HPK-L Installation/Operating Manualksb.co.il/_Uploads/dbsAttachedFiles/oparaion.pdf · HPK-L without external cooling Standard programme Installation/Operating Manual. Installation/Operating

Thermal Oil / Hot Water Pump

HPK-L

without external coolingStandard programme

Installation/OperatingManual

Installation/Operating Manual HPK-LOriginal operating manual KSB Aktiengesellschaft 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 25.01.2010

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) .......................................................... 16

4.1 General description ....................................................................................... 16

4.2 Designation ................................................................................................... 16

4.3 Name plate .................................................................................................... 17

4.4 Design details ................................................................................................ 17

4.5 Configuration and function ......................................................................... 19

4.6 Noise characteristics ..................................................................................... 20

4.7 Scope of supply ............................................................................................. 20

4.8 Dimensions and weights ............................................................................... 20

5 Installation at Site ............................................................................. 21

5.1 Safety regulations ......................................................................................... 21

5.2 Checking the site before installation ........................................................... 21

5.3 Installing the pump set ................................................................................. 21

5.4 Piping ............................................................................................................. 23

Contents

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5.5 Protective equipment ................................................................................... 26

5.6 Checking the coupling alignment ................................................................ 26

5.7 Aligning the pump and motor ..................................................................... 27

5.8 Electrical connection ..................................................................................... 29

5.9 Checking the direction of rotation .............................................................. 30

6 Commissioning/Start-up/Shutdown ................................................. 32

6.1 Commissioning/start-up ................................................................................ 32

6.2 Operating limits ............................................................................................ 36

6.3 Shutdown/storage/preservation ................................................................... 38

6.4 Returning to service after storage ............................................................... 39

7 Servicing/Maintenance ...................................................................... 40

7.1 Safety regulations ......................................................................................... 40

7.2 Servicing/inspection ...................................................................................... 40

7.3 Drainage/disposal .......................................................................................... 43

7.4 Dismantling the pump set ............................................................................ 43

7.5 Reassembling the pump set .......................................................................... 47

7.6 Tightening torques ....................................................................................... 51

7.7 Spare parts stock ........................................................................................... 51

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

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

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

10 EC Declaration of Conformity .......................................................... 59

11 Certificate of Decontamination ....................................................... 60

Index .................................................................................................. 61

Contents

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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

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1 General

1.1 Principles

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

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

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

Noise characteristics (⇨ Section 4.6 Page 20)

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 49)

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 documentation1) Operating manuals and other documentation ofaccessories and integrated machinery components

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

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Symbol Description1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

HPK-L 7 of 62

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

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.Explosion protectionThis symbol identifies information about avoiding explosions inpotentially explosive atmospheres in accordance with EC Directive94/9/EC (ATEX).General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies informationabout protection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 General

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

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

This manual must be read and completely understood by the responsible specialistpersonnel/operators prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pump must always be complied with and bekept in a perfectly legible condition at all times. This applies to, for example:

▪ Arrow indicating the direction of rotation

▪ Markings for connections

▪ Name plate

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

2.3 Intended use

The pump (set) may only be operated in the operating conditions which aredescribed in the other applicable documentation.

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

▪ Do not operate partially assembled pumps/pump sets.

! DANGER

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▪ Only use the pump to handle the fluids specified in the data sheet or productliterature of the respective design variant.

▪ Never operate the pump without the fluid to be handled.

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

▪ Observe the maximum flow rates indicated in the data sheet or productliterature (to prevent overheating, mechanical seal damage, cavitation damage,bearing damage, etc).

▪ Do not throttle the flow rate on the suction side of the pump (to preventcavitation damage).

▪ Consult the manufacturer about any use or mode of operation not described inthe data sheet or product literature.

Prevention of foreseeable misuse

▪ Never open discharge-side shut-off elements further than permitted.

– The maximum flow rate specified in the data sheet or product literaturewould be exceeded.

– Risk of cavitation damage

▪ Never exceed the permissible operating limits specified in the data sheet orproduct literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain andinspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved ininstallation, operation, maintenance and inspection must be clearly defined by theoperator.

Deficits in knowledge must be rectified by sufficiently trained specialist personneltraining and instructing the personnel who will carry out the respective tasks. Ifrequired, the operator can commission the manufacturer/supplier to train thepersonnel.

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

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

▪ Non-compliance with these operating instructions will lead to forfeiture ofwarranty cover and of any and all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

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

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

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HPK-L 9 of 62

▪ 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.

▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3Page 43)

▪ 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 32)

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 instructions on explosion protection given in this section whenoperating the pump in potentially explosive atmospheres.

! DANGER

2 Safety

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

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on 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 in addition, the operator of the system isresponsible for observing the specified temperature classes and fluid temperature(operating temperature).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 Maximum 400 °C2)

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

with the manufacturer

In the area of the rolling element bearings, based on an ambient temperature of40 °C and assuming proper service and operation, compliance with the requirementsof temperature class T4 is warranted. If the ambient temperature exceeds 40 °C,contact the manufacturer.

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

Pump

Shaft coupling

Motor

Temperature class T4

Temperature class T6

2) Depending on the material variant.

2 Safety

HPK-L 11 of 62

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

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 (⇨ Section 6.2.3 Page 37) refer to waterand water-like fluids. Longer operating periods with these fluids and at the flowrates indicated will not cause an additional increase in the temperatures on thepump surface. However, if the physical properties of the fluids handled are differentfrom water, 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 37) can be used to check if an additional heat build-up may leadto a hazardous temperature increase at the pump surface.

2 Safety

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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 tackles as follows.

Fig. 1: Transporting the pump

Fig. 2: Transporting the complete pump set

Fig. 3: Transporting the pump on baseplate

CAUTIONPump (set) or bare shaft end must not hit any objects.???Damage to the ceramic plain bearing!

▷ Secure them to provide protection.

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.


HPK-L 13 of 62

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

▷ For outdoor storage cover the pump (set) or the packaged pump (set) andaccessories with waterproof material.

CAUTIONWet, contaminated or damaged openings and connectionsLeakage or damage to the pump set!

▷ Only remove caps/covers from the openings of the pump set at the time ofinstallation.

Store the pump (set) in a dry, protected room where the atmospheric humidity is asconstant as possible.

Rotate the shaft by hand once a month, e.g. via the motor fan.

If properly stored indoors, the pump set is protected for a maximum of 12 months.New pumps/pump sets are supplied by our factory duly prepared for storage.

For storing a pump (set) which has already been operated, observe the relevantinstructions. (⇨ Section 6.3.1 Page 38)

3.3 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 43)

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 gas must be blown through the pump for dryingpurposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump set. (⇨ Section 11 Page 60)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


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

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


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4 Description of the Pump (Set)

4.1 General description

▪ Heat transfer liquid pump with shaft seal

Pump for handling hot water or organic heat transfer fluids in piping or tanksystems.

Standard design for plants (large heating systems, forced circulation boilers, districtheating systems, etc).

4.2 Designation

Example: HPK- L S 4 80- 200

Table 5: Key to the designation

Code DescriptionHPK Type seriesL Air-cooledS Material of wetted components4 Pressure class80 Nominal discharge nozzle diameter [mm]200 Nominal impeller diameter [mm]

4.2.1 Materials

Table 6: Materials

PartNo.

Designation HPK-L materials

S, S4 E E4102 Volute casing JS1025 GP240GH+N 1.7706161 Casing cover P250GH P250GH P250GH210 Shaft 1.4021+

QT7001.4021+QT700

1.4021+QT700

230 Impeller JL1040 JL1040 JL1040310.10 Plain bearing SSiC SSiC SSiC330 Bearing bracket

(=seal housing)JS1025 JS1025 JS1025

476 Seat ring holder 1.4021+QT700

1.4021+QT700

1.4021+QT700

502.01 Casing wear ring JL1040 - -523 Shaft sleeve 1.4021+

QT7001.4021+QT700

1.4021+QT700

545.21 Bearing bush (product-lubricated)

SSiC SSiC SSiC

920.95 Impeller nut A4 A4 A4

Pressure class: (blank) = PN25 4 = PN40


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4.3 Name plate

2009

m³/h m 1/min

6

1

2

3

4

5

HPK-LE4 100-250

9971572908 000 10001287

297885

Fig. 4: HPK-LE4 name plate

1 Type series 2 KSB order number3 Flow rate 4 Speed5 Year of construction 6 Head

4.4 Design details

Design

▪ Volute casing pump

▪ Horizontal installation

▪ Back pull-out design

▪ Single-stage

▪ Meets technical requirements to ISO 5199

▪ Dimensions and ratings in accordance with EN 22 858/ISO 2858complemented by pumps with nominal diameters DN 25, DN 200, DN 250 andnominal impeller diameter 500 mm.

Pump cas ing

▪ Single or double volute, depending on the pump size

▪ Radially split volute casing

Volute casing with pump feet below

Fig. 5: Pump feet below

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

DANGERCombustible fluidsExplosion hazard!

▷ The pump casing must be made of ductile material containing no more than 7.5% magnesium (see EN 13463-1).

Impel ler type

▪ Closed radial impeller with multiply curved vanes

▪ Back vanes reduce axial thrust


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Shaft seal

NOTESeal designs and types other than specified herein shall only be used in exceptionalcases and only after prior consultation with the manufacturer.

▪ Single-acting, balanced standardised mechanical seal

– The seal chamber is located between the product-lubricated pump-end plainbearing and the outboard, motor-end rolling element bearing.

Mechanical seal in "dead end" arrangement

1. Never use mechanical seals which have not been approved by KSB.

2. Due to the complex conditions which need to be fulfilled for heat transfer liquidpumps, the use of mechanical seals not approved by KSB shall not be covered byKSB's scope of warranty.

Fig. 6: Mechanical seal in "dead end" arrangement

The seal chamber is cooled by cooling fins and ambient cooling air.

There is no external cooling system!

Motor-end bearing:

▪ Fixed bearing

▪ Grease-packed angular contact ball bearings sealed for life

▪ Axial joint rings on both sides

▪ Axial movement of the rotor limited to maximum 0.5 mm

Pump-end bearing:

▪ Radial bearing

▪ Absorbs radial loads only

▪ Product-lubricated ceramic bearings

Example: P03

Table 7: Bearing bracket designation

Designation DescriptionL Air-cooled bearing bracket with integrated shaft seal chamberP Process design03 Size code (based on the dimensions of seal chamber and shaft end)

Refer to the data sheet to find your bearing design.

Table 8: Bearing design

KSB designation FAG designation SKF designationB.G B-TVP-UA BECBPB.G.8 B-TVP-UA 80 BEC86P

Design specifications

Bearing bracketdesignation

Bearings used


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Table 9: Standard bearing assembly

Bearingbracket

Pump end Motor end

Plain bearing (diameter in mm) Angular contact ball bearingLP02 SSiC, 37 mm 2 x 7307 B.GLP03 SSiC, 50 mm 2 x 7307 B.GLP04 SSiC, 50 mm 2 x 7309 B.G.8LP05 SSiC, 62 mm 2 x 7313 B.GLP06 SSiC, 72 mm 2 x 7315 B.G

4.5 Configuration and function

1

3

2

6

109

4

8

7

5

Fig. 7: Sectional drawing

1 Clearance gap 2 Discharge nozzle3 Casing cover 4 Drive shaft5 Bearing bracket 6 Shaft seal7 Suction nozzle 8 Impeller9 Plain bearing, pump end 10 Rolling element bearing, motor

end

The pump is designed with an axial fluid inlet and a radial or tangential outlet. Thehydraulic system runs in its own bearings and is connected to the motor by a shaftcoupling.

The fluid enters the pump axially via a suction nozzle (7) and is accelerated outwardin a cylindrical flow by the rotating impeller (8). 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 inlet. The hydraulic system isclosed with a casing cover (3) at the rear side of the impeller; the shaft (4) enters thecasing via the casing cover (3). The shaft passage through the cover is sealed towardsthe atmosphere with a shaft seal (6). The shaft runs in a pump-end plain bearing (9)and a motor-end rolling element bearing (10). The bearings are supported by abearing bracket (5) linked with the pump casing and/or casing cover.

Design

Function


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The pump is sealed by a standardised mechanical seal.

4.6 Noise characteristics

Table 10: Surface sound pressure level LpA3) 4)

Ratedpowerinput

PN[kW]

Pump Pump set2900 rpm

[dB]

1450 rpm

[dB]

960 rpm760 rpm

[dB]

2900 rpm

[dB]

1450 rpm

[dB]

960 rpm760 rpm

[dB]1 54 53 52 63 58 562 56 55 53 66 60 583 57 56 55 68 62 604 59 58 56 69 63 616 61 59 58 71 65 628 62 61 59 72 66 6411 64 63 61 74 68 6515 66 65 63 75 69 6719 67 66 64 76 70 6822 68 67 65 77 71 6830 70 68 66 78 72 7037 71 70 67 79 73 7045 72 71 68 80 74 7155 73 72 69 80 74 7275 75 73 71 81 76 7390 76 74 71 82 76 73110 77 75 72 82 77 74132 78 76 73 83 77 75160 79 77 74 84 78 75200 80 78 75 84 79 76250 81 79 - 85 80 -

4.7 Scope of supply

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

▪ Pump

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

▪ Flexible coupling with or without spacer

▪ Coupling guard to EN 294

▪ Baseplate (to ISO 3661), cast or welded, for pump and motor, in torsion-resistantdesign

▪ Channel section steel or folded steel plate

▪ As required

4.8 Dimensions and weights

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

Sealing

Drive

Shaft coupling

Contact guard

Baseplate

Special accessories

3) Spatial average; as per ISO 3744 and EN 12639; valid for operating range Q/Qopt = 0.8 - 1.1 and non-cavitating pumpoperation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.

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


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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. 8: 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.


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✓ 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 align it with the help of a spiritlevel placed on the shaft and discharge nozzle.Permissible deviation: 0.2 mm/m.

2. Use shims (2) for height compensation, if necessary. Always fit shims between the baseplate/foundation frame and the foundationitself; always insert them to the left and right of the foundation bolts (4) and inclose proximity to these bolts. For a bolt-to-bolt clearance > 800 mm, fit additional shims (3) halfway betweenthe adjoining holes. All shims must lie perfectly flush.

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

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

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

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

7. Grout the baseplate using low-shrinkage concrete with a standard particle sizeand a water/cement ratio of ≤ 0.5.Produce flowability with the help of a solvent.Perform secondary treatment of the concrete to DIN 1045.

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

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

5.3.2 Installation without foundation

4

1

2

3

Fig. 9: Adjusting elements

1, 3 Lock nut 2 Adjusting nut4 Adjusting element

✓ The installation surface has the required strength and characteristics.

1. Position the pump set on the adjusting elements (4) and align it with the help ofa spirit level (on the shaft/discharge nozzle).

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

3. Turn the adjusting nut (2) until any differences in height have beencompensated.


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4. Re-tighten the lock nuts (1, 3) at the adjusting elements (4).

5.4 Piping

5.4.1 Connecting the piping

DANGERExcessive 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.

▷ 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 42).

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


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1

2Fig. 10: 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

[+]Fy

Fz

Fx

Fx

Fz

Fy

Fx

Fz

Fy

My

Mz

Mx

Forces and moments at the pump nozzles

The resulting permissible forces havebeen determined according to thefollowing formulas:

The data on forces and moments apply to static pipelines only. If the limits areexceeded, they must be checked and verified.If a computerised strength analysis is required, please contact KSB! The values are only applicable if the pump is installed on a completely groutedbaseplate and bolted to a rigid and level foundation.

The forces and moments were determined on the basis of API 610 (6th edition), table2, values doubled.


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Table 11: Forces and moments at the pump nozzles

Pumpsizes

Suction nozzle[N]

Discharge nozzle[N]

Suction nozzle[Nm]

Discharge nozzle[Nm]

Fx Fy Fz Fres Fx FyTens

+FyPress- Fz Fres Mx My Mz Mx My Mz

25-160 25-200

1050 700 850 1100 500 350 650 450 700 550 450 300 400 300 200

32-12532-16032-20032-250

1350 900 1100 1400 700 450 850 550 900 700 550 350 450 350 250

40-16040-20040-25040-315

1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 550 450 300

50-16050-20050-25050-315

2150 1400 1700 2200 1100 700 1350 900 1400 1450 1100 750 700 550 350

65-16065-20065-25065-315

2700 1750 2150 2750 1400 900 1750 1150 1800 2000 1500 1000 1150 850 600

80-16080-20080-25080-31580-400

3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 750

100-200100-250100-315100-400

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

125-250125-315125-400

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

150-250150-315150-400150-500

7350 4700 5700 7400 3750 2350 4700 3100 4850 5300 3850 2650 3450 2650 1750

200-250 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650200-315200-400200-500

10000 6700 8000 10450 5700 3550 7350 4700 7400 7500 5700 3650 5300 3850 2650

250-315250-400250-500

12000 8000 10000 12800 8000 5000 10000 6700 10450 9150 6900 4500 7500 5700 3650

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


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1.00

0.75

0.80

0.85

0.90

0.95

0.50

0.55

0.60

0.65

0.70

400350300250200150120

JL1040

GP240GH+NJS1025

1.4408

°C

Correction coefficient

Fig. 11: Temperature correction coefficients

No reduction is necessary for material 1.7706.

5.4.3 Auxiliary connections

The pump works without any external cooling system.The mechanical seal does not require any cooling liquid, sealing liquid or flushingliquid.

5.5 Protective equipment

DANGERAn explosive atmosphere forms due to insufficient ventingExplosion hazard!

▷ Never close or cover the perforation of the bearing bracket guards (e.g. byinsulation).

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

▷ 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

DANGERInadmissible temperatures at the coupling or bearings due to misalignment of thecouplingExplosion hazard!

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


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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.

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).


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5.7.1 Motors with levelling screw

1

3

2

Fig. 13: Motor with levelling screw

1 Hexagon head bolt 2 Levelling screw3 Lock nut


1. Check the coupling alignment.

2. Unscrew the hexagon head bolts (1) at the motor and the lock nuts (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 lock nuts (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.

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.


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1Fig. 14: Pump set with shim

1 Shim


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.


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).



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).


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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.

5.8.1 Setting the time relay

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

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

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

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

5.8.2 Connecting the motor

NOTEIn compliance with DIN VDE 0530 - Part 8, three-phase motors are always wired forclockwise rotation (looking at the motor shaft stub).The pump's direction of rotation is indicated by an arrow on the pump.

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

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

5.9 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.


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

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

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

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

▷ Check the direction of rotation. If required, interchange any two phases tocorrect the direction of rotation.

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

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

2. Check the direction of 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.


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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, including the bearing bracket (mechanical seal chamber), has beenprimed with the fluid to be handled.

▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 30)

▪ The lubricants have been checked.

▪ After prolonged shutdown of the pump (set), the activities described in (⇨Section 6.4 Page 39) have been carried out.

NOTEThe hot water shall comply with the minimum requirements of the VdTÜV regulationsTCH 1466/AGFW 5-15 (edition 2.89). Do not exceed the following limits:

Table 13: Limits for hot water

LimitsElectrical conductivity < 250 µs/cmpH value at 25°C 9-10.5Silicates (SiO2) < 10 mg/l

Solids < 5 mg/l

NOTENo warranty can be given on the service life of the mechanical seal for hot water with anelectrical conductivity exceeding 250 µs/cm and for hot water with unknown water quality

For ultra-pure water (fully desalinated, demineralised water) with an electricalconductivity < 2 µs/cm, the temperature at the seal faces must be at least 20 % belowthe boiling point.

NOTEWhen conditioners producing a greasy film on the seal faces are used, e.g. Maxigard,Antifrogen N, Preventol Cl-2, KeboX, Nalfleet 9-11, no warranty can be given on the seallife because of their adverse effect on the seal. In such cases please contact KSB.

6.1.2 Filling in lubricants

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

6.1.3 Shaft seal

Shaft seals are fitted prior to delivery. Observe the instructions on dismantling (⇨ Section 7.4.8 Page 46) or reassembly (⇨Section 7.5.3 Page 48) .

NOTEWhen new plants are commissioned and a large amount of foreign matter is in thesystem, expect short service lives of the mechanical seal during the initial phase of plantoperation.


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NOTEOnly modify the specified sealing concepts and seal types after consultation with KSB.

Due to the complex conditions in hot water systems, the use of mechanical seals notapproved by KSB shall not be covered by KSB's scope of warranty.

6.1.4 Filling and venting the pump

DANGERAn explosive atmosphere forms 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.

DANGERShaft seal failure caused by dry runningHot or toxic fluid could escape!Damage to the pump!

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

1. Vent the pump and suction line and fill them with the fluid to be handled.

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

In the as-supplied condition, auxiliary connection 13 D for venting the seal chamber isclosed with a screwed plug with vent hole 903.85.

High-temperature pumps must be vented before they are commissioned.

As soon as gas stops escaping, close screwed plug 903.85 to prevent any hot fluidfrom flowing into the mechanical seal chamber.

13 D

Fig. 15: Auxiliary connection 13 D

13D Screwed plug 903.85

NOTEOn request, the screwed plug can be replaced by a valve in the discharge pipe forcommissioning to safely drain gases and hot fluids during venting.For temperatures exceeding 200° and pressures exceeding 25 bar, use a vent valve andvent line.

1. Switch off the pump and let it run down to a standstill.

2. Let gases drain reliably.???

3. Close the shut-off elements as required by the system configuration.

4. To vent the bearing bracket undo screwed plug 903.85 by approx. 1/2 turn at atime until no more gas escapes.

Excessive venting shall be avoided, as hot product from the piping system will flowthrough the volute casing into the mechanical seal chamber and result in an

Venting the seal chamber

Venting during pumpoperation

Excessive venting


HPK-L 33 of 62

inadmissible heat build-up in the mechanical seal. The vent valve must be closedagain as soon as no further gases escape.

6.1.5 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 26)




6.1.6 Cooling of the mechanical seal chamber

The mechanical seal chamber is integrated in the bearing bracket and cooled by theambient temperature via cooling fins.

An integrated fan impeller ensures a continuous cooling air flow.

An unobstructed supply of cooling air to the fan hood and fan impeller must beensured at all times!

1. In exceptional cases, the pump can be operated without the integrated fanimpeller. If the coarse dust blocks the cooling air intake, the following parts also have tobe removed:

▪ Fan hood 832

▪ Guard 680

Cooling air flow with a cooling air velocity of at least 4 m/s in the proximity of thecooling fins.The cooling air flow is generated by the motor cooling device or an external fan.

6.1.7 Heating up/keeping warm the pump (set)

CAUTIONPump blockageDamage to the pump!

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

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

▪ Make sure the temperature is increased continuously.

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

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

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

Fluid temperatures above150 °C

Temperature difference


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6.1.8 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.

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

▷ Switch off the pump (set) immediately.

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

✓ The system piping has been cleaned.

✓ Pump, suction line and inlet tank, if any, have been vented and filled with thefluid to be pumped.

✓ 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 comply with the dutypoint.

DANGERSeal leakage at operating temperatureHot or toxic fluid could escape!

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

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


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

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

6.1.9 Checking the shaft seal

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

Slight leakage at the seal is permissible and desirable.

If the leakage exceeds 8 l/h the seal is defective and needs to be replaced.

6.1.10 Shutdown

✓ 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.

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

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

For prolonged shutdown periods:

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

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

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

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

6.2 Operating limits

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

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

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

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

Mechanical seal


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6.2.1 Ambient temperature

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

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table 14: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °CMinimum See data sheet.

6.2.2 Frequency of starts

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

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

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

Table 15: Frequency of starts

Motor rating [kW]

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

up to 12 15up to 100 10

more than 100 5

CAUTIONRe-start while motor is still running downDamage to the pump (set)!

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

6.2.3 Flow rate

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

▪ Short-time operation: Qmin5) =0.1xQopt

6)

▪ Continuous operation: Qmin5) =0.3xQopt 6)

▪ 2-pole operation: Qmax7) =1,1xQopt 6)

▪ 4-pole operation: Qmax7) =1.25xQopt

6)

The data refer to water and water-like fluids. Longer operating periods with thesefluids and at the flow rates indicated will not cause an additional increase in the

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


HPK-L 37 of 62

temperatures on the pump surface. However, if the physical properties of the fluidshandled are different from water, the calculation formula below must be used tocheck if an additional heat build-up may lead to a dangerous temperature increase atthe pump surface. If necessary, the minimum flow must be increased.

Table 16: 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.

CAUTIONExcessive density of the fluid handledMotor overload!

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

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

6.2.5 Abrasive fluids

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

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for 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 43) and the safetyinstructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page43)

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).


38 of 62 HPK-L

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 32) and the operating limits (⇨ Section 6.2 Page 36) .

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. (⇨ Section 7 Page 40)

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

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

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


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7 Servicing/Maintenance

7.1 Safety regulations

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

▷ Service the pump set regularly.

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

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

WARNINGPump set started up inadvertentlyRisk of injury by moving parts!

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

▷ Make sure that the pump set cannot be switched on accidentally.

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

▷ Observe all relevant laws.

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

▷ Decontaminate pumps handling fluids posing a health hazard.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the pump (set) with a minimum of maintenanceexpenditure and work.

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

Never use force when dismantling and reassembling a pump set.

7.2 Servicing/inspection

7.2.1 Supervision of operation

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

▷ Regularly check the lubricant level.

▷ Regularly check the rolling element bearings for running noises.


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

CAUTIONIncreased wear due to dry runningDamage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Never close the shut-off element in the suction line and/or supply line duringpump operation.

CAUTIONExcessive fluid temperatureDamage 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 36)

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 rolling element bearings for running noises.Vibrations, noise and an increase in current input occurring during unchangedoperating conditions indicate wear.

▪ Monitor the correct functioning of any auxiliary connections.

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

▪ Monitor the stand-by pump.To make sure that the stand-by pumps are ready for operation, start them uponce a week.

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

CAUTIONOperation outside the permissible bearing temperatureDamage to the pump!

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


HPK-L 41 of 62

7.2.2.1 Checking the coupling

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

7.2.2.2 Checking the clearance gaps

To check the clearance gaps, remove the back pull-out unit. If the clearance gap is larger than permitted (see the following table), replace casingwear ring 502.01 with a new one.The clearance gaps given refer to the diameter.

Table 17: Clearance gaps between impeller and casing / between impeller and casingwear ring

HPK-LS/-LS4 HPK-LE/-LE4up to DN 65 0.40 mm + 0.1 0.60 mm + 0.1DN 80 to DN 200 0.50 mm + 0.1 0.60 mm + 0.1DN 250 and above 0.65 mm + 0.1 0.75 mm + 0.1

All HPK-LS/-LS4 pumps are fitted with casing wear rings.

Table 18: Clearance gaps in the plain bearing

Bearing bracket Bearing clearanceLP02 0.03 mm + 0.045LP03 0.05 mm + 0.045LP04 0.05 mm + 0.045LP05 0.05 mm + 0.05LP06 0.05 mm + 0.05

NOTEIf the clearances given are exceeded by more than 1 mm (referring to the diameter)replace the affected components or restore the original clearance by means of a casingwear ring. Contact KSB.

7.2.2.3 Cleaning filters

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

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

▷ Clean filter in appropriate intervals.

7.2.3 Lubrication and lubricant change of rolling element bearings

7.2.3.1 Grease lubrication

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

7.2.3.1.1 Grease quality

We recommend using Petro-Canada Peerless LLG high-temperature grease or anequivalent product for lubrication. Under unfavourable operating conditions, e.g.high room temperature, high atmospheric humidity, dust-laden air, aggressiveatmosphere etc., check the bearings earlier and, if required, clean and re-lubricatethem, preferably with Petro-Canada Peerless LLG.


42 of 62 HPK-L

7.2.3.1.2 Grease quantities

Bearing bracket Bearings Grease qty. per singlebearing

LP02 7307 BG 6.5 to 8 gLP03 7307 BG 6.5 to 8 gLP04 7309 BG 13 to 15.5 gLP05 7313 BG 23 to 26 gLP06 7315 BG 29 to 33 g

The grease quantity indicated must be used for each single bearing of a bearing pair.

7.2.3.1.3 Intervals

▪ Under suitable operating conditions the grease-lubricated bearings will run for25,000 operating hours.

▪ Under unfavourable operating conditions (e.g. high room temperature, highatmospheric humidity, dust-laden air, aggressive industrial atmosphere) checkthe bearings earlier and clean and re-lubricate them, if required.

▪ Replace the rolling element bearings after 25,000 operating hours or 3 years ofcontinuous operation.

7.3 Drainage/disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

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

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

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

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

Use connection 6B to drain the fluid handled (see auxiliary connections).

7.4 Dismantling the pump set

7.4.1 General notes/Safety regulations

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

▷ Properly shut down the pump set.

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

▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 43)

▷ Close any auxiliary connections.

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


HPK-L 43 of 62

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.

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

▷ Wear protective clothing.

▷ Always use an appropriate tool to remove gaskets/joint rings.

Observe the general safety instructions and information (⇨ Section 7.1 Page 40).

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

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

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

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.

NOTEIt is recommended to place a drip pan under the pump along its entire length to collectany fluid escaping during dismantling.

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.

7.4.3 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.


44 of 62 HPK-L

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

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

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 43) to (⇨ Section 7.4.3 Page44) have been observed/carried out.

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. Loop a rope tightly around the neck of bearing bracket 330.

4. Undo hexagon nut 920.01 at the volute casing.

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

6. If necessary, clean the threaded holes for forcing screws 901.31 and use forcingscrews.

7. Remove and dispose of joint ring 411.10.

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

7.4.5 Removing the impeller


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

1. Undo hexagon nut 920.95.

2. Remove disc 550.87 from shaft 210.

3. Pull impeller 230 off shaft 210.

4. Remove keys 940.1.

7.4.6 Removing the plain bearing


1. Pull cup spring 950.23 and taper lock ring 515.21 off the shaft. If possible, alsopull out taper lock ring 515.22 and bearing sleeve 529.21 in the process.

7.4.7 Dismantling the bearings


✓ The bearing is kept in a clean and level assembly area.

1. Undo the socket head cap screw or grub screw in the coupling hub and use anextractor to pull the coupling half off the pump shaft. Remove key 940.02.

2. Loosen hexagon head bolts 901.84 and remove fan hood 832.


HPK-L 45 of 62

3. For work on the rolling element bearings or mechanical seal, casing cover 161need not be disassembled from bearing bracket 330. In all other cases, unscrewhexagon nuts 920.04 and pull bearing bracket 330 out of casing cover 161.

4. Undo socket head cap screws 914.02.

5. Gently drive shaft 210 together with rolling element bearings 320.02, bearingcover 360.02, fan impeller 831, seat ring holder 476 and mechanical seal 433 outof bearing bracket 330 towards the drive end.

6. Pull taper lock ring 515.22 and bearing sleeve 529.21 off the shaft (unless this hasalready been done).

7. Pull taper lock ring 515.22 and bearing sleeve 529.21 out of the bearing bracket(unless this has already been done).

8. Bend open lockwasher 931.01, unscrew keywayed nut 920.21 (right-hand thread).Remove lockwasher 931.01, fan impeller 831, bearing cover 360.02, spacer sleeve525.24 and drive-end ring 500.32.

9. Undo grub screws 904.32.

10. Remove support disc 550.59 (LP02 and LP03 only) and O-ring 412.07.

11. Pull shaft sleeve 523 with mechanical seal 433.02 off shaft 210 towards the pumpend.

12. Pull out seat ring holder 476 with the seat ring of the mechanical seal towardsthe pump end.

13. Take the seat ring out of seat ring holder 476.

14. Pull bearing 320.02 off the shaft. Remove thrower 507.12, spacer sleeve 525.03and pump-end ring 500.32 from shaft 210.

NOTEThe bearings are packed with grease and must not be heated up for dismantling, or, ifheated up, they must be re-packed with grease!

7.4.8 Removing the mechanical seals


✓ The bearing bracket is kept in a clean and level assembly area.

1. Undo grub screws 904.32.

2. Remove support disc 550.59 (LP02 and LP03 only) and O-ring 412.07.

3. Pull shaft sleeve 523 with mechanical seal 433.02 off shaft 210 towards the pumpend.

4. Remove seat ring holder 476 with the seat ring of the mechanical seal towardsthe pump end.

5. Take the seat ring out of seat ring holder 476.

7.4.9 Removing the plain bearing bush


✓ The bearing bracket is kept in a clean and level assembly area.

1. Remove circlip 932.05.

2. Completely pull bearing bush 545.21 and tolerance ring 500.61 out of thebearing bracket.


46 of 62 HPK-L

7.5 Reassembling the pump set

7.5.1 General notes/Safety regulations

CAUTIONImproper reassemblyDamage to the pump!

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

▷ Use original spare parts only.

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

▪ Gaskets

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

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

▪ O-rings

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

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

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

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

▪ Assembly adhesives

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

– Should assembly adhesives be required after all, use a commercially availablecontact adhesive (e.g. "Pattex").

– Only apply adhesive at selected points and in thin layers.

– Never use quick-setting adhesives (cyanoacrylate adhesives).

– Coat the locating surfaces of the individual components and screwedconnections with graphite or similar before reassembly.

For reassembly, tighten all screws and bolts as specified in this manual. (⇨ Section 7.6Page 51)

7.5.2 Installing the bearings

✓ 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. Slip thrower 507.12, spacer sleeve 525.03 (for LP02 - LP04 only) and ring 500.32onto shaft 210.

2. Press angular contact ball bearing 320.02 onto the shaft as far as it will go.

NOTEAngular contact ball bearings must be installed in "O" arrangement. Angular contact ballbearings installed in pairs must always be from the same manufacturer.

Sequence

Seal elements

Tightening torques


HPK-L 47 of 62

NOTEThe bearings are packed with grease and must not be heated up for reassembly, or, ifheated up, they must be re-packed with grease!

3. Push spacer sleeve 525.24 onto shaft 210 and use a C-spanner to tightenkeywayed nut 920.21 without lockwasher 931.01. Then unscrew the keywayednut again.

4. Slip ring 500.32, bearing cover 360.02 and fan impeller 831 onto the shaft.

5. Put a few spots of Molykote on the contact faces of the lockwasher and thelocknut. Then slip on lockwasher 931.01.

6. Tighten locknut 920.21 and bend back the lockwasher.

7.5.3 Installing the shaft seal

7.5.3.1 Installing the mechanical seal


✓ 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.

NOTEOnly remove the protective wrapping of the contact faces immediately before assemblytakes place.

1. Insert the seat ring and the secondary seals of the mechanical seal into seat ringholder 476 and push them onto the shaft from the pump end.

2. Push the rotating components of the mechanical seal (torque-transmittingelement, springs, spring-loaded ring, secondary seal, etc.) onto shaft sleeve 523 asa complete sub-assembly. Push this sub-assembly until it will not go any further.Then lock it with the grub screws.

3. For LP02 and LP03: Push shaft sleeve 523 onto shaft 210. The shaft sleeve is correctly positioned on the shaft when its pump-end face ("S"in the following Fig.) is aligned with the mark on the shaft ("M" in the followingFig).

4. Guide O-ring 412.07 and support disc 550.59 carefully along the shaft and pressthem into the recess of shaft sleeve 523.

5. Screw in grub screws 904.32 by several turns to hold the support disc in place.

6. For LP04, LP05 and LP06: Insert O-ring 412.07 into shaft sleeve 523. Carefullyguide the shaft sleeve along the shaft. On pumps with bearing bracket size LP04 to LP06, no mark is provided on theshaft; in this case, align the shaft sleeve with the shaft collar.

7. In doing so, the springs of the mechanical seal are compressed and the seal facesare pressed against each other.

8. Firmly tighten all grub screws 904.32.

9. When all components have been mounted on the shaft, make sure that thecontact faces are slightly pre-loaded by the springs of the mechanical seal (seethe following Fig).

10. Verify the correct axial position of shaft sleeve 523 and mechanical seal 433.02 onshaft 210.


48 of 62 HPK-L

CAUTIONIncorrect position of the mechanical sealHot fluid or steam may spurt out during operation!

▷ Make sure the mechanical seal is seated properly.

LP02,LP03

LP04,LP05,LP06

Mechanical seal M = marking on the shaft; S = face of the shaft sleeve

Table 19: List of components of the mechanical seal (not available as individualparts)

Part No. Description Part No. Description412.1 O-ring 477 Spring412.2 O-ring 485 Torque-transmitting

element472 Spring-loaded ring 520 Sleeve474 Thrust ring 904 Grub screw475 Seat ring

7.5.4 Fitting the plain bearing bush

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 47) to (⇨ Section 7.5.3.1 Page48) have been observed/carried out.

1. If bearing bush 545.21 needs to be replaced, also replace the tolerance ring500.61 in the groove of the bearing bracket

2. Swiftly press bearing bush 545.21 evenly into the bearing carrier (risk offractures: do not subject it to any blows).

3. Insert ring 932.05 into the groove of the bearing carrier to secure the bearingbush axially.

7.5.5 Fitting the bearing carrier


1. Place guard 680 onto the bearing bracket.

2. Fit O-ring 412.82 on the seat ring holder.

3. Push shaft 210 with all assembled components into the bearing bracket.

4. Fasten the bearing cover with socket head cap screws 914.02.

5. Carefully insert joint ring 411.11.

6. Place bearing bracket 330 into casing cover 161 and firmly tighten it with nuts920.04.


HPK-L 49 of 62

7.5.6 Fitting the plain bearing


1. Clean all parts of plain bearing (sleeve) 310.10 and make sure that there are nodirt particles between the conical surfaces of the bearing parts. Otherwise, theparts will not be centred correctly, which will result in failure of the plainbearing.

2. Prior to reassembly check whether the bearing parts and the impeller can beeasily fitted on shaft 210.

3. Slip taper lock ring 515.22, bearing sleeve 529.21, taper lock ring 515.21 and cupspring 950.23 onto the shaft.Mount cup springs 950.23 in such a way that the outside diameter of the cupspring rests against taper lock ring 515.21.

7.5.7 Fitting the impeller


1. Insert key 940.01 and push impeller 230 onto shaft 210.

2. Insert disc 550.87 and tighten hexagon nut 920.95 with a torque wrench. -- Tighten evenly to prevent damage to the bearings. -- Rotate the shaft by handseveral times while tightening the nut (the shaft must be easy to rotate). Stopthe tightening procedure if the shaft seems to be blocked. Loosen the nut andrepeat the tightening procedure. If the shaft is blocked repeatedly, dismantle thecomponents again and check for cleanliness and correct dimensions.

3. After the rotating pump assembly (pump without casing) has been assembled,check the radial shaft run-out at the impeller. Maximum permissible run-out: 0.15 mm.

7.5.8 Fitting the back pull-out unit


1. Carefully insert joint ring 411.10 into volute casing 102.

2. Guide the rotating pump assembly into volute casing 102 and tighten nut 920.01.

3. Check whether the rotor can easily be turned by hand.

4. Bolt support foot 183 to bearing bracket 330 and to the baseplate.

5. Mount fan hood 832 and fasten it together with guard 680, using hexagon headbolts 901.84.

6. Insert key 940.02. Fasten the coupling half on the shaft.

7.5.9 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 27)

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


50 of 62 HPK-L

7.6 Tightening torques

7.6.1 Tightening torques of volute casing/bearing carrier

The threaded connections between volute casing and casing cover (902.01/920.01),between casing cover and bearing bracket (902.04/920.04) and between bearingcover and bearing bracket (914.02) as well as the hexagon nut for impeller fastening920.95 and grub screws 904.32 for fastening the shaft sleeve must be tightened witha torque wrench. Observe the tightening torques given in the table.

Table 20: Tightening torques for screwed connections [Nm]

Part number Screw Material / Stamp mark902.01902.04

Stud DIN 939

1.7709+QT / GA Monix 3K / MM

920.01920.04

Hexagon nutISO 4032

1.7218+QT+A2D / G Monix 3K / MM (M3K)

Thread Brand-newthreads8)

-15 %9) -20 %9) Brand-newthreads8)

-15 %9) -20 %9)

M12 80 68 64 130 111 104M16 190 162 152 320 272 256M20 330 281 264 620 572 496

914.02 Socket head capscrewDIN 7984

8.8 / 8.8

Thread Brand-new threads8) -15 %9) -20 %9)

M8 25 21 20M10 35 30 28M12 59 50 47

904.32 Grub screwDIN 916

A4-50 / -

Thread M6 5 - 9

920.95 Hexagon nutISO 8673

A4 / A4

Thread Brand-new threads -15 %9) -20 %9)

M16x1.5 100 85 80M20x1.5 120 102 96M24x1.5 150 128 120M30x2 350 298 280

7.7 Spare parts stock

7.7.1 Ordering spare parts

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

▪ Type series

▪ Pump size

▪ KSB order number

▪ Material variant

▪ Year of construction

Refer to the name plate for all data. (⇨ Section 4.3 Page 17)

8) These values are determined on the basis of a friction coefficient μ = 0.12.9) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.


HPK-L 51 of 62

Also supply the following data:

▪ Part description

▪ Part No.

▪ Quantity of spare parts

▪ Shipping address

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

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

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

Table 21: Quantity of spare parts for recommended spare parts stock

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

more Quantity of spare parts210 Shaft 1 1 2 2 2 3 30 %230 Impeller 1 1 2 2 2 3 30 %310.10 Plain bearing (product-

lubricated)2 3 4 5 6 8 100 %

320.02 Angular contact ballbearing (set)

1 1 2 2 3 4 55 %

330 Bearing bracket - - - - - 1 2433 Mechanical seal 1 1 2 2 2 3 25 %502.0110) Casing wear ring 2 2 2 3 3 4 50 %523 Shaft sleeve 1 1 1 2 2 2 20 %545.21 Bearing bush (product-

lubricated)2 3 4 5 6 8 100 %

--- Seal elements (set) 4 6 8 8 9 12 150 %

7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

NOTEVolute casing 102 and impeller 230 are not interchangeable between different pumpsizes.

10) Provided as a standard feature on HPK-LS and HPK-LS4 only. Optional feature on HPK-LE and HPK-LE4


52 of 62 HPK-L

Table 22: Interchangeability of pump componentsB

eari

ng

bra

cket

Pum

p s

ize

Description

Cas

ing

co

ver

Sup

po

rt f

oo

t

Shaf

t

Plai

n b

eari

ng

An

gu

lar

con

tact

bal

l bea

rin

g

Bea

rin

g b

rack

et

Bea

rin

g c

ove

r

Mec

han

ical

sea

l

Seat

rin

g h

old

er

Cas

ing

wea

r ri

ng

Thro

wer

Shaf

t sl

eeve

Spac

er s

leev

e

Spac

er s

leev

e

Bea

rin

g b

ush

Gu

ard

Fan

imp

elle

r

Fan

ho

od

Hex

ago

n n

ut

Part No.

161

183

210

310.

10

320.

02

330

360

433.

02

476

502.

01

507.

01

523

525.

03

525.

24

545.

21

680

831

832

920.

95

LP02 32-125 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 125-160 2 2532-160 2 140-160 2 250-160 3 325-200 2 3 2532-200 3 140-200 3 250-200 3 3

LP03 65-160 3 4 2 2 2 2 2 7 2 280-160 5 965-200 4 5 880-200 5 10

100-200 6 1232-250 5 5 640-250 5 550-250 5 465-250 6 880-250 7 1140-315 6 6 550-315 7 7

LP04 100-250 5 8 3 2 3 2 3 3 13 2 3 2 2 2 2 2 2125-250 9 15150-250 10 1665-315 6 8 980-315 9 12

100-315 9 14125-315 10 1680-400 7 10 27100-400 10 14125-400 11 15

LP05 200-250 8 13 4 3 4 4 3 4 4 17 3 4 3 3 3 3 3 3 3150-315 9 12 18200-315 13 19250-315 16 5 21150-400 10 12 18200-400 13 20150-500 11 14 18200-500 17 28


HPK-L 53 of 62

Bea

rin

g b

rack

et

Pum

p s

ize

Description

Cas

ing

co

ver

Sup

po

rt f

oo

t

Shaf

t

Plai

n b

eari

ng

An

gu

lar

con

tact

bal

l bea

rin

g

Bea

rin

g b

rack

et

Bea

rin

g c

ove

r

Mec

han

ical

sea

l

Seat

rin

g h

old

er

Cas

ing

wea

r ri

ng

Thro

wer

Shaf

t sl

eeve

Spac

er s

leev

e

Spac

er s

leev

e

Bea

rin

g b

ush

Gu

ard

Fan

imp

elle

r

Fan

ho

od

Hex

ago

n n

ut

Part No.

161

183

210

310.

10

320.

02

330

360

433.

02

476

502.

01

507.

01

523

525.

03

525.

24

545.

21

680

831

832

920.

95

LP06 250-400 12 17 6 4 5 5 4 5 5 22 4 5 4 4 4 3 3 3 4250-500 13 15 23


54 of 62 HPK-L

8 Trouble-shootingPump delivers insufficient flow rate

Motor overload

Excessive pump discharge pressure

Excessive bearing temperature

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Excessive rise of temperature inside the pump

Table 23: Trouble-shooting

A B C D E F G H Possible cause Remedy 11)

X Pump delivers against an excessivelyhigh discharge pressure.

Re-adjust to duty point.Check system for impurities.Fit a larger impeller. 12)

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

vented or primed.Vent and/or prime.

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

Fit a vent valve.X X X Suction head is too high/NPSH available

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

X Air intake at the shaft seal. Clean barrier fluid duct, supply externalbarrier fluid, if necessary, or increase barrierfluid pressure.Fit new shaft seal.

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

X Speed is too low. 12)

- operation with frequency inverter- operation without frequency inverter

- Increase voltage/frequency at the frequencyinverter within the permissible range.- Check the voltage

X X Impeller 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. 12)

X Density or viscosity of the fluidpumped is higher than stated in thepurchase order.

Contact KSB.

X X Speed is too high. Reduce speed. 12)

X Use of unsuitable materials Change the material combination. X Defective seal Fit new seal between volute casing and

discharge cover. X Worn shaft seal Fit new shaft seal.

Check flushing liquid / barrier fluid.

A

B

C

D

E

F

G

H

11) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.12) Contact KSB.

8 Trouble-shooting

HPK-L 55 of 62

A B C D E F G H Possible cause Remedy 11)

X X Score marks or roughness on shaftprotecting sleeve / shaft sleeve

Replace shaft protecting sleeve / shaft sleeve.Fit new shaft seal.

X Dismantle to find out. Repair necessary. X Vibrations during pump operation. Correct the suction conditions.

Re-align the pump.Re-balance the impeller.Increase the pressure at the pump suctionnozzle.

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

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

X Insufficient or excessive quantity oflubricant or unsuitable lubricant.

Top up, reduce or change lubricant.

X Non-compliance with specifiedcoupling distance.

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 the impeller.Re-balance the impeller.

X Defective bearing(s) Fit new bearing(s). X X X Insufficient flow rate Increase the minimum flow rate. X Incorrect inflow of circulation liquid Increase the free cross-section.

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

8 Trouble-shooting

56 of 62 HPK-L

9 Related Documents

9.1 General assembly drawing with list of components

Fig. 16: General assembly drawing HPK-LS/LE/LS4/LE4

Bearing bracket P04 Bearing bracket P05/P06

Part No. Description Scope of supply102 Volute casing with joint ring 411.01/.02/.03/.04/.10, casing wear ring 502.0113) , Zylinderstift

561.0113) , stud 902.01, screwed plug 903.01/.02/.03/.04, hexagon nut 920.01161 Casing cover with joint ring 411.11, hexagon head bolt 901.31, stud 902.04, hexagon nut

920.04183 Support foot with hexagon head bolt 901.04, spring washer 930.01*210 Shaft with disc 550.87, keywayed nut 920.21, hexagon nut 920.95, lockwasher

931.01, key 940.01/.02230 Impeller *310.10 Plain bearing (sleeve) with taper lock rings 515.21/.22, bearing sleeve 529.21, cup spring 950.23

13) For HPK-LS/LS4 only

9 Related Documents

HPK-L 57 of 62

Part No. Description Scope of supply*320.02 Angular contact ball

bearing

*330 Bearing bracket 330 Bearing bracket

(complete)Comprising all parts marked *.

*360.02 Bearing cover *411.20 Joint ring *411.85 Joint ring *433.02 Mechanical seal *476 Seat ring holder *500.32 Ring *500.61 Tolerance ring *507.12 Thrower *523 Shaft sleeve with O-ring 412.07, support disc 550.59 (LP02 and LP03 only), grub screws

904.32*525.03 Spacer sleeve *525.24 Spacer sleeve *545.21 Bearing bush *550.87 Disc *561.52 Grooved pin *680 Guard *720.22 Nipple joint *831 Fan impeller *832 Fan hood * 901.84 Hexagon head bolt *903.20 Screwed plug *903.85 Screwed plug *914.02 Socket head cap screw *920.95 Hexagon nut *932.05 Circlip 99-9 Set of seal elements with joint ring 411.01/.02/.03/.04/.10/.11/.20/.85, O-ring 412.07/.82

9 Related Documents

58 of 62 HPK-L

10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

HPK-L

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 were applied:

– ISO 12100-1/A1, ISO 12100-2/A1,

– ISO 14121-1,

– EN 809/A1

Pegnitz, 29 December 2009

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

Name

Function

Responsible for compiling the technical documentationKSB Aktiengesellschaft

Bahnhofplatz 1

91257 Pegnitz (Germany)

10 EC Declaration of Conformity

HPK-L 59 of 62

11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number14) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled14) : ................................................................................................................................

Please tick where applicable14) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return14) : ................................................................................................................................ 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

14) Required fields

11 Certificate of Decontamination

60 of 62 HPK-L

Index

AAbrasive fluids 38

BBearing temperature 41

CCertificate of decontamination 60Clearance gaps 42Commissioning/start-up 32Coupling 42Coupling alignment 27

DDescription of the fluid handled 16Design 17, 19Designation 16Direction of rotation 31Dismantling 44Disposal 14

EExplosion protection 11, 21, 26, 28, 29, 30, 33, 35, 37,40, 41

FFilling and venting 33Filter 23, 42Final check 34Flow rate 37Frequency of starts 37Function 19

HHeating speed 34Heating up 34

IImpeller type 17Installation

Installation on foundation 21Installation without foundation 22

Installation at site 21Intended use 8Interchangeability of pump components 52

KKeeping the pump warm 34

MMaintenance/repair 40Mechanical seal 36Misuse 9Monitoring equipment 12

NNoise characteristics 20

OOperating limits 8Order number 6Ordering spare parts 51Other applicable documents 6

PPartly completed machinery 6Permissible forces and moments at the pump nozzles24Piping 23Preservation 14, 39

RReassembly 44Return to supplier 14Returning to service 39Running noises 40, 41

SSafety 8Safety awareness 9Scope of supply 20Shaft seal 18Shutdown 36, 39Spare parts stock 52Start-up 35Storage 14, 39

TTemperature difference 34Temperature limits 11Trouble-shooting 55

Index

HPK-L 61 of 62

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

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