66
Thermal Oil / Hot Water Pump Etanorm SYT Installation/Operating Manual Order number:

Etanorm SYT Installation/Operating Manual · Etanorm SYT Installation/Operating Manual Order number: ... Installation/Operating Manual Etanorm SYT Original operating manual KSB Aktiengesellschaft

Embed Size (px)

Citation preview

Thermal Oil / Hot Water Pump

Etanorm SYT

Installation/OperatingManual

Order number:

KULLANICI
Text Box
URSAN POMPA LTD. STI.

Installation/Operating Manual Etanorm SYTOriginal operating manual KSB Aktiengesellschaft Pegnitz All rights reserved. Contents provided herein must neither be distributed, copied, reproduced,processed for any other purpose, nor otherwise transmitted to a third party without KSB´s expresswritten consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 17.03.2010

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 ......................................................................... 16

4.6 Noise characteristics ...................................................................................... 17

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

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

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

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

5.2 Checking the site before installation ........................................................... 19

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

5.4 Piping ............................................................................................................. 21

Contents

Etanorm SYT 3 of 66

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

5.6 Checking the coupling alignment ................................................................ 25

5.7 Aligning the pump and motor ..................................................................... 26

5.8 Electrical connection ..................................................................................... 28

5.9 Checking the direction of rotation .............................................................. 28

6 Commissioning/Start-up/Shutdown ................................................. 30

6.1 Commissioning/start-up ................................................................................ 30

6.2 Operating limits ............................................................................................ 33

6.3 Shutdown/storage/preservation ................................................................... 35

6.4 Returning to service after storage ............................................................... 35

7 Servicing/Maintenance ...................................................................... 37

7.1 Safety regulations ......................................................................................... 37

7.2 Servicing/inspection ...................................................................................... 37

7.3 Drainage/disposal .......................................................................................... 40

7.4 Dismantling the pump set ............................................................................ 41

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

7.6 Tightening torques ....................................................................................... 48

7.7 Spare parts stock ........................................................................................... 49

8 Trouble-shooting ............................................................................... 53

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

9.1 Exploded views and lists of components ..................................................... 55

9.2 Wiring diagrams for double-acting mechanical seal .................................. 61

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

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

Index .................................................................................................. 64

Contents

4 of 66 Etanorm SYT

Glossary

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

Back pull-out unitPump without pump casing; partly completedmachinery

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.

Discharge lineThe line which is connected to the dischargenozzle

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

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

Glossary

Etanorm SYT 5 of 66

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 numberclearly identify the pump (set) and serve as identification for all further businessprocesses.

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

Noise characteristics (⇨ Section 4.6 Page 17)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, please refer to the sub-sections under Servicing/Maintenance. (⇨ Section 7.5.5 Page 47)

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist 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 66 Etanorm SYT

Symbol Description1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

Etanorm SYT 7 of 66

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 meeting all local regulations which are not taken intoaccount 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

8 of 66 Etanorm SYT

▪ 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

Etanorm SYT 9 of 66

▪ 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 6.1.7 Page 32)

▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3Page 40)

▪ 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 30)

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 66 Etanorm SYT

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 only. Example of such marking: II 2 G c TX Refer 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 must be considered separately.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on thesurface of the pump casing, at the shaft seal and in the bearing areas. The 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 Maximum permissible fluidtemperature

T1 Temperature limit of the pumpT2 280 ℃T3 185 ℃T4 120 ℃T5 85 ℃T6 Only after consultation

with the manufacturer

In the following cases, and if ambient temperatures are higher, contact themanufacturer.

Compliance with temperature class T5 is warranted for the area of the rollingelement bearings based on an ambient temperature of 40°C, assuming that thepump set is properly serviced and operated and that the surfaces in the bearing areaare freely exposed to the atmosphere.

If temperature class T6 has to be complied with, special measures may have to betaken with regard to the bearing temperatures.

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

Pump

Shaft coupling

Motor

Temperature class T5

Temperature class T6

2 Safety

Etanorm SYT 11 of 66

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.

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 34) refer to water and water-like liquids. Longer operating periods with these fluids and at the flow ratesindicated will not cause an additional increase in the temperatures on the pumpsurface. However, if the physical properties of the fluids handled are different fromwater, it is essential to check if an additional heat build-up may occur and if theminimum flow rate must therefore be increased. The calculation formula in (⇨Section 6.2.3 Page 34) can be used to check if an additional heat build-up may leadto a hazardous temperature increase at the pump surface.

2 Safety

12 of 66 Etanorm SYT

3 Transport/Temporary Storage/Disposal

3.1 Transport

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

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

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

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

▷ Observe the local accident prevention regulations.

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

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

Fig. 1: Transporting the pump

max. 90 °

Fig. 2: Transporting the complete pump set

max. 90 °

Fig. 3: Transporting the pump on the baseplate

3.2 Storage and preservation

If commissioning is to take place some time after delivery, we recommend that 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.

3 Transport/Temporary Storage/Disposal

Etanorm SYT 13 of 66

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. (⇨ Section 6.3.1 Page 35)

3.3 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 40)

2. Always flush and clean the pump, particularly if it has been used for 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 63)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.

3 Transport/Temporary Storage/Disposal

14 of 66 Etanorm SYT

4 Description of the Pump (Set)

4.1 General description

Pump for handling fluids in heat transfer systems (DIN 4754) or for hot watercirculation

4.2 Designation

Example: EN 80 - 160 S Y T 8

Table 5: Key to the designation

Code DescriptionEtanorm Type series80 Nominal discharge nozzle diameter [mm]160 Nominal impeller diameter [mm]S Casing made of nodular cast ironYT Thermal oil/hot water variant8 Shaft seal, mechanical seal AQ1VGG

4.3 Name plate

Etanorm SYT 80-250 SYT89970857065 000100 / 01Q 160 m3/h l H 77 m

16.5 mm2/sn 2970 1/min l 2009

AktiengesellschaftD-67227 Frankenthal

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

1

2

5

4

3

9

8

76

Fig. 4: Name plate Etanorm SYT

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 Head

9 Year of construction

4.4 Design details

Design

▪ Volute casing pump

▪ Back pull-out design

▪ Horizontal installation

▪ Single-stage

▪ Dimensions and ratings to EN 733

Pump cas ing

▪ Radially split volute casing

4 Description of the Pump (Set)

Etanorm SYT 15 of 66

▪ Replaceable casing wear rings

▪ Volute casing with integrally cast pump feet

Impel ler type

▪ Closed radial impeller with multiply curved vanes

Bearings

Motor-end bearing:

▪ Radial ball bearing

▪ Grease lubrication

Table 6: Rolling element bearing

Shaft unit Code25 6306-2RS/C3 PCP-LLG35 6309-2RS/C3 PCP-LLG55 6311-2RS/C3 PCP-LLG

▪ Grease-packed for life (high melting point grease), with sealing washers on bothsides

Pump-end bearing:

▪ Plain bearing

▪ Product-lubricated

Shaft seal

▪ Standardised mechanical seal to EN 12756

Optional:

▪ Double-acting mechanical seal

4.5 Configuration and function

1 2 3 4 5

6 7 8 9 10

Fig. 5: Sectional drawing

4 Description of the Pump (Set)

16 of 66 Etanorm SYT

1 Clearance gap 2 Discharge nozzle3 Casing cover 4 Shaft5 Bearing bracket 6 Suction nozzle7 Impeller 8 Plain bearing9 Shaft seal 10 Rolling element bearing, motor

end

The pump is designed with an axial fluid inlet and a radial outlet. The hydraulicsystem runs in its own bearings and is connected to the motor by a shaft coupling.

The fluid enters the pump axially via a suction nozzle (6) and is accelerated outwardin a cylindrical flow by the rotating impeller (7). The flow profile of the pump casingconverts the kinetic energy of the fluid into pressure energy. The fluid is pumped tothe discharge nozzle (2), where it leaves the pump. The clearance gap (1) preventsany fluid from flowing back from the casing into the suction nozzle. The hydraulicsystem is closed with a casing cover (3) at the rear side of the impeller; the shaft (4)enters the casing via the casing cover. The shaft passage through the bearing bracketis sealed towards the atmosphere with a shaft seal (9). The shaft runs in a plainbearing and a rolling element bearing (8 and 10); the bearings are supported by abearing bracket (5) linked with the pump casing and/or casing cover.

The pump is sealed by a standardised mechanical seal.If the pump is fitted with a double-acting mechanical seal, the pump is connected toa quench pot. The unpressurised quench liquid supply serves to prevent any leakageof the fluid handled towards the atmosphere. It also prevents any contact betweenthe fluid and the lubricating grease of the rolling element bearing, especially forfluids which have a tendency to creep.

4.6 Noise characteristics

Table 7: Sound pressure level measured at surfaces LpA2) 3)

Rated powerinput

PN

[kW]

Pump Pump set1450 rpm

[dB]2900 rpm

[dB]1450 rpm

[dB]2900 rpm

[dB]

0.55 47 48 55 640.75 48 50 56 661.1 50 52 57 661.5 52 54 58 672.2 54 56 59 673 55 57 60 684 57 59 61 68

5.5 59 61 62 707.5 60 62 64 7111 62 64 65 7315 64 66 67 74

18.5 65 67 68 7522 66 68 69 7630 67 70 70 7737 68 71 71 7845 69 72 73 7855 70 73 74 7975 72 75 75 8090 73 76 76 81

110 74 77 77 81

Design

Function

Sealing

2) Spatial average to ISO 3744 and EN 12639. Applies to non-cavitating pump operation in the range Q/Qopt = 0.8 - 1.1. Ifnoise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.

3) Increase for 60 Hz operation: 3500 rpm, +3 dB; 1750 rpm +1 dB

4 Description of the Pump (Set)

Etanorm SYT 17 of 66

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

CAUTIONExcessive temperature due to insufficient coolingDamage to the pump set!

▷ Only use electric motors whose cooling air flows in axial direction towards thepump end.

▷ Ensure an air velocity ≥ 3 m/s measured in the area of the bearing end plate onthe drive side.

▷ If the pump is driven by a combustion engine, only use engines whose coolingair is sucked in or blown out via the coupling/flywheel.

▪ Flexible coupling with or without spacer

▪ Coupling guard to EN 294

DANGERRisk of ignition by frictional sparksRisk of explosion!

▷ Choose a coupling guard material that is non-sparking in the event ofmechanical contact (see DIN EN 13463-1).

▷ If any coupling parts are made of aluminium, a brass coupling guard must beused.

▪ Channel section steel or folded steel plate

Optional:

▪ Cast baseplate (to ISO 3661)

▪ As required

4.8 Dimensions and weights

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

Drive

Shaft coupling

Contact guard

Baseplate

Special accessories

4 Description of the Pump (Set)

18 of 66 Etanorm SYT

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 Checking the site before installation

Place of instal lat ion

WARNINGInstallation on foundations which are unsecured and cannot support the loadPersonal injury and damage to property!

▷ Make sure the foundation concrete is of sufficient strength (min. X0 toDIN 1045).

▷ Only place the pump set on a foundation whose concrete has set firmly.

▷ Only place the pump set on a horizontal and level surface.

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

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

5.3 Installing the pump set

Always install the pump set in horizontal position.

DANGERExcessive temperatures due to improper installationExplosion hazard!

▷ Install the pump in horizontal position to ensure self-venting of the pump.

5.3.1 Installation on the foundation

12

43Fig. 6: Fitting the shims

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

800 mm4 Foundation bolt

✓ The foundation has the required strength and characteristics.

5 Installation at Site

Etanorm SYT 19 of 66

✓ The foundation has been prepared in accordance with the dimensions given inthe outline drawing / general arrangement drawing.

1. Position the pump set on the foundation and use a spirit level to align shaft anddischarge nozzle.Permissible deviation: 0.2 mm/m

2. If required, use shims (2) to adjust the height. Always fit shims immediately to the left and right of the foundation bolts (4)between the baseplate/foundation frame and the foundation itself.For a bolt-to-bolt clearance > 800 mm, fit additional shims (3) halfway betweenthe adjoining holes. All shims must lie perfectly flush.

3. Insert the foundation bolts (4) into the holes provided.

4. Use concrete to set the foundation bolts (4) into the foundation.

5. Wait until the concrete has set firmly, then align the baseplate.

6. Tighten the foundation bolts (4) evenly and firmly.

NOTEFor baseplates more than 400 mm wide it is recommended to grout the baseplate withlow-shrinkage concrete.

NOTEFor baseplates made of grey cast iron it is recommended to grout the baseplate with low-shrinkage concrete.

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

5.3.2 Installation without foundation

4

1

2

3

Fig. 7: Adjusting the levelling elements

1, 3 Locknut 2 Levelling nut4 Levelling element

✓ The installation surface has the required strength and characteristics.

1. Position the pump set on the levelling elements (4) and align it with the help of aspirit level (on the shaft/discharge nozzle).

2. To adjust any differences in height, loosen the bolts and locknuts (1, 3) of thelevelling elements (4).

3. Turn the levelling nut (2) until any differences in height have been compensated.

4. Re-tighten the locknuts (1, 3) at the levelling elements (4).

5 Installation at Site

20 of 66 Etanorm SYT

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 22)

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

CAUTIONIncorrect earthing during welding work at the pipingDestruction of rolling element bearings (pitting effect)!

▷ Never earth the electric welding equipment on the pump or baseplate.

▷ Prevent current flowing through the rolling element bearings.

NOTEIt is recommended to install check and shut-off elements in the system, depending on thetype of plant and pump. However, such elements must not obstruct proper drainage orhinder disassembly of the pump.

✓ The suction lift line/suction head line has been laid with a rising/downward slopetowards the pump.

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

✓ To prevent excessive pressure losses, adapters to larger diameters have a diffuserangle of approximately 8°.

✓ 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 the suctionand discharge nozzles of the pump.

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

▷ Free the piping from any impurities.

▷ If necessary, install a filter.

▷ Observe the instructions in (⇨ Section 7.2.2.3 Page 40).

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

5 Installation at Site

Etanorm SYT 21 of 66

1

2Fig. 8: Filter in the piping

1 Differential pressure gauge 2 Filter

NOTEUse a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) ofcorrosion-resistant material.Use a filter three times the diameter of the piping.Conical filters have proved suitable.

4. Connect the pump nozzles with the piping.

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

FV

FVmax

2FH

FHmax

2

Mtmax

Mt

2

+ + - 1

FV

FH

FH

FVFH

FH

Fig. 9: Forces and moments at the pump nozzles

The following condition must be met:

∑IFVI, ∑IFHI, and ∑IMtI are the sums of the absolute values of the respective loadsacting on the nozzles. Neither the load direction nor the load distribution among thenozzles are taken into account in these sums.

Table 8: Forces and moments at the pump nozzles4)

Size t = 20 °C t = 300 °CF Vmax

[kN]

FHmax

[kN]

Mtmax

[kNm]

FVmax

[kN]

FHmax

[kN]

Mtmax

[kNm]32-125.1 3.65 2.59 0.58 3.15 2.24 0.532-160.1 3.56 2.51 0.51 3.08 2.17 0.44

4) The values indicated apply to nodular cast iron JS1025.

5 Installation at Site

22 of 66 Etanorm SYT

Size t = 20 °C t = 300 °CF Vmax

[kN]

FHmax

[kN]

Mtmax

[kNm]

FVmax

[kN]

FHmax

[kN]

Mtmax

[kNm]32-200.1 3.6 2.43 0.51 3.11 2.10 0.4432-160 3.56 2.51 0.51 3.08 2.17 0.4432-200 3.65 2.43 0.51 3.11 2.10 0.4432-250 3.65 2.43 0.51 3.11 2.10 0.4440-160 3.81 2.67 0.81 3.29 2.31 0.740-200 3.81 2.67 0.81 3.29 2.31 0.740-250 4.21 2.92 0.58 3.64 2.52 0.540-315 4.09 2.84 0.55 3.54 2.46 0.4850-160 3.97 2.67 1.11 3.43 2.31 0.9650-200 4.21 2.92 1.11 3.64 2.52 0.9650-250 4.58 3.32 0.87 3.96 2.87 0.7550-315 4.54 3.24 0.84 3.92 2.80 0.7365-160 4.42 3.04 1.16 3.82 2.63 165-200 5.27 3.89 1.79 4.55 3.36 1.5565-250 5.27 3.89 1.79 4.55 3.36 1.5565-315 5.43 4.05 1.62 4.69 3.5 1.480-160 5.43 4.05 1.91 4.69 3.5 1.6580-200 6.08 4.74 2.44 5.25 4.1 2.180-250 6.16 4.78 2.44 5.32 4.13 2.180-315 6.28 4.86 2.78 5.43 4.20 2.4100-160 7.7 6.28 3.6 6.65 5.43 3.1100-200 7.7 6.28 3.6 6.65 5.43 3.1100-250 7.86 6.48 3.47 6.79 5.6 3100-315 7.57 6.16 3.18 6.54 5.32 2.75125-200 9.5 8.5 5.1 8.21 7.34 4.4125-250 9.84 8.71 5.1 8.5 7.53 4.4125-315 9.32 8.1 4.75 8.05 7 4.1125-400 9.32 7.9 4.63 7.97 6.83 4150-315 10.53 9.72 5.67 9.1 8.4 4.9150-400 10.53 9.72 5.67 9.1 8.4 4.9

5.4.3 Vacuum balance line

NOTEWhere fluid has to be pumped out of a vessel under vacuum, it is recommended to installa vacuum balance line.

The following rules apply to vacuum balance lines:

▪ Minimum nominal line diameter 25 mm.

▪ The line extends above the highest permissible fluid level in the vessel.

5 Installation at Site

Etanorm SYT 23 of 66

1 2

5

43

6Fig. 10: Vacuum balance system

1 Vessel under vacuum 2 Vacuum balance line3 Shut-off valve 4 Swing check valve5 Main shut-off valve 6 Vacuum-tight shut-off valve

NOTEAn additional line fitted with a shut-off valve – from the pump discharge nozzle to thebalance line – facilitates venting of the pump before start-up.

5.4.4 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.

Fig. 11: Connections 24E and 24A

24 A Outlet quench liquid 24 E Inlet quench liquid

For designs with double-acting mechanical seal, use connections 24A and 24E toconnect the pump set to the quench system.Connect the quench pot in accordance with the manufacturer's instructions.

Double-acting mechanicalseal

5 Installation at Site

24 of 66 Etanorm SYT

5.5 Protective equipment

DANGERAn explosive atmosphere forms due to insufficient ventingExplosion hazard!

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

WARNINGThe volute casing and casing/discharge cover take on the same temperature as the fluidhandledRisk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

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

▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover.

5.6 Checking the coupling alignment

DANGERImpermissible temperatures at the coupling or bearings caused by misalignment of thecouplingExplosion hazard!

▷ Make sure that the coupling is correctly aligned at all times.

CAUTIONMisalignment of pump and motor shaftsDamage to pump, motor and coupling!

▷ Always check the coupling after the pump has been installed and connected tothe piping.

▷ Also check the coupling of pump sets supplied with pump and motor mountedon the same baseplate.

BA

A B

a) b)

B

B

A

A

1

1 2 21

1

Fig. 12: a) Checking the coupling alignment and b) Aligning a spacer-type coupling

1 Straight-edge 2 Wedge gauge

✓ The coupling guard and step guard, if any, have been removed.

5 Installation at Site

Etanorm SYT 25 of 66

1. Loosen the support foot and re-tighten it without transmitting any stresses andstrains.

2. Place the straight-edge axially on both coupling halves.

3. Leave the straight-edge in this position and turn the coupling by hand. The coupling is correctly aligned if the distances A) and B) to the respective shaftsare the same at all points around the circumference.The radial and axial deviation of both coupling halves must not exceed 0.1 mmduring standstill as well as at operating temperature and under inlet pressure.

4. Check the distance between the two coupling halves around the circumference. The coupling is correctly aligned if the distance between the two coupling halvesis the same at all points around the circumference.The radial and axial deviation of both coupling halves must not exceed 0.1 mmduring standstill as well as at operating temperature and under inlet pressure.

5.7 Aligning the pump and motor

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

5.7.1 Motors with levelling screw

1

3

2

Fig. 13: Motor with levelling screw

1 Hexagon head bolt 2 Levelling screw3 Locknut

✓ The coupling guard and step guard, if any, have been removed.

1. Check the coupling alignment.

2. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at thebaseplate.

3. Turn the levelling screws (2) by hand or by means of an open-jawed wrench untilthe coupling alignment is correct.

4. Re-tighten the hexagon head bolts (1) at the motor and the locknuts (3) at thebaseplate.

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

WARNINGUnprotected rotating couplingRisk of injury by rotating shafts!

▷ Always operate the pump set with a coupling guard.If the customer specifically requests not to include a coupling guard in KSB'sdelivery, then the operator must supply one!

▷ Observe all relevant regulations for selecting a coupling guard.

5 Installation at Site

26 of 66 Etanorm SYT

DANGERRisk of ignition by frictional sparksExplosion hazard!

▷ Choose a coupling guard material that is non-sparking in the event ofmechanical contact (see DIN EN 13463-1).

6. Re-install the coupling guard and step guard, if any.

7. Check the distance between coupling and coupling guard.The coupling guard must not touch the coupling.

5.7.2 Motors without levelling screw

Any differences in the centre heights of the pump and motor shafts are compensatedby means of shims.

1Fig. 14: Pump set with shim

1 Shim

✓ The coupling guard and step guard, if any, have been removed.

1. Check the coupling alignment.

2. Unscrew the hexagon head bolts at the motor.

3. Insert shims underneath the motor feet until the difference in shaft centre heighthas been compensated.

4. Re-tighten the hexagon head bolts.

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

WARNINGUnprotected rotating couplingRisk of injury by rotating shafts!

▷ Always operate the pump set with a coupling guard.If the customer specifically requests not to include a coupling guard in KSB'sdelivery, then the operator must supply one!

▷ Observe all relevant regulations for selecting a coupling guard.

DANGERRisk of ignition by frictional sparksExplosion hazard!

▷ Choose a coupling guard material that is non-sparking in the event ofmechanical contact (see DIN EN 13463-1).

6. Re-install the coupling guard and step guard, if any.

7. Check the distance between coupling and coupling guard.The coupling guard must not touch the coupling.

5 Installation at Site

Etanorm SYT 27 of 66

5.8 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.

5.9 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.

▷ Separate the pump from the motor to check the direction of rotation.

WARNINGHands or objects inside the pump casingRisk of injuries, damage to the pump!

▷ Never insert your hands or any other objects into the pump.

▷ Check that the inside of the pump is free from any foreign objects.

CAUTIONIncorrect direction of rotation with non-reversible mechanical sealDamage to the mechanical seal and leakage!

▷ Separate the pump from the motor to check the direction of rotation.

5 Installation at Site

28 of 66 Etanorm SYT

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 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 is running in the wrong direction of rotation, check the electricalconnection of the motor and the control system, if necessary.

5 Installation at Site

Etanorm SYT 29 of 66

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 and the bearing bracket have been primed with the fluid to behandled. (⇨ Section 6.1.3 Page 30)

▪ The quench system, if any, has been filled with the quench liquid. (⇨ Section 6.1.2Page 30)

▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 28)

▪ All auxiliary connections required are connected and operational.

▪ The lubricants have been checked. (⇨ Section 7.2.3 Page 40)

▪ After prolonged shutdown of the pump (set), the activities described in (⇨Section 6.4 Page 35) have been carried out.

6.1.2 Quench liquid supply

The quench liquid has to be compatible with and suitable for mixing with the fluidhandled.

For synthetic heat transfer oils, it is advisable to use a mineral oil based thermal fluidor a different mineral oil as the quench liquid.Heat transfer oils of the diphyl group are not suitable as quench liquids.

6.1.3 Priming and venting the pump

DANGERRisk of potentially explosive atmosphere inside the pumpExplosion hazard!

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

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.

1. Remove screwed plug 903.1 (connection 6D) to prime and vent the bearinghousing.

2. Vent the pump and suction line and prime both with the fluid to be handled.Via the inlet line the pump can be primed with fluid to be handled from thesystem.

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

4. Fully open all auxiliary feed lines (barrier fluid, flushing liquid, etc), if applicable.

5. Open the shut-off element, if any, in the vacuum balance line and close thevacuum-tight shut-off element, if any. (⇨ Section 5.4.3 Page 23)

Permissible quench liquids

6 Commissioning/Start-up/Shutdown

30 of 66 Etanorm SYT

WARNINGHot 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).

NOTEFor design-inherent reasons a remaining gas volume in the hydraulic system cannot beexcluded after the pump has been primed for commissioning/start-up. However, once themotor is started up the pumping effect will immediately fill this volume with the fluidhandled.

6. Close the vent hole (connection 6D) with screwed plug 903.1.

6.1.4 Final check

1. Remove the coupling guard and step guard, if any.

2. Check the coupling alignment; re-align the coupling, if required. (⇨ Section 5.6Page 25)

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

4. Re-install the coupling guard and step guard, if any.

5. Check the distance between coupling and coupling guard.The coupling guard must not touch the coupling.

NOTEThe coupling alignment check must be repeated after the pump has reached operatingtemperature.

6.1.5 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 as specified.

▷ Always operate the pump within the permissible operating range.

6 Commissioning/Start-up/Shutdown

Etanorm SYT 31 of 66

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

▷ Switch off the pump (set) immediately.

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

✓ The system piping has been cleaned.

✓ The pump, suction line and inlet tank, if any, have been vented and primed withthe fluid to be handled.

✓ The filling and venting lines have been closed.

CAUTIONStart-up against open discharge lineMotor overload!

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

▷ Use a soft starter.

▷ Use speed control.

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

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

3. Start up the motor.

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

CAUTIONMisalignment of pump and couplingDamage to pump, motor and coupling!

▷ When the operating temperature has been reached, switch off the pump setand check the coupling alignment.

5. Check the coupling alignment and re-align the coupling, if required.

6.1.6 Checking the shaft seal

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

NOTEMechanical seal failure may result in the fluid handled penetrating into the rolling elementbearing, where it may damage the grease fill. Whenever fluid leakage occurs, the rollingelement bearing should therefore also be replaced as a precaution. This is particularlyimportant when the pump is handling synthetic heat transfer fluids.

6.1.7 Shutdown

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

▷ Depending on the type of installation, the pump set requires sufficient after-runtime – with the heat source switched off – until the fluid handled has cooleddown.

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

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

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

Mechanical seal

6 Commissioning/Start-up/Shutdown

32 of 66 Etanorm SYT

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.

For prolonged shutdown periods:

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

2. Close the auxiliary connections. If the fluid handled is fed in under vacuum, also supply the shaft seal with barrierfluid during standstill.

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

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

6.2 Operating limits

DANGERNon-compliance with operating limits for pressure, temperature and speedExplosion hazard!Hot or toxic fluid may escape!

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

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

▷ Never operate the pump at temperatures exceeding those specified in the datasheet or on the name plate unless the written consent of the manufacturer hasbeen obtained.

6.2.1 Ambient temperature

Observe the following parameters and values during operation:

Table 9: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °CMinimum See data sheet.

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

▷ Observe the specified limits for permissible ambient temperatures.

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).

6 Commissioning/Start-up/Shutdown

Etanorm SYT 33 of 66

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). 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.

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

Table 10: Flow rate

Temperature range (t) Minimum flow rate Maximum flow rate-30 to +350 °C ≈ 25 % of QOpt See hydraulic characteristic

curves

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

Table 11: Key

Symbol Description Unitc Specific heat capacity J/kg Kg Gravitational constant m/s²H Pump head mTf 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 Commissioning/Start-up/Shutdown

34 of 66 Etanorm SYT

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, plain bearing and shaft seal are to be expected. In this case, reducethe intervals commonly recommended for servicing and maintenance.

6.2.6 Permissible speed

Table 12: Permissible speed for pump control systems with continuously variablespeed adjustment

n min

[rpm]nmax

[rpm]800 -

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 once a month or once every three months forapproximately 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 40) and the safetyinstructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page41)

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 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 30) and the operating limits. (⇨ Section 6.2 Page 33)

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. (⇨ Section 7 Page 37)

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

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

6 Commissioning/Start-up/Shutdown

Etanorm SYT 35 of 66

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

6 Commissioning/Start-up/Shutdown

36 of 66 Etanorm SYT

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!

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

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

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

DANGERRisk 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.

7 Servicing/Maintenance

Etanorm SYT 37 of 66

DANGERExcessive 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.

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 33)

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

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

▪ Check the shaft seal.

▪ Check the static seals for leakages.

▪ Check the bearings for running noises.Vibrations, noise and an increase in current input occurring during 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.

▪ Check the quench liquid level.Make sure the quench pot always contains sufficient quench liquid.

NOTEIf the liquid level in the quench pot rises, fluid from the pump has mixed with the quenchliquid, which indicates leakage at the pump-end mechanical seal. During start-up it isnormal for the liquid level in the quench pot to rise until the operating temperature hasbeen reached.

NOTEIf the liquid level in the quench pot drops rapidly, this indicates leakage at the drive-endmechanical seal. In this case, the quench liquid could mix with the grease of rollingelement bearing 321 and affect the lubrication. Check the rolling element bearing andreplace it, if required.

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

7 Servicing/Maintenance

38 of 66 Etanorm SYT

CAUTIONOperation outside the permissible bearing temperatureDamage to the pump!

▷ The rolling element bearing temperature of the pump (set) must never exceed90 °C (measured on the outside of the bearing bracket).

NOTEAfter commissioning, increased temperatures may occur at grease-lubricated rollingelement bearings due to the running-in process. The final bearing temperature is onlyreached after a certain period of operation (up to 48 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 coupling guard, plastic components and other guards ofrotating parts for deformation and sufficient distance from rotating parts.

7.2.2.1 Checking the coupling

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

7.2.2.2 Checking the clearance gaps

Clearance gaps between impel ler and cas ing

For checking the clearance gaps remove the impeller, if required. (⇨ Section 7.4.5Page 42)If the clearance gap is larger than permitted (see the following table), replace casingwear rings 502.1 and/or 502.2 with new ones.The clearance gaps given refer to the diameter.

Table 13: Clearance gaps between impeller and casing / between impeller and casingcover

Permissible clearance gap in[mm]

New 0.3Maximum permissible enlargement 0.9

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 Servicing/Maintenance

Etanorm SYT 39 of 66

Plain bearing c learances

Table 14: Plain bearing clearances in mm

Shaft unit Permissible clearance

[mm]New Maximum permissible

enlargement25 0.08 - 0.13 0.3535 0.08 - 0.13 0.455 0.08 - 0.13 0.4

7.2.2.3 Cleaning filters

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

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

▷ Clean filter in appropriate intervals.

7.2.3 Lubricating the rolling element bearing

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

▷ Regularly check the bearing seal.

The bearings are delivered packed for life with a special high-temperature grease.

7.2.3.1 Intervals

Under normal operating conditions the grease-packed rolling element bearing willrun for 15,000 operating hours. Under unfavourable operating conditions (e.g. highroom temperature, high atmospheric humidity, dust-laden air, aggressive industrialatmosphere etc.), check the rolling element bearing earlier and replace it, if required.

7.2.4 Lubricating the plain bearing

The pump-end plain bearing is lubricated by the fluid handled. It is maintenance-free.

7.3 Drainage/disposal

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. For draining the fluid handled use connection 6B (see drawing of auxiliaryconnections).

2. If noxious, explosive, hot or other hazardous fluids have been handled, flush thepump.

7 Servicing/Maintenance

40 of 66 Etanorm SYT

Always flush and clean the pump before transporting it to the workshop. Providea cleaning record for the pump.

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 7.1 Page 37)

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

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

NOTEAll maintenance, service and installation work can be carried out by KSB Service. Findyour contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/contact".

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

▷ Properly shut down the pump set. (⇨ Section 6.1.7 Page 32)

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

▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 40)

▷ Close any auxiliary connections.

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

NOTEAfter a prolonged period of operation the individual parts may be hard to pull off theshaft. If this is the case, use a brand name penetrating agent and/or - if possible - anappropriate pull-off device.

7.4.2 Preparing the pump set

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

2. Disconnect and remove all auxiliary pipework.

3. Remove the coupling guard.

4. Remove the coupling spacer, if any.

7 Servicing/Maintenance

Etanorm SYT 41 of 66

7.4.3 Dismantling the motor

NOTEFor pump sets with spacer-type couplings, the back pull-out unit can be removed whilethe motor remains bolted to the baseplate.

1. Disconnect the motor from the power supply.

2. Unbolt the motor from the baseplate.

3. Shift the motor to separate it from the pump.

WARNINGMotor tipping overRisk of squashing hands and feet!

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

7.4.4 Removing the back pull-out unit

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.3 Page42) have been observed/carried out.

✓ On pump sets without spacer-type coupling, the motor has been removed.

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

▷ Suspend or support the bearing bracket at the pump end.

1. If required, suspend or support bearing bracket 330 to prevent it from tippingover.

2. Unbolt support foot 183 from the baseplate.

3. Undo nuts 920.1 at the volute casing.

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

5. Remove and dispose of joint ring 411.4.

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

▷ Wear protective clothing.

▷ Always use an appropriate tool to remove joint rings.

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

7.4.5 Removing the impeller

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.4 Page42) 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 keys 940.1 from shaft 210.

7 Servicing/Maintenance

42 of 66 Etanorm SYT

7.4.6 Dismantling the shaft seal

7.4.6.1 Removing the pump assembly from the bearing bracket — all shaft units

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.5 Page42) have been observed/carried out.

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

1. Undo nuts 920.2.

2. Pull bearing bracket 330 out of discharge cover 163.

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

▷ Wear protective clothing.

▷ Always use an appropriate tool to remove joint rings.

3. Remove and dispose of joint ring 411.3.

4. Remove bearing cover 360.

5. Remove circlip 932.2.

6. Press shaft 210 out of bearing bracket 330.

7.4.6.1.1 Dismantling a single-acting mechanical seal — shaft units 25 and 35

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.6.1 Page43) have been observed/carried out.

1. Remove circlip 932.1 and support disc 550.2.

2. Pull bearing 321 off shaft 210.

3. Remove support disc 550.1 and seat ring holder 476.

4. Press the seat ring of mechanical seal 433 out of seat ring holder 476.

5. Remove the rotating assembly of mechanical seal 433 (spring-loaded ring) fromshaft 210.

7.4.6.1.2 Dismantling a single-acting mechanical seal — shaft unit 55

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.6.1 Page43) have been observed/carried out.

1. Remove circlip 932.4 and support disc 550.5.

2. Remove the rotating assembly of mechanical seal 433 (spring-loaded ring) fromthe shaft.

3. Remove seat ring holder 476.

4. Press the seat ring of mechanical seal 433 out of seat ring holder 476.

7.4.6.1.3 Dismantling a double-acting mechanical seal — shaft units 25 and 35

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.6.1 Page43) have been observed/carried out.

1. Remove circlip 932.1 and support disc 550.2.

2. Pull bearing 321 off shaft 210.

3. Remove support disc 550.1 and seat ring holder 476.

4. Press the seat ring of mechanical seal 433.2 out of seat ring holder 476.

5. Remove spacer sleeve 525.

7 Servicing/Maintenance

Etanorm SYT 43 of 66

6. Remove the rotating assembly of mechanical seal 433.2 (spring-loaded ring) fromthe shaft.

7. Remove circlip 932.5 and support disc 550.6.

8. Remove seat ring holder 476.1.

9. Press the seat ring of mechanical seal 433.1 out of seat ring holder 476.1.

10. Remove the rotating assembly of mechanical seal 433.1 (spring-loaded ring) fromthe shaft.

7.4.6.1.4 Dismantling a double-acting mechanical seal — shaft unit 55

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.6.1 Page43) have been observed/carried out.

1. Remove circlip 932.4 and support disc 550.5.

2. Remove the rotating assembly of mechanical seal 433.1 (spring-loaded ring) fromthe shaft.

3. Remove seat ring holder 476.1.

4. Press the seat ring of mechanical seal 433.1 out of seat ring holder 476.1.

5. Remove spacer sleeve 525.

6. Remove circlip 932.5 and support disc 550.6.

7. Remove the rotating assembly of mechanical seal 433.2 (spring-loaded ring) fromthe shaft.

8. Remove seat ring holder 476.

9. Press the seat ring of mechanical seal 433.2 out of seat ring holder 476.

7.4.7 Removing the plain bearing

Removing the carbon bearing

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.6.1 Page43) have been observed/carried out.

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

Removing the S iC bearing

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.6.1 Page43) have been observed/carried out.

1. Remove circlip 932.7.

2. Pull bearing sleeve 529 off shaft 210.

3. Remove circlip 932.6.

4. Push bush 540.1 and bearing bush 381 out of bearing bracket 330 from the driveend.

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 or exploded view.

Sequence

7 Servicing/Maintenance

44 of 66 Etanorm SYT

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.

Should an assembly adhesive be required after all, use a commercially availablecontact adhesive (e.g. "Pattex") or sealant (e.g. HYLOMAR or Epple 33).

Only apply adhesive at selected points and in thin layers.

Never use quick-setting adhesives (cyanoacrylate adhesives).

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

For reassembly, tighten all screws/bolts as specified in this manual. (⇨ Section 7.6Page 48)

7.5.2 Installing the plain bearing

Fitt ing the carbon bear ing

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

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

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

✓ The sealing surfaces have been cleaned.

1. Press plain bearing 310 carefully into bearing bracket 330 until it will not go anyfurther.

F itt ing the S iC bearing

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

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

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

✓ The sealing surfaces have been cleaned.

1. Push bearing sleeve 529 onto shaft 210.

2. Fit circlip 932.7.

3. Fit O-rings 412.3 at both sides of bearing bush 381.

4. Carefully press bearing bush 381 into bearing bracket 330.

5. Fit bush 540.1.

6. Fit circlip 932.6.

7.5.3 Installing the shaft seal

Always observe the following rules when installing the mechanical seal:

▪ Work cleanly and accurately.

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

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

7.5.3.1 Installing a single-acting mechanical seal — shaft units 25 and 35

1. Clean the seat ring location in seat ring holder 476.

2. Carefully insert the seat ring of mechanical seal 433 into seat ring holder 476. Press it in evenly.

3. Slide the rotating assembly of the mechanical seal (spring-loaded ring) onto shaft210.

Seal elements

Assembly adhesives

Tightening torques

Installing the mechanicalseal

7 Servicing/Maintenance

Etanorm SYT 45 of 66

4. Fit seat ring holder 476 with O-Ring 412.1.

5. Fit support disc 550.1.

6. Press radial ball bearing 321 onto the shaft and secure it with support disc 550.2and circlip 932.1.

7.5.3.2 Installing a single-acting mechanical seal — shaft unit 55

1. Clean the seat ring location in seat ring holder 476.

2. Carefully insert the seat ring of mechanical seal 433 into seat ring holder 476.Make sure to apply pressure evenly.

3. Fit seat ring holder 476 with O-Ring 412.1.

4. Slide the rotating assembly of the mechanical seal (spring-loaded ring) onto shaft210.

5. Fit support disc 550.5 and circlip 932.4.

7.5.3.3 Installing a double-acting mechanical seal — shaft units 25 and 35

1. Clean the seat ring location of seat ring holders 476 and 476.1.

2. Insert the seat rings of mechanical seals 433.1 and 433.2 into seat ring holders476 and 476.1.Press them in evenly.

3. Slide the rotating assembly of the mechanical seal 433.1 (spring-loaded ring)onto shaft 210.

4. Fit seat ring holder 476.1 with O-Ring 412.2.

5. Fit circlip 932.5 and support disc 550.6.

6. Slide the rotating assembly of mechanical seal 433.2 (spring-loaded ring) ontoshaft 210.

7. Fit spacer sleeve 525.

8. Fit seat ring holder 476 with O-Ring 412.1.

9. Fit support disc 550.1.

10. Press radial ball bearing 321 onto the shaft and secure it with support disc 550.2and circlip 932.1.

7.5.3.4 Installing a double-acting mechanical seal — shaft unit 55

1. Clean the seat ring location of seat ring holders 476 and 476.1.

2. Insert the seat rings of mechanical seals 433.1 and 433.2 into seat ring holders476 and 476.1. Press them in evenly.

3. Slide the rotating assembly of mechanical seal 433.2 (spring-loaded ring) ontoshaft 210.

4. Fit circlip 932.5 and support disc 550.6.

5. Fit spacer sleeve 525 with seat ring holder 476.1 and O-Ring 412.2.

6. Slide the rotating assembly of mechanical seal 433.1 (spring-loaded ring) ontoshaft 210.

7. Fit circlip 932.4 and support disc 550.5.

7.5.3.5 Installing the shaft assembly in the bearing bracket — all shaft units

1. Carefully press the shaft assembly into bearing bracket 330.

2. Fit circlip 932.2.

3. Fit bearing cover 360.

7 Servicing/Maintenance

46 of 66 Etanorm SYT

7.5.4 Fitting the impeller

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 44) to (⇨ Section 7.5.3 Page45) have been observed/carried out.

✓ The assembled bearing bracket as well as the individual parts are kept in a cleanand level assembly area.

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

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

✓ The sealing surfaces have been cleaned.

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

2. Fasten impeller nut 920.3, spring washer 930 and disc 550.3, if any (see table:Tightening torques for screwed connections at the pump (⇨ Section 7.6 Page48)).

7.5.5 Installing the back pull-out unit

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

▷ Suspend or support the bearing bracket at the pump end.

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 44) to (⇨ Section 7.5.4 Page47) have been observed/carried out.

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

✓ The sealing surfaces have been cleaned.

✓ For back pull-out units without coupling, install the coupling in accordance withthe manufacturer's instructions.

1. Insert new joint ring 411.4 into volute casing 102.

2. If required, prevent the back pull-out unit from tipping over, e.g. by suspendingor supporting it. Then push it into volute casing 102.

3. Tighten nut 920.1 at the volute casing. Observe the tightening torques.

4. Fasten support foot 183 to the baseplate with a foundation bolt.

7.5.6 Mounting the motor

NOTESteps 1 and 2 do not apply to versions with spacer-type coupling.

1. Shift the motor to connect it to the pump via the coupling.

2. Fasten the motor to the baseplate.

3. Align the pump. (⇨ Section 5.7 Page 26)

4. Connect the motor to the power supply (refer to manufacturer's productliterature).

7 Servicing/Maintenance

Etanorm SYT 47 of 66

7.6 Tightening torques

7.6.1 Tightening torques for the pump

Fig. 15: Tightening points at the pump

Table 15: Tightening torques for screwed connections at the pump

Position Thread size Rated torque5)

[Nm]901.2 M12 50902.1/920.1 M10 35

M12 50902.2/920.2 M8 20

M10 35920.3 M12 x1.5 55

M24 x 1.5 130M30 x 1.5 170

7.6.2 Tightening torques for the pump set

1215:5/2

1 2 3 466

5

Fig. 16: Tightening points at the pump set

Table 16: Tightening torques for the pump set

Position Thread size Ratedtorque

[Nm]

Description

1 M12

M16

M20

30

75

75

Pump on baseplate

2 M12 303 M24 x 1.5

M36 x 1.5

140

140

Levelling screws in baseplate

5) Valid for unlubricated threads

7 Servicing/Maintenance

48 of 66 Etanorm SYT

Position Thread size Ratedtorque

[Nm]

Description

4 M6

M8

M10

M12

M16

M20

M24

10

10

15

30

75

140

140

Motor on baseplate or

motor on levelling screws or shims

5 M6

M8

M10

13

18

44

Coupling (only for spacer-typecoupling made by Flender)

6 M6 10 Coupling guard

7.7 Spare parts stock

7.7.1 Ordering spare parts

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

▪ Type series

▪ Material variant

▪ Size

▪ Seal code

▪ KSB order number

▪ Order item number

▪ Consecutive number

▪ Year of construction

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

Also supply the following data:

▪ Description

▪ Part No.

▪ Quantity of spare parts

▪ Shipping address

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

Refer to the exploded view or general assembly drawing for part numbers anddescriptions. (⇨ Section 9.1 Page 55)

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

Table 17: Quantity of spare parts for recommended spare parts stock

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

more210 Shaft 1 1 1 2 2 2 20 %230 Impeller6) 1 1 1 2 2 2 20 %310 Plain bearing 2 3 4 5 7 9 100 %321 Radial ball bearing 1 1 2 2 2 3 25 %

6) Including casing wear ring 502.2

7 Servicing/Maintenance

Etanorm SYT 49 of 66

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

more330 Bearing bracket7) - - - - - 1 2433 Mechanical seal8) 1 1 2 2 3 3 25 %502.1/.2 Casing wear ring 1 1 1 2 2 2 20 %411.3/.4 Joint ring 4 6 8 8 9 12 150 %412 O-ring9) 4 6 8 8 9 10 100 %- Torque-transmitting

coupling elements (set)1 1 2 2 3 4 30 %

7) Complete bearing bracket. Example of a pump set with single-acting mechanical seal and carbon plain bearing: shaft 210,plain bearing 310, radial ball bearing 321, bearing bracket 330, bearing cover 360, joint ring 411.1, O-ring 412.1/.2,mechanical seal 433, seat ring holder 476, disc 550.1/.2/.3, hexagon head bolt 901.1, screwed plug 903, plug 916, hexagonnut 920.3, spring washer 930, circlip 932.1/.2

8) For double-acting mechanical seals double the quantity.9) For double-acting mechanical seal: parts 412.1 and 412.2

7 Servicing/Maintenance

50 of 66 Etanorm SYT

7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

Table 18: Interchangeability of pump componentsEt

ano

rm S

YT

Shaf

t u

nit

Etab

loc

SYT

Etal

ine

SYT

Description

Dis

char

ge

cove

r

Sup

po

rt f

oo

t10)

Shaf

t 10

)

Imp

elle

r

Plai

n b

eari

ng

Dee

p-g

roo

ve b

all b

eari

ng

10)

Bea

rin

g b

rack

et10

)

Bea

rin

g h

ou

sin

g11

)

Bea

rin

g c

ove

r10)

Mec

han

ical

sea

l10)

12)

Mec

han

ical

sea

l11)

Seal

co

ver11

)

Seat

rin

g h

old

er10

)

Cas

ing

wea

r ri

ng

, su

ctio

n s

ide

Cas

ing

wea

r ri

ng

, dis

char

ge

sid

e

Part No.

163

183

210

230

310

321

330

350

360

433

433

471

476

502.

1

502.

2

32-125.5 25 32-125.1/. - 1 1 1 O O 1 1 1 1 1 3 1 1 1 X32-160.1 25 32-160.1/. 40-160/.. 1 2 1 1 O 1 1 1 1 1 3 1 1 1 332-200.1 25 32-200.1/. 40-200/.. 2 3 1 2 O 1 1 1 1 1 3 1 1 1 332-160 25 32-160/.. 50-160/.. 1 2 1 1 O 1 1 1 1 1 3 1 1 1 332-200 25 32-200/.. 50-200/.. 2 3 1 2 O 1 1 1 1 1 3 1 1 1 332-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 1 1040-160 25 40-160/.. 65-160/.. 1 2 1 O O 1 1 1 1 1 3 1 1 2 340-200 25 40-200/.. 65-200/.. 2 3 1 O O 1 1 1 1 1 3 1 1 O 340-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 2 1040-315 35 - - O 7 2 O 3 2 2 - 2 2 - - 2 2 1350-160 25 50-160/.. 80-160/.. 1 3 1 O O 1 1 1 1 1 3 1 1 3 350-200 25 50-200/.. 80-200/.. 2 3 1 O O 1 1 1 1 1 3 1 1 3 350-250 25 - - 3 4 1 O 2 1 1 - 1 1 - - 1 3 1050-315 35 - - 7 7 2 O 3 2 2 - 2 2 - - 2 4 1165-160 25 65-160/.. 100-160/.. 4 3 1 O O 1 1 1 1 1 3 1 1 4 565-200 25 65-200/.. - O 4 1 O O 1 1 - 1 1 - - 1 4 565-250 35 - - O 5 2 O 3 2 2 - 2 2 - - 2 5 1365-315 35 - - 7 7 2 O 3 2 2 - 2 2 - - 2 5 1180-160 25 80-160/.. 100-170/.. 4 4 1 O O 1 1 - 1 1 - - 1 6 580-200 35 - - 5 O 2 O 3 2 2 - 2 2 - - 2 6 1180-250 35 - - 6 5 2 O 3 2 2 - 2 2 - - 2 6 1180-315 35 - - 7 6 2 O 3 2 2 - 2 2 - - 2 6 11100-160 35 - - 5 5 2 O 3 2 2 - 2 2 - - 2 7 11100-200 35 - - 5 5 2 O 3 2 2 - 2 2 - - 2 7 11100-250 35 - - 6 7 2 O 3 2 2 - 2 2 - - 2 7 11100-315 35 - - 7 6 2 O 3 2 2 - 2 2 - - 2 7 11125-200 35 - - O 6 2 O 3 2 2 - 2 2 - - 2 8 O125-250 35 - - O 6 2 O 3 2 2 - 2 2 - - 2 8 O125-315 55 - - 8 9 3 O 3 3 3 - 3 2 - - 3 8 12125-400 55 - - 9 8 3 O 3 3 3 - 3 2 - - 3 8 12150-315 55 - - 8 9 3 O 3 3 3 - 3 2 - - 3 9 12150-400.1 55 - - 10 8 3 O 3 3 3 - 3 2 - - 3 9 -

10) Etanorm SYT only11) Etabloc SYT/Etaline SYT only12) Single-acting mechanical seal 433 not interchangeable with double-acting mechanical seal 433.1/.2

7 Servicing/Maintenance

Etanorm SYT 51 of 66

Table 19: Key to the symbols

Symbol DescriptionX Components differO Component not fitted

7 Servicing/Maintenance

52 of 66 Etanorm SYT

8 Trouble-shootingPump delivers insufficient flow rate

Motor is overloaded

Excessive pump discharge pressure

Increased bearing temperature

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Impermissible rise of temperature inside the pump

Table 20: Trouble-shooting

A B C D E F G H Possible cause Remedy13)

X Pump delivers against an excessivelyhigh discharge pressure.

Re-adjust to duty point.

Check system for impurities.Fit a larger impeller.14)

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

vented or primed.Vent and/or prime.

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

Fit vent valve.X X X Suction head is too high, NPSHavailable

(positive suction head) is too low.Check/alter fluid level.Install pump at lower level.Fully open shut-off element in suction/inletline.Change suction line if friction losses in suctionline are too high.Check any strainers installed/suction opening.Observe permissible speed of pressure fall.

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

X Speed is too low.

- Operation with frequency inverter

- Operation without frequency inverter

- Increase voltage/frequency at FI inpermissible range.- Check voltage.

X X Wear of internal parts Replace worn parts by new ones. X X Pump back pressure is lower than

specified in the purchase order.Re-adjust to duty point.In the case of persistent overloading, turndown impeller.14)

X Density or viscosity of the fluid handledis higher than stated in the purchaseorder.

Contact KSB.

X X Speed is too high. Reduce speed.14)

X Defective seal Fit new seal between volute casing anddischarge cover or between discharge coverand bearing bracket.

A

B

C

D

E

F

G

H

13) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.14) Contact KSB.

8 Trouble-shooting

Etanorm SYT 53 of 66

A B C D E F G H Possible cause Remedy13)

X Joint ring not pre-loaded sufficiently Increase pre-loading of the joint ring atoperating temperature:

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 920.1at the discharge cover.

4. Start up the pump set. (⇨ Section 6 Page30)

X Worn shaft seal Replace shaft seal.Check flushing liquid/barrier fluid.

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

X X X The pump set is misaligned. Re-align the pump set. X X X Pump is warped or sympathetic

vibrations in the piping.Check pipeline connections and secure fixingof pump; if required, reduce distancesbetween pipe clamps.Fix pipelines using anti-vibration material.

X Increased axial thrust14) Clean balancing holes in the impeller.Replace the casing wear rings.

X Non-compliance with specified couplingdistance

Correct distance according to the generalarrangement drawing.

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

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

X Defective bearing Fit new bearing. X X X Insufficient flow rate Increase the minimum flow rate.

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

8 Trouble-shooting

54 of 66 Etanorm SYT

9 Related Documents

9.1 Exploded views and lists of components

9.1.1 Etanorm SYT, SU 25

Fig. 17: Exploded view Etanorm SYT, SU 25

Table 21: List of components

Part No. Description Part No. Description Part No. Description102 Volute casing 412.1 O-ring 930 Spring washer163 Discharge cover 433 Mechanical seal 932.1/.2 Circlip183 Support foot 476 Seat ring holder 940.1/.2 Key210 Shaft 502.1/.215) Casing wear ring 99-20 Repair kit230 Impeller 550.1/.2/.3 Disc 310 Plain bearing 901.2 Hexagon head bolt 321 Radial ball bearing 902.1/.2 Stud with reduced

shank1M Connection for

pressure gauge330 Bearing bracket 903.1/.2 Screwed plug 6B Fluid drain360 Bearing cover 914 Pan head screw 6D Fluid vent411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 8B Leakage drain

15) 502.2 not for pump size 32-125.1

9 Related Documents

Etanorm SYT 55 of 66

9.1.2 Etanorm SYT, SU 25 with double-acting mechanical seal

Fig. 18: Exploded view of Etanorm SYT, SU 25 with double-acting mechanical seal

Table 22: List of components

Part No. Description Part No. Description Part No. Description102 Volute casing 433.1/.2 Mechanical seal 930 Spring washer163 Discharge cover 476/476.1 Seat ring holder 932.1/.2/.5 Circlip183 Support foot 940.1/.2 Key210 Shaft 502.1/.216) Casing wear ring 99-20 Repair kit230 Impeller 525 Spacer sleeve 310 Plain bearing 550.1/.2/.3/.6 Disc 24A Outlet of the quench

liquid321 Radial ball bearing 901.2 Hexagon head bolt 24E Inlet of the quench

liquid330 Bearing bracket 902.1/.2 Stud with reduced

shank1M Connection for

pressure gauge360 Bearing cover 903.1/.2 Screwed plug 6B Fluid drain411.1/.3/.4/.5 Joint ring 914 Pan head screw 6D Fluid vent412.1/.2 O-ring 920.1/.2/.3 Nut 8B Leakage drain

16) 502.2 not for pump size 32-125.1

9 Related Documents

56 of 66 Etanorm SYT

9.1.3 Etanorm SYT, SU 35

Fig. 19: Exploded view Etanorm SYT, SU 35

Table 23: List of components

Part No. Description Part No. Description Part No. Description102 Volute casing 412.1 O-ring 930 Spring washer163 Discharge cover 433 Mechanical seal 932.1/.2/.4 Circlip183 Support foot 476 Seat ring holder 940.1/.2 Key210 Shaft 502.1/.2 Casing wear ring 99-20 Repair kit230 Impeller 550.1/.2/.5 Disc 310 Plain bearing 901.2 Hexagon head bolt 321 Radial ball bearing 902.1/.2 Stud with reduced

shank1M Connection for

pressure gauge330 Bearing bracket 903.1/.2 Screwed plug 6B Fluid drain360 Bearing cover 914 Pan head screw 6D Fluid vent411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 8B Leakage drain

9 Related Documents

Etanorm SYT 57 of 66

9.1.4 Etanorm SYT, SU 35 with double-acting mechanical seal

Fig. 20: Exploded view of Etanorm SYT, SU 35 with double-acting mechanical seal

Table 24: List of components

Part No. Description Part No. Description Part No. Description102 Volute casing 433.1/.2 Mechanical seal 932.1/.2/.4/.5 Circlip163 Discharge cover 476/476.1 Seat ring holder 940.1/.2 Key183 Support foot 502.1/.2 Casing wear ring 99-20 Repair kit210 Shaft 525 Spacer sleeve 230 Impeller 550.1/.2/.5/.6 Disc 310 Plain bearing 901.2 Hexagon head bolt 24A Outlet of the quench

liquid321 Radial ball bearing 902.1/.2 Stud with reduced

shank24E Inlet of the quench

liquid330 Bearing bracket 903.1/.2 Screwed plug 1M Connection for

pressure gauge360 Bearing cover 914 Pan head screw 6B Fluid drain411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 6D Fluid vent412.1/.2 O-ring 930 Spring washer 8B Leakage drain

9 Related Documents

58 of 66 Etanorm SYT

9.1.5 Etanorm SYT, SU 55

UG1289004

Fig. 21: Exploded view Etanorm SYT, SU 55

Table 25: List of components

Part No. Description Part No. Description Part No. Description102 Volute casing 412.1 O-ring 930 Spring washer163 Discharge cover 433 Mechanical seal 932.1/.2/.4 Circlip183 Support foot 476 Seat ring holder 940.1/.2 Key210 Shaft 502.1/.217) Casing wear ring 99-20 Repair kit230 Impeller 550.1/.2/.5 Disc 310 Plain bearing 901.2 Hexagon head bolt 321 Radial ball bearing 902.1/.2 Stud with reduced

shank1M Connection for

pressure gauge330 Bearing bracket 903.1/.2 Screwed plug 6B Fluid drain360 Bearing cover 914 Pan head screw 6D Fluid vent411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 8B Leakage drain

17) 502.2 not for pump size 150-400.1

9 Related Documents

Etanorm SYT 59 of 66

9.1.6 Etanorm SYT, SU 55 with double-acting mechanical seal

UG1289009

Fig. 22: Exploded view of Etanorm SYT, SU 55 with double-acting mechanical seal

Table 26: List of components

Part No. Description Part No. Description Part No. Description102 Volute casing 433.1/.2 Mechanical seal 932.1/.2/.4/.5 Circlip163 Discharge cover 476/476.1 Seat ring holder 940.1/.2 Key183 Support foot 502.1/.218) Casing wear ring 99-20 Repair kit210 Shaft 525 Spacer sleeve 230 Impeller 550.1/.2/.5/.6 Disc 310 Plain bearing 901.2 Hexagon head bolt 24A Outlet of the quench

liquid321 Radial ball bearing 902.1/.2 Stud with reduced

shank24E Inlet of the quench

liquid330 Bearing bracket 903.1/.2 Screwed plug 1M Connection for

pressure gauge360 Bearing cover 914 Pan head screw 6B Fluid drain411.1/.3/.4/.5 Joint ring 920.1/.2/.3 Nut 6D Fluid vent412.1/.2 O-ring 930 Spring washer 8B Leakage drain

18) Not for pump size 150-400.1

9 Related Documents

60 of 66 Etanorm SYT

9.1.7 Etanorm SYT with SiC plain bearing

Fig. 23: Exploded view of Etanorm SYT, SIC plain bearing

Table 27: List of components

Part No. Description Part No. Description Part No. Description381 Bearing cartridge 412.3 O-ring 529 Bearing sleeve540.1 Bush 561 Grooved pin 932.6/.7 Circlip

9.2 Wiring diagrams for double-acting mechanical seal

Fig. 24: Wiring diagram for double-acting mechanical seal

1M.1/.2 Connection for pressure gauge6B Fluid drain6D Fluid vent8B Leakage drain24A Outlet of the quench liquid24E Inlet of the quench liquid

9 Related Documents

Etanorm SYT 61 of 66

10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

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

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

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

▪ is in conformity with the provisions of the following directives as applicable in their current version:

– EC Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100-1/A1, ISO 12100-2/A1,

– ISO 14121-1,

– EN 809/A1

Frankenthal, 29 December 2009

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

Name

Function

Responsible for compiling the technical documentationKSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

10 EC Declaration of Conformity

62 of 66 Etanorm SYT

11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number19) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled19) : ................................................................................................................................

Please tick where applicable19) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return19) : ................................................................................................................................ Comments: ................................................................................................................................ ................................................................................................................................ The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placingat your disposal.

On sealless pumps, the rotor has been removed from the pump for cleaning.

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

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

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

19) Required fields

11 Certificate of Decontamination

Etanorm SYT 63 of 66

Index

AAbrasive fluids 35

BBearing temperature 38Bearings 16

CCertificate of decontamination 63Clearance gaps 39Commissioning/start-up 30Coupling 39Coupling alignment 25

DDesign 15, 16Designation 15Direction of rotation 29Dismantling 41Disposal 14

EExplosion protection 11, 18, 19, 25, 27, 28, 30, 31, 33,34, 37, 38, 39, 40

FFault/malfunction 53Filling and venting 30Filter 21, 40Final check 31Frequency of starts 34Function 16

GGrease lubrication

Intervals 40

IImpeller type 16Installation

Installation on the foundation 19Installation without foundation 20

Installation at site 19Intended use 8Interchangeability of pump components 51

MMaintenance/repair 37Mechanical seal 32Misuse 9Monitoring equipment 12

NName plate 15Noise characteristics 17

OOperating limits 8, 33Order number 6Ordering spare parts 49Other applicable documents 6

PPartly completed machinery 6Permissible forces at the pump nozzles 22Piping 21Preservation 14, 35Pump casing 15

RReassembly 41, 44Return to supplier 14Returning to service 35

SSafety 8Safety awareness 9Scope of supply 18Shaft seal 16Shutdown 35Spare parts stock 49Start-up 32Storage 14, 35

TTemperature limits 11Tightening torques 48Transport 13

Index

64 of 66 Etanorm SYT

KSB Aktiengesellschaft67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)Tel. +49 6233 86-0 • Fax +49 6233 86-3401www.ksb.com

1226

.8-1

0

KULLANICI
Text Box
Ursan Pompa Armatür ve Endüstriyel Ürünler San. Tic. Ltd. Sti. Güzeller Mah. Bagdat Cad. No: 601/A 41400 Gebze / KOCAELI Tel: (0.262) 642 05 60 - 641 84 15 - 641 82 60 Fax: (0.262) 642 39 79 e-mail: [email protected] - [email protected] www.ursanpompa.com