KWPOperating Instructions2361.8/6-10 G3

KWP non-clogging centrifugal pump

Directive 94/9/ECMaterial variants: GN, GC2, C2

Casing design 2Material variants: GH, HCasing designs 2 and 3

Bearing brackets P 03 to P12Gland packing / Mechanical seal

Installation modes 3, 4H, 3Z

Materials: GN = complete pump in JL1040 (standard variant),

impeller and wear plate in ERNGC2 = Same as GN, impeller in Noridur 1.4593C2 = complete hydraulics in Noridur 1.4593GH = casing in JL1040, impeller and wear plate in NORIHARDH = complete hydraulics in NORIHARD

Works No.: __________________________________

Type Series: __________________________________

These operating instructions contain fundamentalinformation and precautionary notes. Please read

the manual thoroughly prior to installation of unit,electrical connection and commissioning. It is imperativeto comply with all other operating instructions referring tocomponents of individual units.

This manual shall always be kept close to the unit�slocation of operation or directly on the pump set.

KWP

2

Contents

Page

1 General 4

2 Safety 42.1 Marking of Instructions in the Manual 42.2 Personnel Qualification and Training 42.3 Non-compliance with Safety Instructions 42.4 Safety Awareness 42.5 Safety Instructions for the Operator / User 42.6 Safety Instructions for Maintenance,

Inspection and Installation Work 5

2.7 Unauthorized Modification andManufacture of Spare Parts 5

2.8 Unauthorized Modes of Operation 52.9 Explosion Protection 52.9.1 Unit Fill 52.9.2 Marking 5

2.9.3 Checking the Direction of Rotation 52.9.4 Pump Operating Mode 52.9.5 Temperature Limits 52.9.6 Maintenance 6

3 Transport and Interim Storage 63.1 Transport 63.2 Interim Storage / Preservation 6

4 Description of the Product andAccessories 6

4.1 Technical Specification 64.2 Designation 74.3 Design Details 74.3.1 Pump Casing 74.3.2 Impeller Form 7

4.3.3 Shaft Seal 74.3.4 Bearings 84.3.5 Permissible Forces and Moments at the

Pump Nozzles 84.3.6 Noise Characteristics 94.4 Accessories 94.5 Dimensions and Weights 9

5 Installation at Site 95.1 Safety Regulations 95.2 Checks to Be Carried out Prior to Installation 95.3 Installing the Pump / Unit 105.3.1 Aligning the Pump / Drive - Fig. 3 - Direct

Coupling 105.3.2 Aligning the Pump / Drive - Fig. 4H/3Z -

Belt Drive 10

5.3.2.1 Mounting the Motor 115.3.2.2 Mounting the Pulleys 115.3.2.3 V-Belt Installation and Maintenance 115.3.3 Place of Installation 115.4 Connecting the Piping 115.4.1 Auxiliary Connections 12

5.4.2 Coupling/Belt Guard 125.5 Final Check 125.6 Connection to Power Supply 12

Page6 Commissioning, Start-up / Shutdown 12

6.1 Commissioning 126.1.1 Lubricants 126.1.2 Shaft Seal 126.1.3 Priming the Pump and Checks to be

Carried out 126.1.4 Checking the Direction of Rotation 136.1.5 Cleaning the Plant Piping 13

6.1.6 Start-up Strainer 136.1.7 Start-up 136.1.8 Shutdown 136.2 Operating Limits 136.2.1 Temperature of Fluid Handled, Ambient

Temperature, Bearing Temperature 13

6.2.2 Switching Frequency 136.2.3 Density of the Fluid Handled 136.2.4 Abrasive Fluids 136.2.5 Minimum/Maximum Flow 146.3 Shutdown / Storage / Preservation 146.3.1 Storage of New Pumps 14

6.3.2 Measures to Be Taken for ProlongedShutdown 14

6.4 Returning to Service after Storage 14

7 Maintenance / Repair 147.1 General Instructions 147.2 Maintenance / Inspection 147.2.1 Supervision of Operation 14

7.2.2 Lubrication and Lubricant Change 147.3 Drainage / Disposal 147.4 Dismantling 157.4.1 Fundamental Instructions and

Recommendations 157.4.2 Dismantling (General) 157.5 Reassembly 16

7.5.1 General Instructions 167.5.2 Reassembly (General) 167.5.3 Tightening Torques 177.5.4 Mounting the Shaft Seal 17-187.5.5 Clearances 197.6 Spare Parts Stock 19

7.6.1 Recommended Spare Parts Stock for 2Years� Operation 19

7.6.2 Interchangeability of Pump Components 20

8 Trouble-shooting 21

9 General Assembly Drawings and Lists ofComponents 22-25

9.1 Pumps on Bearing Brackets P 03ax to P 06x 22/239.2 Pumps on Bearing Brackets P 08s to P 12s 24/25

KWP

3

Index

Section PageAbrasive Fluids 6.2.4 13

Accessories 4.4 9Aligning the Pump / Drive - Fig. 3 - Direct

Coupling 5.3.1 10Aligning the Pump / Drive - Fig. 4H/3Z -

Belt Drive 5.3.2 10Auxiliary Connections 5.4.1 12Bearings 4.3.4 8Checking the Direction of Rotation 2.9.3/ 5/

6.1.4 13Checks to Be Carried out Prior to Installation 5.2 9Cleaning the Plant Piping 6.1.5 13Clearances 7.5.5 19Commissioning 6.1 12

Commissioning, Start-up / Shutdown 6 12Connecting the Piping 5.4 11Connection to Power Supply 5.6 12Coupling/Belt Guard 5.4.2 12Density of the Fluid Handled 6.2.3 13

Description of the Product andAccessories 4 6

Design Details 4.3 7

Designation 4.2 7Dimensions and Weights 4.5 9Dismantling 7.4 15Dismantling (General) 7.4.2 15Drainage / Disposal 7.3 14

Explosion Protection 2.9 5Final Check 5.5 12Fundamental Instructions and

Recommendations 7.4.1 15

General 1 4

General Assembly Drawings and Lists ofComponents 9 22-25

General Instructions 7.1/ 14/7.5.1 16

Impeller Form 4.3.2 7

Installation at Site 5 9Installing the Pump / Unit 5.3 10Interchangeability of Pump Components 7.6.2 20Interim Storage / Preservation 3.2 6Lubricants 6.1.1 12Lubrication and Lubricant Change 7.2.2 14

Maintenance 2.9.6 6Maintenance / Inspection 7.2 14

Maintenance / Repair 7 14Marking 2.9.2 5Marking of Instructions in the Manual 2.1 4Measures to Be Taken for Prolonged

Shutdown 6.3.2 14

Minimum/Maximum Flow 6.2.5 14

Section PageMounting the Motor 5.3.2.1 11

Mounting the Pulleys 5.3.2.2 11Mounting the Shaft Seal 7.5.4 17-18Noise Characteristics 4.3.6 9Non-compliance with Safety Instructions 2.3 4Operating Limits 6.2 13Permissible Forces and Moments at the

Pump Nozzles 4.3.5 8

Personnel Qualification and Training 2.2 4Place of Installation 5.3.3 11Priming the Pump and Checks to be

Carried out 6.1.3 12Pump Casing 4.3.1 7Pump Operating Mode 2.9.4 5

Pumps on Bearing Brackets P 03ax to P 06x 9.1 22/23Pumps on Bearing Brackets P 08s to P 12s 9.2 24/25Reassembly 7.5 16Reassembly (General) 7.5.2 16Recommended Spare Parts Stock for 2

Years� Operation 7.6.1 19Returning to Service after Storage 6.4 14

Safety 2 4Safety Awareness 2.4 4Safety Instructions for Maintenance,

Inspection and Installation Work 2.6 5Safety Instructions for the Operator / User 2.5 4Safety Regulations 5.1 9Shaft Seal 4.3.3/ 7/

6.1.2 12Shutdown 6.1.8 13Shutdown / Storage / Preservation 6.3 14Spare Parts Stock 7.6 19Start-up 6.1.7 13Start-up Strainer 6.1.6 13

Storage of New Pumps 6.3.1 14Supervision of Operation 7.2.1 14Switching Frequency 6.2.2 13Technical Specification 4.1 6Temperature Limits 2.9.5 5Temperature of Fluid Handled, Ambient

Temperature, Bearing Temperature 6.2.1 13

Tightening Torques 7.5.3 17Transport 3.1 6

Transport and Interim Storage 3 6

Trouble-shooting 8 21Unauthorized Modes of Operation 2.8 5Unauthorized Modification and

Manufacture of Spare Parts 2.7 5Unit Fill 2.9.1 5

V-Belt Installation and Maintenance 5.3.2.3 11

Caution

Caution

KWP

4

1 GeneralThis KSB pump has been developed in accord-ance with state-of-the-art technology; it is

manufactured with utmost care and subject to continuousquality control.

These operating instructions are intended to facilitate familiar-ization with the pump and its designated use.

The manual contains important information for reliable, properand efficient operation. Compliance with the operating instruc-tions is of vital importance to ensure reliability and a long servicelife of the pump and to avoid any risks.

These operating instructions do not take into account localregulations; the operator must ensure that such regulations arestrictly observed by all, including the personnel called in forinstallation.

This pump / unit must not be operated beyond the limitvalues specified in the technical documentation for the

fluid handled, capacity, speed, density, pressure, temperatureand motor rating. Make sure that operation is in accordancewith the instructions laid down in this manual or in the contractdocumentation. (Contact the manufacturer, if required.)

The name plate indicates the type series / size, main operatingdata and works number; please quote this information in allqueries, repeat orders and particularly when ordering spareparts.

If you need any additional information or instructions exceedingthe scope of this manual or in case of damage please contactKSB�s nearest customer service centre.

For noise characteristics please refer to section 4.3.6.

2 SafetyThese operating instructions contain fundamental informationwhich must be complied with during installation, operation,monitoring and maintenance. Therefore this operating manualmust be read and understood both by the installing personneland the responsible trained personnel / operators prior to in-stallation and commissioning, and it must always be kept closeto the location of operation of the machine / unit for easy access.Not only must the general safety instructions laid down in thischapter on �Safety� be complied with, but also the safetyinstructions outlined under specific headings, particularly if thepump/unit is operated in potentially explosive atmospheres(see section 2.9).

2.1 Marking of Instructions in the ManualThe safety instructions contained in this manual whosenon-observance might cause hazards to persons are speciallymarked with the symbol

general hazard sign to ISO 7000 - 0434The electrical danger warning sign is

safety sign to IEC 417 - 5036,and special instructions concerning explosion protection aremarked

The word

is used to introduce safety instructions whose non-observancemay lead to damage to the machine and its functions.Instructions attached directly to the machine, e.g.- arrow indicating the direction of rotation- markings for fluid connectionsmust always be complied with and be kept in a perfectly legiblecondition at all times.

2.2 Personnel Qualification and TrainingAll personnel involved in the operation, maintenance,inspection and installation of the unit must be fully qualified tocarry out the work involved. Personnel responsibilities, competence and supervision mustbe clearly defined by the operator. If the personnel in question isnot already in possession of the requisite know-how,appropriate training and instruction must be provided. Ifrequired, the operator may commission the manufacturer /supplier to take care of such training. In addition, the operator isresponsible for ensuring that the contents of the operatinginstructions are fully understood by the responsible personnel.

2.3 Non-compliance with Safety InstructionsNon-compliance with safety instructions can jeopardize thesafety of personnel, the environment and the machine / unititself. Non-compliance with these safety instructions will alsolead to forfeiture of any and all rights to claims for damages.

In particular, non-compliance can, for example, result in:

- failure of important unit/system functions,

- failure of prescribed maintenance and servicing practices,

- hazard to persons by electrical, mechanical and chemicaleffects as well as explosion,

- hazard to the environment due to leakage of hazardoussubstances

2.4 Safety AwarenessIt is imperative to comply with the safety instructions containedin this manual, the relevant national and international explosionprotection regulations, health and safety regulations and theoperator�s own internal work, operation and safety regulations.

Ex symbol relates to additional requirements which mustbe adhered to when the pump is operated in potentially

explosive atmospheres.

2.5 Safety Instructions for the Operator / User- Any hot or cold components that could pose a hazard must be

equipped with a guard by the operator.

- Guards which are fitted to prevent accidental contact withmoving parts (e.g. coupling) must not be removed whilst theunit is operating.

- Leakages (e.g. at the shaft seal) of hazardous fluids (e.g. ex-plosive, toxic, hot) must be contained so as to avoid anydanger to persons or the environment. Pertinent legal provi-sions must be adhered to.

- Electrical hazards must be eliminated. (In this respect refer tothe relevant safety regulations applicable to differentcountries and/or the local energy supply companies.)

If the pumps/units are located in potentially explosiveatmospheres, it is imperative to make sure that unauthor-

ized modes of operation are prevented. Non-compliance mayresult in the specified temperature limits being exceeded.

N.B.:

N.B.:

Caution

KWP

5

2.6 Safety Instructions for Maintenance, Inspectionand Installation Work

The operator is responsible for ensuring that all maintenance,inspection and installation work be performed by authorized,qualified specialist personnel who are thoroughly familiar withthe manual.The pump must have cooled down to ambient temperature,pump pressure must have been released and the pump musthave been drained.Work on the machine / unit must be carried out only duringstandstill. The shutdown procedure described in the manual fortaking the unit out of service must be adhered to without fail.Pumps or pump units handling fluids injurious to health must bedecontaminated.Immediately following completion of the work, allsafety-relevant and protective devices must be re-installed and/ or re-activated.Please observe all instructions set out in the chapter on�Commissioning/Start-up� before returning the unit to service.

2.7 Unauthorized Modification and Manufacture ofSpare Parts

Modifications or alterations of the equipment supplied are onlypermitted after consultation with the manufacturer and to theextent permitted by the manufacturer . Original spare parts andaccessories authorized by the manufacturer ensure safety. Theuse of other parts can invalidate any liability of the manufacturerfor consequential damage.

2.8 Unauthorized Modes of OperationThe warranty relating to the operating reliability and safety of theunit supplied is only valid if the equipment is used in accordancewith its designated use as described in the following sections.The limits stated in the data sheet must not be exceeded underany circumstances.

2.9 Explosion ProtectionIf the pumps/units are installed in potentially explosiveatmospheres, the measures and instructions given in the

following sections 2.9.1 to 2.9.6 must be adhered to without fail,to ensure explosion protection.

2.9.1 Unit FillIt is assumed that the system of suction and dischargelines and thus the wetted pump internals are completely

filled with the fluid to be handled at all times during pumpoperation, so that an explosive atmosphere is prevented.

If the operator cannot warrant this condition, appropriatemonitoring devices must be used.

In addition, it is imperative to make sure that theseal chambers, auxiliary systems of the shaft

seal and the heating and cooling systems are properly filled.

2.9.2 Marking

The marking on the pump only refers to the pump part,i.e. the coupling and motor must be regarded separately.

The coupling must have an EC manufacturer�s declaration. Thedriver must be regarded separately.Example of marking on the pump part: Ex II 2 G T1 - T5The marking indicates the theoretically available temperaturerange as stipulated by the respective temperature classes. Thetemperatures permitted for the individual pump variants areoutlined in section 2.9.5.

2.9.3 Checking the Direction of Rotation (see also 6.1.4)If the explosion hazard also exists during the installationphase, the direction of rotation must never be checked

by starting up the unfilled pump unit, even for a short period, toprevent temperature increases resulting from contact betweenrotating and stationary components.

2.9.4 Pump Operating ModeMake sure that the pump is always started up with thesuction-side shut-off valve fully open and the discharge-sideshut-off valve slightly open. However, the pump can also bestarted up against a closed swing check valve. Thedischarge-side shut-off valve shall be adjusted to comply withthe duty point immediately following the run-up process (see6.1.7 ).Pump operation with the shut-off valves in the suctionand/or discharge pipes closed is not permitted.

In this condition, there is a risk of the pump casingtaking on high surface temperatures after a very

short time, due to a rapid temperature rise in the pumped fluidinside the pump.Additionally, the resulting rapid pressure build-up inside thepump may cause excessive stresses on the pump materials oreven bursting.The minimum flows indicated in section 6.2.5 refer to water andwater-like liquids. Longer operating periods with these liquidsand at the flow rates indicated will not cause an additionalincrease in the temperatures on the pump surface. However, ifthe physical properties of the fluids handled are different fromwater, it is essential to check if an additional heat build-up mayoccur and if the minimum flow rate must therefore be increased.To check, proceed as described in section 6.2.5.In addition, the instructions given in section 6 of this operatingmanual must be observed.

Both gland packings and mechanical seals mayexceed the specified temperature limits if run dry.

Dry running may not only result from an inadequately filledseal chamber, but also from excessive gas content in thefluid handled.Pump operation outside its specified operating range mayalso result in dry running.In potentially explosive atmospheres, gland packings shallonly be used if combined with a suitable temperaturemonitoring device.

2.9.5 Temperature LimitsIn normal pump operation, the highest temperatures areto be expected on the surface of the pump casing, at the

shaft seal and in the bearing areas. The surface temperature atthe pump casing corresponds to the temperature of the fluidhandled. If the pump is heated, it must be ensured that the temperatureclasses stipulated for the plant are observed.In the bearing bracket area, the unit surfaces must be freelyexposed to the atmosphere.In any case, responsibility for compliance with thespecified fluid temperature (operating temperature) lieswith the plant operator. The maximum permissible fluidtemperature depends on the temperature class to becomplied with.The table below lists the temperature classes to EN 13463-1and the resulting theoretical temperature limits of the fluidhandled. In stipulating these temperatures, any temperaturerise in the shaft seal area has already been taken into account.

Temperature classto EN 13463-1:

Temperature limit of fluid handled

T5T4T3T2T1

85 °C120 °C185 °C280 °C

max. 400 °C *)

*) depending on material variant

Safety note:The permissible operating temperature of thepump in question is indicated on the data sheet. If

the pump is to be operated at a higher temperature, the datasheet is missing or if the pump is part of a pool of pumps, themaximum permissible operating temperature must be enquiredfrom the pump manufacturer.

2361:18/2

1333:28/4

2361:49/5

Caution

KWP

6

Based on an ambient temperature of 40°C and propermaintenance and operation, compliance with temperatureclass T4 is warranted in the area of the rolling element bearings.A special design is required for compliance with temperatureclass T6 in the bearing area. In such cases, and if ambienttemperature exceeds 40°C, contact the manufacturer.

2.9.6 MaintenanceOnly a pump unit which is properly serviced andmaintained in perfect technical condition will give safe

and reliable operation.This also applies to the reliable function of the rolling elementbearings whose actual lifetime largely depends on theoperating mode and operating conditions.Regular checks of the lubricant and the running noises willprevent the risk of excessive temperatures as a result ofbearings running hot or defective bearing seals (also seesection 7.2.2.2).The correct function of the shaft seal must be checked regularly.Any auxiliary systems installed must be monitored, ifnecessary, to make sure they function correctly.Gland packings must be tightened correctly, to preventexcessive temperatures due to packings running hot.

3 Transport and Interim Storage3.1 TransportTransport of the unit requires proper preparation and handling.Always make sure that the pump or the unit remains in horizon-tal position during transport and cannot slip out of the transportsuspension arrangement. Do not use lifting slings on the freeshaft end of the pump or on the motor eyebolt.

If the pump / unit slips out of the suspension arrange-ment, it may cause personal injury and damage to

property.

Fig. 3.1-1 Transport of the pump

Fig. 3.1-2 Transport of the complete unit

Fig. 3.1-3 Transport of the complete unit

Fig. 3.1-4 Transport of the complete unit (3Z)

3.2 Interim Storage (Indoors) / PreservationWhen the unit is temporarily put into storage, only the wettedlow alloy components (e.g. JL1040, JS1025, GP240GH+Netc.) must be preserved. Commercially available preservativescan be used for this purpose. Please observe the manufactu-rer�s instructions for application / removal.The relevant procedure is described in section 6.3.The unit / pump should be stored in a dry room where theatmospheric humidity is as constant as possible.If stored outdoors, the unit and crates must be covered bywaterproof material to avoid any contact with humidity.

Protect all stored goods against humidity, dirt,vermin and unauthorized access!

All openings of the assembled unit components are closed andmust only be opened when required during installation.All blank parts and surfaces of the pump are oiled or greased(silicone-free oil and grease) to protect them against corrosion.

4 Description of the Product and Ac-cessories

4.1 Technical SpecificationFor handling all kinds of pulps not liable to plait, as well as stocksuspensions up to 5 % bone dry.

This pump is used in the chemical and process engineering in-dustries, paper and pulp industries, sugar, food and beveragesindustries, in flue gas desulphurization and coal upgrading andin the treatment of industrial effluents.

D00481

D00475

D00476

D00477D00479

D00478

KWP

7

4.2 DesignationKWP K A 100 - 250

Type seriesImpeller formAdditional codeDischarge nozzle DNNominal impeller dia. in mm

Impeller forms:K = channel-type impellerF = free-flow impellerO = open multi-vane impellerAdditional codes:A = Mechanical seal (in the casing cover)M = Mechanical seal (with seal cover)

4.3 Design DetailsHorizontal, non-self-priming, radially split volute casing pump inback pull-out design, with impeller adapted to meet applicationrequirements, single-flow, single-stage (other impeller formsand pump sizes on request).

4.3.1 Pump CasingRadially split, consisting of pump casing with integrally cast suc-tion and discharge nozzles and discharge cover. The dischargecover includes an integrally cast (GN, GC2, C2) or bolted (GH,H) stuffing box housing; the pump casing is fitted with a wearplate.

For handling combustible fluids, the pump casing mustbe made of ductile material with a maximum magnesium

content of 7.5 % (see EN 13463-1). This is a standard feature inall KSB supplies.

Fig. 4.3-1 Discharge cover with integrally cast stuffing boxhousing (casing design 2); material variant: GN, GC2, C2,

Fig. 4.3-2 Discharge cover with bolted stuffing box housing(casing design 3); material variant: GH, H

Fig. 4.3-3 For mechanical seal: discharge cover with conicalsealing chamber (A-cover); material variant: GN,GC2, C2, GH, H

4.3.2 Impeller FormK-impeller:closed channel-type impeller forcontaminated, solids-laden,non-gaseous liquids not liable to plait.As closed multi-vane impeller foruncontaminated or slightlycontaminated liquids containing no orvery little gas.

F-impeller:open free-flow impeller for liquidscontaining large solids and matter liableto plait, as well as liquids withentrapped air and gas.

O-impeller:Open multi-vane impeller foruncontaminated or slightlycontaminated liquids as well as liquidsliable to form deposits and bunch, withlittle entrapped gas.

4.3.3 Shaft SealSingle-acting mechanical seal in conical seal chamber or glandpacking with connection for barrier or flushing liquid.

Gland Packing

Fig. 4.3-4 Standard design

Mechanical seal

Installation examples:

�A� Design (in casing cover).

Single-acting mechanical seal, Single-acting mechanical seal, unbalanced stationary

Tandem arrrangement with quench

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0 50 100 150 200 250 300

C2k=f(t)

The forces and moments were determined on the basis of API 610(8th edition), table 2, doubled values

The resulting permissible forces have been determined according to

Fres D � Fx2 + Fz

2 and Fres S � Fy2 + Fz

2

Calculation of permissible forces and moments, if t > 20 °CPerm. force/moment = k (T) x force/moment tableExample: t = 100 °C

Material C2 ⇒ k = 0.825 ⇒ multiplication of values in table by 0.825The data on forces and moments apply to static pipelines only. If the limits areexceeded, they must be checked and verified. If a computerized strength analy-sis is required, please contact KSB.The values are only applicable if the pump is installed on a completely groutedbaseplate and bolted to a rigid and level foundation.If temperatures exceed 20 °C, the values indicated must be reduced in accord-ance with the above diagram.

Discharge nozzle

Suction nozzle

KWP

8

4.3.4 BearingsBearing bracket in back pullout design with axially adjustablerotor (ax, sx, x) for adjusting the gap between the impeller andthe wear plate. Oil-lubricated rolling element bearings (oil bath lubrication)

Bearing Bearings installed Quantity of lubricant

bracket pump endDIN 5412

motor endDIN 628 Oil in litres

P 03 axP 04 axP 05 axP 06 xP 08 sxP 10 axP 12 sx

NU 409NU 411NU 413NU 413NU 416NU 324NU 324

2 x 7309 BG2 x 7311 BG2 x 7313 BG2 x 7313 BG2 x 7319 BG2 x 7224 BG2 x 7224 BG

0.50.61.81.84.54.04.0

For the applicable bearing bracket design please refer to the data sheet.

4.3.5 Permissible Forces and Moments at the Pump Nozzles

Material variant C2 = NORIDURPump Forces Moments

size DN nozzle Suction nozzle Discharge nozzle Suction nozzle Discharge nozzle

SS DS in N in N in Nm in Nm

F x F y F z F res F x Ftension+ Fypressure- F z F res M x M y M z M x M y M z

40-250 65 40 3145 2065 2515 3235 1527 990 1975 1255 1975 2065 1525 1080 990 810 540

40-315 80 40 3860 2515 3055 3950 2605 1975 1345

50-200 65 50 3145 2065 2515 3235 1527 990 1975 1255 1975 2065 1525 1080 1255 990 630

50-400 80 50 3860 2515 3055 3950 1975 1255 2425 1615 2515 2605 1975 1345

65-20065-31565-400

808080

656565

3860 2515 3055 3950 2515 1615 3145 2065 3235 2605 1975 1345 2065 1525 1080

80-25080-31580-400

100100100

808080

4850 3145 3860 4940 3055 1975 3860 2515 3950 3595 2695 1795 2605 1975 1345

80-500 125 80 6645 4310 5300 6825 4940 3770 2515

100-250100-315100-400

125125125

100100100

6645 4310 5300 6825 3860 2425 4850 3145 5030 4940 3770 2515 3595 2695 1795

125-315125-400125-500

150150150

125125125

8445 5570 6735 8710 5300 3325 6645 4310 6825 6200 4760 3145 4940 3770 2515

150-315150-400

150150

150150

8445 5570 6735 8710 6735 4220 8445 5570 8710 6200 4760 3145 6200 4760 3145

200-320200-400200-500

200200200

200200200

13205 8445 10240 13295 10240 6380 13205 8445 13295 9520 6915 4760 9520 6915 4760

250-315250-400250-500250-630

250250250250

250250250250

17965 12035 14370 18770 14370 8980 17965 12035 18770 13470 10240 6555 13470 10240 6555

300-400300-500

300300

300300

21555 14370 17965 22995 17965 11045 21555 14370 22995 16435 12395 8085 16435 12395 8085

350-400350-500350-630

350350350

350350350

23980 15630 19220 24790 19220 12035 23980 15630 24790 17155 12845 8445 17155 12845 8445

KWP

9

Material variant GN. GH. GC2 . H = Cast iron, NorihardPump Forces Moments

size DN nozzle Suction nozzle Discharge nozzle Suction nozzle Discharge nozzle

SS DS in N in N in Nm in Nm

F x F y F z F res F x Ftension+ Fypressure- F z F res M x M y M z M x M y M z

40-250 65 40 1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 550 450 300

40-315 80 40 2150 1400 1700 2200

850 550 1100 700 1100

1450 1100 750

550 450 300

50-200 65 50 1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 700 550 350

50-400 80 50 2150 1400 1700 2200 1100 700 1350 900 1400 1450 1100 750

700 550 350

65-20065-31565-400

808080

656565

2150 1400 1700 2200 1400 900 1750 1150 1800 1450 1100 750 1150 850 600

80-25080-31580-400

100100100

808080

2700 1750 2150 2750 1700 1100 2150 1400 2200 2000 1500 1000 1450 1100 750

80-500 125 80 3700 2400 2950 3800 2750 2100 1400

100-250100-315100-400

125125125

100100100

3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000

125-315125-400125-500

150150150

125125125

4700 3100 3750 4750 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400

150-315150-400

150150

150150

4700 3100 3750 4850 3750 2350 4700 3100 4850 3450 2650 1750 3450 2650 1750

200-320200-400200-500

200200200

200200200

7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650

250-315250-400250-500250-630

250250250250

250250250250

10000 6700 8000 10450 8000 5000 10000 6700 6700 7500 5700 3650 7500 5700 3650

300-400300-500

300300

300300

12000 8000 10000 12800 10000 6150 12000 8000 12800 9150 6900 4500 9150 6900 4500

350-400350-500350-630

350350350

350350350

13350 8700 10700 13800 10700 6700 13350 8700 13800 9550 7150 4700 9550 7150 4700

Application range: up to 200 °C (no reduction)For other pump sizes please contact KSB.

4.3.6 Noise CharacteristicsRatedpower

Sound pressure level L pA (dB) 1) 2)power

input PNPump with motor Pump onlyinput PN

(kW) 29001/min

14501/min

960/7601/min

29001/min

14501/min

960/7601/min

1.5 62.5 56.5 55.0 54.0 52.0 51.0

2.2 64.5 58.5 52.5 55.0 53.0 52.0

3.0 67.0 60.5 59.0 57.0 55.0 53.5

4.0 68.5 62.0 60.5 58.0 57.0 55.0

5.5 70.0 63.5 63.0 59.5 57.5 57.0

7.5 71.0 65.0 63.5 61.0 58.5 57.5

11.0 72.5 67.0 65.5 62.5 60.5 59.5

15.0 74.0 68.0 66.5 64.0 61.5 60.5

18.5 74.5 68.5 67.5 65.0 62.5 61.5

22.0 75.0 69.0 68.0 66.0 63.5 62.5

30.0 76.0 70.5 69.0 67.0 65.0 63.5

37.0 76.5 71.0 69.5 68.0 65.5 64.5

45.0 77.0 71.5 70.5 68.5 66.5 65.5

55.0 78.0 72.5 71.0 69.5 67.5 66.5

75.0 - 73.5 72.0 - 68.5 67.5

90.0 - 74.0 72.5 - 69.5 68.5

110.0 - 74.5 73.0 - 70.5 69.5

132.0 - 75.0 73.5 - 72.0 71.0

160.0 - 75.5 74.0 - 73.0 72.0

200.0 - 76.0 74.5 - 75.0 73.5

250.0 - 80.0 79.0 - 76.0 75.0

N.B.: Add 2 dB for belt-driven units!

1) Measured at a distance of 1 m from the pump outline (as per DIN 45635Part 1 and 24). Room and foundation influences have not been in-cluded. The tolerance for these factors is 1 to 2 dB.

2) Increase for 60 Hz operationPump without motor: ---Pump with motor: 3500min-1: +3dB, 1750min-1: +1dB, 1160min-1: - - - dB

4.4 Accessories

Coupling: flexible coupling with / without spacer sleeve or belt drive

Contact guard: coupling guard / belt guardBaseplate cast or welded, for the complete unit (pump (to ISO 3661): and motor); in torsion-resistant design

If a complete unit is supplied, coupling and coupling guard orbelt drive with beld guard are provided by the supplier.Special accessories: as required

4.5 Dimensions and Weights

For dimensions and weights please refer to the generalarrangement drawing.

5 Installation at Site5.1 Safety Regulations

Equipment operated in potentially explosiveatmospheres must comply with the relevant

explosion protection regulations. This is indicated on thepump name plate and motor name plate (see 2.9).

5.2 Checks to be Carried out Prior to InstallationAll structural work required must have been prepared inaccordance with the dimensions stated in the dimensiontable / general arrangement drawing.The concrete foundations shall have sufficient strength(min. class X0) to ensure safe and functional installation inaccordance with DIN 1045 or equivalent standards.Make sure that the concrete foundation has set firmly beforeplacing the unit on it. Its surface must be truly horizontal andeven. The foundation bolts must be inserted in the baseplateholes.

Shim Shim

Foundation bolts

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

≥ 800Shim

Caution

Straight-edge

Straight-edge Gauge

a

a b

b

a b

a b

Gauge

Straight-edge

Straight-edge

Support foot Baseplate

Hex. head bolt

Adjusting screw

Lock nut

1211:128

Caution

KWP

10

5.3 Installing the Pump / UnitThe instructions given below refer to pump installation on agrouted baseplate and rigid foundation. After placing the pump on the foundation, align it with the helpof a spirit level placed on the shaft/discharge nozzle.Permissible deviation 0.2 mm/m. The correct distance betweenthe coupling halves as specified in the general arrangementdrawing must be observed. Shims shall be fitted between thebaseplate and the foundation itself; they shall always beinserted to the left and right of the foundation bolts and in closeproximity to these bolts. For a bolt-to-bolt clearance > 800 mm,additional shims shall be inserted halfway between theadjoining holes. All shims must lie perfectly flush.Insert the foundation bolts and set them into the foundationusing concrete. When the concrete has set, align the baseplateas described in section 5.3.1 and tighten the foundation boltsevenly and firmly. Then grout the baseplate usinglow-shrinkage concrete with a standard particle size and awater/concrete ratio of ≤ 0.5. The flowability must be producedwith the help of a solvent. Secondary treatment of the concreteto DIN 1045 is an absolute necessity.

Fig 5.3-1 Fitting required shimsTo ensure low-noise operation, the unit can be mounted onvibration dampers (please confirm with KSB first). Expansionjoints can be fitted between pump and suction/discharge line.The so-called �foundationless installation� on a baseplate andwith horizontally flexible adjusting elements is permissible. Forpermissible forces and moments please refer to the generalarrangement drawing of the pump.

5.3.1 Aligning the Pump/Drive (Fig. 3)

After fastening the baseplate on the foundationand connecting the piping, the coupling must be

thoroughly checked and the pump set be realigned (at themotor), if required.Prior to checking the alignment/realignment, loosen supportfoot 183 and re-tighten without transmitting any stresses orstrains.Coupling check and realignment must be effected even if pumpand motor are supplied completely assembled and aligned on acommon baseplate.The pump set is correctly aligned, if a straight-edge placedaxially on both coupling halves is the same distance from eachshaft at all points around the circumference. In addition, thedistance between the two coupling halves must remain thesame all around the circumference. Use a feeler gauge, awedge gauge or a dial micrometer to verify (see Figures 5.3-2and 5.3-3).

Fig. 5.3-2: Aligning the coupling with the help of a gauge and astraight-edge

Fig. 5.3-3: Aligning a spacer-type couplingThe radial and axial deviation (tolerance) between the twocoupling halves must not exceed 0.1 mm.

Improper alignment of the unit can cause damage to boththe coupling and the unit itself!

Motor alignment by means of adjusting screwsIn order to realign the coupling, first loosen the 4 hex. head boltson the motor as well as the lock nuts.Turn adjusting screw by hand or by means of an open-jawedwrench until the coupling alignment is correct. Then re-tightenthe 4 hex. head bolts and the lock nuts.

Fig. 5.3-4: Aligning the motor by means of adjusting screws

5.3.2 Aligning the Pump/Drive Fig. 4H/3Z - Belt Drive

Belt-driven pump sets must always be earthed. The con-dition of the belts must be checked regularly. The belts

must be made of conductive material.After fastening the baseplate on the foundationand connecting the piping, the belt drive must be

thoroughly checked and the V-belts be re-tensioned, if required.

Caution

KWP

11

5.3.2.1Mounting the Motor

Insert threaded rods 904.23/.24 in motor support plate81-54.01. Place motor support plate with threaded rods onto thebearing bracket (4H) or baseplate (3Z) and fasten withhex. nuts 920.23/.24.Use bolts 901.62 and discs 550.62 to fasten the motoron motor support plate 81-54.01.

5.3.2.2Mounting the PulleysGeneral information on taper bushes:

Taper bushes are used for achieving a kind of clampingfit between the hub of a pulley and the shaft. Only an Allan key is required for mounting and removing thepulleys. Identical grub screws are used for clamping andremoving.Taper bushes are cylindrical on the inside and taperedon the outside, and split along their entire length. On thelarger front face, bushes up to size 3030 are fitted with2, and bushes of size 3535 and above with 3 cylindricalhalf bores without threads parallel to the shaft axis. Theother half bore in the hub of the pulley is threaded.Grub screws are inserted into these front bores until theywill not go any further, using an Allan key. When thescrews are tightened, the hub is pulled onto the taperedbore and the bush is thus pressed onto the shaft.For wedge belt pulleys, the manner of fastening de-scribed above is generally sufficient for power transmis-sion. A key connection is necessary, where the opera-ting torque of the pulley is higher than the correspondingslip torque of the bush, and for shock loads. Therefore,all taper bushes are provided with a keyway.

Mount pulley 882.01 onto pump shaft by means oftaper bush 540.02.Mount pulley 882.02 onto motor shaft by means oftaper bush 540.03.

5.3.2.3V-belt Installation and Maintenance

Do not operate the pump without V-belt guard (see section5.4.2, belt guard, in the operating instructions).In normal design, the belts are suitable for ambienttemperatures of -30°C to +70 °C.

Installation:Before commencing work at the V-belt, make sure that thepump is secured in such a way that it cannot be switched onaccidentally.

1. The pulleys 882.01/.02 must be properly aligned. Misalign-ment of the pulleys will result in the V-belts being warped,thus causing increased wear on the flanks and generatinga high running noise.

2. The pulleys must be free from burs, rust and dirt. Dirtypulleys will cause premature destruction of the V-belts.

3. The V-belts must be fitted by hand without using force. Forthis purpose, reduce the distance between the pulleys bymoving the threaded rods 904.23/.24 / 920.63/.64 down-wards. Pulling the V-belts under tension over the edges ofthe pulleys or using metal tools can cause invisible damageto the tissue which will substantially reduce the service lifeof the V-belts.

4. V-belts must be properly tensioned.

- Insufficient tension will result in inadequate transmissionof power and premature wear caused by excessive slip.Excessive tension will cause excessive expansion, unne-cessary flexing work and high temperatures which will re-sult in a reduced service life. Additionally, high tensioncreates an unnecessarily high load on the bearings of theshaft.

5. Check the belt tension after a short break-in period and cor-rect it, if necessary. - Improperly tensioned V-belts will failprematurely.

6. Multiple V-belt drives must be equipped with V-belts of thesame length. When one belt fails, always replace the com-plete set. Old and new V-belts cannot be used in one setbecause V-belts tend to expand during operation.

7. Using belt wax or similar substances is not necessary. Theperformance of a belt drive is assured by correct tension.

8. Protect V-belts from oil mist, dripping oil and other chemi-cals. Sustained exposure to these substances will causeswelling or other failure of the belts.

Tension check for V-belts

Test force Fe = Newton

Deflection distance of individual belts te = mm

The set of V-belts consists of:Nos. Dimension: x Lw

dwg = mmdwk = mm n = 1/minanorm. = mm

5.3.3 Place of Installation

The volute casing and discharge cover take on roughlythe same temperature as the fluid handled. The

discharge cover, bearing bracket and bearing housing must notbe insulated.Take the necessary precautions to avoid burns.

5.4 Connecting the PipingNever use the pump itself as an anchorage pointfor the piping. The permissible pipeline forces

must not be exceeded (see section 4.3.5).Suction lift lines shall be laid with a rising slope towards thepump and suction head lines with a downward slope towardsthe pump. The pipelines must be anchored in close proximity tothe pump and connected without transmitting any stresses orstrains. The nominal diameters of the pipelines shall be at leastequal to the nominal diameters of the pump nozzles.

It is recommended to install check and shut-off elements in thesystem, depending on the type of plant and pump. It must be ensured, however, that the pump can still be drainedand dismantled without problems.Thermal expansions of the pipelines must be compensated byappropriate measures so as not to impose any extra loads onthe pump exceeding the permissible pipeline forces andmoments.

An excessive, impermissible increase in the pipelineforces may cause leaks on the pump where the fluid

handled can escape into the atmosphere. Danger of life when toxic or hot fluids are handled.The flange covers on the pump suction and discharge nozzlesmust be removed prior to installation in the piping.

Caution

Caution

Oil level in reservoirduring filling procedure

Vent/filler plug

Oil levelsight glass, ifapplicable

Position of reservoir fortopping up oil

Oil level in bearing bracketand connection elbow

Drain plug

Caution

Caution

Caution

KWP

12

5.4.1 Auxiliary ConnectionsThe dimensions and locations of the auxiliary connections(cooling, heating, barrier liquid, flushing liquid etc.) are indicatedon the general arrangement drawing or piping layout.

These connections are required for proper func-tioning of the pump and are therefore of vital

importance!

5.4.2 Coupling Guard/Belt GuardIn compliance with accident prevention regulations thepump must not be operated without a coupling guard or

belt guard. If the customer specifically requests not to includea coupling guard / belt guard in our delivery, then the operatormust supply one. In this case, it is important to make sure thatthe materials selected for coupling and coupling guard, or beltdrive and belt guard, are non-sparking in the event of mechani-cal contact. KSB�s scope of supply meets this requirement.

5.5 Final CheckRe-check the alignment as described in section 5.3 and verifythe correct distance between the coupling and the couplingguard, or belt drive and belt guard, as applicable.It must be easy to rotate the shaft by hand at the coupling orpulley.

5.6 Connection to Power SupplyConnection to the power supply must be effected by atrained electrician only. Check available mains voltage

against the data on the motor rating plate and select appropriatestart-up method.We strongly recommend to use a motor protection device(motor protection switch).

In potentially explosive atmospheres, compliance withIEC60079-14 is an additional requirement for electrical

connection.

6 Commissioning, Start-up / ShutdownCompliance with the following requirements is ofparamount importance. Damage resulting from

non-compliance shall not be covered by the scope of warranty.

6.1 Commissioning

Before starting up the pump make sure that the followingrequirements have been checked and fulfilled.

Mechanical seals are fitted in the factory. The mechanical sealis operational when it is in contact with the pumped fluid.

If a constant-level oiler is provided, screw same into the uppertapping hole of the bearing bracket prior to adding the oil (see6.1.1).

The operating data, the oil level, if required (6.1.1), and thedirection of rotation (6.1.4) must have been checked. The pump set must have been primed (6.1.3).

- Make sure that the unit has been properly connected to theelectric power supply and is equipped with all protectiondevices.

- Make sure that all auxiliary connections (5.4.1) are connect-ed and functioning.

- If the pump has been out of service for a longer period oftime, proceed in accordance with section 6.4.

6.1.1 LubricantsOil-lubricated bearingsThe bearing bracket has to be filled with lubricating oil. Thequality of oil required is outlined in section 7.2.2.3 and thequantity in section 4.3.4.

Fig. 6.1-1: Oil fillProcedure:Remove vent plug. Pour in the oil through the vent plug tappinghole after having hinged down the reservoir of the constant-level oiler until oil appears in the vertical portion of the connec-tion elbow (see Fig. 6.1-1). Then fill the reservoir of the con-stant-level oiler with oil and snap it back into operating position.Screw vent plug in again. After a short time check whether theoil level in the reservoir has dropped. It is important to keep thereservoir properly filled at all times.If access to the vent plug is difficult or impossible, e.g. in caseswhere the motor is arranged above the pump (piggy-backarrangement), the oil can be filled in through the connectionelbow of the constant-level oiler.

The oil level must always be below the level of thevent opening arranged at the top edge of the con-

nection elbow. The seat must be absolutely dry. For checkingthe oil level we recommend to slowly drain oil through the drainplug until the constant-level oiler starts to operate, i.e. until airbubbles can be seen in the oiler.If no constant-level oiler is provided on the bearing bracket,make sure that the oil level reaches the centreline of the oil levelsight glass arranged at the side of the bearing bracket.

6.1.2 Shaft SealThe gland packing for the gland packing variant issupplied with the pump, but as a separate,

non-fitted item (exception: pure graphite packings).We recommend to use pre-stressed packing rings from KSB�sscope of supply. For non-KSB brands, please note the manu-facturer�s instructions regarding installation and use (seesection 2.7).Prior to commissioning, the gland packing supplied with thepump must be fitted as described in section 7.5.4 (except forpure graphite packings).

Mechanical seals are fitted prior to delivery.On variants with buffer liquid reservoir, the reser-

voir must be filled in accordance with the general arrangementdrawing.On variants with double-acting mechanical seal, apply barrierpressure as specified in the general arrangement drawing priorto starting up the pump.External supply requires application of the quantities and pres-sures specified in the data sheet and general arrangementdrawing.

6.1.3 Priming the Pump and Checks to Be Carried outBefore start-up, the pump, suction line and (if applicable) thethermosiphon tank must be vented and primed. The shut-offelement in the suction line must be fully open.Fully open all auxiliary connections provided (flushing, barrier,cooling liquid, etc.) and check the throughflow.

Caution

Caution

Caution

Caution

Caution

Caution

Caution

KWP

13

For water cooling, use suitable non-aggressive cooling waternot liable to form deposits and not containing suspended solids.(Hardness: on average 5; pH > 8, or conditioned and neutralwith regard to mechanical corrosion).Inlet temperature tE = 10 to 30 °COutlet temperature tA max. 45 °C

Dry-running will result in increased wear onthe gland packing and shaft protecting sleeve

or failure of the mechanical seal and must be avoided!

6.1.4 Checking the Direction of RotationWhen the unit has been connected to the electric power supply,verify the following (local and national regulations have to betaken into account separately):

For trouble-free operation of the pump, thecorrect direction of rotation of the impeller is of

paramount importance. If running in the wrong direction ofrotation, the pump cannot reach its duty point; vibrations andoverheating will be the consequence. The unit or the shaft sealmight be damaged.

Correct direction of rotation:The direction of rotation must correspond to the direction indica-ted by the arrow on the pump. This can be verified by switchingthe pump on and then off again immediately.

Before checking the direction of rotation make sure thatthere is no foreign matter in the pump casing.

Never put your hands or any other objects into the pump.Do not run the pump without liquid whilechecking the direction of rotation. If there is

no fluid handled available, the motor�s direction of rotation mustbe checked with the pump/motor coupling removed. If the pumpis fitted with a gland packing, short start-up will not pose anyrisks.If the pump runs in the wrong direction of rotation, interchangetwo of the three phases in the control cabinet or motor terminalbox.The safety instructions set forth in section 2.9.3 must be com-plied with.

6.1.5 Cleaning the Plant PipingThe cleaning operation mode and duration for flushingand pickling service must be matched to the casing and

seal materials used.

6.1.6 Start-up StrainerIf a start-up strainer has been fitted to protect the pumps againstdirt and/or to retain contamination from the plant, the strainer�scontamination level must be monitored by measuring the diffe-rential pressure so as to ensure adequate inlet pressure for thepump.For installation and monitoring, see additional instruction sheet.

6.1.7 Start-upBefore starting the pump, ensure that the shut-off valve in thesuction line is fully open! The pump may be started up againsta closed discharge-side swing check valve or slightly openshut-off valve. Only after the pump has reached full rotationalspeed shall the shut-off valve in the discharge line be openedslowly and adjusted to comply with the duty point. When startingup against an open discharge-side shut-off valve, take the re-sulting increase in input power into account!

Pump operation with the shut-off valves inthe discharge and suction pipes closed is

not permitted.The permissible pressure and temperature limits might beexceeded. In extreme cases, the pump may burst.

After the operating temperature has beenreached and/or in the event of leakage, switch off

the unit and re-tighten the bolts between lantern and casing.Check the coupling alignment at operatingtemperature as described in section 5.3.1 and

re-align, if necessary.

6.1.8 ShutdownClose the shut-off element in the discharge line.If the discharge line is equipped with a non-return or checkvalve, the shut-off element may remain open. If shut-off is notpossible, the pump will run in reverse rotation. The reverserunaway speed must be lower than the rated speed.Switch off the drive, making sure that the unit runs smoothlydown to a standstill.Close the auxiliary connections but only turn off the coolingliquid supply (if applicable) after the pump has cooled down.The shaft seal in pumps where the liquid is fed in under vacuummust also be supplied with barrier liquid during standstill.In the event of frost and/or prolonged shutdowns, the pump -and if applicable the cooling chambers - must be drained orotherwise protected against freezing.

6.2 Operating LimitsThe pump�s/unit�s application limits regarding pressure,temperature and speed are stated on the data sheet and

must be strictly adhered to.If a data sheet is not available, contact KSB.

6.2.1 Temperature of the Fluid Handled, Ambient Temperature, Bearing Temperature

Do not operate the pump at temperaturesexceeding those specified on the data sheet or

the name plate unless the written consent of the manufacturerhas been obtained. Damage resulting from disregarding this warning will not becovered by the KSB warranty.Bearing temperatures as described in section 7.2.1 must beobserved.

The safety instructions set forth in section 2.9 must becomplied with.

6.2.2 Switching FrequencyThe start-up frequency usually depends on the max.temperature increase of the motor. It largely depends on thepower reserves of the motor in steady-state operation and onthe starting conditions (d.o.l., star-delta, moments of inertia,etc.)For start-up with the discharge side gate valve slightly open, thefollowing limits may be used for orientation. These limits arebased on the assumption that start-ups are regularly spaced inthe period indicated.

Motor rating (kW) max. S (Start-ups/h)up to 12 15

up to 100 10above 100 5

If the above switching frequencies are exceeded, pleasecontact the motor manufacturers or KSB.

6.2.3 Density of the Fluid HandledThe power input of the pump will increase in proportion to thedensity of the fluid handled. To avoid overloading of the motor,pump and coupling/belt drive, the density of the fluid mustcomply with the data specified on the purchase order.

6.2.4 Abrasive FluidsWhen the pump handles liquids containing abrasive sub-stances, increased wear of the hydraulic system and the shaftseal are to be expected. The intervals recommended for servi-cing and maintenance must be shortened.

Caution

Caution

KWP

14

6.2.5 Minimum/Maximum FlowUnless specified otherwise in the characteristic curves or on thedata sheets, the following applies:Qmin = 0.1 x Qopt for short operationQmin = 0.3 x Qopt for continuous operationQmax = 1.1 x Qopt for 2-pole operationQmax = 1.25 x Qopt for 4-pole operationQopt = optimum efficiencyThe data refer to water and water-like liquids. However, if thephysical properties of the fluids handled are different fromwater, the calculation formula below must be used to check if anadditional heat build-up may lead to a dangerous temperatureincrease at the pump surface. If necessary, the minimum flowmust be increased.

T o = T f + ∆ ϑ

g * H∆ ϑ = * ( 1 - η )

c * ηc Specific heat [J / kg K]g Acceleration due to gravity [m/s�]H Pump head [m]T f Temperature of fluid handled [°C]T o Temperature of casing surface [°C]η Pump efficiency at duty point [ -]∆ ϑ Temperature difference [°C]

6.3 Shutdown / Storage / PreservationEach KSB pump leaves the factory carefully assembled. If com-missioning is to take place some time after delivery, we recom-mend that the following measures be taken for pump storage.

6.3.1 Storage of New Pumps- New pumps are supplied by our factory duly prepared for

storage. Maximum protection for up to 12 months, if the pump isproperly stored indoors.

- Store the pump in a dry location.- Rotate the pump rotor by hand once a month.

6.3.2 Measures to Be Taken for Prolonged Shutdown1. The pump remains installed; periodic check of operation

In order to make sure that the pump is always ready forinstant start-up and to prevent the formation of depositswithin the pump and the pump intake area, start up the pumpset regularly once a month or once every 3 months for a shorttime (approx. 5 minutes) during prolonged shutdownperiods. Prior to an operation check run ensure that there issufficient liquid available for operating the pump.

2. The pump is removed from the pipe and storedBefore putting the pump into storage carry out all checksspecified in sections 7.1 to 7.4. Then apply appropriatepreservatives:- Spray-coat the inside wall of the pump casing, and in parti-

cular the impeller clearance areas, with a preservative.Spray the preservative through the suction and dischargenozzles. It is advisable to close the nozzles (for ex. withplastic caps or similar).

- If the pumps are out of service for more than one year, allelastomer seals must be replaced.

6.4 Returning to Service after StorageBefore returning the pump to service carry out all checks andmaintenance work specified in sections 7.1 and 7.2.

In addition, the instructions laid down in the sections on�Commissioning� (6.1) and �Operating Limits� (6.2) must

be observed.Upon completion of the work, all safety-related and pro-tective equipment must be properly refitted and/or reacti-

vated before starting the pump set.

7 Maintenance / Repair7.1 General InstructionsThe operator is responsible for ensuring that all maintenance,inspection and installation work is carried out by authorized,duly qualified staff who are thoroughly familiar with these opera-ting instructions.A regular maintenance schedule will help avoid expensiverepairs and contribute to trouble-free, reliable operation of thepump with a minimum of maintenance expenditure and work.

Work on the unit must only be carried out with theelectrical connections disconnected. Make sure that

the pump set cannot be switched on accidentally (dangerto life!).

Pumps handling liquids posing health hazards mustbe decontaminated. When draining the fluid see to it

that there is no risk to persons or the environment. All rele-vant laws must be adhered to (danger to life!).

7.2 Maintenance / Inspection7.2.1 Supervision of Operation

The pump shall run quietly and free from vibra-tions at all times. The pump must never be

allowed to run dry.Prolonged operation against a closed shut-off element isnot permitted. When operating the pump set with the

shut-off valve in the discharge line slightly open for a short pe-riod of time, the permissible pressure and temperature limitsmust not be exceeded.

A special design is required to comply with temperatureclass T6 in the bearing area. In such cases, and if

ambient temperature exceeds 40°C, contact the manufacturer.Verify correct oil level as described in section 6.1.1.The shut-off elements and the auxiliary feed lines must not beclosed during operation.The gland packing (if any) must drip slightly during operation.The gland cover shall only be gently tightened.Any stand-by pumps installed shall be switched on and thenimmediately off again once a week to keep them operational.Attention shall be paid to the correct functioning of the auxiliaryconnections.The cooling system must be thoroughly cleaned at least oncea year to ensure proper cooling. Take the pump out of servicefor this purpose.

If the flexible coupling elements begin to showsigns of wear, they must be replaced in due time.

7.2.2 Lubrication and Lubricant Change

7.2.2.1 LubricationThe rolling element bearings are lubricated with mineral oil. Thelubricant change intervals as well as the required quantity andquality are specified below.

7.2.2.2 Oil Change (Operating Hours)Temperature at thebearing

First oil changeafter

All subsequent oil changes after everybearing after

Bearing bracket

> + 50 °C 300 operating hours

up to P 04 6000 operatinghours 1)

The above intervals are recommended.They must be shortened, if the oil is liableto get contaminated.

from P 05 8000operatinghours 1)

1) at least once a year

Fig. 7.2-1

Caution

Caution

KWP

15

Procedure:Remove screwed plug below the constant-level oiler (oil levelsight glass) and drain off the oil. After drainage of the bearingbracket, screw in the plug again and fill with fresh oil asdescribed in section 6.1.1.

Please observe the local laws applicable to dis-posal of such substances.

7.2.2.3 Oil QualityThe bearing bracket shall be filled with lubricating oil quality SAE20W/ 20 HD or CLP 68 to DIN 51 517. For oil quantity please refer to section 4.3.4, table �bearing sizes�

Lubricant dataSpeed/

temperature1)

Kinematic viscosityν at 50 °C

Density ρat 15 °C

Flashpoint

Solidificationpoint (Pour point)equal to/lowerthan

Lubricantto DIN51517

n = 1/min t = °C

cSt � E g/cm3 °C °C

n up to 3500t up to 80

36 � 4 4.8 0.895 150 - 9 C 36

n up to 3500t 80 - 120

68 � 6 9.0 0.900 175 - 9 C 68

n up to 3500t -15 -+60

25 � 4 3.5 0.895 150 -25 C-T 25 2)

1) min. ambient temperature and max. bearing temperature2) Special pourpoint requirements may be agreed for individual orders.

7.3 Drainage / DisposalIf the pump was used for handling liquids posinghealth hazards, see to it that there is no risk to per-

sons or the environment when draining the fluid. All relevantlaws must be heeded. If required, wear safety clothing and aprotective mask.If the fluids handled by the pumps leave residues which mightlead to corrosion when coming into contact with atmospherichumidity, or which might ignite when coming into contact withoxygen, then the unit must be flushed through, neutralized, andthen for drying purposes anhydrous gas shall be blown throughthe pump. Use connections 6B to drain the pump set.The flushing liquid used and any liquid residues in the pumpmust be properly collected and disposed of without posing anyrisk to persons or the environment.

7.4 DismantlingBefore dismantling, secure the pump so as to make sureit cannot be switched on accidentally. The shut-off

elements in the suction and discharge lines must be closed.The pump must have cooled down to ambient temperature, itmust be drained and its pressure must be released.Dismantling and reassembly must always be carried out inaccordance with the relevant sectional drawing.

7.4.1 Fundamental Instructions and RecommendationsRepair and maintenance work to the pump must only be carriedout by specially trained personnel, using original spare parts(see 2.7).Observe the safety regulations laid down in section 7.1.Any work on the motor shall be governed by the specifica-tions and regulations of the respective motor supplier.Dismantling and reassembly must always be carried out inaccordance with the relevant general assembly drawing. The general assembly drawing and other relevant docu-ments are found in the annex. The dismantling sequencecan be derived from the general assembly drawing. In caseof damage you can always contact our service depart-ments.

7.4.2 Dismantling (General)1. Drain the oil as described in 7.2.2.2.

2. Remove the belt guard or coupling guard, as applicable.

3. Dismantle the coupling spacer sleeve or, if not applicable,remove the drive, or remove belts and pulleys.

4. Disconnect and remove all auxiliary feed lines.

5. Loop a rope tightly around the top stay of bearing bracketlantern 344.

6. Unscrew hex. head bolt 901.04 and baseplate fixing boltson support foot 183; remove the support foot.

7. Unscrew and remove hex. nuts 920.01 and pull completebearing bracket 330 out of pump casing 101 together withshaft 210, impeller 230 and bearing bracket lantern 344using forcing screws 901.31. Clean the screw threadsbeforehand. Do not damage joint ring 411.10.

8. Removing the impeller:

From pumps with bearing brackets P 03 ax, P 04 ax, P 05 ax, P 06x:Undo impeller screw 906 (right-hand thread) and removeO-ring 412.03. Pull off impeller 230 using a pull-off deviceand remove key 940.01.

From pumps with bearing brackets P 08 sx, P 10 ax, P 12 sx:Unscrew impeller cap 260.01 and remove O-ring 412.03.Bend back lockwasher 931.02, unscrew hex. head bolt901.87 and remove lockwasher and disc 550.87. Pull offimpeller 230 using a pull-off device and remove key 940.01.

9. Dismantling the shaft seal:For mechanical seal version please refer to the supplementat the end of these operating instructions or section 7.4.2.1,if the mechanical seal is integrated in the discharge cover(A-cover).For gland packing version, remove gland cover 452.01 afterhaving loosened hex. nuts 920.02. Carefully remove discs550.01. Remove discharge cover 163 with gland packingand drip plate 463.01.Remove the gland packing from the packing chamber.Carefully force out neck bush 456.01.

10. Unscrew hex. nuts 920.04 and remove bearing bracketlantern 344. Pull shaft protecting sleeve 524.01 with O-ring412.06 off the shaft. Bend back and remove thrower 507.01.

11. After having unscrewed the hex. socket head cap screw inthe coupling hub, pull the coupling half off the pump shaftusing a pull-off device and remove key 940.02.

12. Dismantle bearing covers 360.01 and 360.02 at the pumpand drive ends, respectively, after having unscrewed hex.socket head cap screws 914.01/.02.

13. Use grub screw 904.01 to carefully drive shaft 210 togetherwith bearing carrier 382, angular contact ball bearing320.02 and the inner race of cylindrical roller bearing 322.01out of the bearing bracket 330 towards the drive end.

14. Remove support disc 550.23. Take out circlips 932.01/.02.Remove cylindrical roller bearing 322.01 (roller cage) fromthe bearing bracket.

15. Pull bearing carrier 382 with O-ring 412.02 off angularcontact ball bearing 320.02.

16. Bend back lockwasher 931.01, unscrew keywayed nut920.21 (right-hand thread), remove lockwasher.

17. Heat up angular contact ball bearing 320.02 and the innerrace of cylindrical roller bearing 322.01 and pull them off theshaft.

18. Examine wear plate 135.01 for signs of wear and remove itfrom the pump casing, if necessary.To remove the wear plate, remove hex. head bolts 901.03(hex. socket head cap screws 914.05) with joint rings411.13. Make sure not to damage O-rings 412.05 and412.75.

19. Clean all the components and examine them for signs ofwear. Touch up the damaged components or replace themby new ones.

411.10

433.02 524.01 163 507.01

Caution

Caution

Caution

KWP

16

7.4.2.1Dismantling the Mechanical Seal Integrated in the Discharge Cover (A-Cover)

(For KSB mechanical seal observe supplementary operatinginstructions 1070.84-90)

Dismantling the discharge cover1. Dismantle the pump in acc. with section 7.4.2. Also refer to

the supplement �General drawing of mechanical seal�.

2. Remove impeller screw 906, O-ring 412.03, impeller 230and key 940.01 in accordance with the sectional drawing.

3. In accordance with section 7.4.2 paras. 1-4, unscrew thehex. socket head cap screw in the coupling hub, pull thecoupling half off the pump shaft using a pull-off device andremove key 940.02.

4. Clamp in the bearing bracket at the motor end of the shaft invertical position. Use a vice to clamp discharge cover 163 tobearing bracket lantern 344, if necessary.

5. Disengage shaft protecting sleeve 524.01 with rotating sealassembly at the bearing cover end by inserting a suitabletool between the shaft protecting sleeve and thrower507.01, and push it off the shaft.

6. Disengage the locking device and pull the rotating sealassembly 433.02 off the shaft protecting sleeve in a straightmovement without twisting it. For part descriptions pleaserefer to the supplement �General drawing of mechanicalseal�.

7. Remove discharge cover 163 with joint ring 411.11 and seatring with secondary seal. Press the seat ring with thesecondary seal out of the casing cover.

8. Proceed as set forth in section 7.4.2.

7.5 Reassembly

7.5.1 General InstructionsThe pump shall be reassembled in accordance with the rulesof sound engineering practice.Clean all dismantled components and check them for signs ofwear. Verify the dimensions given in section 7.5.5. Damaged orworn components are to be replaced by original spare parts.Make sure that the seal faces are clean and that O-rings andgaskets are properly fitted.It is recommended to use new sealing elements (O-rings/gas-kets) whenever the pump is reassembled. Make sure that newgaskets have the same thickness as the old ones.Gaskets made of graphite or other asbestos-free material mustalways be fitted without using lubricants such as copper greaseor graphite paste.Avoid the use of mounting aids as far as possible. Should amounting aid be required after all, use a commercially available

contact adhesive (e.g. Pattex). The adhesive shall only beapplied at selected points (3 to 4 spots) and in thin layers. Donot use cyanoacrylate adhesives (quick-setting adhesives).If in certain cases mounting aids or anti-adhesives other thandescribed herein are required, please contact the sealing mate-rial manufacturer.

All graphite gaskets must only be used once!

Never use O-rings that have been glued together from materialsold by the metre.

Do not coat O-ring with graphite or similar prod-ucts. Use animal fats or silicone-base or PTFE-

base lubricants instead.The locating surfaces of the individual components shall becoated with graphite or similar before reassembly. The same applies to screwed connections.

7.5.2 Reassembly (General)Reassembly is effected in reverse order to dismantling. Use thegeneral assembly drawing and the list of components for orien-tation.All screws and bolts must be properly tightened during assem-bly. For the required torques please refer to sections 7.5.3.1 and7.5.3.2.1. Use only the bearing types and sizes specified in section

4.3.4. Angular contact ball bearing 320.02 and the innerrace of cylindrical roller bearing 322.01 must be heated up inan oil bath to approx. 80 °C before slipping them onto theshaft until they abut against the shaft shoulder.

The angular contact ball bearings 320.02must be installed in �O� arrangement!

Angular contact ball bearings installed in pairs must alwaysbe from the same manufacturer.After having mounted angular contact ball bearings 320.02,screw on and tighten keywayed nut 920.21 using aC-wrench and without fitting lockwasher 931.01. Let the ballbearing cool down to approx. 5 °C above ambient tempera-ture.Re-tighten the keywayed nut, then unscrew it again. Put afew spots of Molykote on the contact faces of the lock-washer and of the keywayed nut, slip on the lockwasher,firmly tighten the keywayed nut and bend over the lock-washer.

2. When mounting bearing covers 360.01/.02, take care not todamage radial shaft seal rings 421.01/.02 or V-rings411.77/.78.

3. For mounting the gland packing, observe the instructions insection 7.5.4.For mounting the mechanical seal, observe the supplementat the end of these operating instructions.Check the sliding fit of the shaft protecting sleeve on theshaft.

4. Carefully insert the impeller joint ring making sure the ringand sealing surfaces are clean.

5. After installation in the pump casing, which has remained inthe piping, the rotor shall be adjusted as follows:For closed impellers (KWPK) and open impellers(KWPO):Loosen grub screws 904.01 and push the rotor towards thepump end by tightening hex. socket head cap screws914.02 until the back vanes abut against wear plate 135.01.Measure the axial gap between bearing bracket 330 andbearing carrier 382. Loosen hex. socket head cap screws914.02 and pull the rotor back out again towards the driveend, using grub screws 901.01. The remaining gapbetween impeller and wear plate shall be set to 0.5 mm, onpumps with nominal size DN 300 to DN 450 to 0.6 mm, DN500 to DN 600 to 0.7 mm. Tighten hex. socket head capscrews 914.02 to fix the rotor in this position.

Caution

Caution

2361:38/4

2361:124

2361:121

KWP

17

Caution !All screws and bolts must be tightened evenly!For free-flow impellers (KWPF):Loosen hex. socket head cap screws 914.02 and pull backthe rotor by tightening grub screws 904.01 until the back va-nes abut against discharge cover 163. Measure the axialgap between bearing bracket 330 and bearing carrier 382.Loosen grub screws 904.01 and push the rotor 1.5 mmtowards the pump side, using hex. socket head cap screws914.02. Use grub screws 904.01 to fix the rotor in thisposition.Caution !All screws and bolts must be tightened evenly!

6. After installation in the pump casing, which has remained inthe piping, the coupling alignment must be checked asdescribed in section 5.3.1. or belts and belt tension shall bechecked as outlined in section 5.3.2.

7. Fill in oil as described in section 6.1.1

7.5.3 Tightening Torques

7.5.3.1Tightening Torques of the Casing Bolts(part no. 902.01/920.01)

Thread Material Ck 35Nm

Material A4-70Nm

M 12M 16M 20

40100190

55140200

Warning: Pumps with NORIHARD casing (NH 153)Studs on material variant NH 153 must not betightened with an impact screw driver. Wheninserting studs, make sure that they can be screwedin easily right up to the thread end.

7.5.3.2 Tightening Torques of the Impeller Screw (part no. 906)

Bearing bracket Tightening torque in NmP 03 axP 04 axP 05 axP 06 x

P 08sx/P10ax/P12sx

5050120180360

7.5.4 Mounting the Shaft Seal7.5.4.1 Gland Packing

For pure graphite packings, refer to the supple-mentary operating instructions!

Always use pre-stressed packing rings.Mounting instructions (with the pump disassembled):Bolt stuffing box housing 456.01 to discharge cover 163. Pressneck bush 456.01 into discharge cover 163. For packing designas shown in Fig. 7.5-1 also insert lantern ring 458.01. Insert first packing ring so that the cut edge is in horizontal posi-tion. Hold the packing ring and slide the shaft protecting sleeve(the chamfered side coming first) from the pump end into thegland packing chamber. Slightly expand the packing ring�s in-side diameter by sliding the shaft protecting sleeve back andforth. Withdraw the shaft protecting sleeve and insert thesecond packing ring with its cut edge displaced by 90 °C. Repeat the expanding procedure. Insert lantern ring 458.01 (forpacking design as shown in Fig. 7.5-1). Insert all subsequentpacking rings. When the last packing ring has been inserted,the shaft protecting sleeve is left in the gland packing chamber.Insert stuffing box ring 454.01 so that the joint face is in verticalposition to the gland cover. Slide on gland cover 452.01 andslightly tighten it by hand using the two hex. nuts 920.02. Makesure to insert discs 550.01. Install the complete assembly of discharge cover/stuffing boxhousing with shaft protecting sleeve in the pump.

The gland packing must leak slightly during ope-ration. The throughflow of the barrier and flushing

liquid connections provided must be permanently checked.When the gland packing has been re-tightened up to the stop, acompletely new packing must be fitted.

7.5.4.2 Gland Packing Chamber Dimensions/Number of Packing Rings

Bearingbracket

Number of packing rings Length of pack-ing chamberbracket

with lanternring

withoutlantern ring

Ø di Ø da � l1 l2

P03ax 4 1) 6 45 65 10 64 8P04ax 4 1) 6 55 75 10 64 8

P05ax 4 1) 6 70 95 12.5 79 8

P06x 4 1) 6 80 105 12.5 79 10

P08sx 4 1) 6 100 132 16 103 10P10ax 4 1) 6 120 152 16 103 7

P12sx 4 1) 6 140 172 16 103 7

1) for packing design as per fig. 7.5-3: one spacer and 3 packing rings

Fig. 7.5-1 Packing with barrier liquid connection (standard design)

2542:22

2361:123

433.02 524.01 163 507.01

411.10

2721

:294

KWP

18

Fig. 7.5-2 Packing without lantern ring

Fig. 7.5-3 Packing with flushing liquid connection

7.5.4.3 Mounting the Mechanical Seal

(For KSB mechanical seal observe supplementary operatinginstructions 1070.84-90)For mounting the mechanical seal, please refer to the supple-ment at the end of these operating instructions or to section7.5.4.4 if the mechanical seal is integrated in the dischargecover.

7.5.4.4 Mounting the Mechanical Seal Integrated in theDischarge Cover (A-cover)

Mounting the discharge cover

1. Installation is effected in reverse order to dismantling. Alsorefer to the supplement �General drawing of mechanicalseal�.

2. We recommend to place the shaft in vertical position duringreassembly as well.

3. Mount the seat ring with the secondary seal carefully in thedischarge cover 163.

4. Check the sliding fit of shaft protecting sleeve 524.01 on theshaft.

5. Slip the spacer and rotating seal assembly 433.02 onto theshaft protecting sleeve and engage as stipulated by the sealmanufacturer.Caution! Make sure not to damage the surface of the shaftprotecting sleeve when mounting the rotating seal assem-bly. The seal faces shall be wetted with a lubricant compati-ble with the pumped product.

6. Mount bearing bracket lantern 344 on the pre-assembledbearing bracket 330. Slip on the pre-assembled dischargecover 163 with joint ring 411.11 and clamp it provisionally tothe bearing bracket lantern. Slip-on the pre-assembledshaft protecting sleeve and insert key 940.01 and joint ring411.32. Mount impeller 230. Insert joint ring 411.31 andtighten impeller screw 906 in acc. with section 7.5.3.2.

D00472

KWPK

D00473

KWPO

D00474

KWPF

The axial clearance betweenback vanes and dischargecover shall be 1.5 mm.

The axial clearance between thewear plate and the impeller shallbe 0.5 mm.

Mec

hani

cal

seal

KWP

19

7.5.5 Clearances

The axial clearance between thewear plate and the impeller shallbe 0.5 mm, on pump sizes DN 300to DN 450 0.6 mm.

7.6 Spare Parts Stock

When ordering spare parts please always quote the followingdata stated on the pump name plate:

Type series: here: KWPPump size:Works No.:

7.6.1 Recommended Spare Parts Stock for 2 Years� Operation to DIN 24296

Part No. Description Number of pumps (including stand-by pumps)2 3 4 5 6 and 7 8 and 9 10 and more

Quantity of spare parts135.01 Wear plate, suction side 2) 2 2 2 3 3 4 50%210 Shaft 1 1 1 2 2 2 20%230 Impeller 1 1 1 2 2 2 20%320.02 Angular contact ball bearing (set) 1 1 2 2 2 3 25%322.01 Cylindrical roller bearing 1 1 2 2 2 3 25%330 Bearing bracket cpl. - - - - - 1 2 off433.01 Mechanical seal cpl. 1) 1 1 2 2 2 3 25%

orSpring-loaded ring 1) 2 3 4 5 6 7 90%Seat ring 1) 2 3 4 5 6 7 90%Seal at the seat ring 1) 2 3 4 5 7 9 100%Seal at the spring-loaded ring 1) 2 3 4 5 7 9 100%Spring (set) 1) 1 1 1 1 2 2 20%

456.01 Neck bush 1 1 2 2 2 3 30%461.01 Gland packing (set) 4 4 6 6 6 8 100%524.01 Shaft protecting sleeve 2 2 2 3 3 4 50%- - - Gaskets for pump casing (set) 4 6 8 8 9 12 150%

1) alternatively2) on KWP 250-315, 300-400 and 350-400 casing wear ring instead of wear plate

40-2

50

50-2

00

65-2

00

80-2

50

65-3

15

65-4

00

40-3

15

50-4

00

80-3

11

100-

250

100-

315

100-

400

80-4

00

150-

315

150-

400

200-

320

50-2

01

65-2

01

80-2

51

65-3

13

80-3

15

100-

251

80-4

03

150-

311

100-

403

100-

253

200-

500

300-

400

300-

500

350-

400

350-

500

350-

630

200-

501

250-

400

250-

500

250-

630

400-

500

400-

503

350-

633

350-

503

350-

504

300-

503

250-

634

250-

505

250-

503

250-

403

200-

503

80-5

00

125-

500

125-

503

200-

400

200-

403

250-

315

300-

400

300-

500

350-

400

350-

500

350-

630

400-

500

400-

583

350-

633

350-

503

350-

504

300-

503

500-

544

400-

710

400-

713

500-

630

500-

633

500-

634

500-

635

500-

637

200-

500

200-

501

250-

400

250-

500

250-

630

250-

634

250-

505

250-

503

250-

403

200-

503

400-

503

400-

533

200-

500

300-

500

350-

500

350-

630

200-

501

250-

500

250-

630

400-

533

350-

633

350-

503

350-

504

300-

503

250-

634

250-

505

250-

503

200-

503

400-

583

500-

544

400-

710

400-

713

500-

630

500-

633

500-

634

500-

635

500-

637

400-

500

400-

503

KWP

20

7.6.2 Interchangeability of Pump ComponentsPart No. Description Bearing bracketPart No. Description

P 03 ax P 04 ax P 05 ax

101135.01163210230320/322330344451.01452.01454.01458.01461502.01507524.01906

Pump casingWear plate, suction-sideDischarge coverShaftImpellerRolling element bearingBearing bracketBearing bracket lanternStuffing box housingGland coverStuffing box ringLantern ringGland packingCasing wear ringThrowerShaft protecting sleeveImpeller screw

1111111111111-111

2221211211111-111

2221

3311211111-111

3321311211111-111

3321

3411211111-111

4411411111111-111

4411

3511111111-111

5532522322222-222

6642622422222-222

7732722322222-222

73032

3622322222-222

8842822422222-222

9932922322222-222

9932

3722322222-222

101052

1022122222-222

101052

3822122222-222

103152

3922122222-222

1111321122322222-222

121263

1233533333-333

123263

4033533333-333

131363

1333533333-333

133363

4133533333-333

161673

1633633333-333

161673

4233633333-333

171763

1733533333-333

181873

1833633333-333

Part No. Description Bearing bracketPart No. Description

P 06 x P 08 sx

101135.01163210230320/322330344451.01452.01454.01458.01461502.01507524.01906

Pump casingWear plate, suction-sideDischarge coverShaftImpellerRolling element bearingBearing bracketBearing bracket lanternStuffing box housingGland coverStuffing box ringLantern ringGland packingCasing wear ringThrowerShaft protecting sleeveImpeller screw

191984

1944744444-444

202094

2044744444-444

203494

4344744444-444

2121104

2144544444-444

2135104

4444544444-444

22-

114

2244644444

33444

2322124

2355855555-555

3336124

4555855555-555

2337124

4655855555-555

2423134

2455955555-555

2438134

4755955555-555

2524124

2555855555-555

2539124

4855855555-555

2540124

4955855555-555

2625144

2655955555-555

2641144

5055955555-555

27-

134

2755955555

34556

2826124

2855855555-555

3342124

5155855555-555

29-

134

2955955555

35555

3027124

3055855555-555

3043124

5255855555-555

3044124

5355855555-555

3128144

3155955555-555

3145144

5455955555-555

3229124

3255855555-555

3246124

5555855555-555

Part No. Description Bearing bracketPart No. Description

P 10 ax

101135.01163210230320/322330344451.01452.01454.01458.01461502.01507524.01906

Pump casingWear plate, suction-sideDischarge coverShaftImpellerRolling element bearingBearing bracketBearing bracket lanternStuffing box housingGland coverStuffing box ringLantern ringGland packingCasing wear ringThrowerShaft protecting sleeveImpeller screw

2322155

5666866666-665

3336155

5766866666-665

2337155

5866866666-665

2423165

5966966666-665

2438165

6066966666-665

2524155

6166866666-665

2539155

6266866666-665

2540155

6366866666-665

2625175

6466

1066666-665

2641175

6566

1066666-665

27-

165

6666966666

34666

2826155

6766866666-665

3342155

6866866666-665

29-

165

6966966666

35667

3027155

7066866666-665

3043155

7166866666-665

3044155

7266866666-665

3128175

7366

1066666-665

3145175

7466

1066666-665

3229155

7566866666-665

3246155

7666866666-665

3447205

77661166666-665

3548215

7866

1066666-665

3649225

7966

1066666-665

3650225

8066

1066666-665

3751235

8166

1066666-665

3852175

8266

1066666-665

3853175

8366

1066666-665

3854175

8466

1066666-665

3855175

8566

1066666-665

3856175

8666

1066666-665

Part No. Description Bearing bracketPart No. Description

P 12 sx

101135.01163210230320/322330344451.01452.01454.01458.01461502.01507524.01906

Pump casingWear plate, suction-sideDischarge coverShaftImpellerRolling element bearingBearing bracketBearing bracket lanternStuffing box housingGland coverStuffing box ringLantern ringGland packingCasing wear ringThrowerShaft protecting sleeveImpeller screw

2322186

8777877777-775

3336186

8877877777-775

2337186

8977877777-775

2524186

9077877777-775

2539186

9177877777-775

2540186

9277877777-775

2625196

9377

1077777-775

2641196

9477

1077777-775

2826186

9577877777-775

3342186

9677877777-775

3027186

9777877777-775

3043186

9877877777-775

3044186

9977877777-775

3128196

10077

1077777-775

3145196

10177

1077777-775

3229186

10277877777-775

-46186

10377877777-775

3447246

104771177777-775

3548256

10577

1077777-775

3649266

10677

1077777-775

3650266

10777

1077777-775

3751276

10877

1077777-775

3852196

10977

1077777-775

3853196

11077

1077777-775

3854196

11177

1077777-775

3855196

11277

1077777-775

3856196

11377

1077777-775

The components featuring the same number in a line are interchangeable.

Pum

p de

liver

s in

suffi

cien

t flo

w r

ate

Mot

or is

ove

rload

ed

Exc

essi

ve p

ump

disc

harg

e pr

essu

re

Incr

ease

in b

earin

g te

mpe

ratu

re

Leak

age

at t

he p

ump

Exc

essi

ve le

akag

e at

the

sha

ft se

al

Vib

ratio

ns d

urin

g pu

mp

oper

atio

n

Exc

essi

ve r

ise

of t

empe

ratu

re in

side

the

pum

p

KWP

21

8 Trouble-shooting

Cause Remedy 1)

* Pump delivers against an excessively high discharge pressure. Re-adjust duty point.

* Excessively high back pressure. Check plant for impurities.Increase the speed (turbine, I.C. engine)

* * * Pump or piping are not completely vented or primed. Vent and/or prime.

* Supply line or impeller clogged. Remove deposits in the pump and/or piping.

* Formation of air pockets in the piping. Alter piping layout.Fit a vent valve.

* * * Pump is warped or sympathetic vibrations in piping. Check pipeline connections and secure fixing of pump; if re-quired, reduce the distances between the pipe clamps.Fix the pipelines using anti-vibration material.

* * * Suction head is too high/NPSHavailable (positive suction head)is too low.

Check/alter liquid level.Fully open shut-off valve in the suction line.Change suction line, if the friction losses in the suction line aretoo high.Check any strainers installed/suction opening.Observe permissible speed of pressure fall.

* Increased axial thrust. 2) Correct rotor adjustment.

* Air intake at the shaft seal. Fit new shaft seal.

* Wrong direction of rotation. Interchange two of the phases of the power supply cable.

* * Motor is running on two phases only. Replace the defective fuse.Check the electric cable connections.

* Speed is too low. 2) Increase speed.

* Defective bearings. Fit new bearings.

* * * Insufficient rate of flow. Increase the minimum rate of flow.

* * Wear of internal pump parts. Replace worn components by new ones.

* * Pump back pressure is lower than specified in the purchaseorder.

Adjust duty point accurately.

* Density or viscosity of the fluid pumped is higher than stated inthe purchase order.

2)

* Use of unsuitable materials. Change the material combination.

* * Speed is too high. Reduce the speed. 2)

* Tie bolts/seals and gaskets. Tighten the bolts.Fit new seals and gaskets.

* Worn shaft seal. Fit new shaft seal.

* * Score marks or roughness on shaft protecting sleeve. Fit new shaft protecting sleeve.Fit new shaft seal/check the balancing line.Check throttling bush/throttling sleeve clearances.

* Lack of cooling liquid or dirty cooling chamber. Increase cooling liquid quantity.Clean out cooling chamber.Purify/clean cooling liquid.

* Stuffing box ring, cover plate, seal cover have been tightenedincorrectly; wrong packing material.

Correct.

* Vibrations during pump operation. Improve suction conditions.Re-align the pump.Re-balance the impeller.Increase the pressure at the pump suction nozzle.

* * * The unit is misaligned. Check the coupling; re-align, if required.

* Insufficient or excessive quantity of lubricant or unsuitablelubricant.

Top up, reduce or change lubricant.

* Non-compliance with specified coupling distance. Correct distance according to the general arrangement drawing.

* Operating voltage is too low. Increase the voltage.

* Rotor is out of balance. Clean the impeller.Re-balance the impeller.

1) The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. 2) Contact KSB.

Coo

labl

e st

uffin

g bo

x

D00

399

KWP

22

9 General Assembly Drawings with Lists of Components9.1 Pumps on Bearing Brackets P 03 ax to P 06 x

KW

PWhen ordering spare parts please always specify the type series/pump size, works No. (stamped on the name plate and on thesuction nozzle flange), motor No. (serial No.), year of construc-tion, quantity required, part No., description, material, fluidhandled, general assembly drawing no. and mode of dispatch.

Part No. Description Scope of supply101 Pump casing with joint ring 411.011)/.021)/.031)/.10, hex. head bolt 901.01, stud 902.01, screwed plug 903.011)/.021)/.031), hex. nut 920.01135.01 3) Wear plate (suction-side) with joint ring 411.13, O-ring 412.05/.75, hex. head bolt 901.03, hex. socket head cap screw 914.05163 2) Discharge cover (A-cover)163 Discharge cover (with bolted with gasket 400.05, joint ring 411.26, hex. head bolt 901.22

stuffing box housing)183 Support foot with hex. socket head cap screw 914.04, spring washer 930.01210 Shaft with keywayed nut 920.21, lockwasher 931.01, key 940.01/.02230 Impeller with gasket 400.04320.02 Angular contact ball bearing322.01 Cylindrical roller bearing330 Bearing bracket330 Bearing bracket (complete) with bearing cover 360.01, bearing carrier 382, gasket 400.01, joint ring 411.46, O-ring 412.02, radial shaft seal ring 421.01/.02,

support disc 550.23, constant-level oiler 638, vent plug 672, screwed plug 903.46, hex. socket head cap screw 914.01/.02, circlip 932.01/.03344 Bearing bracket lantern with forcing screw 901.31, stud 902.04, hex. nut 920.04360.01 Bearing cover with gasket 400.01, hex. socket head cap screw 914.01382 Bearing carrier with O-ring 412.02, grub screw 904.01, hex. socket head cap screw 914.02, circlip 932.03421.01/.02 Radial shaft seal ring451.01 1) Stuffing box housing with gasket 400.05, joint ring 411.16/.17/.18/.19/.26, drip plate 463.01, disc 550.01, stud 902.02, screwed plug 903.16/.17/.18/.19,

hex. nut 920.02452.01 1) Gland cover454.01 1) Stuffing box ring, split456.01 1) Neck bush458.01 1) Lantern ring, split461.01 1) Gland packing507.01 Thrower524.01 Shaft protecting sleeve with O-ring 412.06906 Impeller screw with O-ring 412.0399-9 Set of sealing elements with gasket 400.01/.02/.03/.04, joint ring 411.01/.02/.03/.10/.13/.46, O-ring 412.02/.03/.05/.06/.751) if fitted2) on pumps with mechanical seal3) on 250-315 casing wear ring 502.01 instead of wear plate

23

D00

399

Coo

labl

e st

uffin

g bo

x

KWP

24

9.2 Pumps on Bearing Brackets P 08s to P 12 s

KW

PWhen ordering spare parts please always specify the type series/pump size, works No. (stamped on the name plate and on thesuction nozzle flange), motor No. (serial No.), year of construc-tion, quantity required, part No., description, material, fluidhandled, general assembly drawing No. and mode of dispatch.

Part No. Description Scope of supply101 Pump casing with joint ring 411.011)/.021)/.031)/.10, hex. head bolt 901.01, stud 902.01, screwed plug 903.011)/.021)/.031), hex. nut 920.01135.01 4) Wear plate (suction-side) with joint ring 411.12/.13, O-ring 412.05/.75, hex. head bolt 901.03, hex. socket head cap screw 914.05163 5) Discharge cover (A-cover)163 Discharge cover (with integrally with joint ring 411.16/.17, drip plate 463.01, disc 550.01, stud 902.02, screwed plug 903.16/.17, hex. nut 920.02

cast stuffing box housing)163 Discharge cover (with bolted with gasket 400.05, joint ring 411.26, hex. head bolt 901.22

stuffing box housing)183 Support foot with shims 89-4.02, hex. head bolt 901.04, spring washer 930.01210 Shaft with ring 500.21, keywayed nut 920.21, lockwasher 931.01, key 940.01/.02230 Impeller with O-ring 412.06260.01 Impeller cap with O-ring 412.03, disc 550.87, hex. head bolt 901.87, lockwasher 931.02320.02 Angular contact ball bearing322.01 Cylindrical roller bearing330 Bearing bracket330 Bearing bracket (complete) with bearing cover 360.01, gasket 400.01, joint ring 411.46, V-ring 411.77/.78, support disc 550.23, constant-level oiler 638,

vent plug 672, hex. head bolt 901.91/.95, screwed plug 903.46, hex. socket head cap screw 914.01, circlip 932.01/.03344 Bearing bracket lantern with forcing screw 901.31, stud 902.04, hex. nut 920.04, hex. head bolt 901.22360.01 Bearing cover with gasket 400.01, hex. socket head cap screw 914.01, thrower 507.11, O-ring 412.06382 Bearing carrier with O-ring 412.02, shims 89-4.12411.77/.78 V-ring451.01 1) Stuffing box housing 3) with gasket 400.05, joint ring 411.16/.17/.18/.19/.26, drip plate 463.01, disc 550.01, stud 902.02, screwed plug 903.16/.17/.18/.19,

hex. nut 920.02452.01 1) Gland cover454.01 1) Stuffing box ring, split456.01 1) Neck bush458.01 1) Lantern ring, split461.01 1) Gland packing507.01/.11/.12 Thrower524.01 Shaft protecting sleeve with O-ring 412.0699-9 Set of sealing elements with gasket 400.01/.02, joint ring 411.01/.02/.03/.12/.13/.46, O-ring 412.02/.03/.05/.06

1) if fitted2) accessory, not included in standard scope of supply3) for bolted stuffing box housing4) on 300-400 and 350-500 casing wear ring 502.01 instead of wear plate5) on pumps with mechanical seal

25

KWP

26

KWP

27

2361

.8/6

-10

15.1

2.20

03S

ubje

ct t

o te

chni

cal m

odifi

catio

n w

ithou

t pr

ior

notic

e.

KSB AktiengesellschaftP.O. Box 1361, 91253 Pegnitz • Bahnhofplatz 1, 91257 Pegnitz (Germany)Tel. +49 9241 71-0 • Fax +49 9241 71-1791 • www.ksb.com

KWP