Etaline SYT

7/27/2019 Etaline SYT

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Thermal Oil / Hot Water Pump

Etabloc SYT/ Etaline SYT

Close-coupled or in-line design

Installation/OperatingManual



Legal information/Copyright

Installation/Operating Manual Etabloc SYT/ Etaline SYT

Original operating manual

KSB Aktiengesellschaft

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited orprocessed for any other purpose, nor otherwise transmitted, published or made available to a third party withoutKSB's express written consent.

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft Frankenthal 25.01.2013



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 Checking the condition upon delivery .......................................................... 13

3.2 Transport ......................................................................................................... 13

3.3 Storage/preservation ...................................................................................... 14

3.4 Return to supplier ........................................................................................... 15

3.5 Disposal ...........................................................................................................15

4 Description of the Pump (Set) ............................................................17

4.1 General description ........................................................................................ 17

4.2 Product Information as per Regulation No. 547/2012 (for Water Pumps witha Maximum Shaft Power of 150 kW) Implementing "Ecodesign" Directive2009/125/EC ..................................................................................................... 17

4.3 Designation .................................................................................................... 17

4.4 Name plate ...................................................................................................... 17

4.5 Design details .................................................................................................. 17

4.6 Configuration and function ........................................................................... 18

4.7 Noise characteristics .......................................................................................19

4.8 Scope of supply ............................................................................................... 19

4.9 Dimensions and weights ................................................................................19

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

5.1 Safety regulations ........................................................................................... 20

5.2 Checks to be carried out prior to installation ............................................... 20

Contents

Etabloc SYT/ Etaline SYT 3 of 52



5.3 Installing the pump set .................................................................................. 20

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

5.5 Enclosure/insulation .......................................................................................22

5.6 Electrical connection ...................................................................................... 23

5.7 Checking the direction of rotation ................................................................ 24

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

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

6.2 Operating limits .............................................................................................. 28

6.3 Shutdown/storage/preservation .................................................................... 30

6.4 Returning to service .......................................................................................30

7 Servicing/Maintenance .......................................................................32

7.1 Safety regulations ........................................................................................... 32

7.2 Maintenance/inspection ................................................................................. 33

7.3 Drainage/cleaning ..........................................................................................35

7.4 Dismantling the pump set .............................................................................. 35

7.5 Reassembling the pump set ........................................................................... 38

7.6 Tightening torques ......................................................................................... 41

7.7 Spare parts stock ............................................................................................. 41

8 Trouble-shooting ................................................................................44

9 Related Documents ............................................................................46

9.1 Exploded views and list of components ........................................................ 46

10 EC Declaration of Conformity ...........................................................48

11 Certificate of Decontamination .........................................................49

Index ....................................................................................................50

Contents

4 of 52 Etabloc SYT/ Etaline SYT



Glossary

Back pull-out design

The complete back pull-out unit can be pulledout without having to remove the pump casingfrom the piping.

Back pull-out unit

Pump without pump casing; partly completedmachinery

Certificate of decontamination

A certificate of decontamination is enclosed bythe customer when returning the product tothe manufacturer to certify that the producthas been properly drained to eliminate anyenvironmental and health hazards arising fromcomponents in contact with the fluid handled.

Close-coupled design

Motor directly fitted to the pump via a flangeor a drive lantern

Discharge line

The line which is connected to the dischargenozzle

Hydraulic system

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

In-line design

Suction and discharge nozzle are arrangedopposite each other on the same axis

Pool of pumps

Pumps which are purchased and storedindependently of their later use

Pump

Machine without drive, additional componentsor accessories

Pump set

Complete pump set consisting of pump, drive,additional components and accessories

Suction lift line/suction head line

The line which is connected to the suctionnozzle

Glossary




1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variantsindicated on the front cover. The manual describes the proper and safe use of thisequipment in all phases 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 numberuniquely identify the pump (set) and serve as identification for all further businessprocesses.

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

Noise characteristics (⇨ Section 4.7 Page 19)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, refer to the sub-sectionsunder Servicing/Maintenance.(⇨ Section 7.5.5 Page 39)

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 Contents

Data sheet Description of the technical data of the pump (set)General arrangement drawing/

outline drawing

Description of mating and installation dimensions

for the pump (set), weightsDrawing of auxiliary connections Description of auxiliary connectionsHydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power input

General assembly drawing1) Sectional drawing of the pump

Sub-supplier product literature1) Operating manuals and other product literaturedescribing 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

Drawing for assembly Sectional drawing for fitting the shaft seal

For accessories and/or integrated machinery components observe the relevantmanufacturer's product literature.

1.5 Symbols

Table 2: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with thestep-by-step instructions

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

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

1 General




Symbol Description

1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General




2 Safety

All 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 Directive

94/9/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 information aboutprotection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 GeneralThis manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent personal injuryand damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the specialist personnel/ operators responsible 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 nottaken into account in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits described in theother applicable documents.(⇨ Section 1.4 Page 6)

▪ Only operate pumps/pump sets which are in perfect technical condition.

▪ Do not operate the pump (set) in partially assembled condition.

▪ Only use the pump to handle the fluids described in the data sheet or productliterature of the pump model.

! DANGER

2 Safety




▪ Never operate the pump without the fluid handled.

▪ Observe the minimum flow rates indicated in the data sheet or product literature(to prevent overheating, bearing damage, etc).

▪ Observe the maximum flow rates indicated in the data sheet or 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 transport, install, operate, maintainand inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved intransport, installation, operation, maintenance and inspection must be clearlydefined by the operator.

Deficits in knowledge must be rectified by means of training and instructionprovided by sufficiently trained specialist personnel. If required, the operator cancommission the manufacturer/supplier to train the personnel.

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

personnel.

2.5 Consequences and risks caused by non-compliance with these 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

▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2 Safety




2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and checkthat the guards function properly.

▪ Do not remove any contact guards during operation.

▪ Provide the personnel with protective equipment and make sure it is used.

▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.

explosive, toxic, hot) so as to avoid any danger to persons and the environment.Adhere to all relevant laws.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

▪ If shutting down the pump does not increase potential risk, fit an emergency-stop control device in the immediate vicinity of the pump (set) during pump setinstallation.

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 resulting damage.

▪ The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughlyfamiliar with the manual.

▪ Only carry out work on the pump (set) during standstill of the pump.

▪ The pump casing must have cooled down to ambient temperature.

▪ Pump pressure must have been released and the pump must have been drained.

▪ When taking the pump set out of service always adhere to the proceduredescribed in the manual.(⇨ Section 6.1.5 Page 27)(⇨ Section 6.3 Page 30)

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

Page 35)

▪ 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.

Only pumps/pump sets marked as explosion-proof and identified as such in the datasheet may be used in potentially explosive atmospheres.

Special conditions apply to the operation of explosion-proof pump sets to ECDirective 94/9/EC (ATEX).Especially adhere to the sections in this manual marked with the Ex symbol and thefollowing sections(⇨ Section 2.10.1 Page 11) to(⇨ Section 2.10.4 Page 12) (⇨ Section

2.10.3 Page 11).

The explosion-proof status of the pump set is only assured if the pump set is used in

accordance with its intended use.

! DANGER

2 Safety




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 TXRefer to the Temperature Limits table for the temperatures permitted for theindividual pump variants. (⇨ Section 2.10.2 Page 11)

An EC manufacturer's declaration is required for the shaft coupling; the shaftcoupling must be marked accordingly.

The motor has its own marking. The marking is maintained on the condition that thetemperatures the pump causes to develop at the motor flange and motor shaft arepermitted by the motor manufacturer.The motors fitted by KSB on pumps with ATEX certification meet this condition.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on the

surface of the pump casing and at the shaft seal.The surface temperature at the pump casing corresponds to the temperature of thefluid handled. If the pump is heated, the operator of the system is responsible forobserving the specified temperature classes and fluid temperature (operatingtemperature).The table below lists the temperature classes and the resulting theoreticaltemperature limits of the fluid handled. (A possible temperature rise in the shaft sealarea has already been taken into account).

The temperature class specifies the maximum permissible temperature at the surfaceof the pump set during operation. For the permissible operating temperature of thepump in question refer to the data sheet.

Table 4: Temperature limits

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

temperatureT1 Temperature limit of the pumpT2 280 °CT3 185 °CT4 120 °CT5 85 °CT6 Only after consultation

with the manufacturer

If the pump is to be operated at a higher temperature, the data sheet is missing or ifthe pump is part of a pool of pumps, contact KSB for the maximum permissibleoperating temperature.

If a pump is supplied without motor (as part of a pool of pumps), the motor specifiedin the pump data sheet must meet the following conditions:

▪ The permissible temperature limits at the motor flange and motor shaft must behigher than the temperatures generated by the pump.

▪ Contact the manufacturer for the actual pump temperatures.

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.

Pump

Shaft coupling

Motor

Motor supplied by theoperator

2 Safety




2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.2.3.1 Page 29) 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

6.2.3.1 Page 29) can be used to check whether an additional heat build-up may leadto a hazardous temperature increase at the pump surface.

2 Safety




3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and

notify KSB or the supplying dealer (as applicable) and the insurer about thedamage in writing immediately.

3.2 Transport

DANGER

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

▷ Always transport the pump (set) in the specified position.

▷ Never attach the suspension arrangement to the free shaft end or the motoreyebolt.

▷ Give due attention to the weight data and the centre of gravity.▷ Observe the applicable local health and safety regulations.

▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.

CAUTION

Incorrect transport of the pumpDamage to the shaft seal!

▷ For transport, lock the pump shaft with a suitable transport lock to prevent anymovement of the shaft.

When transporting the pump without motor, shaft 210 must be locked.

1. Undo screws 914.3.

2. Remove guard 680.

3. Insert lockwashers 931 into the shaft groove.

4. Tighten nuts 920.

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

Fig. 1: Transporting the back pull-out unit





UG 1383724:003/01

Fig. 2: Transporting the back pull-out unit with motor

UG 1383724:001/01

Fig. 3: Transporting the pump

UG 1383724:002/01

Fig. 4: Transporting the pump set

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for pump (set) storage.





CAUTION

Damage during storage by humidity, dirt, or verminCorrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessorieswith waterproof material.

CAUTION

Wet, 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 instructionsin(⇨ Section 6.3.1 Page 30) .

3.4 Return to supplier

1. Drain the pump as per operating instructions.(⇨ Section 7.3 Page 35)

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 (set) leave residues which might lead tocorrosion when coming into contact with atmospheric humidity, or which mightignite when coming into contact with oxygen, the pump set must 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).Always indicate any safety and decontamination measures taken.

NOTE

If required, a blank certificate of decontamination can be downloaded from theKSB web site at: www.ksb.com/certificate_of_decontamination

3.5 Disposal

WARNING

Fluids, consumables and supplies which are hot or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ 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



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

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



3. Dispose of materials in accordance with local regulations or in anothercontrolled manner.





4 Description of the Pump (Set)

4.1 General description

▪ Close-coupled pump with shaft seal

Pump for handling thermal oil or hot water

4.2 Product Information as per Regulation No. 547/2012 (for Water Pumpswith a Maximum Shaft Power of 150 kW) Implementing "Ecodesign"Directive 2009/125/EC

▪ This product is designed for use above 120 °C only.

▪ Further technical data see data sheet.

4.3 Designation

Example: Etabloc 80-160 / 150 2 S Y T

Table 5: Key to the designation

Code DescriptionEtabloc Type series80 Nominal discharge nozzle diameter [mm]160 Nominal impeller diameter [mm]150 Motor rating: kW x 10 (example 15 kW)2 Number of motor polesS Casing made of nodular cast ironY T Thermal oil/hot water variant

4.4 Name plate

991234567 000100 / 01Q 100 m3 /h l H 9 m

1 mm2 /s I

n 2900 U/min l 2008

Aktiengesellschaft

D-67227 Frankenthal

Id-No. 00 117 385 ZN 3804 - C 37 x 52

Etabloc SYT 80-160 / 150 2 SYT1

2

5

4

3

9

8

7

6

Fig. 5: Etabloc SYT/Etaline SYT name plate (example)1 Type series, size and version 2 KSB order number (ten digits)3 Flow rate 4 Speed5 Kinematic viscosity of the fluid

handled6 Order item number (six digits)

7 Consecutive number (two digits) 8 Head9 Year of construction

4.5 Design details

Design

▪ Volute casing pump

▪ Close-coupled design/in-line design





▪ Single-stage

▪ Horizontal/vertical installation

▪ Back pull-out design

▪ Ratings to EN 733

▪ Rigid connection between pump and motor

Pump casing

▪ Radially split volute casing

▪ Replaceable casing wear rings

▪ Volute casing with integrally cast pump feet

▪ In-line design

Impeller type

▪ Closed radial impeller

Shaft seal

▪ Standardised mechanical seal to EN 12756

Bearings

▪ Grease-packed radial ball bearing

▪ Product-lubricated plain bearing

4.6 Configuration and function

1 2 53 4

6 7 8 9 10

Fig. 6: Etaline SYT sectional drawing

1 Clearance gap 2 Discharge nozzle3 Casing cover 4 Drive lantern5 Motor housing 6 Suction nozzle7 Impeller 8 Plain bearing9 Shaft seal 10 Stub shaft

The pump is designed with a radial fluid inlet (suction nozzle) and a radial outlet(discharge nozzle) arranged on the same axis. The hydraulic system is rigidlyconnected to the motor by a shaft coupling.

Etabloc SYT

Etaline SYT

Design





The fluid enters the pump via the suction nozzle (6) and is accelerated outward bythe rotating impeller (7). In the flow passage of the pump casing the kinetic energyof the fluid is converted into pressure energy. The fluid is pumped to the dischargenozzle (2), where it leaves the pump. The clearance gap (1) prevents any fluid fromflowing back from the casing to the suction nozzle. The hydraulic system is closedwith a casing cover (3) at the rear side of the impeller; the stub shaft (10) enters thecasing via the casing cover (3). The shaft passage through the cover is sealed to the

atmosphere with a dynamic shaft seal (9). The stub shaft runs in a plain bearing (8)and the motor's rolling element bearings. The motor housing (5) is linked with thepump casing and the casing cover via the drive lantern (4).

The pump is sealed by a standardised mechanical seal.

4.7 Noise characteristics

Table 6: Surface sound pressure level LpA2)3)

Rated power input PN[kW] Pump set

1450 rpm[dB]

2900 rpm[dB]

0,55 55 -

0,75 56 661,1 57 661,5 58 672,2 59 673 60 684 61 68

5,5 62 707,5 64 7111 65 7315 67 74

18,5 68 7522 69 76

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

▪ Pump

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

▪ Drive lantern guard to EN 294

4.9 Dimensions and weights

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

Function

Sealing

Drive

Contact guard

2) 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 warranted: Add +3 dB for measuring and constructional tolerance.3) Increase for 60 Hz operation, 3500 rpm: +3 dB, 1750 rpm: +1 dB,





5 Installation at Site

5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheresExplosion hazard!Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations.

▷ Observe the information in the data sheet and on the name plates of pump andmotor.

5.2 Checks to be carried out prior to installation

Place of installation

WARNING

Installation on mounting surface which is unsecured and cannot support the loadPersonal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets therequirements of exposure class XC1 to EN 206-1.

▷ The mounting surface must have set and must be completely horizontal andeven.

▷ Observe the weights indicated.

1. Check the structural requirements.All structural work required must have been prepared in accordance with thedimensions stated in the outline drawing/general arrangement drawing.

5.3 Installing the pump set

CAUTION

Ingress of leakage into the motorDamage to the pump!

▷ Never install the pump set with the "motor below".

1. Position the pump set on the foundation and fasten it.

2. Place a spirit level on the discharge nozzle and/or suction nozzle/motor to levelthe pump set.

5.4 Piping

5.4.1 Connecting the piping

DANGER

Excessive 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.

▷ Take appropriate measures to compensate thermal expansion of the piping.





CAUTION

Incorrect 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.

NOTE

It is recommended to install check and shut-off elements in the system, dependingon the type of plant and pump. However, such elements must not obstruct properdrainage or hinder disassembly of the pump.

✓ The suction lift line has been laid with a rising slope, the suction head line with adownward slope towards the pump.

✓ A flow stabilisation section having a length equivalent to at least twice thediameter of the suction flange has been provided upstream of the suction flange.

✓ The nominal diameters of the pipelines are equal to or greater than 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 of new installations).

2. Before installing the pump in the piping, remove the flange covers on thesuction and discharge nozzles of the pump.

CAUTION

Welding beads, scale and other impurities in the pipingDamage to the pump!

▷ Free the piping from any impurities.

▷ If necessary, install a filter.

▷ Comply with the instructions set out in (⇨ Section 7.2.2.2 Page 35).

3. If required, install a filter in the piping (see drawing: Filter in the piping).

1

2

Fig. 7: Filter in the piping

1 Differential pressure gauge 2 Filter

NOTE

It is recommended to install a fine filter made of corrosion-resistant material for therun-in phase of the system.Use a filter with a filter area three times the cross-section of the piping.Conical filters have proved suitable.





NOTE

Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter)made of corrosion-resistant material.Use a filter with a filter area three times the cross-section of the piping.Conical filters have proved suitable.

1. Connect the pump nozzles to the piping.

CAUTION

Aggressive 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

No piping-induced forces and moments (from warped pipelines or thermalexpansion, for example) must act on the pump.

5.4.3 Auxiliary connections

DANGER

Formation of a potentially explosive atmosphere as a result of incompatible fluidsmixing in auxiliary feed linesRisk of burns!Explosion hazard!

▷ Verify compatibility of barrier fluid/quench liquid with fluid handled.

WARNING

Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushingliquid, etc.)Risk of injury from escaping fluid!Risk of burns!Malfunction of the pump!

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

▷ Use the auxiliary connections provided.

5.5 Enclosure/insulation

DANGER

Explosive atmosphere forming due to insufficient ventingExplosion hazard!

▷ Make sure the space between the casing cover/discharge cover and the motorflange is sufficiently vented.

▷ Do not cover the perforated holes of the contact guards at the drive lantern(e.g. by insulation).





WARNING

The volute casing and casing/discharge cover take on the same temperature as thefluid handledRisk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

CAUTION

Heat build-up inside the drive lanternDamage to the bearing!

▷ Never insulate the casing cover and the drive lantern.

5.6 Electrical connection

DANGER

Incorrect electrical installation

Explosion hazard!

▷ For electrical installation, also observe the requirements of IEC 60079-14.

▷ Always connect explosion-proof motors via a motor protection switch.

DANGER

Work on the pump set by unqualified personnelDanger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualifiedelectrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

WARNING

Incorrect 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.

NOTE

A motor protection device is recommended.

5.6.1 Setting the time relay

CAUTION

Switchover between star and delta on three-phase motors with star-delta startingtakes too long.Damage to the pump (set)!

▷ Keep switch-over intervals between star and delta as short as possible.

Table 7: Time relay settings for star-delta starting:

Motor rating Y time to be set

≤ 30 kW < 3 s> 30 kW < 5 s





5.6.2 Earthing

DANGER

Electrostatic chargingExplosion hazard!Fire hazard!

Damage to the pump set!▷ Connect the PE conductor to the earthing terminal provided.

5.6.3 Connecting the motor

NOTE

In compliance with IEC 60034-8, three-phase motors are always wired for clockwiserotation (looking at the motor shaft stub).The pump's direction of rotation is indicated by an arrow on the pump.

1. Match the motor's direction of rotation to that of the pump.

2. Observe the manufacturer's product literature supplied with the motor.

5.7 Checking the direction of rotation

DANGER

Temperature increases 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.

WARNING

Hands inside the pump casingRisk of injuries, damage to the pump!

▷ Always disconnect the pump set from the power supply and secure it againstunintentional start-up before inserting your hands or other objects into thepump.

CAUTION

Drive and pump running in the wrong direction of rotationDamage to the pump!

▷ Refer to the arrow indicating the direction of rotation on the pump.

▷ Check the direction of rotation. If required, check the electrical connection andcorrect the direction of rotation.

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

1. Start the pump set and stop it again immediately to determine the motor'sdirection of rotation.

2. Check the direction of rotationThe 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 commissioning/starting up the pump set, make sure that the followingconditions are met:

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

▪ The pump has been primed with the fluid to be handled.

▪ The direction of rotation has been checked.(⇨ Section 5.7 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 30) have been carried out.

▪ The lockwashers have been pulled out of the shaft groove.

6.1.2 Priming and venting the pump

DANGER

Formation of a potentially explosive atmosphere as a result of incompatible fluidsmixing in auxiliary feed linesRisk of burns!Explosion hazard!

▷ Verify compatibility of barrier fluid/quench liquid with fluid handled.

DANGER

Risk of potentially explosive atmosphere inside the pumpExplosion hazard!

▷ 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.

DANGER

Shaft seal failure caused by insufficient lubrication

Hot or toxic fluid could escape!Damage to the pump!

▷ Before starting up the pump set, vent the pump and suction line and primeboth with the fluid to be handled.

NOTE

In the run-in phase of the system, it is recommended to vent the pump repeatedlyvia the screw plug on the bearing bracket.

1. Vent the pump and suction line and prime both with the fluid to be handled.The pump can be primed with the fluid handled from the system via the inletline.Remove screw plug 903.1 to prime and vent the bearing housing.

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





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

WARNING

Hot water escaping under pressure when the vent plug is openedRisk of electric shock!Risk of scalding!

▷ Protect the electric components against escaping fluid.▷ Wear protective clothing (e.g. gloves).

4. Close the vent hole (connection 6D or 6D.1/.2/.3) with screw plug 903.1 or 903.2(see table below).

Table 8: Installation of Etabloc SYT/Etaline SYT

Installation examples Connections

Installation of Etabloc SYT

1M 6D

6B

8B

8B

1M 6B

6D

UG 1383724:004/01

U G

1 3 8 3 7 2 4 : 0 0 5 / 0 1 1M Connection for pressure gauge

6B Fluid drain6D Fluid priming and venting8B Leakage drain

Installation of Etaline SYT

1M.16D.1

1M.26B.1

8B

6D.3

6D.3 8B

1M.26D.2

6B.2

1M.16D.1

UG 1383985:001/01

U G 1

3 8 3

9 8 5 : 0 0 2 / 0 1 1M.1/.2 Connection for pressure gauge

6B1/.2. Fluid drain6D.1/.2/.3 Fluid priming and venting8B Leakage drain

6.1.3 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits if the pump isoperated with the suction and/or discharge line closed.Explosion hazard!Leakage of hot or toxic fluids!

▷ Never operate the pump with the shut-off elements in the suction line and/ordischarge line closed.

▷ Only start up the pump set with the discharge-side shut-off element slightly orfully open.





DANGER

Excessive temperatures due to dry running or excessive gas content in the fluidhandledExplosion hazard!Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Prime the pump as specified.

▷ Always operate the pump within the permissible operating range.

CAUTION

Abnormal noises, vibrations, temperatures or leakageDamage to the pump!

▷ Switch off the pump (set) immediately.

▷ Eliminate the causes before returning the pump set to service.

✓ The system piping has been cleaned.

✓ The pump, suction line and inlet tank, if any, have been vented and primed with

the fluid to be handled.✓ The filling and venting lines have been closed.

CAUTION

Start-up against open discharge lineMotor overload!

▷ Make sure the motor has sufficient power reserves.

▷ Use a soft starter.

▷ Use speed control.

1. Fully open the shut-off element in the suction head/suction lift line.

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

3. 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.

6.1.4 Checking the shaft seal

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

6.1.5 Shutdown

CAUTION

Heat build-up inside the pumpDamage to the shaft seal!

▷ Depending on the type of installation, the pump set requires sufficient after-run time – with the heat source switched off – until the fluid handled hascooled down.

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

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

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

Mechanical seal





NOTE

If the discharge line is equipped with a non-return or check valve, the shut-offelement in the discharge line may remain open, provided the site's requirementsand regulations are taken into account and observed.

For prolonged shutdown periods:

1. Close the shut-off element in the suction line.2. Close the auxiliary connections.

If the fluid handled is fed in under vacuum, also supply the shaft seal withbarrier fluid during standstill.

CAUTION

Risk 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

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled andspeedExplosion hazard!Hot or toxic fluid could escape!

▷ Comply with the operating data indicated in the data sheet.

▷ Never use the pump for handling fluids it is not designed for.

▷ Avoid prolonged operation against a closed shut-off element.

▷ Never operate the pump at temperatures, pressures or rotational speedsexceeding those specified in the data sheet or on the name plate unless thewritten consent of the manufacturer has been obtained.

6.2.1 Ambient temperature

CAUTION

Operation 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 9: Permissible ambient temperaturesPermissible ambient temperature Value

Maximum 40 °CMinimum See data sheet.





6.2.2 Frequency of starts

DANGER

Excessive 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). Provided that the start-ups are evenly spaced over the period indicated, thepump set can be started not more than 15 times per hour with the discharge-sidegate valve slightly open.

CAUTION

Re-starting while motor is still running downDamage to the pump (set)!

▷ Do not re-start the pump set before the pump rotor has come to a standstill.

6.2.3 Fluid handled

6.2.3.1 Flow rate

Table 10: Flow rate

Minimum flow rate Maximum flow rate

≈ 15 % of Qopt. 4) See hydraulic characteristic curves

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

×

×

×

Table 11: Key

Symbol Description Unit

c Specific heat capacity J/kg Kg Gravitational constant m/s²

H Pump head mTf Temperature of the fluid handled °C

To

Temperature at the casing surface °C

Pump efficiency at duty point -Temperature difference K

6.2.3.2 Density of the fluid handled

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

4) Duty point at maximum efficiency





CAUTION

Impermissibly high density of the fluid handledMotor overload!

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

▷ Make sure the motor has sufficient power reserves.

6.2.3.3 Abrasive fluids

Do not exceed the maximum permissible solids content specified in the data sheet.When the pump handles fluids containing abrasive substances, increased wear of thehydraulic system and shaft seal are to be expected. In this case, reduce the commonlyrecommended inspection intervals.

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains installed

✓ Sufficient fluid is supplied for the operation check run of the pump.

1. Start up the pump (set) regularly between once a month and once every 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) is removed and stored

✓ The pump has been properly drained (⇨ Section 7.3 Page 35) and the safety

instructions for dismantling the pump have been observed.(⇨ Section 7.4.1 Page

35)

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 and discharge nozzles.It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).

3. Oil or grease all exposed machined parts and surfaces of the pump (withsilicone-free oil or grease, food-approved, if required) to protect them againstcorrosion.Observe the additional instructions.(⇨ Section 3.3 Page 14)

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

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

6.4 Returning to service

For returning the pump to service observe the sections on commissioning/start-up (⇨Section 6.1 Page 25) and the operating limits.(⇨ Section 6.2 Page 28)

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service.(⇨ Section 7 Page 32)

WARNING

Failure to re-install or re-activate protective devicesRisk of personal injury from moving parts or escaping fluid!

▷ As soon as the work is complete, re-install and/or re-activate any safety-relevantand protective devices.





NOTE

If the pump has been out of service for more than one year, replace all elastomerseals.





7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Improperly serviced pump setRisk of explosion!Damage to the pump set!

▷ Service the pump set regularly.

▷ Prepare a maintenance schedule with special emphasis on the shaft seal.

The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughly familiarwith the manual.

WARNING

Unintentional starting of pump setRisk of injury by moving parts!

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

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

WARNING

Fluids and supplies posing a health hazard and/or hot fluids or suppliesRisk of injury!

▷ Observe all relevant laws.

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

▷ Decontaminate pumps which handle fluids posing a health hazard.

WARNING

Insufficient stabilityRisk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to preventtipping or falling over.

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.

NOTE

All maintenance, service and installation work can be carried out by KSB Service orauthorised workshops. Find your contact in the attached "Addresses" booklet or onthe Internet at "www.ksb.com/contact".

Never use force when dismantling and reassembling the pump set.



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

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



7.2 Maintenance/inspection

7.2.1 Supervision of operation

DANGER

Risk of potentially explosive atmosphere inside the pumpExplosion hazard!

▷ 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.

DANGER

Incorrectly serviced shaft sealExplosion hazard!Leakage of hot, toxic fluids!

Damage to the pump set!Risk of burns!Fire hazard!

▷ Regularly service the shaft seal.

DANGER

Excessive temperatures as a result of bearings running hot or defective bearing sealsExplosion hazard!Fire hazard!Damage to the pump set!

▷ Regularly check the rolling element bearings for running noises.

DANGER

Incorrectly serviced barrier fluid systemExplosion hazard!Fire hazard!Damage to the pump set!Hot and/or toxic fluids could escape!

▷ Service the barrier fluid system regularly.

▷ Monitor the barrier fluid pressure.

CAUTION

Increased 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.

CAUTION

Impermissibly high temperature of fluid handledDamage to the pump!

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

▷ Observe the temperature limits in the data sheet and in the section on

operating limits.(⇨ Section 6.2 Page 28)





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

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

▪ Check the shaft seal. (⇨ Section 6.1.4 Page 27)

▪ Check the static seals for 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.

▪ 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 motorhousing).

CAUTION

Operation outside the permissible bearing temperature

Damage to the pump!▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured

on the outside of the motor housing).

NOTE

After commissioning, increased temperatures may occur at grease-lubricated rollingelement bearings due to the running-in process. The final bearing temperature isonly reached after a certain period of operation (up to 48 hours depending on theconditions).

7.2.2 Inspection work

DANGER

Excessive temperatures caused by friction, impact or frictional sparksExplosion hazard!Fire hazard!Damage to the pump set!

▷ Regularly check the cover plates, plastic components and other guards ofrotating parts for deformation and sufficient distance from rotating parts.

7.2.2.1 Checking the clearance gaps

For checking the clearance gaps remove the impeller, if required.If the clearance gap is larger than permitted (see the following table), fit new casing

wear ring 502.1 and, if applicable, 502.2.The clearance gaps given refer to the diameter.

Table 12: Clearance gaps between impeller and casing / between impeller and casingcover

Etabloc SYT/Etaline SYT

New 0.3 mmMaximum permissible enlargement 0.9 mm





7.2.2.2 Cleaning filters

CAUTION

Insufficient inlet pressure due to clogged filter in the suction lineDamage to the pump!

▷ Monitor contamination of filter with suitable means (e.g. differential pressure

gauge).▷ Clean filter at appropriate intervals.

7.2.2.3 Checking the plain bearing clearances

The bearing clearance must not exceed the permissible maximum clearance (see thetable below).

If the permissible maximum clearance is exceeded, fit a new plain bearing 310.

Maximum clearance, plain bearing Nominal clearance, plain bearing

SU 25 0.35 mm 0.08 - 0.13 mm

7.3 Drainage/cleaning

WARNING

Fluids, consumables and supplies which are hot or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

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

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

1. Use connection 6B to drain the fluid handled (see drawing of auxiliaryconnections).

2. Always flush the pump if it has been used for handling noxious, explosive, hotor other hazardous fluids.Always flush and clean the pump before transporting it to the workshop.Provide a cleaning record for the pump.

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

DANGER

Insufficient preparation of work on the pump (set)

Risk of injury!▷ Properly shut down the pump set.(⇨ Section 6.1.5 Page 27)

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

▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 35)

▷ Close any auxiliary connections.

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

WARNING

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

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

qualified personnel.





WARNING

Hot surfaceRisk of injury!

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

WARNING

Improper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to moveheavy assemblies or components.

WARNING

Thin metal foil used as carrier material in joint ringsRisk of injury (cuts)!

▷ Wear protective clothing.

▷ Always use an appropriate tool to remove joint rings.

Observe the general safety instructions and information(⇨ Section 7.1 Page 32).

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

For dismantling and reassembly observe the exploded views and the generalassembly drawing.

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

NOTE

After a prolonged period of operation the individual components may be hard topull off the shaft. If this is the case, use a brand name penetrating agent and/or - ifpossible - an appropriate puller.

NOTE

It is recommended to place a drip pan under the pump along its entire length tocollect any fluid escaping during dismantling.

7.4.2 Preparing the pump set

1. De-energise the pump set and secure it against unintentional start-up.

2. Reduce pressure in the piping by opening a consumer installation.

3. Disconnect and remove all auxiliary pipework.

7.4.3 Dismantling the motor

WARNING

Motor tipping overRisk of crushing hands and feet!

▷ Suspend or support the motor to prevent it from tipping over.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 35) to(⇨ Section 7.4.2 Page

36) have been observed/carried out.

1. Depending on the pump/motor size, unscrew the bolts that fix the motor footto the foundation.

2. Undo pan head screws 914.3 and remove guard 680.

3. Remove hexagon nuts 920.





4. Insert both lockwashers 931 into the groove in shaft 210.

5. Tighten hexagon nuts 920.

6. Undo socket head cap screw 914.01.

7. Undo hexagon nut 920.7.

8. Remove the motor.

7.4.4 Removing the back pull-out unit

WARNING

Back pull-out unit tipping overRisk of squashing hands and feet!

▷ Suspend or support the back pull-out unit at the pump end.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 35) to(⇨ Section 7.4.3 Page

36) have been observed/carried out.

1. If required, suspend or support the back pull-out unit to prevent it from tippingover.

2. Unbolt support foot 183 (Etabloc SYT).3. Unscrew hexagon nut 920.1 at the discharge cover.

4. Pull the back pull-out unit out of the volute casing.

5. Remove and dispose of gasket 411.4.

6. Place the back pull-out unit on a clean and level surface.

7.4.5 Removing the impeller

✓ The notes and steps stated in(⇨ Section 7.4.1 Page 35) to(⇨ Section 7.4.4 Page 37)

have been observed/carried out.

✓ The back pull-out unit is kept in a clean and level assembly area.

1. Undo impeller nut 920.3 (right-hand thread).

2. Remove impeller 230 with an impeller removal device.

3. Place impeller 230 on a clean and level surface.

4. Remove key 940.1 from shaft 210.

7.4.6 Removing the mechanical seal



✓ The back pull-out unit is kept in a clean and level assembly area.

1. Undo nuts 920.6.

2. Undo seal cover 471 and pull out of bearing housing 350 together with shaft

210.

3. Remove circlip 932.1 and disc 550.2.

4. Remove the rotating part of the mechanical seal (primary ring) from shaft 210.

5. Pull seal cover 471 off shaft 210.

6. Remove the stationary part of the mechanical seal (mating ring) from the sealcover.

7.4.7 Removing the plain bearing

1. Press plain bearing 310 out of bearing housing 350.





7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

WARNING

Improper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to moveheavy assemblies or components.

CAUTION

Improper 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 assembly

drawing or exploded view.

Check O-rings for any damage and replace by new O-rings, if required.

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

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

Avoid the use of assembly adhesives, if possible.

Never use quick-setting adhesives (cyanoacrylate adhesives).

Coat the locating surfaces of the individual components with graphite or similarbefore reassembly.

For reassembly, tighten all screws and bolts as specified in this manual.

7.5.2 Fitting the plain bearing

1. Press plain bearing 310 carefully into bearing housing 350 until it will not goany further.

7.5.3 Installing the mechanical seal

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

▪ Work cleanly and accurately.

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

▪ Prevent any damage to the sealing surfaces or O-rings.✓ The notes and steps stated in (⇨ Section 7.5.1 Page 38) have been observed/

carried out.

✓ The individual parts have been placed in a clean and level assembly area.

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

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

✓ The sealing surfaces have been cleaned.

1. Clean the shaft and the mating ring carrier and gently remove any deposits.

Sequence

Sealing elements

Assembly adhesives

Tightening torques

Fitting themechanical seal





CAUTION

Elastomers in contact with oil/greaseShaft seal failure!

▷ Use water as assembly lubricant.

▷ Never use oil or grease as assembly lubricant.

2. Carefully insert the mating ring into seal cover 471.Make sure to apply pressure evenly.

3. Slide the seal cover onto shaft 210. Secure shaft axially using a suitable device.

4. Slide the rotating assembly of the mechanical seal (primary ring) onto the shaft.Slide on disc 550.2 and secure with circlip 932.1.

5. Push shaft 210 into bearing housing 350 and tighten nuts 920.6.

7.5.4 Fitting the impeller



✓ The pre-assembled unit (motor, shaft, drive lantern, discharge cover) as well as

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

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



1. Insert key 940.1 and push impeller 230 onto shaft 210.

2. Fasten impeller nut 920.3, spring washer 930 and disc 550.3 (see table:Tightening torques for screwed connections on the pump).

7.5.5 Installing the back pull-out unit

WARNING

Back pull-out unit tipping overRisk of squashing hands and feet!

▷ Suspend or support the back pull-out unit at the pump end.





1. If required, suspend or support the back pull-out unit to prevent it from tippingover.

2. Fit new gasket 411.4 into the recess of volute casing 102.

3. Push the back pull-out unit into volute casing 102.4. Depending on the pump size and motor size, fit support foot 183.

5. Fasten hexagon nut 920.1 at volute casing 102.

7.5.6 Mounting the motor

DANGER

Incorrect shaft connectionExplosion hazard!

▷ Connect the shafts between pump and motor as described in this manual.





54

1 2 3

6

1167:455/4

Fig. 8: Fitting the motor shaft stub on the shaft

1 Shaft slot 2 Keyway of the motor shaft end3 Slot of the taper lock ring 4 Taper lock ring5 Motor shaft 6 Shaft



1. Fit the motor shaft stub on shaft 210 and make sure that the keyway of themotor shaft end aligns with the slot in shaft 210 and that both are located

opposite the slot of taper lock ring 515 (see illustration: Fitting the motor shaftstub on the shaft).

2. Tighten socket head cap screw 914.1.

3. Tighten hexagon nut 920.7.

4. Unscrew hexagon nut 920.

902 920

931

UG 1263983:008/03

Fig. 9: Removing the lockwashers

902 Studs 920 Hexagon nuts931 Lockwasher

1. Pull both lockwashers 931 out of the groove in shaft 210.

2. Tighten hexagon nuts 920.

3. Fit guards 680.3 and 680.4.





7.6 Tightening torques

X F E

AXB E

UG 1263983:009/03

Fig. 10: Tightening points at the pump

Table 13: Tightening torques for screwed connections at the pump

Location Thread size Rated torque[Nm]

A M8

M10

20

38B M12 x 1.5 55E M10

M12

M16

38

55

130F M6

M8

15

38X 1/8

3/8

25

80

7.7 Spare parts stock

7.7.1 Ordering spare parts

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

▪ Type series

▪ Material variant

▪ Size

▪ Seal code

▪ KSB order number▪ Order item number

▪ Consecutive number

▪ Year of construction

Refer to the name plate for all data. (⇨ Section 4.4 Page 17)

Also specify the following data:

▪ Description

▪ Part No.

▪ Quantity of spare parts

▪ Shipping address

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





Refer to the exploded view or general assembly drawing for part numbers anddescriptions. (⇨ Section 9.1 Page 46)

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

Table 14: Quantity of spare parts for recommended spare parts stock

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

Quantity of spare parts

210 Shaft5) 1 1 1 2 2 2 20 %

230 Impeller (including casing wear ring502.2)

1 1 1 2 2 2 20 %

310 Plain bearing 2 3 4 5 7 9 100 %350 Bearing housing6) - - - - - 1 2 off

433 Mechanical seal 1 1 2 2 2 3 25 %502.1/.2 Casing wear ring 2 2 2 3 3 4 25 %411.1-/.5 Joint rings (set)7) 4 6 8 8 9 12 150 %

5) Shaft 210 complete, consisting of shaft 210, taper lock ring 515, socket head cap screw 914.1, hexagon nut 920.3, key

940.1, spring washer 930, disc 550.36) Bearing housing 350 complete, consisting of plain bearing 310, bearing housing 350, joint ring 411.1, screw plug 903.1,

fitting 720.27) Joint rings (set) consisting of joint ring 411.1-.5





7.7.3 Interchangeability of Etabloc SYT/Etaline SYT pump components

Components featuring the same number in a column are interchangeable.

Etabloc SYT Etaline SYT

Shut

Description

Vuecan

Dshgco

Shaft (with taper lock ring)

Impe

Panbn

Bnhn

Mehcase

Sco

Cnwrnuosd

Cnwrndshgsd

Part No.

1 1210

2 3 3 4 4 51

52

Motor 80 90 100/112 132 160 180

32-125.1/... 25 ○ 1 2 3 ⃞ ￭￭￭ ○ 1 1 1 1 1 ✘

32-160.1/... 40-160/... 25 ○ 2 ⃞ 3 4 ⃞ ⃞ ⃞ 1 1 1 1 1 1 232-200.1/... 40-200/... 25 ○ 4 2 ⃞ 4 5 ⃞ ⃞ 2 1 1 1 1 1 232-160/... 50-160/... 25 ○ 2 2 ⃞ 4 5 ⃞ ⃞ 1 1 1 1 1 1 232-200/... 50-200/... 25 ○ 4 2 3 ⃞ 5 ⃞ ⃞ 2 1 1 1 1 1 240-160/... 65-160/... 25 ○ 2 2 3 4 5 ⃞ ⃞ ○ 1 1 1 1 ○ 240-200/... 65-200/... 25 ○ 4 2 3 ⃞ 5 6 ⃞ ○ 1 1 1 1 ○ 250-160/... 80-160/... 25 ○ 2 ⃞ 3 ⃞ 5 6 ⃞ ○ 1 1 1 1 2 250-200/... 80-200/... 25 ○ 4 ⃞ 3 4 ⃞ 6 7 ○ 1 1 1 1 2 265-160/... 100-160/... 25 ○ 3 ⃞ 3 4 ⃞ 6 ⃞ ○ 1 1 1 1 3 465-200/... 25 ○ ○⃞ ⃞ 4 ⃞ 6 7 ○ 1 1 1 1 3 4

80-160/... 100-170/... 25 ○ 3 ⃞ 3 4 ⃞ 6 7 ○ 1 1 1 1 ○ 4

Table 15: Key to the symbols

Symbol Description

✘ Component not fitted○ Components differ1 Same number in a column means same component⃞ When other frequencies or power reserves are required for this

pump/motor combination, please contact KSB.￭ This pump/motor combination is not possible

Table 16: Motor/rating

Motor Rating

80 .../054, .../074, .../072, .../112

90 .../114, .../154, .../152, .../222100 .../224, .../304, .../302112 .../404, .../402132 .../554, .../754, .../552, .../752160 .../1104, .../1504, .../1102, .../1502, .../1852180 .../1854, .../2204, .../2202





8 Trouble-shooting

WARNING

Improper remedial work on the pump (set)Risk of injury!

▷ For any work performed in order to remedy faults on the pump (set) observe

the relevant information given in this operating manual or the productliterature provided by the accessories manufacturers.

If problems occur that are not described in the following table, consultation withKSB’s customer service is required.

Pump delivers insufficient flow rate

Motor is overloaded

Excessive pump discharge pressure

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Impermissible rise of temperature inside the pumpTable 17: Trouble-shooting

A B C D E F G H Possible cause Remedy8)

✘ Pump delivers against an excessivelyhigh pressure.

Re-adjust to duty point.

Check system for impurities.Fit a larger impeller.9)

✘ ✘ ✘ Pump and/or piping are not completelyvented and/or primed.

Vent and/or prime.Clean vent hole.

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

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

✘ ✘ ✘ Suction lift is too high/NPSH available

(positive suction head) is too low.

Check/alter fluid level.

Install pump at a lower level.Fully open the shut-off element in the suctionline.Change suction line, if the friction losses inthe suction line are too high.Check any strainers installed.Observe permissible speed of pressure fall.

✘ Wrong direction of rotation Check the electrical connection of the motorand the control system, if any.

✘ ✘ Wear of internal components Replace worn components by new ones.

✘ ✘ ✘ Pump back pressure is lower thanspecified in the purchase order.

Re-adjust to duty point.In the case of persistent overloading, turndown impeller.9)

✘ Density or viscosity of fluid handled

higher than stated in purchase order

9)

✘ Defective gasket Fit new gasket between volute casing anddischarge cover.

✘ Worn shaft seal Fit new shaft seal.

✘ ✘ ✘ Pump is warped or sympatheticvibrations in the piping.

Check the piping connections and securefixing of pump; if required, reduce distancesbetween the pipe clamps.Fix the pipelines using anti-vibration material.

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

A

B

C

D

E

F

G

8)

Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.9) Contact KSB.

8 Trouble-shooting




A B C D E F G H Possible cause Remedy8)

✘ Rotor out of balance Clean the impeller.Re-balance the impeller.

✘ Defective bearing(s) Fit new bearing(s).

✘ ✘ Flow rate is too low Increase the minimum flow rate.

✘ Defective gasket Fit new gasket between volute casing anddischarge cover or between discharge coverand bearing bracket.

✘ Gasket not pre-loaded sufficiently Increase pre-loading of gasket at operatingtemperature:

1. Close the valves on the discharge andsuction side.

2. Allow the pump set to cool down to atemperature below the boiling point ofthe fluid handled.

3. Re-tighten hexagon nuts 920.1 and 920.2at the discharge cover.

4. Start up the pump set.(⇨ Section 6 Page25)

8) 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 Exploded views and list of components

9.1.1 Etabloc SYT exploded view

Fig. 11: Etabloc SYT exploded view

[ Supplied in packaging units only( ) Not available as individual spare part

Table 18: List of components

Part No. Description Part No. Description

102 Volute casing 720.1/.2 Fitting163 Discharge cover 800 Motor

183 Support foot 831 Fan impeller210 Shaft 901.3/.4 Hexagon head bolt230 Impeller 902/.1-.4 Stud310 Plain bearing 903.1/.2 Screw plug341 Drive lantern 914.1/.2 Socket head cap screw350 Bearing housing 914.3 Pan head screw411.1-.5 Joint ring 920/.1-.3/.6-.8 Hexagon nut433 Mechanical seal 920.4 Blind rivet nut471 Seal cover 930 Spring washer502.1./.2 Casing wear ring 931 Lockwasher515 Taper lock ring 932.1 Circlip550.2/.3 Disc 940.1 Key554 Lockwasher 970.1 Name plate680 Guard

9 Related Documents




9.1.2 Etaline SYT exploded view

Fig. 12: Etaline SYT exploded view

[ Supplied in packaging units only( ) Not available as individual spare part

Table 19: List of components

Part No. Description Part No. Description

102 Volute casing 720.1/.2 Fitting163 Discharge cover 800 Motor210 Shaft 831 Fan impeller230 Impeller 902/.1-.4 Stud310 Plain bearing 903.1/.2 Screw plug341 Drive lantern 914.1/.2 Socket head cap screw350 Bearing housing 914.3 Pan head screw411.1/-.5 Joint ring 920/.1-.3/.6-.7 Hexagon nut433 Mechanical seal 920.4 Blind rivet nut471 Seal cover 930 Spring washer502.1/.2 Casing wear ring 931 Lockwasher515 Taper lock ring 932.1 Circlip550.2/.3/.5 Disc 940.1 Key554 Lockwasher 970.1 Name plate680 Guard

9 Related Documents




10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Etabloc, Etabloc SYT, Etaline, Etaline SYT, Etaline Z,Etachrom NC, Etachrom BC, Etanorm, Etanorm SYT,

Etanorm GPV/CPV, Etaprime L, Etaprime B/BN, Vitachrom

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

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

– Pump (set): Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100,

– EN 809/A1

Person authorised to compile the technical file: Name

FunctionAddress (company)Address (Street, No.)Address (post or ZIP code, city) (country)

The EC Declaration of Conformity was issued in/on:

Place, date

..............................10).............................

Name

FunctionCompanyAddress

Address

10) A signed, legally binding declaration of conformity is supplied with the product.

10 EC Declaration of Conformity




11 Certificate of Decontamination

Type ................................................................................................................................Order number/

Order item number11) ................................................................................................................................

Delivery date ................................................................................................................................

Field of application: ................................................................................................................................

Fluid pumped11): ................................................................................................................................

Please tick where applicable11):

⃞⃞⃞⃞

Radioactive Explosive Corrosive Toxic

⃞⃞⃞⃞

Harmful Bio-hazardous Highly flammable Safe

Reason for return11): ................................................................................................................................

Comments: ................................................................................................................................

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

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/ placing at your disposal.

We hereby declare that this product is free from hazardous chemicals, biological or radioactive substances.

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

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

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

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

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

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

11) Required fields

11 Certificate of Decontamination




Index

AAbrasive fluids 30Auxiliary connections 22

BBearing temperature 34

CCertificate of decontamination 49Clearance gaps 34Commissioning/start-up 25

DDesign 17Designation 17Direction of rotation 24Dismantling 36Disposal 15

EExplosion protection 10, 20, 22, 23, 24, 25, 26, 27, 28,29, 32, 33, 34, 39

FFilter 35Frequency of starts 29

IInstallation

Installation on a foundation 20Installation at site 20Intended use 8Interchangeability of pump components 43

MMechanical seal 27Misuse 9Monitoring equipment 11

NNoise characteristics 19

OOperating limits 8, 28Order number 6Ordering spare parts 41Other applicable documents 6

PPartly completed machinery 6Permissible forces at the pump nozzles 22Piping 21Preservation 15, 30Priming and venting 25Product description 17

RReassembly 36, 38Return to supplier 15Returning to service 30

SSafety 8Safety awareness 9Scope of supply 19Servicing/Maintenance 32Shaft seal 18Shutdown 30Spare parts stock 42Start-up 27Storage 15, 30

TTemperature limits 11Tightening torques 41Transport 13Trouble-shooting 44

Index






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