by tapping gently with a mallet.

3. Pull off impeller 230.1 and remove the respective key.4. Remove and dispose of O-ring 412.1.5. Hold the shaft in vertical position, if possible.6. Repeat steps 1-5 up to and including the suction impeller (231).

7.5 Reassembling the pump set

7.5.1 General information/Safety regulationsCAUTIONImproper reassemblyDamage to the pump! Reassemble the pump (set) in accordance with the general rules of sound

engineering practice. Use original spare parts only.

Dismantling the individualstages



CAUTIONElastomers in contact with oil/greaseShaft seal failure! Use water as assembly lubricant. Never use oil or grease as assembly lubricant.

Always reassemble the pump in accordance with the corresponding general assemblydrawing.

Gaskets Always use new gaskets, making sure that they have the same thickness as

the old ones. Always fit gaskets of asbestos-free materials or graphite without using

lubricants (e.g. copper grease, graphite paste). O-rings

Never use O-rings that have been glued together from material sold by themetre.

Always use new O-rings. Assembly adhesives

For gaskets, avoid the use of assembly adhesives, if possible. Should assembly adhesives be required after all, use a commercially available

contact adhesive (e.g. "Pattex"). Only apply adhesive at selected points and in thin layers. Never use quick-setting adhesives (cyanoacrylate adhesives). Coat the locating surfaces of the individual components and screwed

connections with graphite or similar before reassembly.

For reassembly, tighten all screws as specified in this manual. ( Section 7.6 Page54)

7.5.2 Reassembling the hydraulic system Start reassembly from the suction end. Reassemble the pump in vertical position, if possible. The clearance between the last impeller 230.1 or 230.3 and the balance drum

59-4 (or spacer sleeve 525.4) is between 0.7 and 1.2 mm. Use assembling aids for components made of stainless steel (impellers, drum).

Verify suitability for drinking water applications. The assembly consisting of suction casing 106.1 or 106.2 with casing wear ring

502.1 and foot (if any) is on hand. The assembly consisting of shaft 210, half round head grooved pin 561.1 and

shaft nuts 920.5 has been installed.1. Fit key 940.1 and suction impeller 231 on the shaft.2. Fit the assembly of shaft and suction impeller in suction casing 106.1 or 106.2.3. Fit key 940.1.4. Mount stage casing 108.1 with diffuser 171.1 and O-ring 412.1 on the shaft.5. Fit disc 550.1.6. Fit stage impeller 230.1 on the shaft.7. Repeat steps 3-6 up to the last impeller.8. If an intermediate bearing 540.3 is fitted: The intermediate bearing is located in

diffuser 171.1. Make sure to re-install the stages in the correct order as indicatedby the stage numbers applied during dismantling.On the 9.2, 10.2, 11.1 and 12.1 hydraulics, impeller 230.3 is the last impeller.

Sequence

Seal elements

Tightening torques



9. Fit key 940.2, balance drum 59-4 (or spacer sleeve 525.4) and disc 550.3 on theshaft.

10. Fit discharge casing 107 (with O-ring 412.1, foot (if any), drum bush 540.1 (if any)and four studs 902.1).

11. Insert tie bolts 905 with discs 550.4 and nuts 920.4.12. Slightly tighten tie bolts 905.13. Move the pump into horizontal position, setting the pump feet down on a level

surface (e.g. workbench).14. Tighten tie bolts 905 in two steps.

First step: tighten to 50 % of tightening torque; second step: tighten to 100 % oftightening torque. Observe the tightening sequence given.

15. Connect balancing line 710.1 (if balance drum is fitted).

7.5.3 Installing the shaft seal

7.5.3.1 Installing the mechanical sealFor drawings and part numbers refer to the section on the mechanical seal.Uni-direct ional mechanical sealLeft-hand spring

Shaft rotation: anti-clockwise

Shaft rotation: clockwise

Looking at theprimary ring

Right-hand spring

Fig. 21: Uni-directional spring of mechanical sealInstal l ing the mechanical seal

L

D

Fig. 22: Adjusting dimension L for mechanical sealTable 15: Adjusting dimension L for mechanical seal, seal codes 55, 62, 63, 67, 68Size Seal code Diameter D

mechanical seal[mm]

Adjusting dimensionL

[mm]62

100 H12N 50 28

The following rules must be observed when installing the mechanical seal: For installing the mechanical seal, proceed as shown in the seal installation

drawing. Work cleanly and accurately. Only remove the protective wrapping of the seal faces immediately before

installation takes place. Prevent any damage to the sealing surfaces or O-rings. After inserting the mating ring, check that it is plane-parallel in relation to the

casing part.

1

2

3

4Fig. 20: Tie bolts tightening sequence



The surface of the shaft protecting sleeve must be absolutely clean and smooth,and the sleeve's mounting edge must be chamfered.

When sliding the rotating unit onto the shaft protecting sleeve, take appropriatesteps to protect the surface of the shaft protecting sleeve from damage.

The notes and steps stated in ( Section 7.5.1 Page 48) to ( Section 7.5.2 Page49) have been observed/carried out.

The bearing assembly and the individual parts of the mechanical seal are kept ina 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. Depending on the mechanical seal design, proceed as follows:

Instal l ing the standard mechanical seal1. Fit O-ring 412.4 on the shaft.2. Fit seal housing 441.1 with O-ring 412.5 and two studs 902.2 on the shaft.3. Fit the rotating assembly (primary ring) of mechanical seal 433.1 on shaft

protecting sleeve 523.1 (observing adjusting dimension L).4. Slip shaft protecting sleeve 523.1 with the pre-assembled rotating assembly of

mechanical seal 433.1, or shaft sleeve 523.2 with the rotating assembly ofmechanical seal 433.2 (as per seal code) onto the shaft.

5. Fit key 940.2.6. Carefully press the stationary mating ring of mechanical seal 433.1 or 433.2 into

seal cover 471.1.7. Fit seal cover 471.1 with gasket 400.1.8. Insert and tighten nuts 920.3.9. Connect circulation line 710.2 (depending on seal code).

7.5.3.2 Packing

Multitec a Sx Operating Instructions

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