CTN ; CTN-H Installation/Operating Manual - ksb.co.ilksb.co.il/_Uploads/dbsAttachedFiles/OP(6).pdf · CTN ; CTN-H Installation/Operating Manual. ... 7.7 Spare parts stock ... This

Vertical Shaft Submersible Pump for theChemical Industry

CTN ; CTN-H

Installation/OperatingManual

Legal information/Copyright Installation/Operating Manual CTN ; CTN-HOriginal operating manual KSB Aktiengesellschaft 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 KSB´s express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 21.04.2010

Contents

Glossary ................................................................................................ 5

1 General ................................................................................................ 6

1.1 Principles .......................................................................................................... 6

1.2 Installation of partly completed machinery .................................................. 6

1.3 Target group ................................................................................................... 6

1.4 Other applicable documents .......................................................................... 6

1.5 Symbols ............................................................................................................ 6

2 Safety ................................................................................................... 8

2.1 Key to safety symbols/markings ..................................................................... 8

2.2 General ............................................................................................................ 8

2.3 Intended use .................................................................................................... 8

2.4 Personnel qualification and training ............................................................. 9

2.5 Consequences and risks caused by non-compliance with these operatinginstructions ...................................................................................................... 9

2.6 Safety awareness ............................................................................................. 9

2.7 Safety information for the operator/user .................................................... 10

2.8 Safety information for maintenance, inspection and installation work ... 10

2.9 Unauthorised modes of operation ............................................................... 10

2.10 Explosion protection ..................................................................................... 10

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

3.1 Transport ....................................................................................................... 13

3.2 Storage and preservation ............................................................................. 13

3.3 Return to supplier ......................................................................................... 14

3.4 Disposal .......................................................................................................... 14

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

4.1 General description ....................................................................................... 15

4.2 Designation ................................................................................................... 15

4.3 Name plate .................................................................................................... 15

4.4 Design details ................................................................................................ 15

4.5 Configuration and function ......................................................................... 17

4.6 Noise characteristics ...................................................................................... 18

4.7 Scope of supply ............................................................................................. 18

4.8 Dimensions and weights ............................................................................... 18

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

5.1 Safety regulations ......................................................................................... 19

5.2 Checks to be carried out prior to installation ............................................. 19

5.3 Installing the pump set ................................................................................. 19

5.4 Piping ............................................................................................................. 20

Contents

CTN ; CTN-H 3 of 70

5.5 Protective equipment ................................................................................... 22

5.6 Aligning the pump and motor ..................................................................... 22

5.7 Electrical connection ..................................................................................... 23

5.8 Checking the direction of rotation .............................................................. 24

6 Commissioning/Start-up/Shutdown ................................................. 25

6.1 Commissioning/start-up ................................................................................ 25

6.2 Operating limits ............................................................................................ 31

6.3 Shutdown/storage/preservation ................................................................... 33

6.4 Returning to service after storage ............................................................... 33

7 Servicing/Maintenance ...................................................................... 35

7.1 Safety regulations ......................................................................................... 35

7.2 Servicing/inspection ...................................................................................... 35

7.3 Drainage/disposal .......................................................................................... 39

7.4 Dismantling the pump set ............................................................................ 39

7.5 Reassembling the pump set .......................................................................... 44

7.6 Tightening torques ....................................................................................... 52

7.7 Spare parts stock ........................................................................................... 52

8 Trouble-shooting ............................................................................... 55

9 Related Documents ........................................................................... 57

9.1 General assembly drawing with list of components ................................... 57

10 EC Declaration of Conformity .......................................................... 66

11 Certificate of Decontamination ....................................................... 67

Index .................................................................................................. 68

Contents

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Glossary

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

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

Glossary

CTN ; CTN-H 5 of 70

1 General

1.1 Principles

This 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 number clearly 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 machinery

To install partly completed machinery supplied by KSB, refer to the sub-sectionsunder Servicing/Maintenance.

1.3 Target group

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

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document 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 pump

Sub-supplier product literature1) Operating manuals and other product literatureof accessories and integrated machinerycomponents

Spare parts lists1) Description of spare parts

Piping layout1) Description of auxiliary piping

List of components1) Description of all pump components

1.5 Symbols

Table 2: Symbols used in this manual

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

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

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

1 General

6 of 70 CTN ; CTN-H

Symbol Description1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

CTN ; CTN-H 7 of 70

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

2.1 Key to safety symbols/markings

Table 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 notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult 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 General

This 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 use

The 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

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▪ 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 productliterature (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 orproduct literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain 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 chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,the following safety regulations shall be complied with:

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

2 Safety

CTN ; CTN-H 9 of 70

▪ 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 thatthe guards function properly.

▪ Do not remove the contact guard while the pump is running.

▪ Connect an earth conductor to the metal jacket if the fluid handled iselectrostatically 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 themanufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for consequentialdamage.

▪ The operator ensures that all maintenance, inspection and installation work isperformed 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 proceduredescribed in the manual. (⇨ Section 6.1.12 Page 30)

▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3Page 39)

▪ As soon as the work is completed, re-install and/or re-activate any safety-relevantand protective devices. Before returning the product to service, observe allinstructions on commissioning. (⇨ Section 6.1 Page 25)

2.9 Unauthorised modes of operation

Never 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 protection

Always observe the information on explosion protection given in this section whenoperating the pump in potentially explosive atmospheres.

! DANGER

2 Safety

10 of 70 CTN ; CTN-H

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). 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 Marking

The marking on the pump refers to the pump part only. Example of such marking: II 2 G c TX The marking indicates the theoretically available temperature range as defined bythe respective temperature classes. Refer to the Temperature limits table for thetemperatures permitted for the individual pump variants. (⇨ Section 2.10.2 Page11)

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 limits

In normal pump operation, the highest temperatures are to be expected at thesurface of the pump casing, the pipe assembly, the flanged bend, the shaft seal andin the bearing areas. The surface temperature at the pump casing, the pipe assembly and the flangedbend corresponds to the temperature of the fluid handled. If the pump is heated, theoperator of the system is responsible for observing the specified temperature classand fluid temperature (operating temperature).The table below lists the temperature classes and the resulting theoreticaltemperature limits of the fluid handled (a potential temperature rise in the shaft sealarea has 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 thepump in question refer to the data sheet.

Table 4: Temperature limits

Temperature class as per EN 13463-1 Maximum permissible fluidtemperature

T1 Maximum 400 °C2)

T2 280 °CT3 185 °CT4 120 °CT5 85 °CT6 Only after consultation

with the manufacturer

Based on an ambient temperature of 40 °C and proper maintenance and operation,compliance with temperature class T5 is warranted in the area of the rolling elementbearings. If the ambient temperature exceeds 40 °C, contact the manufacturer.

A special design is required to comply with the requirements of temperature class T6in the bearing area.

Misuse, malfunctions or non-compliance with the instructions may result insubstantially higher temperatures.

Pump

Shaft coupling

Motor

Temperature class T5

Temperature class T6

2) Depending on the material variant

2 Safety

CTN ; CTN-H 11 of 70

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 equipment

The 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,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 limits

The minimum flows indicated in (⇨ Section 6.2.3 Page 32) 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 32) 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 Transport

DANGERThe pump (set) could slip out of the suspension arrangementDanger to life from falling parts!

▷ Refer to the weights given in the general arrangement drawing.

▷ Observe the local health and safety regulations.

▷ Use suitable, permitted lifting tackle.

CAUTIONImproper pump transportDamage to the pump!

▷ When transporting and lifting the pump in horizontal position, make sure thatthe pipe assembly is supported evenly at the bearings.

▷ The pipes of the pipe assembly must be positioned one above the other.

▷ Avoid bending stress or sagging.

NOTEVertical pumps with an overall length of up to approx. four metres are supplied fullyassembled. Pumps with a greater overall length are supplied in sub-assemblies and shallbe assembled by a KSB service engineer on site.

To transport the pump/pump set suspend it from the lifting tackle as shown.

Fig. 1: Pump set with supported bearings

3.2 Storage and preservation

If 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 pump (set) or the packaged pump (set) andaccessories 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 ofinstallation.

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 a maximum of 12 months.New pumps/pump sets are supplied by our factory duly prepared for storage.

For storing a pump (set) which has already been operated, observe the relevantinstructions.

3.3 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 39)

2. Always flush and clean the pump, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.

3. If the fluids handled by the pump leave residues which might lead to corrosiondamage 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 67)It is imperative to 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

3.4 Disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pump (set).Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:- Metals- Plastics- Electronic waste- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another controlledmanner.



http://www.ksb.com/GRAS-Cert

4 Description of the Pump (Set)

4.1 General description

▪ Vertical shaft submersible pump for the chemical industry

Vertical pump for handling chemically aggressive fluids with a low solids content.

Vertical pump for handling fluids which must not be allowed to cool down duringprocessing.

4.2 Designation

Example: CTN - C H 40 - 250 / 2

Table 5: Key to the designation

Code DescriptionCTN Type seriesC Material of wetted components

For materials, see data sheetH Additional code, e.g. H = heatable version40 Nominal discharge nozzle diameter [mm]250 Nominal impeller diameter [mm]2 Identification of 2-stage pumps

4.3 Name plate

CTN-C H 40-250/2 9971234567 000100 / 01Q 12 m3/h H 32 m

n 1450 1/min 2009

AktiengesellschaftD-67227 Frankenthal

Id-No. 00 117 377 ZN 3804 - A 52 x 74R

8

7

6

1

2

5

4

3

Fig. 2: CTN/CTN-H name plate

1 Type series, size and version (⇨ Section 4.2 Page 15)

2 KSB order number (ten digits)

3 Flow rate 4 Speed5 Order item number (six digits) 6 Consecutive number (two digits)7 Head 8 Year of construction

4.4 Design details

Design

▪ Radially split vertical shaft submersible pump

▪ Vertical installation

▪ Wet or dry installation

▪ One or two stages

▪ Heatable

Pump cas ing

▪ Volute casing (partly with casing wear ring) and casing cover

CTN

CTN-H

CTN-H



Impel ler type

▪ Closed radial impeller with multiply curved vanes

▪ Sealing clearance on both sides and balancing holes balance axial thrust

Shaft seal

▪ Single or double mechanical seal

▪ Gland packing

Table 6: Seal chamber with different shaft seals (examples)

Basic design Cooled

Single Double

Bearings

▪ Paired angular contact ball bearing for axial fixing of the shaft assembly

▪ Product-lubricated plain bearing for guiding the shaft in the volute casing and inthe pipe assemblies

▪ Grease lubrication

▪ Optional: Oil lubrication

Table 7: Thrust bearing design

KSB designation FAG designation SKF designationB.G B.TVP.UA BECBP

Table 8: Standard bearings: grease-lubricated thrust bearings (rolling elementbearing)

Sizes Bearing size25/40/50 2 x 7206 B.G80/100 2 x 7309 B.G125/150 2 x 7309 B.G200/250 2 x 7313 B.G

Table 9: Optional: oil-lubricated thrust bearings (rolling element bearing)

Sizes Bearing size25/40/50 1 x 6312 DIN 62580/100 2 x 7312 BUA DIN 628125/150 2 x 7315 BUA DIN 628200/250 2 x 7318 BUA DIN 628

Refer to the data sheet for the relevant bearing bracket design.

Gland packing

Mechanical seal

Design specifications

Bearings used



4.5 Configuration and function

1

2

3

4

5

6

7

8

9

1011

12

Fig. 3: Sectional drawing

1 Shaft seal 2 Plain bearing3 Clearance gap 4 Suction nozzle5 Thrust bearing (rolling element

bearing)6 Flanged bend

7 Sole plate 8 Pipe assembly9 Shaft assembly 10 Volute casing11 Impeller 12 Suction cover

Vertical submersible pump with one or two stages. Shaft seal is not in contact withthe fluid handled; pump is not self-priming.

The fluid enters the pump vertically via the suction nozzle (4) and is acceleratedoutward in a cylindrical flow by the rotating impeller (11). The flow profile of thevolute casing (10) converts the kinetic energy of the fluid into pressure energy. Thefluid is pumped through the pipe assembly (8) to the flanged bend (6), where itleaves the pump. The clearance gap (1) prevents any fluid from flowing back fromthe pump casing into the suction cover (12). At the rear side of the impeller, the shaftassembly (9) enters the volute casing (10) which houses the hydraulic system. Theshaft passage through the sole plate (7) is sealed to the atmosphere with a shaft seal(1). Depending on the installation depth, the shaft assembly (9) can either consist of asingle shaft or several shaft sections. Above the sole plate, the shaft assembly issupported radially and axially by thrust bearings (rolling element bearings) (5); belowthe sole plate, it is only supported radially by plain bearings (2).

The pump is sealed by a shaft seal.Standardised mechanical seal or gland packing

Design

Function

Sealing



4.6 Noise characteristics

Table 10: Surface sound pressure level LpA3) 4)

Ratedpower

input PN

[kW]

Pump Pump set2900 rpm

[dB]

1450 rpm

[dB]

960 rpm760 rpm

[dB]

2900 rpm

[dB]

1450 rpm

[dB]

960 rpm760 rpm

[dB]1.5 54 52 51 63 57 562.2 56 54 53 65 60 583 57 56 54 67 61 594 59 57 55 69 63 61

5.5 61 59 57 70 65 627.5 62 60 58 72 66 6411 64 62 60 74 68 6615 66 64 62 75 69 67

18,5 67 65 63 76 70 6822 68 66 64 76 71 6930 69 68 65 77 72 7037 70 69 66 78 72 7145 71 70 67 79 73 7255 72 71 68 79 74 7275 74 72 69 80 75 7390 75 73 70 80 76 74110 76 74 71 81 76 75132 77 75 72 81 77 75160 78 76 73 82 77 76200 79 78 74 83 78 77250 80 79 - 83 79 -

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Pump

▪ Surface-cooled IEC three-phase current squirrel-cage motor

▪ Flexible coupling

▪ Cast or plate material, flange dimensions to EN 1092 or ASME B 16.3

▪ As required

4.8 Dimensions and weights

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

Drive

Shaft coupling

Sole plate

Special accessories

3) Spatial average; as per ISO 3744 and EN 12639. Valid for pump operation in the Q/Qopt = 0.80–1.1 range and for non-cavitating operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.

4) Increase for 60 Hz operation: 3500 rpm+3 dB; 1750 rpm +1 dB; 1160 rpm:±0 dB



5 Installation at Site

5.1 Safety regulations

DANGERImproper 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 andmotor.

5.2 Checks to be carried out prior to installation

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 set

The foundation for the pump is a dome with horizontal flange and correspondingflange connection.

Check the flange with a spirit level and adjust if required.Permitted deviation 0.2 mm/m.

Mounting the dr ive

After mounting and bolting, the drive is centred in the flange of the drive lantern.

Checking the coupl ing

After mounting the drive on the pump, check the clearance between the twocoupling halves on the basis of the general arrangement drawing.If the clearance is too large, reduce the distance between the coupling halves.Check the radial alignment.

1

Fig. 4: Checking the coupling alignment

1 Wedge gauge



5.4 Piping

5.4.1 Connecting the piping

DANGERImpermissible 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 withouttransmitting any stresses or strains.

▷ Observe the permissible forces and moments at the pump nozzles. (⇨ Section5.4.2 Page 21)

▷ 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 nominal diameters of the pipelines are at least equal to the nominaldiameters of the pump nozzles.

✓ Adapters to larger nominal diameters are designed with a diffuser angle ofapprox. 8° to avoid excessive pressure losses.

✓ The pipelines have been anchored in close proximity to the pump and connectedwithout transmitting any stresses or strains.

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections(especially for new installations).

2. Remove the flange covers on the suction nozzles and flanged bends of the pumpbefore installing the pump in the piping.

CAUTIONWeld beads, scale and other impurities in the piping/tankDamage to the pump!

▷ Free the piping from any impurities.

▷ If necessary, install a filter.

▷ Observe the instructions in (⇨ Section 7.2.2.3 Page 37).

3. 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 picklingservice to the casing and seal materials used.



5.4.2 Permissible forces and moments at the pump nozzles

D00203

The resulting permissible forces havebeen determined according to:

Forces and moments acting on theflanged bend

The data on forces and moments apply to static piping loads only. If the limits areexceeded, they must be checked and verified.If computerised strength analysis is required, please contact KSB.

Table 11: Permissible forces and moments acting on the flanged bend

Size Materials Forces (in N) Moments (in Nm)Fx Fy Fz Fres Mx My Mz

25 JL1040 330 310 300 430 140 100 7040 750 700 675 980 330 230 16050 950 900 860 1250 480 320 23080 2100 2000 1900 2760 940 640 460100 2840 2750 2550 3750 1450 990 720125 4500 4260 4050 5880 2000 1360 980150 5180 4900 4600 6730 2300 1560 1120200 7600 7200 6840 9940 3520 2400 1720250 11000 10050 9900 14110 5000 3400 245025 GP240GH+N 1100 1050 990 1440 500 340 25040 1950 1850 1760 2550 850 580 42050 2320 2200 2020 2990 1640 710 51080 5200 4810 4550 6630 2280 1560 1120100 6500 6240 5850 8560 3670 2500 1800125 7540 7150 6760 9840 4160 2840 2030150 8450 8000 7610 11050 4550 3100 2220200 11400 10800 10260 14900 5700 3870 2790250 14300 13060 12870 18340 6500 4420 319025 1.4408 1050 1000 950 1380 420 290 21040 1500 1430 1350 1970 650 440 32050 1780 1690 1600 2330 800 545 39080 4000 3700 3500 5100 1750 1200 870100 5000 4800 4500 6580 2820 1920 1380125 5800 5500 5200 7570 3200 2180 1560150 6500 6160 5850 8500 3500 2380 1710200 7600 7200 6840 9930 3800 2580 1860250 11000 10050 9900 14110 5000 3400 2450

For temperatures of more than 120 °C, the values specified must be reduced in linewith the drop in yield strength of the relevant material (see diagram below).

Correction coefficients depending on material and temperature (see diagram below).



Fig. 5: Temperature correction coefficients

5.4.3 Auxiliary connections

CAUTIONFailure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing liquid,etc.)Malfunction of the pump!

▷ Refer to the general arrangement drawing, the piping layout and pumpmarkings (if any) for the dimensions and locations of auxiliary connections.

▷ Use the auxiliary connections provided.

5.5 Protective equipment

DANGERRisk of potentially explosive atmosphere due to insufficient ventingExplosion hazard!

▷ Ensure adequate venting of the space in the bearing bracket lantern/drivelantern.

▷ Never close or cover the perforations of the contact guard on the drive lantern(e.g. with insulation).

WARNINGThe volute casing, pipe assembly, flanged bend and areas of the sole plate take on thetemperature of the fluid handledRisk of burns!

▷ Insulate the sole plate and flanged bend.

▷ Fit protective equipment.

CAUTIONHeat build-up in the bearing bracketDamage to the bearing!

▷ The bearing bracket lantern and drive lantern must not be insulated.

5.6 Aligning the pump and motor

WARNINGUnprotected rotating couplingRisk of injury by rotating shafts!

▷ Always operate the pump set with a contact guard (coupling guard).



5.7 Electrical connection

DANGERIncorrect 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 pumpsets, IEC 60079 (DIN VDE 0165).

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

1. Check the available mains voltage against the data on the motor name plate.

2. Select an appropriate start-up method.

NOTEIt is recommended to fit a motor protection device.

5.7.1 Setting the time relay

CAUTIONSwitchover between star and delta on three-phase motors with star-delta starting takestoo longDamage to the pump (set)!

▷ Keep switch-over intervals between star and delta as short as possible (see table:Time relay settings for star-delta starting).

Table 12: Time relay settings for star-delta starting:

Motor rating Y time to be set≤ 30 kW < 3 s> 30 kW < 5 s

5.7.2 Connecting the motor

NOTEIn 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 rotation

DANGERTemperature 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.

▷ Decouple 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, interchange any two phases tocorrect the direction of rotation.

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

1. Start the motor and stop it again immediately to determine the motor's directionof 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 runs in the wrong direction of rotation, check the electricalconnection of the motor and the control system, if applicable.



6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

Before starting up the pump set make sure that the following requirements are met:

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

▪ The pump has been primed with the fluid to be handled. (⇨ Section 6.1.4 Page26)

▪ The direction of rotation has been checked. (⇨ Section 5.8 Page 24)

▪ 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 33) have been carried out.

6.1.2 Filling in lubricants

Grease-lubricated bearings have been packed with grease at the factory.

Fill the bearing bracket with lubricating oil.For the oil quality, refer to (⇨ Section 7.2.3.2.2 Page 38)For the oil quantity, refer to (⇨ Section 7.2.3.2.3 Page 38)

✓ The constant-level oiler is screwed into the upper tapping hole of the bearingbracket.

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.

1

2Fig. 6: Constant-level oiler

1 Constant-level oiler 2 Connection elbow of the constant-level oiler

1. Hinge down the reservoir of the constant-level oiler (1).

2. Fill with oil through the open connection elbow.

3. Completely fill the reservoir of the constant-level oiler (1).

4. Snap the constant-level oiler (1) back into its operating position.

Grease-lubricated bearings

Oil-lubricated bearings



5. After approximately 5 minutes, check the oil level in the glass reservoir of theconstant-level oiler (1). The oil reservoir must be properly filled at all times to provide an optimum oillevel. Repeat steps 1 - 4, if necessary.

6. To check the function of the constant-level oiler (1), slowly drain oil via thescrewed plug until air bubbles develop in the reservoir.

NOTEAn excessively high oil level can lead to a temperature rise and to leakage of the fluidhandled or oil.

6.1.3 Shaft seal

Shaft seals are fitted prior to delivery. Observe the instructions on dismantling (⇨ Section 7.4.5 Page 41) or reassembly (⇨Section 7.5.5 Page 47) .

If applicable, fill the reservoir of non-pressurised external fluid in accordance withthe general arrangement drawing.

Prior to starting up the pump, apply barrier pressure as specified in the generalarrangement drawing.

Apply the quantities and pressures specified in the data sheet and the generalarrangement drawing.

6.1.4 Priming and venting the pump

DANGERFormation of a potentially explosive atmosphere inside the pumpExplosion hazard!Risk of damage to the pump!

▷ Make sure that the fluid level does not fall below the minimum level.

▷ The pump internals in contact with the fluid to be handled, including the sealchamber and auxiliary systems must be filled with the fluid to be handled at alltimes.

▷ Provide sufficient inlet pressure.

▷ Provide an appropriate monitoring system.

DANGERPlain bearing failure caused by dry runningExplosion hazard!Risk of damage to the pump!

▷ Make sure that the fluid level does not fall below the minimum level.

DANGERShaft seal failure caused by dry runningHot or toxic fluid/vapours could escape!Risk of damage to the pump!Health hazard!

▷ Monitor the barrier fluid pressure of the mechanical seal.

▷ Tighten the gland packing gently and evenly.

▷ Monitor the barrier/flushing fluid.

1. Make sure that the fluid level does not fall below the minimum level.The pump casing must be fully submerged.

Reservoir of non-pressurised external fluid

Double mechanical seal

External liquid feed

Wet installation



2. Fully open all auxiliary connections (barrier fluid, flushing fluid etc).

1. The pump casing and suction line must be filled with the fluid handled.

2. Fully open the shut-off valve in the suction line.

3. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc).

6.1.5 Final check

1. Remove the contact guard.

2. Check the coupling alignment; re-align the coupling if required. (⇨ Section 5.3Page 19)

3. Check that the coupling and shaft can easily be rotated by hand.

4. Re-mount the contact guard.

5. Check the distance between coupling and contact guard.The coupling and contact guard must not come into contact.

6.1.6 Water cooling

CAUTIONDeposit-forming, aggressive cooling waterDamage to the pump!

▷ Observe the cooling water quality.

Observe the following quality data of the cooling water:

▪ Not deposit forming

▪ Not aggressive

▪ Free from suspended solids

▪ Hardness on average 5 °dH (~1mmol/l)

▪ pH > 8

▪ Conditioned and neutral with regard to mechanical corrosion

▪ Inlet temperature tE= 10 to 30 °COutlet temperature tA= maximum 45 °C

6.1.7 Cooling/heating the shaft seal

The shaft seal chamber, if any, can be cooled. KSB can install a a fan impeller above the shaft seal to dissipate the heat.If required, the shaft seal chamber can also be heated.

WARNINGRotating fan impellerRisk of personal injury!

▷ Only remove the cover plate when the pump has been stopped.

DANGERExcessive surface temperatureExplosion hazard!Risk of burns!

▷ Observe the permissible temperature classes. (⇨ Section 2.10.2 Page 11)

Dry installation



Table 13: Permissible pressure and temperature limits for the shaft seal chamber

Sizes Cooling liquid Inlettemperature

Heating (saturatedvapour)

Quantity Max.pressure

Max.pressure

Max.temperature

[l/min] [bar] [°C] [bar] [°C]25/40/50 2 10 approx. 20 7.1 16580/100 3125/150 4200/250 5

6.1.8 Heating

CTN-H

If pumping fluids which can only be pumped in warm or hot condition, the pipeassemblies must be heated.

DANGERExcessive surface temperatureExplosion hazard!Risk of burns!

▷ Observe the permissible temperature classes. (⇨ Section 2.10.2 Page 11)

CAUTIONLack of heating mediumDamage to the pump!

▷ Provide sufficient quantities of a suitable heating medium.

CAUTIONTime for warming up the pump too shortDamage to the pump!

▷ Check that the pump is sufficiently warmed up throughout.

CAUTIONImpermissibly high temperature of the heating mediumFluid or heating medium could escape!

▷ Observe the application limits of the heating media.

Table 14: Permissible pressure and temperature limits when using saturated vapour

Sizes Heating with saturated vapour, pipe assemblies made of:St 1.4571

Pressure Temperature Pressure Temperature[bar] [°C] [bar] [°C]

25/40/50 7.1 165 7.1 16580/100125/150200/250

Pipe assemblies



Table 15: Permissible pressure and temperature limits when using superheatedvapour

Sizes Heating with superheated vapour, pipe assemblies made of:St 1.4571

Pressure Temperature Pressure Temperature[bar] [°C] [bar] [°C]

25/40/50 18.0 300 14.0 30080/100 15.0 12.0125/150 12.0 12.0200/250 9.8 9.8

The flanged bend can also be heated as part of a special design.

6.1.9 Heating up/keeping warm the pump (set)

CAUTIONPump blockageDamage to the pump!

▷ Prior to pump start-up, heat up the pump as described in the manual.

Observe the following when heating up the pump (set) and keeping it warm:

▪ Make sure the temperature is increased continuously.

▪ Max. heating speed: 10 °C/min (10 K/min)

If the pump is used for handling fluids with fluid temperatures exceeding 150 °C,make sure that the pump has been sufficiently heated throughout before starting itup.

The temperature difference between the pump's surface and the fluid handled mustnot exceed 100 °C (100 K) when the pump is started up.

6.1.10 Start-up

DANGERThe 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/ordischarge line closed.

▷ Only start up the pump set with the discharge-side gate valve slightly or fullyopen.

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/tank as specified. (⇨ Section 6.1.4 Page 26)

▷ 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.

Flanged bend

Fluid temperatures above150 °C

Temperature difference



✓ The system piping has been cleaned.

✓ In a dry installation configuration, the pump and suction line have been ventedand primed with the fluid to be handled.

CAUTIONStart-up against open discharge lineOverloading of the motor!

▷ Use a soft starter.

▷ Use speed control.

▷ Make sure the power reserve of the motor is sufficient.

1. In a dry installation configuration, fully open the shut-off element in the inlet/suction line.

2. Close or slightly open the shut-off element in the discharge line.

3. Start up the motor.

4. Immediately after the pump has reached full rotational speed, slowly open theshut-off element in the discharge line and adjust it to the duty point.

DANGERSeal leakages at operating temperatureHot or toxic fluid could escape!

▷ For dry installation only: Once the operating temperature has been reachedand/or in the event of leakage, switch off the pump set and re-tighten the boltsbetween pipe assembly/suction cover/volute casing.

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

5. For dry installation only: Once the operating temperature has been reached and/or in the event of leakage, switch off the pump set and re-tighten the boltsbetween pipe assembly/suction cover/volute casing.

6. Check the coupling alignment. Re-align the coupling if required. (⇨ Section 5.3Page 19)

6.1.11 Checking the shaft seal

The mechanical seal only leaks slightly or invisibly (as vapour) during operation.Mechanical seals are maintenance-free.

The gland packing must drip slightly (on models with barrier/flushing fluid supply).

DANGERThe temperatures at the gland packing have risen above the permissible limitsExplosion hazard!

▷ Always use suitable temperature monitoring for gland packings.

▷ Gland packings must only be tightened slightly.

6.1.12 Shutdown

✓ The shut-off element in the suction line is and remains open.

✓ On pump sets with double-acting mechanical seal, apply the required pressurespecified in the general arrangement drawing to the mechanical seal chamberalso during standstill.

✓ Also ensure quench liquid supply during pump standstill.

1. Close the shut-off element the discharge line.

2. Switch off the motor and make sure the pump set runs down smoothly to astandstill.

Mechanical seal

Gland packing



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

NOTEIf shut-off is not possible, the pump will run in reverse direction.The reverse runaway speed must be lower than the rated speed.

For prolonged shutdown periods:

1. Close the shut-off element in the suction line.

2. Close the auxiliary connections. If the fluid to be handled is fed in under vacuum, also supply the shaft seal withbarrier fluid during standstill.Only turn off the cooling liquid supply after the pump has cooled down.

CAUTIONRisk of freezing during prolonged pump shutdown periodsDamage to the pump!

▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protectthem against freezing.

6.2 Operating limits

DANGERNon-compliance with operating limits for pressure, temperature and speedHot or toxic fluid could escape!Explosion hazard!

▷ 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 datasheet or on the name plate unless the written consent of the manufacturer hasbeen obtained.

6.2.1 Ambient temperature

CAUTIONOperation outside the permissible ambient temperatureDamage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table 16: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °CMinimum See data sheet.



6.2.2 Frequency of starts

DANGERExcessive surface temperature of the motorExplosion hazard!Damage to the motor!

▷ In case of explosion-proof motors, observe the frequency of starts specified inthe manufacturer's product literature.

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 (d.o.l., 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 17: Frequency of starts

Motor rating [kW]

Maximum number of start-ups [Start-ups/hour]

up to 12 15up to 100 10

more than 100 5

CAUTIONRe-start 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.

6.2.3 Flow rate

Unless specified otherwise in the characteristic curves or in the data sheets, thefollowing applies:

▪ Short-time operation: Qmin5) =0.1xQopt

6)

▪ Continuous operation: Qmin5) =0.3xQopt 6)

▪ 2-pole operation: Qmax7) =1.1xQopt 6)

▪ 4-pole operation: Qmax7) =1.25xQopt

6)

The data refer to water and water-like fluids. Longer operating periods with thesefluids and at the flow rates indicated will not cause an additional increase in thetemperatures on the pump surface. However, if the physical properties of the fluidshandled are different from water, the calculation formula below must be used tocheck if an additional heat build-up may lead to a dangerous temperature increase atthe pump surface. If necessary, the minimum flow must be increased.

Table 18: Key

Symbol Description Unitc Specific heat capacity J/kg Kg Gravitational constant m/s²H Pump head m

5) Minimum permissible flow rate6) Best efficiency point7) Maximum permissible flow rate



Symbol Description UnitTf Temperature of the fluid handled °C

To Temperature at the casing surface °C

Pump efficiency at duty point -Temperature difference °C

6.2.4 Density of the fluid handled

The power input of the pump increases in proportion to the density of the fluidhandled.

CAUTIONImpermissibly high density of the fluid handledMotor overload!

▷ Observe the information on fluid density indicated in the data sheet.

▷ Make sure the power reserve of the motor is sufficient.

6.2.5 Abrasive fluids

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

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

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

The pump (set) i s removed from the pipe and stored

✓ The pump has been properly drained (⇨ Section 7.3 Page 39) and the safetyinstructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page39)

1. Spray-coat the inside wall of the pump casing, and in particular the impellerclearance areas, with a preservative.

2. Spray the preservative through the suction nozzle and flanged bend.It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).

3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil andgrease, food-approved if required) to protect them against corrosion.Observe the additional instructions. (⇨ Section 3.2 Page 13)

If the pump set is to be stored temporarily, only preserve the wetted componentsmade of low alloy materials. Commercially available preservatives can be used for thispurpose. Observe the manufacturer's instructions for application/removal.

Observe any additional instructions and information provided. (⇨ Section 3 Page 13)

6.4 Returning to service after storage

For returning the pump to service observe the sections on commissioning/start-up (⇨Section 6.1 Page 25) and the operating limits. (⇨ Section 6.2 Page 31)



In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. (⇨ Section 7 Page 35)

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 regulations

DANGERImproperly serviced pump setExplosion hazard!Damage to the pump set!

▷ Service the pump set regularly.

▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft sealand 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!

▷ Always make sure the electrical connections are disconnected before carryingout work on the pump set.

▷ Make sure that the pump set cannot be started up accidentally.

WARNINGFluids posing a health hazard or hot fluidsRisk of personal injury!

▷ Observe all relevant laws.

▷ When draining the fluid take appropriate measures to protect persons and theenvironment.

▷ Decontaminate pumps handling 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 Servicing/inspection

7.2.1 Supervision of operation

DANGERExcessive temperatures as a result of thrust bearings (rolling element bearings) runninghot 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.



https://shop.ksb.com/esales/contactfinder/contact.jsp?language=en&country=_C

https://shop.ksb.com/esales/contactfinder/contact.jsp?language=en&country=_C

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 duringpump operation.

CAUTIONImpermissibly high temperature of fluid handledDamage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted (heatingup of the fluid).

▷ Observe the temperature limits in the data sheet and in the section onOperating limits. (⇨ Section 6.2 Page 31)

While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.

▪ When lubricating with oil ensure the oil level is correct. (⇨ Section 6.1.2 Page 25)

▪ Check the shaft seal. (⇨ Section 6.1.11 Page 30)

▪ 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.

▪ Monitor the correct functioning of any auxiliary connections.

▪ Cooling systemTake the pump out of service at least once a year to thoroughly clean the coolingsystem.

▪ 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 at the bearing).

CAUTIONOperation outside the permissible bearing temperatureDamage to the pump!

▷ The bearing temperature of the pump (set) must never exceed 90 °C (measuredat the bearing).

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 h depending on the conditions).

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 contact guard, synthetic material parts and other guards ofrotating parts for deformation and sufficient distance from the rotating parts.



7.2.2.1 Checking the coupling

Check the flexible elements of the coupling. Replace these parts in due time if thereis any sign of wear.

7.2.2.2 Checking the clearance gaps

To check the clearance gaps, the impeller or the two impellers (of two-stage pumps)must be removed. (⇨ Section 7.4.6 Page 41)If the clearance gap is larger than permitted (see the following table), fit new casingwear rings 502.01-0.04.The clearance gaps given refer to the diameter.

Table 19: Clearances between impeller and casing / between impeller and casingwear ring

Nominal diameter of thedischarge nozzle

CTN-G/-C CTN-GH/-CH

up to and including DN 100 0.50 mm + 0.1 0.50 mm + 0.1

DN 125 and above 0.70 mm + 0.1 0.70 mm + 0.1

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!

▷ Take appropriate measures to monitor contamination of filter.

▷ Clean filter in appropriate intervals.

7.2.3 Lubrication and lubricant change of thrust bearings (rolling element bearings)

DANGERExcessive temperatures as a result of thrust bearings (rolling element bearings) runninghot or defective bearing sealsExplosion hazard!Fire hazard!Damage to the pump set!

▷ Regularly check the condition of the lubricant.

7.2.3.1 Grease lubrication

The bearings are supplied packed with high-quality lithium-soap grease.

7.2.3.1.1 Grease quality

Table 20: Grease quality to DIN 51825

Soap basis NLGI grade Worked penetrationat 25 °C in mm/10

Drop point Temperature range

Lithium 2 to 3 220-295 ≥ 175 °C -30 ℃ to 120 ℃



7.2.3.1.2 Grease quantities and intervals

Table 21: Grease change

Size Bearing size Grease refill after hours/required quantity in cm³at a speed of rpm

1450 1750 2900 350025/40/50 2 x 7206BUA 8000/100 7500/100 4000/70 3000/7080/100 2 x 7309BUA 6000/140 4500/140 2000/110 -125/150 2 x 7309BUA 6000/140 4500/140 2000/110 -200/250 2 x 7313BUA 35008) /300 2500/300 - -

7.2.3.2 Oil lubrication

The thrust bearings (rolling element bearings) can be also be lubricated with oil.

7.2.3.2.1 Intervals

Table 22: Oil change intervals

Temperature at thebearing

First oil change All subsequent oilchanges9)

≤ 50 °C After 300 operating hours After 3000 operating hours> 50 °C After 300 operating hours After 2100 operating hours

7.2.3.2.2 Oil quality

Table 23: Oil quality

Designation Symbol to DIN51502

Properties

CLP46 lubricating oilto DIN 51517

orHD 20W/20 SAE

□ Kinematic viscosityat 40 °C

46±4 mm²/s

Flash point (toCleveland)

+175 ℃

Solidification point(pour point)

-15 ℃

Applicationtemperature10)

Higher thanpermissible bearing

temperature

7.2.3.2.3 Oil quantity

Table 24: Oil quantity

Size Bearing size Oil quantity11)

[l]25/40/50 1 x 6312 DIN 625 0.580/100 2 x 7312 BUA DIN 628 0.9125/150 2 x 7315 BUA DIN 628 1.2200/250 2 x 7318 BUA DIN 628 2.1

7.2.4 Radial bearings

In the volute casing and the pipe assemblies the shaft is guided in plain bearingslubricated by the fluid handled.

8) 5200 hours if n = 960 rpm9) At least once a year10) For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.11) Including constant-level oiler



If the fluid handled is contaminated, the bearings can be lubricated by an externalliquid supplied via a lubrication line (special design).

Table 25: External lubrication

Sizes Bearings lubricated byFluid Grease

Quantity perbearing

Pressure forexternal

lubrication

Quantity perbearing

Max.permissiblespeed for

greaselubrication

25/40/50 1.0 l/min 1.5 bar abovetank pressure

4 g/h 1750 rpm80/100 1.5 l/min 1450 rpm125/150 1.5 l/min 1450 rpm200/250 2.5 l/min 960 rpm

7.3 Drainage/disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

If the fluids handled by the pump (set) leave residues which might lead to corrosionwhen coming into contact with atmospheric humidity, or which might ignite whencoming into contact with oxygen, the pump (set) must be flushed through,neutralised, and blown through with anhydrous gas for drying purposes.

7.4 Dismantling the pump set

7.4.1 General notes/Safety regulations

WARNINGUnqualified personnel performing work on the pump (set)Risk of personal injury!

▷ Always have repair and maintenance work performed by specially trained,qualified personnel.

WARNINGHot surfaceRisk of personal injury!

▷ Allow the pump set to cool down to ambient temperature.

Observe the general safety instructions and information. (⇨ Section 7 Page 35)

For any work on the motor, observe the instructions of the relevant motormanufacturer.

For dismantling and reassembly refer to the general assembly drawing. (⇨ Section 9.1Page 57)

In the event of damage you can always contact our service staff.



DANGERInsufficient preparation of work on the pump (set)Risk of personal injury!

▷ Properly shut down the pump set. (⇨ Section 6.1.12 Page 30)

▷ Close the shut-off elements in the suction and discharge line.

▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 39)

▷ Close any auxiliary connections.

▷ Allow the pump set to cool down to ambient temperature.

7.4.2 Preparing the pump set

1. Disconnect the power supply (e.g. at the motor).

2. Disconnect and remove all auxiliary pipework.

3. Undo the bolts and nuts between flanged bend 72-1 and discharge pipe.

4. Undo the bolts and nuts between sole plate 893.02 and tank.Make sure not to damage the gaskets.

5. Lift the pump out of the tank and allow it to drain.

1. Disconnect the power supply (e.g. at the motor).

2. Disconnect and remove all auxiliary pipework.Remove the return line between pump and tank.

3. Undo the bolts and nuts between flanged bend 72-1 and discharge pipe.

4. Undo the screws and nuts between the sole plate 893.02 and foundation.

5. Undo bolts 901.26 and nuts 920.26.Make sure not to damage the gaskets.

6. Lift the pump and allow it to drain.

7.4.3 Dismantling the motor

1. Disconnect the motor from the power supply.

2. Unscrew hexagon nuts 920.11.Remove the motor with the coupling half.

7.4.4 Dismantling the thrust bearings

▪ Work cleanly and accurately.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 39) bis (⇨ Section 7.4.3 Page40) have been observed/carried out.

1. Bend open lockwasher 931.01 and unscrew keywayed nuts 920.21 (right-handthread).Remove both parts from shaft 210. Remove angular contact ball bearing 320.02 and spacer discs 550.21 with bearingbracket lantern 344.

2. Check lip seal 421.03.

3. Remove flanged bend 72-1 from the sole plate.


▪ Do not damage the oil tube.

Pump s ize 25/40/50


1. Remove centring sleeve 526.04 including rolling element bearing 321.02 from theshaft by rotating it (right-hand thread).

Wet installation

Dry installation

Grease-lubricated thrustbearings

Oil-lubricated thrustbearings



2. Unlock and undo keywayed nuts 920.24.

3. Push rolling element bearing 321.02 off the centring sleeve.

4. Remove constant-evel oiler 638.

5. Remove bearing bracket lantern 344 from the sole plate.

Pump s ize 80/100/125/150/200/250


1. Undo socket head cap screw 914.12 and unscrew bearing nut 923 from the shaft(right-hand thread). Remove constant-level oiler 638.

2. Pull centring sleeve 526.04 and angular contact ball bearing 320.02 together withbearing bracket lantern 344 off the shaft.

3. Remove centring sleeve 526.04 and angular contact ball bearing 320.02 from thebearing bracket lantern 344.

4. Unlock and undo keywayed nuts 920.24.

5. Push rolling element bearing 321.02 off the centring sleeve.

6. Remove flanged bend 72-1 from the sole plate.

7.4.5 Dismantling the shaft seal

7.4.5.1 Removing the mechanical seal


1. Remove ring 500.12 with grub screw 904.32 from shaft protecting sleeve 524.02.

2. Undo hexagon nuts 920.09.Remove seal cover 471.09.

3. Pull complete mechanical seal 433 with shaft protecting sleeve 524.02 off driveshaft 213.

4. Dismantle stuffing box housing 451.02.

7.4.5.2 Dismantling the gland packing


1. Unscrew hexagon nuts 920.09.Remove gland follower 452.02.

2. Remove stuffing box ring 454.02, packing ring 461.02 and lantern ring 458.02 (ifany) from stuffing box housing 451.02. Dismantle stuffing box housing 451.02.

7.4.6 Dismantling the hydraulic system


1. Undo bolts 901.28 and nuts 920.28 (and additional studs 902.28 and hexagonnuts 920.28, if applicable).Remove suction cover 162 with joint ring 411.58. Remove casing wear ring 502.01 (if required).

2. Bend open lockwasher 931.02 and unscrew cap nut 920.22. Pull impeller 230.01 off the shaft.Remove key 940.01.

Single-stage pumps



3. Undo bolts 901.29 and nuts 920.29.Remove volute casing 102 with gasket 400.16. Remove casing wear ring 502.02 (if required).


1. Undo bolts 901.27 and nuts 920.27 (and additional studs 902.27 and hexagonnuts 920.27, if applicable).Remove suction cover 162 with joint ring 411.58. Remove casing wear ring 502.01 (if required).

2. Bend open lockwasher 931.02 and unscrew cap nut 920.22. Pull impeller 230.02 off the shaft.Remove key 940.03.

3. Undo bolts 901.28 and nuts 920.28 (and additional studs 902.27 and hexagonnuts 920.27, if applicable).Remove stage casing 108 with joint ring 411.57. Remove casing wear rings 502.03/.04 (if required).

4. Remove bearing bush 545.02 (if applicable and required). Pull spacer sleeve 525 (or bearing sleeve 529.02, if applicable) and impeller 230.01off the shaft. Remove key 940.01.

5. Undo bolts 901.29 and nuts 920.29.Remove volute casing 102 with gasket 400.16. Remove casing wear ring 502.02 (if required).

7.4.7 Removing the pipe assembly and shaft assembly


✓ On heatable designs (CTN-H), the pipes 710.23/.24/.25/.26 with pipe unions731.18/.37/.38/.39/.40/.41 have been dismantled.

1. Undo bolts 901.32 and nuts 920.32.Remove pipe assembly 71-9.01 with gasket 400.18.

2. Remove bearing housing 350.04 with bearing bush 545.03, grooved pin 561.22and O-ring 412.10 (if applicable) from the recess in the pipe assembly (not forCTN-H).

3. If pipe assembly 71-9.02 is fitted, repeat steps 1 to 2.


CAUTIONBending of the shaftDamage to the shaft!

▷ Support the shaft assembly if the shaft is long.

✓ For large installation depths with several shafts 211, 212, 213, these have beendismantled once the threaded coupling 852.01 is accessible, before dismantlingthe next piping assembly.

1. Dismantle shaft 210.

2. If applicable, unscrew threaded couplings 852.02.Inject Caramba, Ferex etc. into the small drilled hole.Hold the threaded coupling and shaft with a wrench and turn them against eachother (right-hand thread).If the threaded coupling cannot be unscrewed, heat the coupling to 180°C andrepeat the process.

7.4.8 Dismantling the bearing sleeves

Shrink-fitted bearing sleeve 529.01/03

Two-stage pumps

Standard design




1. Carefully heat the bearing sleeve using a burner flame and remove with a pull-off device.If this proves difficult, turn off the bearing sleeve using a lathe or split it openalong its length using an abrasive cutting machine.

Bearing sleeve 529.01/03 fastened with parallel pin and grub screw


1. Undo and remove grub screws 904.11/.13.

2. Remove parallel pins 562.18/.19.

Bearing sleeve 529.01/03 fastened with screws (for brittle materials)


1. Unscrew screws 900.18/.19 from the shaft.Pull off the bearing sleeve.

Bearing sleeve 529.01/03 fastened with parallel pin (with special materials and singlepiece SiC sleeve)


1. Carefully bore open parallel pins 561.18/.19 and remove.If the bearing sleeve shows signs of wear and needs to be replaced, it can besmashed and the parallel in can be removed.

Bearing sleeve 529.01/03 fastened with key and grub screw


1. Undo and remove grub screws 904.11/.12.

2. Remove keys 940.05/.07.

Bearing sleeve 529.01/03 fastened with screws (for brittle materials)


1. Unscrew screws 900.18/.19 from the shaft.Pull off the bearing sleeve.

Bearing sleeve 529.01/03 fastened with parallel pin (for hard metal)


1. Carefully bore open parallel pins 561.18/.19 and remove.If the bearing sleeve shows signs of wear and needs to be replaced, it can besmashed and the parallel in can be removed.

7.4.9 Dismantling the bearing bush

In the volute casing


1. Undo hexagon nut 920.10 and grub screw 904.10.Press out bearing bush 545.01.

In the stage casing (for two-stage pumps)


1. Press out bearing bush 545.02 from below.

CTN special design

CTN-H special design



In the intermediate bearing (for large installation depths, the shaft assembly issupported by an intermediate bearing)


1. Remove grub screw 904.12 and bearing bush 545.03.


1. Use an appropriate jig to press bearing bush 545.03 out of pipe assembly 71-9.01.Smash the bearing bush if it is made of carbon.

7.5 Reassembling the pump set

7.5.1 General notes/Safety regulations

CAUTIONImproper reassemblyDamage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of soundengineering practice.

▷ Use original spare parts only.

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

▪ Gaskets

– Always use new gaskets, making sure that they have the same thickness asthe old ones.

– Always fit gaskets of asbestos-free materials or graphite without usinglubricants (e.g. copper grease, graphite paste).

▪ O-rings

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

CAUTIONContact of O-ring with graphite or similar materialFluid could escape!

▷ Do not coat O-ring with graphite or similar material.

▷ Use animal fats or lubricants based on silicone or PTFE.

▪ Assembly adhesives

– For gaskets, avoid the use of assembly adhesives, if possible.

– Should assembly adhesives be required after all, use a commercially availablecontact 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 screwedconnections with graphite or similar before reassembly.

For reassembly, tighten all screws and bolts as specified in this manual. (⇨ Section 7.6Page 52)

7.5.2 Fitting the bearing sleeve

Fitt ing the bearing s leeves

Bearing sleeve made of 1.4122HB500 and 1.4571 (standard design)

CTN

CTN-H

Sequence

Seal elements

Tightening torques

1.4122HB500 and 1.4571



✓ The individual parts are kept in a clean and level assembly area.

✓ All disassembled parts have been cleaned and checked for wear.

✓ Any damaged or worn parts have been corrected or replaced with original spareparts.

✓ The sealing surfaces have been cleaned.

1. Heat the bearing sleeve to approx. 150 to 200 °C and slide quickly onto the shaft.

Bearing sleeve made of SiC (standard design)





1. Heat the bearing sleeve to approx. 200 °C and slide quickly onto the shaft.

CAUTIONImproper reassemblyDamage to the plain bearing

▷ The guide ring with the marking (groove) must always be slipped onto the shaftfirst.

1

2

3

4

Fig. 7: Slide the bearing sleeve onto the shaft

1 Guide ring without marking 2 Press fit3 Guide ring with marking 4 Clearance fit

Bearing sleeve made from brittle and wear-resistant materials, e.g. C30EH, solid SiC(special design)





1. Slip the bearing sleeve onto the shaft and secure with grooved pin 561.18 orhexagon head bolt 900.18.

2. CTN: The grooved pins 561.21/.22 must engage in the recess of the pipe assemblywhen installing bearing housing 350.04.CTN-H: The grooved pins 561.21/.22 must engage in the recess of the pipeassembly when installing centring ring 511.

7.5.3 Assembling the pipe assembly and shaft assembly



✓ Any damaged or worn parts have been replaced by original spare parts.

1. Fasten pipe assembly 71-9.01 with gasket 400.18 to sole plate 893.02 using bolts901.32 and nuts 920.32.

2. Fit stuffing box housing with joint ring 411.47 on sole plate 893.02 using bolts920.05 and nuts 902.05.

3. Fit shaft 210.

SiC

C30EH, solid SiC



4. For large installation depths with several shafts 211, 212, 213, these must beconnected with threaded coupling 852.01 before assembling the next pipingassembly.

5. If threaded coupling 852.01 is installed, the shaft and the threaded couplingmust be held in place with the wrench and tightened against each other (right-hand thread).

6. Insert bearing housing 350.04 with bearing bush 545.03, grooved pin 561.22 andO-Ring 412.10 (if applicable) into the recess in the pipe assembly (not for CTN-H).



CAUTIONBending of the shaftDamage to the shaft!

▷ Support the shaft assembly if the shaft is long.

9. CTN-H: after assembling the pump, fit the pipes 710.23/.24/.25/.26 with pipeunions 731.18/.37/.38/.39/.40/.41.

7.5.4 Reassembly of hydraulic system





1. Fit volute casing 102 with bearing bush 545.01, casing wear ring 502.02 (ifapplicable) and gasket 400.16 to the pipe assembly with bolts 901.29 and nuts920.29.

2. Insert key 940.01 into the shaft.Fit impeller 230.01 with a jig.

3. Insert lockwasher 931.02.

4. Tighten cap nut 920.22.Bend down lockwasher 931.02.

5. Fasten suction cover 162, casing wear ring 502.01 (if applicable) with joint ring411.58 to the volute casing 102 using bolts 920.28 and nuts 901.28 (andadditional studs 902.28 and hexagon nuts 920.28, if applicable).





1. Fit volute casing 102 with bearing bush 545.01, casing wear ring 502.02 (ifapplicable) and gasket 400.16 to the pipe assembly with bolts 901.29 and nuts920.29.

2. Insert key 940.01 into the shaft.Fit impeller 230.01 with a jig.

3. Slip spacer sleeve 525 (or bearing sleeve 529.02, if applicable) onto the shaft.

4. Fit stage casing 108, casing wear rings 502.03/.04, bearing bush 545.02 (ifapplicable) and joint ring 411.57 using bolts 901.28 and nuts 920.28 (andadditional studs 902.28 and hexagon nuts 920.28, if applicable).

5. Insert key 940.03 into the shaft.

6. Fit impeller 230.02 with a jig.Insert lockwasher 931.02.

Single-stage pumps

Two-stage pumps



7. Tighten cap nut 920.22.Bend lockwasher 931.02.

8. Fasten suction cover 162, casing wear ring 502.01 (if applicable) with joint ring411.58 to the stage casing 108 using bolts and nuts 920.27/901.27 (and additionalstuds 920.27 and hexagon nuts 920.27, if applicable).

7.5.5 Installing the shaft seal

7.5.5.1 Installing the mechanical seal

The following rules must be observed when installing the mechanical seal:

▪ For installing the mechanical seal, proceed as shown in the seal installationdrawing.


▪ Only remove the protective wrapping of the seal faces immediately beforeinstallation takes place.

▪ Prevent any damage to the sealing surfaces or O-rings.

▪ After inserting the seat ring, check that it is plane-parallel in relation to thecasing part.

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

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

▪ Wet the contact faces with a drop of oil.





1. Fit the rotating unit of the mechanical seal onto the shaft protecting sleeve.

2. Slip the shaft protecting sleeve with O-ring 412.32 (if applicable) and pre-assembled mechanical seal unit onto the shaft. Make sure that anti-rotational device 562.06 is assembled in the shaft.

3. Carefully press the stationary seat ring of mechanical seal 433 with O-ring intoseal cover 471.01.

4. Screw seal cover 471.01 with the pre-assembled mechanical seal unit to stuffingbox housing 451.02.using bolts 920.09 and nuts 902.09.

5. Attach setting ring 500.12 to the shaft protecting sleeve with grub screw 904.32.

CAUTIONFastening the setting ring to the shaftDamage to the mechanical seal

▷ Secure the setting ring to the shaft with grub screw after setting the axialimpeller clearance. (⇨ Section 7.5.6 Page 49) and (⇨ Section 7.5.7 Page 51)

7.5.5.2 Fitting the gland packing

Always use pre-compressed packing rings.

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 44) to (⇨ Section 7.5.4 Page46) have been observed/carried out.

✓ The assembled bearing as well as the individual parts are kept in a clean andlevel assembly area.






1. Fasten stuffing box housing 451.02 with joint ring 411.47 on sole plate 893.02.

2. If applicable, fasten shaft protecting sleeve 524.02 to the shaft with grub screw904.14.

3. If applicable, check the O-ring.

4. Insert the first packing ring in the stuffing box housing 451.02 so that the cutedge is horizontal.

5. Insert the second packing ring with the cut edge displaced by 90°.

6. Insert lantern ring 458.02.The joint face must be offset from the cut edge of the packing ring.Insert other packing rings in the same way.

7. Insert stuffing box ring 454.02.

8. Fit gland follower 452 and lightly fasten it by hand with the two hexagon nuts920.09; watch discs 550.02.

CAUTIONOver-tightened gland packingDamage to the gland packing

▷ Gently tighten the gland packing.

NOTEThe gland packing has no contact with the fluid handled and only seals against splashesand low gas pressure.

1 2

Fig. 8: Dimensions of the packing chamber/Number of packing rings; 1 = Designwithout shaft protecting sleeve, 2 = Design with shaft protecting sleeve

Table 26: Gland packing chamber

Sizes No. of rings Gland packingchamber

without shaftprotecting sleeve

Packing cross-section

Gland packingchamber

with shaft protectingsleeve

Packing cross-section

Ø di Ø da l Ø di Ø da l

25 / 40 / 50 4 packing rings and 1 lantern ring

or

6 packing rings

35 51 53 8 x 8 45 65 64 10 x 1080 / 100 45 65 64 10 x 10 55 75 64 10 x 10125 / 150 55 75 64 10 x 10 70 95 79 12.5 x 12.5200 / 250 70 95 79 12.5 x 12´.5 80 105 79 12.5 x 12.5

7.5.5.2.1 Barrier fluid for gland packing

The gland packing seals against splashes and vapours.

Gland packings with self-lubricating properties are used. This means no extra barrierfluid or grease is required.



If necessary, clean fluid handled or a fluid compatible with the fluid handled can beused. If no barrier fluid is available, grease can be used in combination with a Conradlubricator.

1

2

3

4

Fig. 9: Conrad lubricator

1 Counternut 2 Upper section3 Plunger 4 Lower section (grease cup)


✓ The lubricator has been cleaned and checked.

✓ The grease container and threads are clean.

1. Screw lower section (4) into the connection for sealing grease.Fill grease cup (4) to the brim with grease.

2. Remove plunger (3) from the upper section.Apply a layer of grease to the inner lining of the upper section.

3. Tighten the bottom screw.

4. Insert plunger (3).The bottom screw must face outwards.

5. Turn the upper section (2) four turns into the lower section(4).

6. Tighten counter nut (1) on the edge of the lower section.

Adjust ing the lubricator

NOTERefill the lubricator approx. every 8 days when working in eight-hour operating periods.

1. Turn the counter nut (1) back by four turns.

2. Screw the upper section (2) in by four turns.

3. Tighten the counternut again (1).

NOTEWhen the upper section is screwed into the lower section completely, the lubricator isemptied.

7.5.6 Assembling thrust bearings

✓ The notes and steps stated inr (⇨ Section 7.5.1 Page 44) bis (⇨ Section 7.5.5 Page47) have been observed/carried out.






1. Heat bearings 320.2 in the oil tank to approx. 80 °C.

2. Slip bearings 320.2 onto the cleaned shaft and into bearing bracket lantern 344until they abut against the spacer discs 550.21.

✓ The oil tube has been checked for clear throughflow.

1. Slip the bearings onto cleaned centring sleeve 526.04.

2. Attach lockwasher 931.03.

3. Screw on keywayed nut 920.24, tighten and secure.The cast notches in bearing bracket lantern 344 and in bearing cover 360 must belocated on top of each other.Check the recess in the gasket so that the oil return grooves can perform theirfunction.

Sett ing the axial impel ler c learance

The impeller is centred in the volute casing, i.e. the axial distance between theimpeller and the suction cover or the impeller and the volute casing (for a single-stage pump) or the stage casing (for a two-stage pump) is the same. To achieve this,assemble the complete pump without angular contact ball bearing 320.02 and drivelantern 341.

Move the shaft down to the lower stop and measure dimension A1.Determine the difference B = A1 - C.

Move the shaft upwards to the upper stop and measure dimension A2.Determine the difference D = A1 - A2.

The required thickness S of the spacer discs is calculated as follows:S = B - D/2

Sizes Dimension C25 / 40 / 50 37.580 / 100 / 125 / 150 53.0200 / 250 69.0

1. Push the set of spacer discs 550.21 onto the shaft to their stop to achievedimension S.

2. Mount angular contact ball bearing 320.02 with keywayed nut 920.21 andlockwasher 931.01.

NOTEInstall angular contact ball bearings in face-to-face arrangement. Angular contact ballbearings installed must always be from the same manufacturer.

Fig. 10: Determining spacer disc thickness S

CTN with oil-lubricatedthrust bearings

CTN, CTN-H



Fig. 11: Assembled thrust bearings with set of spacer discs

3. Carefully slip on bearing cover 360.02 with lip seal 421.04 and screw tight.Check that the rotor can be easily rotated by hand without making grindingnoises.

4. Align the coupling. (⇨ Section 5.3 Page 19)

NOTEThe overall axial clearance of the pump rotor is determined by lowering and pulling therotor up using the centring sleeve.

Setting pump sizes 25/40/50

1. Turn the centring sleeve to the left.Move the rotor to the lower stop.

2. Measure the dimension of the upper edge of the centring sleeve/shaft end.

3. Turn the centring sleeve to the right.Move the rotor to the upper stop.

4. Measure the dimension of the upper edge of the centring sleeve/shaft end.

5. Lower the rotor from the upper stop by 0.5x the overall clearance.One full turn of the centring sleeve will cause the rotor to move upwards ordownwards by 1.5 mm.

6. Secure the centring sleeve with key 940.02 to prevent rotation.If the key cannot be pushed into the recess, then turn the centring sleeve so thatthe nearest recess aligns with the keyway.

Setting pump sizes 80/100/125/150/200/250

1. Turn bearing nut 923 to the left.Move the rotor to the lower stop.

2. Measure the dimension of the upper edge of the bearing nut/shaft end.

3. Turn the bearing nut 923 to the right.Move the rotor to the upper stop.

4. Measure the dimension of the upper edge of the bearing nut/shaft end.

5. Lower the rotor from the upper stop by 0.5x the overall clearance.One full turn of the bearing nut will cause the rotor to move upwards ordownwards by 1.5 mm.

6. Screw the centring sleeve to the bearing nut with socket head cap screws 914.12and secure against rotation.The throughholes in the bearing nut align with the tapped holes in the centringsleeve.

7.5.7 Preloading the mechanical seal

Move the setting ring 500.12 and shaft protecting sleeve in the direction of themotor to the setting dimension of 5 mm (distance to the seal cover) and secure onshaft 210 with grub screw 904.32.

CTN with oil-lubricatedthrust bearings



7.6 Tightening torques

7.6.1 Tightening torques

Use a torque wrench to tighten the screwed connections (902.01/920.01) between thevolute casing and the bearing bracket lantern.

Table 27: Tightening torques for screwed connections

MaterialStud/hexagon nut

C35E+Qt/C 35 A4-70/A4-70 1.7709+QT/1.7258+QT

Stamp onstud/hexagonnut12)

YK/Y A4-70/A4-70 GA/GTightening torques [Nm]

Bearingbracketlantern13)

A B A B A B

Newthreads14)

-15%15)

-20%15)

Newthreads14)

-15%15)

-20%15)

Newthreads14)

-15 %15) -20 %15)

M10 - - - 30 25.5 24 47 30 39.9 25.5 37.6 24M12 40 34 32 55 46.7 44 80 55 68 46.7 64 44M16 100 85 80 155 131.7 124 190 155 161.5 131.7 152 124M20 - - - 200 170 160 330 200 280.5 170 264 160

7.7 Spare parts stock

7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:

▪ Type series

▪ Size

▪ KSB order number

▪ Material variant

▪ Year of construction

Refer to the name plate for all data. (⇨ Section 4.3 Page 15)

Also supply the following data:

▪ Description

▪ Part No.

▪ Quantity of spare parts

▪ Delivery address

▪ Mode of dispatch (freight, mail, express freight, air freight)

Refer to the general assembly drawing for part numbers and descriptions. (⇨ Section9.1 Page 57)

12) Treat unstamped screwed connections like material pair C35/E+QT/C 35.13) A: made of ductile material — except JL 1040; B: made of material JL 104014) These values are determined on the basis of a friction coefficient of μ = 0.12.15) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.



7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296

Table 28: Quantity of spare parts for recommended spare parts stock for CTN, CTN-H

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

more210, 211, 212, 213 Shaft 1 1 1 2 2 2 20 %230.01/.0216) Impeller 1 1 1 2 2 2 20 %320.02 Angular contact ball bearing (set) 1 1 2 2 2 3 25 %321.02 Radial ball bearing17) 1 1 2 2 2 3 25 %

502.01/.02/.03/.0416) Casing wear ring 2 2 2 3 3 4 50 %

529.01/.0316) Bearing sleeve 2 3 4 5 7 9 100 %18)

545.01/.0316) Bearing bush 2 3 4 5 7 9 100 %18)

852 Threaded coupling (set) 1 1 2 2 3 4 30 %- Gaskets for pump casing (set) 4 6 8 8 9 12 150 %- Other seal elements (set) 4 6 8 8 9 10 100 %Variants with mechanical seal:433 Mechanical seal, complete 1 1 2 2 2 3 25 %Variants with gland packing:461.0216) Gland packing (set) 4 4 6 6 6 8 100 %524.02 Shaft protecting sleeve 2 2 2 3 3 4 50 %

16) If fitted17) Oil-lubricated thrust bearings (rolling element bearings) only18) Per number of bearing points



7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

Table 29: Interchangeability of pump components

Size Description

Vo

lute

cas

ing

Stag

e ca

sin

g

Suct

ion

co

ver

Shaf

t

Pum

p s

haf

t

Inte

rmed

iate

sh

aft

Dri

ve s

haf

t

Imp

elle

r

An

gu

lar

con

tact

bal

l bea

rin

g

Rad

ial b

all b

eari

ng

(fo

r o

il-lu

bri

cate

d t

hru

st b

eari

ng

s)

Dri

ve la

nte

rn

Bea

rin

g b

rack

et la

nte

rn

Bea

rin

g h

ou

sin

g

Gla

nd

fo

llow

er

Stu

ffin

g b

ox

rin

g

Lan

tern

rin

g

Gla

nd

pac

kin

g

Cas

ing

wea

r ri

ng

Cas

ing

wea

r ri

ng

Shaf

t p

rote

ctin

g s

leev

e(g

lan

d p

acki

ng

)

Bea

rin

g b

ush

Bea

rin

g b

ush

Pip

e as

sem

bly

Flan

ged

ben

d

Thre

aded

co

up

ling

Sole

pla

te

Part No.

102

108

162

21019

)

21119

)

21219

)

21319

)

230.

01/.0

220)

320.

02

321.

02

34121

)

344

350.

04

452.

0222

)

454.

0222

)

458.

0222

)

461.

0222

)

502.

01/.0

220)

502.

03/.0

420)

524.

02

545.

01/.0

3

545.

02

71-9

.01/

.0220

)

72-1

852

893.

0223

)

25-200 1 - 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 - 1 1 - 1 1 1 125-200/2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 - 1 1 1 140-200 2 - 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 - 1 1 - 1 2 1 140-250 3 - 3 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 - 1 1 - 1 2 1 140-250/2 3 2 3 2 2 1 1 3 1 1 1 1 1 1 1 1 1 2 2 1 1 - 1 2 1 140-280 4 - 4 3 3 1 1 4 1 1 1 1 1 1 1 1 1 3 - 1 1 - 1 2 1 140-280/2 4 3 4 4 4 1 1 4 1 1 1 1 1 1 1 1 1 3 3 1 1 2 1 2 1 150-200 5 - 5 3 3 1 1 5 1 1 1 1 1 1 1 1 1 4 - 1 1 - 1 3 1 150-250 6 - 6 3 3 1 1 6 1 1 1 1 1 1 1 1 1 4 - 1 1 - 1 3 1 150-315 7 - 7 3 3 1 1 7 1 1 1 1 1 1 1 1 1 4 - 1 1 - 1 3 1 150-315/2 7 4 7 4 4 1 1 7 1 1 1 1 1 1 1 1 1 4 4 1 1 2 1 3 1 180-250 8 - 8 5 5 2 2 8 2 2 2 2 2 2 2 2 2 5 - 2 2 - 2 4 2 280-315 9 - 9 5 5 2 2 9 2 2 2 2 2 2 2 2 2 5 - 2 2 - 2 4 2 280-315/2 9 5 9 6 6 2 2 9 2 2 2 2 2 2 2 2 2 5 5 2 2 3 2 4 2 2100-250 10 - 10 5 5 2 2 10 2 2 2 2 2 2 2 2 2 5 - 2 2 - 2 5 2 2100-315 11 - 11 5 5 2 2 11 2 2 2 2 2 2 2 2 2 5 - 2 2 - 2 5 2 2100-315/2 11 6 11 6 6 2 2 11 2 2 2 2 2 2 2 2 2 5 5 2 2 3 2 5 2 2125-315 12 - 12 7 7 3 3 12 3 3 3 3 3 3 3 3 3 6 - 3 3 - 3 6 3 3125-315/2 12 7 12 8 8 3 3 12 3 3 3 3 3 3 3 3 3 6 6 3 3 4 3 6 3 3150-250 13 - 13 7 7 3 3 13 3 3 3 3 3 3 3 3 3 7 - 3 3 - 3 7 3 3200-315 14 - 14 9 9 4 4 14 4 4 4 4 4 4 4 4 4 8 - 4 4 - 4 8 4 4250-315 15 - 15 9 9 4 4 15 4 4 4 4 4 4 4 4 4 9 - 4 4 - 5 9 4 5250-400 16 - 16 9 9 4 4 16 4 4 4 4 4 4 4 4 4 10 - 4 4 - 6 9 4 6

19) For identical lengths20) If fitted21) For identical motors22) Only for identical seal types23) For identical nominal diameters



8 Trouble-shootingPump delivers insufficient flow rate

Motor is overloaded

Excessive pump discharge pressure

Increased bearing temperature

Leakage at the pump

Vibrations during pump operation

Impermissible rise of temperature inside the pump

Table 30: Trouble-shooting

A B C D E F G Possible cause Remedy 24)

X Pump delivers against an excessively highdischarge pressure.

Re-adjust duty point.Check system for impurities.Fit a larger impeller. 25)

Increase the speed (turbine, I.C. engine).X X X Pump or piping are not completely vented

or primed.Vent and/or prime.

X Supply line or impeller clogged. Remove deposits in the pump and/or piping.X Formation of air pockets in the piping Alter piping layout.

Fit vent valve.X X X Suction head is too high/NPSHavailable (positive

suction head) is too low.Check/alter liquid level.Install pump at a lower level.Fully open shut-off element in the suctionline.Change suction line if the friction losses inthe suction line are too high.Check any strainers installed/suctionopening.Observe the permissible speed of pressurefall

X Wrong direction of rotation Interchange two of the phases of the powercable.

X Speed is too low.

- Operation with frequency inverter- Operation without frequency inverter

- Increase voltage/frequency at the FI withinthe permissible range.- Check voltage.

X X Impeller Replace worn parts by new ones. X X Pump back pressure is lower than specified

in purchase orderAdjust duty point accurately. In the case of persistent overloading, turndown impeller. 25)

X Density or viscosity of the fluid handled ishigher than stated in the purchase order.

Contact KSB.

X Gland follower too tight or askew Correct. X X Speed is too high. Reduce speed. 25) 26)

X Worn shaft seal Fit new shaft seal.Check flushing liquid / barrier fluid.

X Vibrations during pump operation Correct suction conditions.Re-align the pump.Re-balance the impeller.Increase pressure at the pump suctionnozzle.

A

B

C

D

E

F

G

24) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.25) Contact KSB.26) The fault can be remedied by changing the impeller diameter.

8 Trouble-shooting


A B C D E F G Possible cause Remedy 24)

X X X Pump warped or sympathetic vibrations inpiping

Check pipeline connections and secure fixingof pump; if required, reduce the distancesbetween the pipe clamps.Fix the pipelines using anti-vibrationmaterial.

X X Insufficient or excessive quantity of lubricantor unsuitable lubricant.

Top up, reduce or change lubricant.

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

X Connection bolts have worked loose. Re-tighten bolts.Fit new sealing elements.

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

X X Defective bearing(s) Fit new bearing(s). X X Insufficient flow rate Increase the minimum flow rate.X Air intake at pump inlet Increase the minimum fluid level. X System-induced vibrations25)

24) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

8 Trouble-shooting


9 Related Documents

9.1 General assembly drawing with list of components

9.1.1 CTN

Fig. 12: CTN general assembly drawing

9 Related Documents


902.09920.09550.02452.02454.02411.47461.02451.02

904.14

412.32

K/H

458.02

524.02

562.06

Standard design, without shaft protectingsleeve

Design with shaft protecting sleeve andlantern ring in the gland packing; can becooled/heated

901.28(902.28) 920.28

901.27(902.27) 920.27

411.57

230.01

525

108

940.03

230.02

411.58

502.03/561.07

502.04/561.08

529.02

545.02

561.09

Detail of two-stage pumpSizes: 25-200/2 and 40-250/2Additional lock for PTFE bearings

Detail of two-stage pumpSizes: 40-280/2, 50-315/2, 80-315/2,100-315/2, 125-315/2

Table 31: List of components

Part No. Description Scope of supply102 Volute casing with gasket 400.16, casing wear ring 502.0227) , grooved pin 561.0627) ,

grub screw 904.0428) 27) /.10, hexagon head bolt 901.2827) , stud902.2827) , hexagon nut 920.10/.28

108 Stage casing29) with joint ring 411.58, casing wear ring 502.03/.04, grub screw 904.0727)

28) /.0827) 28) , bearing bush 545.0227) , grooved pin 561.0927) , hexagonhead bolt 901.2727) , stud 902.2727) , hexagon nut 920.27

153 Suction nozzle27) with gasket 400.03, hexagon head bolt 901.26, hexagon nut 920.26162 Suction cover with joint ring 411.57, casing wear ring 502.0127) , grooved pin 561.0127)

28) , grub screw 904.0327) 28)

210 Shaft30) 28) with set of spacer discs 550.21, keywayed nut 920.21, cap nut 920.22,parallel pin 562.0627) , lockwasher 931.01/.02, key 940.01/.02/.0329)

211 Pump shaft with cap nut 920.22, lockwasher 931.02, key 930.01/.0329)

212 Intermediate shaft28) 213 Drive shaft with set of spacer discs 550.21, parallel pin 562.0627) , with keywayed

nut 920.21, lockwasher 931.01, key 940.02230.01/.02 Impeller For two-stage pumps, specify whether for 1st or 2nd stage

27) If fitted28) Not shown29) Only for two-stage pumps30) If only one shaft is fitted: For large installation depths, the shaft assembly consists of a pump shaft and drive shaft or pump

shaft, intermediate shaft(s) and drive shaft

9 Related Documents


Part No. Description Scope of supply320.02 Angular contact ball

bearing

341 Drive lantern with disc 550.69, guard 680.01, hexagon head bolt 901.69, stud 902.11,hexagon nut 920.11

344 Bearing bracket lantern with bearing cover 360.02, lip seal 421.03/.04, hexagon head bolt901.3727) , studs 902.06, socket head cap screw 914.02, hexagon nut920.06

350.04 Bearing housing with O-ring 412.1027) 28) , bearing bush 545.03, grooved pin 561.22, grubscrew 904.12

421.03/.04 Lip seal 451.02 Stuffing box housing with joint ring 411.3327) 28) /.3427) 28) /.47, disc 550.02, stud 902.09,

screwed plug 903.3327) 28) /.3427) 28) , hexagon nut 920.09452.02 Gland follower 454.02 Stuffing box ring 458.02 Lantern ring 461.02 Gland packing 502.01/.02 Casing wear ring27) with grooved pin 561.0127) 28) /.0627) 28) , grub screw 904.0327) 28) /.0427) 28)

502.03/.04 Casing wear ring27) 29) with grooved pin 561.0727) 28) /.0827) 28) , grub screw 904.3427) 28) /.3527) 28)

524.02 Shaft protectingsleeve27)

with O-ring 412.32, grub screw 904.14

525 Spacer sleeve29)

529.01/.0327) Bearing sleeve with grooved pin 561.18/.1927) or screw 900.18/.1927)

529.02 Bearing sleeve 545.01 Bearing bush 545.02/.03 Bearing bush27) 550.21 Set of spacer discs 71-9.01 Pipe assembly31) with gasket 400.18, hexagon head bolt 901.29, hexagon nut 920.2971-9.02 Pipe assembly31) with gasket 400.17, hexagon head bolt 901.32, hexagon nut 920.3272-1 Flanged bend with gasket 400.17852.01 Threaded coupling 893.02 Sole plate with joint ring 411.47, disc 550.17, eyebolt 900.03, studs

902.05/.12/.30/.31, hexagon nuts 920.05/.12/.30/.31

31) 71-9.01/.02/.03 etc. for several pipe assemblies, counted from the pump

9 Related Documents


9.1.2 CTN-H

Fig. 13: CTN-H general assembly drawing

9 Related Documents


904.14

412.32

K/H

458.02

524.02

562.06

901.28(902.28) 920.28

901.27(902.27) 920.27

411.57

230.01

525

108

940.03

230.02

411.58

502.03/561.07

502.04/561.08

529.02

545.02

561.09

Design with shaft protecting sleeveand lantern ring in the glandpacking; can be cooled/heated




Part No. Description Scope of supply102 Volute casing with gasket 400.16, casing wear ring 502.0227) , grooved pin 561.0227)

28) , grub screw 904.0427) 28) /.10/.1527) , hexagon head bolt 901.2827) , stud902.2827) , hexagon nut 920.10/.2827)

108 Stage casing29) with joint ring 411.58, casing wear ring 502.0327) /.04,27) grub screw904.0727) /.0827) , bearing bush 545.0227) , grooved pin 561.0927) 28) ,hexagon head bolt 901.2727) , stud 902.2727) , hexagon nut 920.27

153 Suction nozzle27) with gasket 400.03, hexagon head bolt 901.26, hexagon nut 920.26162 Suction cover with joint ring 411.57, casing wear ring 502.0127) , grooved pin 561.0127)

28) , grub screw 904.0327) 28)

210 Shaft30) 28) with set of spacer discs 550.21, keywayed nut 920.21, cap nut 920.22,lockwasher 931.01/.02, key 940.01/.02/.0329) /.0627) 28) /.0727) 28)

211 Pump shaft with cap nut 920.22, lockwasher 931.02, key 940.01/.0329) /.0627) 28)

212 Intermediate shaft28) 213 Drive shaft with set of spacer discs 550.21, parallel pin 562.0627) , with keywayed

nut 920.21, lockwasher 931.01, key 940.0227) 28)

230.01/.0229) Impeller For two-stage pumps, specify whether for 1st or 2nd stage320.02 Angular contact ball

bearing

341 Drive lantern with coupling guard 681.0528) , screw 900.1628) , stud 902.11, hexagonnut 920.11

344 Bearing bracket lantern with bearing cover 360.02, lip seal 421.02/.03, cover plate 680.0328) ,screw 900.1528) , studs 902.06, socket head cap screw 914.02, hexagonnut 920.06

421.02/.03 Lip seal 451.02 Stuffing box housing with joint ring 411.3327) 28) /.3427) 28) /.47, disc 550.01, stud 902.09,

screwed plug 903.3327) 28) /.3427) 28) , hexagon nut 920.09452.02 Gland follower 454.02 Stuffing box ring 458.02 Lantern ring 461.02 Gland packing 502.01/.02 Casing wear ring27) with grooved pin 561.0127) 28) /.0227) 28) , grub screw 904.0327) 28) /.0427) 28)

502.03/.04 Casing wear ring27) 29) with grooved pin 561.0727) 28) /.0827) 28) , grub screw 904.3427) 28) /.3527) 28)

511 Centring ring with grooved pin 561.22524.02 Shaft protecting

sleeve27)with O-ring 412.32, grub screw 904.14, key 940.0727) 28)

525 Spacer sleeve29)

9 Related Documents


Part No. Description Scope of supply529.01/.0327) Bearing sleeve with grooved pin 561.18/.1927) 28) or screw 900.18/.1927) 28) or grub screw

904.11/.1227) 28)

529.0229) Bearing sleeve 545.01 Bearing bush 545.0227) 29) /.0327) Bearing bush with grooved pin 561.21 (for 545.03)550.21 Set of spacer discs 71-9.01 Pipe assembly31) with gasket 400.18, hexagon head bolt 901.29, hexagon nut 920.2971-9.02 Pipe assembly31) with gasket 400.17, hexagon head bolt 901.32, hexagon nut 920.32

710.2327) 28) -.26 Pipe with pipe union 731.18/.3727) 28) /.3827) 28) /.39/.40/.4172-1 Flanged bend with gasket 400.17852 Threaded coupling 893.02 Sole plate with disc 550.17, eyebolt 900.03, studs 902.05/.12/.30/.31, hexagon nuts

920.05/.12/.30/.31

9 Related Documents


9.1.3 CTN with oil-lubricated thrust bearings

Fig. 14: General assembly drawing for CTN with oil-lubricated thrust bearings

9 Related Documents


904.14

412.32

K/H

458.02

524.02

562.06

901.28(902.28) 920.28

901.27(902.27) 920.27

411.57

230.01

525

108

940.03

230.02

411.58

502.03/561.07

502.04/561.08

529.02

545.02

561.09

Design with shaft protecting sleeveand lantern ring in the glandpacking; can be cooled/heated



902.

3092

0.30

451.

0241

1.47

893.

02

641

931.

0352

6.04

400.

3490

4.20

923

940.

02

914.

1242

1.02

360.

0294

0.11

320.

0240

0.21

902.

3192

0.31

72-1

901.

6955

0.69

680.

01

341

902.

1192

0.11

900.

0355

0.17

902.

1292

0.12

400.

17

902.

0592

0.05

902.

0692

0.06

508.

02

914.

02

638

920.

74

903.

4641

1.46

913.

0141

1.82

34490

1.94

Fig. 15: Bearings for pump sizes 80/100/125/150/200/250


Part No. Description Scope of supply102 Volute casing with gasket 400.16, casing wear ring 502.0227) 28) , grooved pin 561.0627)

28) , grub screw 904.0427) 28) /.10/.1527) , hexagon head bolt 901.2827) , stud902.2827) , hexagon nut 920.10/.2827)

108 Stage casing29) with joint ring 411.5829) , casing wear ring 502.03/.0427) 28) , grub screw904.07/.0827) 28) , bearing bush 545.0227) 28) , grooved pin 561.0927) 28) ,hexagon head bolt 901.2727) 29) 28) , stud 902.2727) 29) 28) , hexagon nut920.2727) 29) 28)

153 Suction nozzle with gasket 400.03, hexagon head bolt 901.26, hexagon nut 920.26162 Suction cover with joint ring 411.57, casing wear ring 502.0127) , grooved pin 561.0127)

28) , grub screw 904.0327) 28)

210 Shaft30) 28) with cap nut 920.22, lockwasher 931.02, key 940.01/.02/.0329) /.1127)

211 Pump shaft with cap nut 920.22, lockwasher 931.02, key 940.01/.0329)

212 Intermediate shaft28) 213 Drive shaft with key 940.02/.1127)

230.01/.02 Impeller For two-stage pumps, specify whether for 1st or 2nd stage

9 Related Documents


Part No. Description Scope of supply320.02 Rolling element

bearing

321.02 Radial ball bearing 341 Drive lantern with coupling guard 681.0528) , screw 900.1628) , stud bolt 902.11,

hexagon nut 920.11344 Bearing bracket lantern with bearing cover 360.02, gasket 400.34, joint ring 411.46, lip seal

421.02, studs 902.06, screwed plug 903.46, vent plug 913.01, sockethead cap screw 914.02, hexagon nut 920.06

350.04 Bearing housing with O-ring 412.1027) 28) , bearing bush 545.03, grooved pin 561.22,grooved pin 561.2327) , grub screw 904.1227) 28)

421.02 Lip seal 451.02 Stuffing box housing with joint ring 411.3327) 28) /.47, disc 550.01, stud 902.09, screwed plug

903.33/.3427) 28) , hexagon nut 920.09452.02 Gland follower 454.02 Stuffing box ring 458.02 Lantern ring 461.02 Gland packing 502.01/.02 Casing wear ring27) with grooved pin 561.01/.0227) 28) , grub screw 904.03/.0427) 28)

502.03/.04 Casing wear ring27) 29) with grooved pin 561.07/.0827) 28) , grub screw 904.34/0.3527) 28)

524.02 Shaft protectingsleeve27)

with O-ring 412.3228) , grub screw 904.1428) , parallel pin 562.06

525 Spacer sleeve29) 526.04 Centring sleeve with keywayed nut 920.24, lockwasher 931.03529.01/.03 Bearing sleeve27) with grooved parallel pin 561.18/.1927) or screw 900.18/.1927) or grub

screw 904.11/.12529.02 Bearing sleeve 545.01 Bearing bush 545.02/.03 Bearing bush 638 Constant-level oiler 641 Oil level pipe with hexagon head bolt 901.94, gasket 400.2171-9.01 Pipe assembly31) with gasket 400.18, hexagon head bolt 901.29, hexagon nut 920.2971-9.02 Pipe assembly31) with gasket 400.17, hexagon head bolt 901.3228) , hexagon nut 920.3228)

72-1 Flanged bend with gasket 400.17852.01 Threaded coupling 893.02 Sole plate with disc 550.17, eyebolt 900.03, studs 902.05/.12/.30/.31, hexagon nuts

920.05/.12/.30/.31923 Bearing nut27) with socket head cap screw 914.12

9 Related Documents


10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

CTN, CTN-H

KSB order number: ...................................................................................................

▪ is in conformity with the provisions of the following directives as amended from time to time:

– EC Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100-1/A1, ISO 12100-2/A1,

– ISO 14121-1,

– EN 809/A1

Halle, 29 December 2009

...........................................................

Name

Function

Responsible for compiling the technical documentationKSB Aktiengesellschaft

Turmstraße 92

06110 Halle (Germany)

10 EC Declaration of Conformity


11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number32) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled32) : ................................................................................................................................

Please tick where applicable32) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return32) : ................................................................................................................................ Comments: ................................................................................................................................ ................................................................................................................................ The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placingat your disposal.

On seal-less pumps, the rotor has been removed from the pump for cleaning.

⃞ No special safety precautions are required for further handling.⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

............................................................................................................................................................... ............................................................................................................................................................... We confirm that the above data and information are correct and complete and that dispatch is effected in accordance withthe relevant legal provisions.

.................................................................... ....................................................... .......................................................Place, date and signature Address Company stamp

32) Required fields

11 Certificate of Decontamination


Index

AAbrasive fluids 33

BBearing temperature 36

CCertificate of decontamination 67Clearance gaps 37Commissioning/start-up 25Constant-level oiler 25Coupling 37

DDesign 17Designation 15Direction of rotation 24Dismantling 39Disposal 14

EExplosion protection 11, 19, 22, 23, 24, 26, 27, 28, 29,30, 32, 35, 36, 37

FFilter 37Final check 27Flow rate 32Frequency of starts 32

GGland packing 30Grease lubrication

Grease quality 37

HHeating speed 29Heating up 29

IInstallation at site 19Intended use 8Interchangeability of pump components 54

KKeeping the pump warm 29

MMaintenance/repair 35Mechanical seal 30Misuse 9Monitoring equipment 12

NNoise characteristics 18

OOil lubrication

Intervals 38Oil quality 38

Operating limits 8Order number 6Other applicable documents 6

PPartly completed machinery 6Permissible forces and moments at the pump nozzles21Preservation 14, 33

RReturn to supplier 14Returning to service 34Running noises 35, 36

SSafety 8Safety awareness 9Scope of supply 18Shutdown 30, 33Spare parts 52Spare parts stock 53Start-up 30Storage 14, 33

TTemperature difference 29Temperature limits 11Tightening torques 52Trouble-shooting 55

WWater cooling 27

Index


KSB AktiengesellschaftP.O. Box 1361 • 91253 Pegnitz • Bahnhofplatz 1, 91257 Pegnitz (Germany) Tel. +49 9241 71-0 • Fax +49 9241 71-1793www.ksb.com

2711

.8-1

0