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					Operating instructions
1384.8/5 -- 10                                                                                       Omega
                                                                                         Volute casing pump
                                                                                                with radial impeller




                                                                                                        Pump unit
                                                                                           Horizontal installation -- 3 E




 Works-No.:                    see nameplate


                               The operating manual contains important information and hazard/danger
                               warnings. It is imperative to read the instructions set out in the manual prior
              !                to installation, making electrical connections and commissioning. Additional
                               operating instructions relating to the components of this plant will also have
                               to be observed.


                               In principle if any work has to be carried out to the plant all electrical supplies
                               (inclusive of the control cable) should be disconnected at the mains supply
                               switch. The plant has to be safeguarded against accidental starting.




Ident--No.:       01 059 616
                                       Omega




    For usage in hazardous locations
    refer to supplementary operating
    instructions 1387.81.




2
                                                                                                                                                                                               Omega


Contents                                                                                                                                                                                             Page
1      General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                            4
2      Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                           4
2.1    Marking of Instructions in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                            4
2.2    Personnel Qualification and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                           4
2.3    Non--Compliance with Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                 4
2.4    Safety Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .               4
2.5    Safety Instructions for the Operator / User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                              5
2.6    Safety Instructions for Maintenance, Inspection and Installation Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                    5
2.7    Unauthorized Modification and Manufacture of Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                               5
2.8    Unauthorized Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                            5
3      Transport and Interim Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                5
3.1    Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .        5
3.2    Interim Storage / Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                       6
4      Description of the Product and Accesories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                            6
4.1    Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                6
4.2    Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .          7
4.3    Design Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .           7
4.4    Types of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .              7
4.5    Accessories (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                 7
4.6    Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                     7
5      Installation at Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                   7
5.1    Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .               7
5.2    Checks to Be Carried out Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                 7
5.3    Installing the Pump / Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                 8
5.4    Connecting the Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                  8
5.5    Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .          8
6                          -up / Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
       Commissioning, Start-                                                                                                                                                                            9
6.1    Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .              9
6.2    Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .         9
6.3    Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .      9
6.4    Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .              9
6.5    Shutdown / Storage / Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                           10
6.6    Returning to Service after Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                        10
7      Maintenance / Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                      10
7.1    General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .              10
7.2    Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                  11
7.3    Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .         11
7.4    Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .          12
7.5    Instructions for Replacing Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                14
7.6    Monitoring schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .               15
8      Special Instructions for Subassemblies (Shaft Seal Variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                        16
8.1    Gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .           16
8.2    Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                         17
9      Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                               32
10     Forces and Moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                        34
11            -Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
       Trouble-                                                                                                                                                                                        35
11.1   General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .     35
11.2   Trouble--shooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                 36
12     Routine Maintenance and Inspection Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                              40
13     Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                              41


                                                                                                                                                                                                        3
                                                                                                                             Omega

1         General                                                     The word

This KSB pump has been developed in accordance with
state- -the-
     -of-   -art technology; it is manufactured with ut-                                       Caution
most care and subject to continuous quality control.
These operating instructions are intended to facilitate familiari-    is used to introduce safety instructions whose non--observance
zation with the pump and its designated use.                          may lead to damage to the machine and its functions.
The manual contains important information for reliable, proper        Instructions attached directly to the machine, e.g.
and efficient operation. Compliance with the operating instruc-
tions is of vital importance to ensure reliability and a long ser-    -- arrow indicating the direction of rotation
vice life of the pump and to avoid any risks.                         -- markings for fluid connections
These operating instructions do not take into account local re-       must always be complied with and be kept in perfectly legible
gulations; the operator must ensure that such regulations are         condition at all times.
strictly observed by all, including the personnel called in for in-
stallation.                                                           2.2        Personnel Qualification and Training
This pump / unit must not be operated beyond the limit values         All personnel involved in the operation, maintenance, inspec-
specified in the technical documentation for the medium hand-         tion and installation of the machine must be fully qualified to
led, capacity, speed, density, pressure, temperature and motor        carry out the work involved.
rating. Make sure that operation is in accordance with the in-
structions laid down in this manual or in the contract documen-       Personnel responsibilities, competence and supervision must
tation.                                                               be clearly defined by the operator. If the personnel in question
                                                                      is not already in possession of the requisite know--how, appro-
The name plate indicates the type series / size, main operating       priate training and instruction must be provided. If required, the
data and works / series number; please quote this information         operator may commission the manufacturer / supplier to take
in all queries, repeat orders and particularly when ordering          care of such training. In addition, the operator is responsible for
spare parts.                                                          ensuring that the contents of the operating instructions are fully
If you need any additional information or instructions exceeding      understood by the responsible personnel.
the scope of this manual or in case of damage please contact
KSB’s nearest customer service centre.                                2.3           -Compliance with Safety Instructions
                                                                                 Non-
                                                                      Non--compliance with safety instructions can jeopardize the sa-
                                                                      fety of personnel, the environment and the machine itself. Non--
2         Safety                                                      compliance with these safety instructions will also lead to forfei-
These operating instructions contain fundamental information          ture of any and all rights to claims for damages.
which must be complied with during installation, operation and        In particular, non--compliance can, for example, result in:
maintenance. Therefore this operating manual must be read
and understood both by the installing personnel and the re-           -- failure of important machine / unit functions
sponsible trained personnel / operators prior to installation and     -- failure of prescribed maintenance and servicing practices
commissioning, and it must always be kept close to the location       -- hazard to persons by electrical, mechanical and chemical
of operation of the machine / unit for easy access.                       effects
Not only must the general safety instructions laid down in this       -- hazard to the environment due to leakage of hazardous
chapter on ”Safety” be complied with, but also the safety in-             substances
structions outlined under specific headings.
                                                                      2.4        Safety Awareness
2.1       Marking of Instructions in the Manual
                                                                      It is imperative to comply with the safety instructions contained
The safety instructions contained in this manual whose non--          in this manual, the relevant national health and safety regula-
observance might cause hazards to persons are specially mar-          tions and the operator’s own internal work, operation and safety
ked with the general hazard sign, namely                              regulations.




safety sign in accordance with DIN 4844 -- W9.
The electrical danger warning sign is




safety sign in accordance with DIN 4844 -- W8.




4
                                                                                                                               Omega

2.5         Safety Instructions for the Operator / User               3          Transport and Interim Storage
--    Any hot or cold components that could pose a hazard must
      be equipped with a guard by the operator.                       3.1        Transport
--    Guards which are fitted to prevent accidental contact with
                                                                      Transport of the unit requires proper preparation and handling.
      moving parts (e.g. coupling) must not be removed whilst the
                                                                      Always make sure that the pump or the unit remains in horizon-
      machine is operating.
                                                                      tal position during transport and cannot slip out of the transport
--    Leakages (e.g. at the shaft seal) of hazardous media hand-      suspension arrangement. Do not use lifting slings on the free
      led (e.g. explosive, toxic, hot) must be contained so as to     shaft end of the pump or on the motor eyebolt.
      avoid any danger to persons and the environment. Perti-
                                                                              Also make sure that the coupling guard is not damaged
      nent legal provisions must be adhered to.
                                                                              by the sling arrangement.If the pump / unit slips out of
--    Electrical hazards must be eliminated. (In this respect refer           the suspension arrangement, it may cause personal in-
      to the relevant safety regulations applicable to different              jury and damage to property.
      countries and/or the local energy supply companies.)
                                                                      Transport in horizontal position is recommended in all cases,
                                                                      since this ensures stable positioning of the unit without any risk
2.6         Safety Instructions for Maintenance,                      of accident, whatever the method of transport, e.g. road, rail or
            Inspection and Installation Work                          ship, etc.
The operator is responsible for ensuring that all maintenance,        For transport purposes the unit shall be secured on suitable pal-
inspection and installation work be performed by authorized,          lets or sleds. All loose and movable parts must be secured.
qualified specialist personnel who are thoroughly familiar with
the manual.
Work on the machine must be carried out only during standstill.
The shutdown procedure described in the manual for taking the
machine out of service must be adhered to without fail.
Pumps or pump units handling media injurious to health must
be decontaminated.
Immediately following completion of the work, all safety--rele-
vant and protective devices must be re--installed and/or re--acti-
vated.
Please observe all instructions set out in the chapter on ”Com-
missioning” before returning the machine to service.

2.7         Unauthorized Modification and
            Manufacture of Spare Parts
Modifications or alterations of the machine are only permitted        Fig.1:    Transport of pump                    (Fig.0)
after consultation with the manufacturer. Original spare parts
and accessories authorized by the manufacturer ensure safety.
The use of other parts can invalidate any liability of the manu-
facturer for consequential damage.

2.8         Unauthorized Modes of Operation
The warranty relating to the operating reliability and safety of
the pump / unit supplied is only valid if the machine is used in
accordance with its designated use as described in section 1
of these operating instructions. The limits stated in the data
sheet must not be exceeded under any circumstances.



                                                                      Fig.2:     Transport of motor
                                                                               The motor eyebolts must only be used for lifting the mo-
                                                                               tor alone, never for lifting the complete unit.




                                                                                                                                      5
                                                                                                                      Omega




Fig.3:    Never transport the unit as shown above!           Fig.4c:              Transport of unit (without motor)

                                                                                  -- motor sizes 315 and above
                                                                                  -- or total weight (unit) of 1500 kg and above

                                                                       Safe transport in horizontal position must be ensured by
                                                                       suitable transport facilities. Make sure the pump cannot
                                                                       slip out of the transport arrangement.


                                                             3.2         Interim Storage / Preservation
                                                             When the unit is temporarily put into storage, only the wetted
                                                             low alloy components, e.g. JL1040 (GG--25) must be preser-
                                                             ved. Commercially available preservatives can be used for this
                                                             purpose. Please observe the manufacturer’s instructions for
                                                             application / removal.
Fig.4a:           Transport of complete unit
                  (horizontal installation type 3E)

                   -- up to motor size 280 (IEC standard)    4           Description of the Product and
                   -- or up to a total weight of 1500 kg                 Accesories
                  Observe angles of pull when lifting.
                  Angle of pull > 90_ not permitted.         4.1         Technical Specification
                  Use two separate sets of lifting slings!   Design
                                                             The KSB pump of the Omega series is a horizontally installed,
                                                             single--stage, axially split volute casing pump with double--en-
                                                             try radial impeller. Connection flanges are manufactured accor-
                                                             ding to EN, DIN, ISO, BS or ASME, as preferred.
                                                             Fields of application
                                                             In waterworks, irrigation and drainage pumping stations, power
                                                             stations, for industrial water supply, dock installations, fire ex-
                                                             tinguishing systems, refineries, pipelines and tank farms, also
                                                             for handling crude oil and refinery intermediates




Fig.4b:           Transport of complete unit

                   -- up to motor size 280 (IEC standard)
                   -- or up to a total weight of 1500 kg




6
                                                                                                                               Omega

4.2        Designation                                                 4.5         Accessories (optional)
                                Omega          XXX       XXX      X    The following accessories are available:
Type series                                                                                        g
                                                                                             Configuration                 Omega
Discharge nozzle DN mm                                                  Accessories                                Fig.0           3E
Nominal impeller dia.                                                   Motor                                       ----           x 1)
Impeller type (A,B,C)                                                   Baseplate/baseframe                         ----           x 1)
                                                                        Coupling and coupling guard                 ----           x 1)
4.3        Design Details                                               Sealing and flushing water pi-               x              x
                                                                        ping
4.3.1      Pump Casing                                                  Set of pressure gauges                      x               x
Axially split volute casing with replaceable casing wear rings.         Cyclone separator with pipework             x               x
Suction and discharge nozzles in lower half of casing are at the        Vent valve (manual or automatic)            x               x
same level (inline version).                                            Temperature sensor for rolling              x               x
                                                                        element bearings (PT 100)
4.3.2      Impeller                                                     Signal transmitter for PT 100               x               x
The double--entry radial impeller is manufactured for the opera-        Drain line                                  x               x
ting data provided in each case. Also with impeller wear rings,        1)   included in standard scope of supply
if requested.
In double--entry radial impellers the axial thrust is largely balan-   4.6         Dimensions and Weights
ced.
                                                                       For dimensions and weights please refer to the tables in the ap-
4.3.3      Pump Shaft                                                  pendix.
The shaft is fully sealed against the liquid being pumped. Shaft--
protecting sleeves are fitted in the seal area.
                                                                       5           Installation at Site
4.3.4      Shaft Seal
The shaft seals at the drive end and non--drive end are gland          5.1         Safety Regulations
packings or mechanical seals, as requested.
                                                                               Electrical equipment operated in ”zone 1” hazardous
4.3.5      Bearings and Lubrication                                            locations must comply with the explosion protection
                                                                               regulations. This is indicated on the motor rating pla-
The pump is fitted with covered deep--groove ball bearings                     te.
which are grease--lubricated for life.
                                                                       If the equipment is installed in hazardous locations, the applica-
The fixed bearing at the non--drive end is located on a bush to
                                                                       ble local explosion protection regulations and the regulations of
permit rapid changing without removing the rotor or upper half.
                                                                       the test certificate supplied with the equipment and issued by
                                                                       the responsible approval authorities must be observed and
4.4        Types of Installation                                       complied with.
The pump set is installed in configuration 3E -- horizontal instal-    The test certificate must be kept close to the location of opera-
lation, direct--coupled (see appendix).                                tion for easy access (e.g. foreman’s office).

                                                                       5.2         Checks to Be Carried out Prior to
                                                                                   Installation
                                                                       All structural work required must have been prepared in accor-
                                                                       dance with the dimensions and loads stated in the dimension
                                                                       table / installation plan.
                                                                       The concrete foundations shall have sufficient strength
                                                                       (min. BN 25) to ensure safe and functional installation in
                                                                       accordance with DIN 1045 or equivalent standards.
                                                                       Make sure that the concrete foundation has set firmly before
                                                                       placing the unit on it. Its surface shall be truly horizontal and
                                                                       even.




                                                                                                                                          7
                                                                                                                              Omega

5.3         Installing the Pump / Unit                                 5.4       Connecting the Piping
    Caution     Before setting up the pump, check the                    Caution        Never use the pump itself as an anchorage
                operating data. Ensure that the data on the                             point for the piping.
name plate matches the data in the order and the system data,
e.g. operating voltage, frequency, pumped liquid temperature           Suction lift lines shall be laid with a rising slope towards the
etc.                                                                   pump and suction head lines with a downward slope towards
                                                                       the pump. The pipelines shall be anchored in close proximity to
After placing the pump on the foundation, align it with the help       the pump and connected without transmitting any stresses or
of a spirit level. Shims shall be fitted between the baseplate and     strains. Their weight must not exert any load on the pump. With
the foundation itself; they shall always be inserted to the left and   short pipelines, the nominal diameters shall be at least equal to
right of the foundation bolts and in close proximity to these          the nominal diameters of the pump nozzles. For long pipelines
bolts. For a bolt--to--bolt clearance of more than 1000 mm, addi-      the most economical nominal diameter has to be determined
tional shims shall be inserted halfway between the adjoining           from case to case.
holes. All shims must lie perfectly flush.                             Any additional loads on the discharge and suction nozz-
                                                                       les, e.g. caused by:
           Shim                 Shim             Shim
                                                                       Weight of the water--filled pipes, changes in the length of pipes
                                                                       owing to temperature fluctuations, reaction forces due to unbra-
                                       1000                            ced expansion joints must not exceed the values stated in the
                                                                       installation plan.
                                                                               An excessive, impermissible increase in the pipeline
                                                                               forces may cause leaks on the pump where the medium
                                                                               handled can escape into the atmosphere.
                                                                               Danger of life when hot media are handled!
                           Foundation bolts
                                     1000                              The flange covers on the pump suction and discharge nozzles
                                                                       must be removed prior to installation in the piping.
Fig.5: Fitting required shims                                          5.4.1     Auxiliary Connections
Insert the foundation bolts and set them into the foundation           The locations of the auxiliary connections (sealing liquid, flus-
using concrete. When the concrete has set, align the baseplate         hing liquid, etc.) are indicated on the installation plan or piping
as described in section 5.3.2 and tighten the foundation bolts         layout (see appendix).
evenly and firmly. Then grout the baseplate using low shrinkage
concrete, making sure no cavities remain.                              Please refer to the appendix for detailed assembly instructions.
5.3.1       Removing Rotor Lock                                          Caution        These connections are required for proper
                                                                                        functioning of the pump and are therefore of
This is not necessary for a horizontally installed pump, since no                       vital importance!
locking device is fitted.
                                                                       5.4.2       Coupling Guard
5.3.2       Aligning the Pump / Drive
                                                                               In compliance with the accident prevention regulations
         Improper alignment of the unit can cause damage to
                                                                               the pump must not be operated without a coupling
         both the coupling and the unit itself!
                                                                       guard. If the customer specifically requests not to include a cou-
A pump set in horizontal installation type 3E is correctly aligned,    pling guard in our delivery, then the operator must supply one.
if a straight--edge placed axially on both coupling halves is the
same distance from each shaft at all points around the circum-
ference. In addition, the distance between the two coupling hal-       5.5       Final Check
ves must remain the same all around the circumference. Use             Re--check the alignment as described in section 5.3.2.
a feeler gauge, a wedge gauge or a dial micrometer to verify           It must be easy to rotate the shaft by hand at the coupling.
(see fig. 6).                                                                          Check the integrity and proper functioning of all
                                                                          Caution
                                                                                       connections.
               straight edge




           straight edge          gauge


Fig.6:   Coupling alignment, using gauge and straight edge
         Special instructions see appendix




8
                                                                                                                                Omega

6                             -up /
          Commissioning, Start-                                      Correct direction of rotation:
          Shutdown                                                   The direction of rotation must correspond to the direction indi-
                                                                     cated by the arrow on the pump. This can be verified by swit-
    Caution   Compliance with the following requirements is
                                                                     ching the pump on and then off again immediately.
              of paramount importance. Damage resulting
from non--compliance shall not be covered by the scope of                   Before checking the direction of rotation make sure that
warranty.                                                                   there is no foreign matter in the pump casing.
                                                                     Never put your hands or any other objects into the pump!
6.1       Commissioning                                              6.4.2           -up
                                                                                Start-
Before starting up the pump make sure that the following requi-
                                                                                         If a non--return valve is not fitted at the di--
rements have been checked and fulfilled:                               Caution           scharge--side, close the discharge--side
-- Has the pump been firmly bolted to the foundation?                                    gate valve.
-- Have the coupling and pump unit been aligned as speci-            If a shut--off valve is fitted in the suction line, open it fully.
   fied?
                                                                     All additional connections for flushing or sealing liquid etc., if fit-
-- Can the unit be easily rotated by hand at the coupling?           ted, must be opened fully and the flow must be checked.
   (Carry out at least one full rotation)
                                                                     Switch on the motor.
-- Are the pipes properly fitted?
-- Has the coupling guard been fitted?                               As soon as the pump starts to deliver -- this can be recognised
                                                                     by the rising gauge pressure -- slowly open the discharge--side
-- Have staff been informed about sources of danger and              gate valve fully.
   measures been taken to comply with the accident preven-
   tion regulations?                                                   Caution         The pump may operate against the closed gate
                                                                                       valve only during start--up and shutdown, as
-- Correct start--up procedure for suction lift operation.           otherwise inadmissible temperature rise occurs resulting in
-- Is the unit protected against overload (appropriate safety        damage.
   valve)?
-- Have the seals been fitted as described in the appendix?          6.4.3      Pump Operating Range
-- Have any additional devices been prepared and fitted as           The flow rate ”Q” adjusts itself automatically to the delivery
   specified in the appendix?                                        head according to the H--Q characteristic. The pump’s permit-
-- Has the pump been vented as specified in section 6.3.?            ted operating range is subject to limits, which have separate
                                                                     causes.
6.2       Shaft Seal                                                 1. Part load operating limit for low flow rate

For commissioning the shaft seal please refer to section 8.1 /       This limit is indicated in the H--Q characteristic by Qmin or by the
8.2. If the pump has been out of service for a prolonged period,     discontinuation of the characteristic curve.
the measures specified in section 6.6 must be carried out.              Caution         It is not permissible to operate the pump in the
                                                                                        range from Q=0 to Qmin. Prolonged operation
                                                                     in this range causes greatly increased mechanical loads which
6.3       Venting                                                    the components cannot withstand.
Before start--up, the pump and the pipes must be vented and
filled with the liquid to be pumped. This is done at the vent plug   Brief passage through the critical range is permissible, e.g. du-
on the casing (903). For suction lift operation, the pump must       ring start--up
also be evacuated, i.e. a vacuum must be produced.                   2. NPSH--related limits in the part load and overload ranges
                                                                     These two limits are determined by the ratio of NPSHrequired to
6.4       Commissioning                                              NPSHavailable. They are determined as follows:

6.4.1   Checking the Direction of Rotation
  Caution    For trouble--free operation of the pump, the
             correct direction of rotation of the impeller is of
paramount importance.
If running in the wrong direction of rotation, the pump cannot re-
ach its duty point; vibrations and overheating will be the conse-
quence. The unit or the shaft seal might be damaged.




                                                                                                                                            9
                                                                                                                               Omega

The intersections of NPSHrequired and NPSHavailable are pro-           6.5.2      Measures to be Taken for Prolonged Shutdown
jected onto the H--Q characteristic, where they indicate the ope-
                                                                       1. The pump remains installed; periodic check of opera-
rating limits (refer to the diagram below). Checking of the
                                                                          tion
NPSH--related operating limit is not necessary for operating the
pump under design conditions. If system--related changes oc-           In order to make sure that the pump is always ready for instant
cur, an NPSH check must be carried out. If necessary, consult          start--up and to prevent the formation of deposits within the
the nearest after--sales service centre.                               pump and the pump intake area, start up the pump set regularly
                                                                       once a month or once every 3 month for a short time (approx.
                                                                       5 minutes) during prolonged shutdown periods. Prior to an ope-
                                                                       ration check run ensure that there is sufficient liquid available
                                                                       for operating the pump.
                                                                       2. The pump is removed from the pipe and stored
                                                                       Before putting the pump into storage carry out all checks speci-
                                    Qmin
                                                                       fied in sections 7.1 to 7.4. Then apply appropriate preservati-
                                               NPSHrequired            ves:
                                                                       -- Spray--coat the inside wall of the pump casing, and in parti-
                                                                           cular the impeller clearance areas, with a preservative.
                                                                           Spray the preservative through the suction and discharge
                                                 NPSHavailable             nozzles. It is advisable to close the nozzles (for ex. with pla-
                                                                           stic caps or similar).

                                                                       6.6        Returning to Service after Storage
                                                                       Before returning the pump to service carry out all checks and
                                                                       maintenance work specified in sections 5.1 and 5.2.
                                                                              In addition, the instructions laid down in section 6.1
                                                                              ”Commissioning” and section 6.4.3 ”Operating limits”
                                                                              must be observed.
6.4.4      Shutdown
Close the shut--off element in the discharge line. If the di-                  Upon completion of the work, all safety--related and pro-
                                                                               tective equipment must be properly refitted and / or re-
scharge line is equipped with a check valve, the shut--off ele-
                                                                               activated before starting the pump set.
ment may remain open, provided there is back pressure in the
line.
      The shut--off element in the suction line must not be clo-
      sed when switching off the pump. Switch off the motor,           7          Maintenance / Repair
making sure that the unit runs smoothly down to a standstill.
Depending on the system the pump shall have an adequate af-            7.1        General Instructions
ter--run period -- with the heat source switched off -- to allow the   The operator is responsible for ensuring that all maintenance,
medium handled to cool down sufficiently to avoid any heat             inspection and installation work is carried out by authorized,
build--up within the pump.                                             duly qualified staff who are thouroughly familiar with these ope-
In the case of prolonged shutdown, the shut--off element in the        rating instructions.
suction line has to be closed.                                         A regular maintenance schedule will help avoid expensive re-
Close the auxiliary connections.                                       pairs and contribute to trouble--free, reliable operation of the
In the event of frost and / or prolonged shutdowns, the pump           pump with a minimum of maintenance expenditure and work.
must be drained or otherwise protected against freezing.
                                                                               Work on the pump and the motor must only be car-
                                                                               ried out with the electrical connections disconnec-
6.5        Shutdown / Storage / Preservation                           ted. Make sure that the pump set cannot be switched on ac-
Each KSB pump leaves the factory carefully assembled. If com-          cidentally (danger of life!).
missioning is to take place some time after delivery, we recom-                Pumps handling liquids posing health hazards must be
mend that the following measures be taken for pump storage.                    decontaminated. When draining the medium see to it
                                                                       that there is no risk to persons or the environment. All relevant
6.5.1      Storage of New Pumps                                        laws must be adhered to (danger of life!).
-- New pumps are supplied by our factory duly prepared for
    storage.
    Maximum protection for up to 12 months, if the pump is pro-
    perly stored indoors.
-- Store the pump in a dry location.




10
                                                                                                                            Omega

7.2       Maintenance / Inspection                                    Dismantling and reassembly must always be carried out in ac-
                                                                      cordance with the relevant general drawing. The general dra-
7.2.1   Supervision of Operation                                      wing and other relevant documents are found in the annex. The
            The pump shall run quietly and free from                  dismantling sequence can be derived from the general dra-
  Caution                                                             wing.
            vibrations at all times. The pump must never be
            allowed to run dry.                                       In case of damage you can always contact our nearest custo-
        Prolonged operation against a closed shut--off element        mer service centre.
        is not permitted in order to prevent the medium handled
                                                                      7.3.2     Preparations for Dismantling
        from heating up.
                                                                      The pump is designed so that the complete rotor can be remo-
At room temperatures of up to 30 _C (86 _F) the bearing tempe-        ved in the sequence described below without removing the suc-
rature shall be below 90 _C (194 _F). At higher room tempera-         tion or discharge pipe or disturbing the alignment of the pump
tures, the bearing temperature shall be below 100 _C (212 _F).        unit:
        During pump operation the shut--off element in the inlet      -- Close the suction and discharge--side gate valves and drain
        line must not be closed.                                          the pump by opening the drain plug (903.01 bottom) and
                                                                          vent plug (903.01 top).
Any stand--by pumps installed shall be switched on and then
immediately off again once a week to keep them operational.           -- Remove any pipes between additional equipment and the
Attention shall be paid to the correct functioning of the auxiliary       pump.
connections.                                                          -- Remove the coupling guard. Decouple pump--side coupling
                                                                          half as described in the appendix.
  Caution      If the flexible coupling elements begin to show
               signs of wear, they must be replaced in due            -- Loosen and push back the seal cover (471), if a mechanical
time. See section ”Coupling”.                                             seal is fitted.
                                                                      -- Undo the flange screws (901.01 / 901.02) and separate the
If an external supply of sealing, flushing or lubricating liquid is       upper casing half (105.02) from the lower casing half
used, make sure supply pressure is 1.0 to 2.0 bar higher than             (105.01) with the aid of the forcing screws. Remove with lif-
pressure at the suction nozzle.                                           ting gear. The interior of the pump (impeller with casing
On pumps fitted with a gland packing the packing must drip                wear rings, shaft seal) is now accessible for inspection.
slightly during operation. The gland cover should therefore only      -- Remove the screwed connection (901.04) between bearing
be gently tightened. (See section 8 ”Special instructions for             housing (350.01) and bearing brackets. Also undo the nuts
subassemblies, shaft seal variants”).                                     (920.05) and bolts (901.07) which secure the bearing cover
                                                                          (360).
7.2.2     Shaft Seal Maintenance
                                                                      -- Press the bearing housing out of the recesses and lift the
For required maintenance work on gland packings please refer              rotor out of the lower casing half. For further disassembly,
to section 8.1. ”Shaft seal”. Mechanical seals are mainte-                place securely in horizontal position.
nance--free.
                                                                      -- Pull off the bearing housing of the fixed bearing (opposite
7.2.3     Bearing Maintenance                                             the drive end).
The bearings are maintenance--free and greased for life. No           -- Undo and remove the keywayed nuts (920.03).
re--lubrication is required.                                          -- Remove the deep--groove ball bearing (321) with bush
                                                                          (520) from the shaft.
7.3       Dismantling                                                 -- Remove the bearing cover (360).
       Before dismantling, secure the pump so as to make sure         -- Remove the V--ring (412.02) from the shaft--protecting
       it cannot be switched on accidentally. The shut--off ele-          sleeve (524.01).
ments in the suction and discharge lines must be closed. The          -- Pull off the shaft--protecting sleeve (524.01).
pump must have cooled down to ambient temperature, pump               -- Remove the shaft seal housing (441).
pressure must be released and the pump must be drained.
                                                                      -- The impeller (234) is located with a sliding fit on the shaft
Dismantling and reassembly must always be carried out in ac-              and can normally be removed easily. In case of difficulty, it
cordance with the relevant sectional drawing.                             can be loosened by gently tapping the hub with a wooden
                                                                          hammer.
7.3.1     Fundamental Instructions and
                                                                      -- Remove the second shaft protection sleeve (524.01) com-
          Recommendations
                                                                          plete with the shaft seal housing (441), if fitted.
Repair and maintenance work to the pump must only be carried          -- Remove the coupling half.
out by specially trained personnel, using original spare parts.
                                                                      -- Pull off the bearing housing (350.01).
Observe the safety regulations laid down. Any work on the mo-
                                                                      -- Remove the circlip (932) and pull off the deep--groove ball
tor shall be governed by the specifications and regulations of
                                                                          bearing (321).
the respective motor supplier.




                                                                                                                                    11
                                                                                                                        Omega

7.4         Reassembly
Reassembly is effected in reverse order to dismantling. For all
work on the pump unit refer to the general drawing, in conjunc-
tion with the list of components, for orientation.
The rules of sound engineering practice and also the instruc-
tions for removal and installation of shaft seal, bearings, impel-
ler wear rings and casing wear rings (sections 7.5.1 and 7.5.2)
must be observed.
The tightening torques indicated for nuts and bolts shall be ob-
served. The table below indicates the tightening torques for
threads depending on the materials used.
     Property class     (Material)                8.8        10.9         A.-50     A.-70     1.4462       1.4462
                                                                                                        Tigges A.--80
             0.2% yield stress                   640          900         210               450              624
         Rp 02 in N/mm2           1)                                                  250      450
            Metric ISO threads                                             Tightening torque
     coarse--pitch-        fine--pitch-                                         MA in Nm
          M4                                      3.1         4.4         1.0               2.15             3.1
          M5                                      6.1         8.7         2.00              4.25             6.0
          M6                                     10.4        14.9         3.40              7.30             10.3
          M8                                     25.2        36.1         8.30              17.7             25.0
                              M8x1               27.2        39.0         8.90              19.1             27.0
         M10                                     49.5        71.0         16.2              34.8             49.2
                           M10x1.25              52.5        75.4         17.3              36.9             52.3
         M12                                     85.2       122.2         28.0              59.9             84.8
                            M12x1.5              89.5       128.5         29.4              62.9             89.1
                           M12x1.25              93.9       134.7         30.8              66.0             93.1
         M16                                      211       302.7         69.2              148             209.9
                            M16x1.5               226       324.7         74.3              159             225.2
         M20                                      412       591.9         135               290             410.4
                            M20x1.5               461       661.0         151               324             458.3
         M24                                      710       1019.6        233         276         500       706.9
                              M24x2               780       1118.6        256         305         548       775.6
         M27                                     1050       1501.3        343         409         736      1040.9
                              M27x2              1130       1627.1        372         443         797      1128.1
         M30                                     1420       2036.4        466         554        1000      1411.9
                              M30x2              1580       2269.9        519         618        1110      1573.8
         M33                                     1940       2779.4        636          ----      1360      1927.0
                              M33x2              2130       3062.6        700          ----      1500      2123.4
         M36                                     2480       3552.3        812          ----      1740      2462.9
                              M36x3              2630       3775.4        863          ----      1850      2617.6
1)   Nominal values to DIN ISO 898 Part 1, DIN 267 Part 11 and DIN 267 Part 18
It is imperative to lock and seal the screwed connections spe-
cially marked in the general drawings.                                                 ALTEMP Q NB 50 grease
Symbols for screwed connections to be locked and sealed:



                                                                                       Sealed with Loctite 574




12
                                                                                                                                   Omega

O--rings and V--rings must be replaced and their seats on the           Push the sleeve (520) with deep--groove ball bearing (321) onto
shaft must be cleaned. In addition, all the sealing elements            the pump shaft (211) with key (940.01) inserted.
must be fitted into the respective components before installa-          Tension the rotor parts elastically with keywayed nut (920) and
tion.                                                                   cup spring (950). For this purpose tension the cup spring (950)
For assembling the rotor, position the pump shaft (211) secu-           to blocking point and then undo the keywayed nut (920) again
rely. All fits, threads and sliding fits of the shaft must be cleaned   by half a turn (180_).
and coated with assembly paste.
                                                                          Caution      This measure is essential to compensate for
Insert the keys required for assembly into the pump shaft (211).                       differences in thermal expansion between the
Mount the impeller (234), which has a sliding fit. When fitting the     pump shaft (211) and the components fitted on it.
impeller, observe the direction of rotation (see diagram below).
                                                                        Rotor assembly is now complete.
                                                                        Insert the rotor into the pump casing.
                                                                        Apply Loctite 574 to the casing wear ring surfaces and the sea-
                                                                        ling surfaces of the casing.
                                                                        Install the rotor, making sure that the direction of rotation is cor-
                                                                        rect.
                                                                        Align the rotor and ensure that the fixing pins are correctly sea-
                                                                        ted in the casing.
                                                                        The pins (561.01) must be positioned as shown in the diagram
                                                                        below.
For assembling the casing wear rings (502), observe section
7.5.2 ”Replacing the casing wear rings”.                                The bearing housings (350.01) must be fastened to the bearing
                                                                        brackets by means of the screwed connections (901.04), with
Put the casing wear rings onto the running surfaces of the im-          the sealing cap (580) inserted at the non--drive end. The seating
peller. Ensure that the bezels of the rings are on the outside (to-     positions are determined by the recesses.
wards the bearing). Insert the pins required for fixing the casing
wear rings.                                                             Fit the bearing covers.
The remaining components are fitted first on the movable bea-           To assemble the casing cover, apply Loctite 574 to the casing
ring side (i.e. the drive side) of the pump shaft.                      joint surface of the lower casing half.
                                                                        Tighten the flange bolts diagonally from the inside towards the
Push the shaft protecting sleeve (524.01) onto the pump shaft           outside.
(211). Ensure that the groove provided engages in the key of
the impeller.                                                           Insert the key for fitting the coupling into the pump shaft (211).
                                                                        When fitting the coupling and accessories, refer to the relevant
Push the shaft seal housing (441) onto the shaft and install            section of the operating instructions.
the shaft seal as described in section 8.1, ”Gland packing”.
Slip on V--ring (411.01).
Insert the radial shaft seal ring (421.02) into the bearing cover
(360) and push the bearing cover over the shaft.
Heat the deep--grooved ball bearing (321) and fit it onto the
pump shaft (211). It is essential to avoid one--sided pressure or
hammer blows on the outer races. The bearing is secured by
the disc (550.01) and the circlip (932).
To fit the shaft protecting sleeve (524.01), shaft seal housing                                 Casing wear rings (502)
(441), V--ring (411.01) and bearing cover (360) at the non--drive
end, proceed as described above for the drive side.
Heat the deep--groove ball bearing (321) and fit it onto the
                                                                                                                          561.01
sleeve (520).




                                                                                                                                          13
                                                                                                                             Omega

7.5       Instructions for Replacing Subassemblies                   After dismantling as described in section 7.3.2, the casing wear
                                                                     rings (502) can be removed. When fitting the rings, ensure that
7.5.1     Replacing the Shaft Seal                                   their bezels are on the outside (towards the bearing). The pins
Proceed as described in section 8.1 and 8.2.                         (561.01) must be positioned as shown in the diagram below.
                                                                     If the impeller has not been fitted with a wear ring at the factory,
7.5.2     Replacing Casing Wear Rings and / or Impeller              and changing the casing wear ring alone does not achieve an-
          Wear Rings                                                 ything close to the required impeller clearance (the impeller
The impeller clearance 1) clearance between impeller 234 and         neck is badly worn by clearance flows), the impeller neck must
casing wear ring 502 is given in the table below.                    be turned off on a lathe (contact KSB before doing so) and an
                                                                     impeller wear ring fitted in addition (available as spare part).
For impeller removal proceed as described in section 7.3,            Alternatively, a new impeller can be supplied at short notice.
”Dismantling”.
Impeller clearances and trim dimensions for impeller wear rings

                                                                 Clearance (as--new)                Dimensions of impeller wear ring
  No.        Pump          Shaft         Nominal               Min.                Max.
              size          unit        clearance           clearance           clearance
                                       (max. perm.)           S min               S max
                                          D2 - D1
                            DW               2                                                           D5                   b
                                           [mm]               [mm]                 [mm]                 [mm]                [mm]
     1      80 - 210                        0.3               0.15                  0.2                134 r6                18
     2      80 - 270                        0.3               0.15                  0.2                134 r6                18
     3      80 - 370                        0.3               0.15                  0.2                134 r6                18
                             40
     4     100 - 250                       0.35               0.17                  0.2                163 r6                22
     5     100 - 310                       0.35               0.17                  0.2                163 r6                22
     6     100 - 375                       0.35               0.17                  0.2                163 r6                22
      7    125 - 230                       0.35               0.18                  0.23               178 r6                22
      8    125 - 290                       0.35               0.18                  0.23               178 r6                22
      9    125 - 365                       0.35               0.18                  0.23               178 r6                22
                             50
     10    125 - 500                       0.35               0.18                  0.23               178 r6                22
     11    150 - 290                       0.45               0.22                  0.26               210 r6                30
     12    150 - 360                       0.45               0.22                  0.26               210 r6                30
     13    150 - 460                       0.45               0.22                  0.26               210 r6                30
     14    150 - 605                       0.45               0.22                  0.26               210 r6                30
                             60
     15    200 - 320                        0.5               0.24                  0.28               243 r6                30
     16    200 - 420                        0.5               0.24                  0.28               243 r6                30
     17    200 - 520                        0.5               0.24                  0.28               243 r6                30
     18    200 - 670         70             0.5               0.24                  0.28               243 r6                30
     19    250 - 370                        0.5               0.24                  0.28               276 r6                30
     20    250 - 480                        0.5               0.24                  0.28               276 r6                30
                             80
     21    250 - 600                        0.5               0.24                  0.28               276 r6                30
     22    250 - 800         90             0.5               0.24                  0.28               276 r6                30
     23    300 - 300         70             0.5               0.24                  0.28               259 r6                30
     24    300 - 435         80             0.6               0.29                  0.35               313 r6                35
     25    300 - 560                        0.6               0.29                  0.35               313 r6                35
                             90
     26    300 - 700                        0.6               0.29                  0.35               313 r6                35
     27    350 - 360         80             0.5               0.24                  0.28               294 r6                35
     28    350 - 430                        0.6               0.32                  0.37               333 r6                35
                             90
     29    350 - 510                        0.6               0.32                  0.37               353 r6                35

                                                                     b
                                                                                 S (min - max)




14
                                                                                                                        Omega

7.6            Monitoring schedule
For a detailed description of the pump version, components
and accessories supplied by KSB please refer to section 13 of
this operating manual.


    Component monitored                          Action                             Value required

    Mechanical seal
                                                 Check for leakage (daily)          see section 8.2 and *
    (if applicable)
    Gland packing
                                                 Check for leakage (daily)          10 to 120 drops / min.
    (if applicable)
    Suction side measuring instrument, ps
                                                 Check pressure (daily)             *
    (if applicable)
    Discharge side measuring instrument, pd
                                                 Check pressure (daily)             *
    (if applicable)
    Thermometer
    (suction / discharge nozzle)                 Check temperature (weekly)         *
    (if applicable)
    Flushing line sight glass                    Check flushing water flow
                                                                                    Water flows
    (if applicable)                              (weekly)
    Vibration measurement
                                                 Check weekly                       *
    (if applicable)
    Bearing temperature
                                                 Check weekly                       Section 7.2
    (if applicable)
                                                                                    Annex from p. 47, detailed manufacturer
    Coupling                                     Check weekly
                                                                                    information
    Drive
                                                 See manufacturer’s documentation   Ensure contact--free installation
    (if applicable)
    Coupling guard                               Check monthly                      No contact permitted
    Earthing connection                          Check monthly                      Connection must be fitted and marked.

*     see list of measuring points (if applicable) in section 13,
      Annex.
In the event of deviations proceed as described in the table gi-
ven in section 11.2 (Trouble--shooting).




                                                                                                                            15
                                                                                                                            Omega

8          Special Instructions for                                    Also note the following:
           Subassemblies (Shaft Seal                                   Leakage and temperature rise: If necessary, shut down the
                                                                       pump. After a short cooling period (approx. 10 to 15 minutes)
           Variants)                                                   the pump can be restarted. The necessary minimum leakage
The shaft seal variant supplied is shown in the purchase order         depends on the liquid being pumped, the pressure, sliding velo-
and order--processing documents.                                       city and temperature. It is approx. 10 to 120 drops per minute
                                                                       (20 drops of water correspond to approx. 1 ml).
8.1        Gland packing                                               Disassembly
The gland packings used by KSB are asbestos--free and suita-           A packing puller must be used for pulling out the packing rings.
ble for drinking water applications.                                   Maintenance
Installation and commissioning                                         Gland packings must be repacked in accordance with the sec-
Before installation, ensure that the gland space is clean (no          tion ”Installation and commissioning” after prolonged stand-
packing remnants or corrosion). The shaft protecting sleeve            still, repair work or heavy leakage. Therefore, the leakage rate
must be bright and have no scoring. Otherwise a new shaft pro-         must be observed during operation, also to avoid possible over-
tecting sleeve must be used.                                           heating.
Cutting the packing rings to size
If moulded packing rings are not available, the rings can best
be cut to size using a special cutting gauge. If no cutting gauge
is available, take a tube with the same diameter as the shaft,
wind the packing around the tube in a spiral and cut the rings
from the spiral. We recommend a straight cut.
Installing the packing rings
Push the packing rings with the stuffing box insert into the gland
space one by one. The joints of the packing rings must be offset
by 90_. The number of rings and the arrangement of the lantern
ring are shown in the general drawing (see appendix). After fit-
ting all the packing rings, put on the stuffing box insert and gland
cover and tighten them so that the packing rings adapt to the
gland space. Then loosen the gland cover again to relieve the
load on the packing. This procedure is not necessary if moulded
packing rings are used.
Commissioning
When the pump is started up, the gland must only be gently tigh-
tened (by hand). A high leakage rate (approx. 50 to 200 drops
per minute), depending on the liquid being pumped, must be ac-
cepted until the packing material has settled and has adapted
to the temperature conditions (approx. 10 to 15 minutes).
Then the gland cover must be carefully and evenly tightened to
reduce the leakage to a minimum. If there is no leakage, there
is a risk that the packing will run hot.




16
                                                                                                     Omega


8.2         Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations)


                                                                        Mechanical seal variants
      No.      Pump size     Shaft unit    Nom. mech. seal          -balanced
                                                                 Non-                       Balanced
                                                size
                                 dw                d           for operating pres--   for operating pressures
                                                                sures up to 16 bar            > 16 bar


       1         80 - 210
       2         80 - 270
       3         80 - 370
                                 40               50               M 7 N 4 / 50             HJ 92 N / 50
       4        100 - 250
       5        100 - 310
       6        100 - 375
       7        125 - 230
       8        125 - 290
       9        125 - 365
                                 50               60               M 7 N 4 / 60             HJ 92 N / 60
      10        125 - 500
      11        150 - 290
      12        150 - 360
      13        150 - 460
      14        150 - 605
                                 60               70               M 7 N 4 / 70             HJ 92 N / 70
      15        200 - 320
      16        200 - 420
      17        200 - 520
      18        200 - 670        70               80               M 7 N 4 / 80             HJ 92 N / 80
      19        250 - 370
      20        250 - 480
                                 80               90               M 7 N 4 / 90             HJ 92 N / 90
      21        250 - 600
      22        250 - 800        90               110             M 74 N / 110              H 75 N / 110
      23        300 - 300        70               80               M 7 N 4 / 80             HJ 92 N / 80
      24        300 - 435        80               90               M 7 N 4 / 90             HJ 92 N / 90
      25        300 - 560
                                 90               110             M 74 N / 110              H 75 N / 110
      26        300 - 700
      27        350 - 360        80               90               M 7 N 4 / 90             HJ 92 N / 90
      28        350 - 430
                                 90               110             M 74 N / 110              H 75 N / 110
      29        350 - 510




                                                                                                           17
                                                                                                                              Omega

8.2.1      Mechanical Seal ”Type M 7 N 4”
           (Shaft unit dw 40 to 80 mm)
The mechanical seal type M 7 N 4 used is a single--acting, bi--
rotational, non--balanced seal which does not require circula-
tion pipework in cold water applications, due to the pump de-
sign.
   Caution       Dry- -running of the seal must be avoided at
                 all costs!
Installation
For the installation of the total seal assembly (mechanical seal,
seal housing) see operating instructions for the pump.
The shaft protection sleeves and also the surfaces of the casing
are subjected to accurate finishing processes with regard to the
O--ring seats, in order to achieve a complete and reliable seal.
Care must be taken during installation to keep these parts ab-
solutely clean, to avoid the surfaces from being damaged and
prevent entry of foreign particles.
The seat ring (8) together with the relevant O--ring (9), is fitted
into the seal cover (see general drawing). The O--ring can be            Item     Description            Material                No. of
lubricated for easy sliding movement. Special attention must be                                                                  items
given to ensure that pressure is applied evenly. The contact
                                                                           1      Housing                Cr-Ni-Mo-steel             1
surfaces are generally fitted dry.
                                                                           2      O--ring                Viton                      1
In mechanical seals of the M7N4 design, the rotating assembly
is supplied as one unit, consisting of a housing and pin ( 1 + 5),         3      Spring                 Cr-Ni-Mo-steel             1
fitted spring loaded ring (6), O--ring (2), spring (3), thrust plate       4      Thrust plate           Cr-Ni-Mo-steel             1
(4) and grub screws (7). The grub screws (7) must be loosened              5      Pin                    Cr-Ni-Mo-steel             2
so far as to prevent them from protruding from the housing (1)             6      Spring--loaded ring    Si-SiC                     1
at the inner diameter. The O--ring (2) can be slightly lubricated
                                                                           7      Grub screw             Cr-Ni-Mo-steel             2
to facilitate assembly.
                                                                           8      Seat ring              Si-SiC                     1
The complete rotating assembly is pushed onto the shaft pro-
                                                                           9      O--ring                Viton                      1
tection sleeve in compliance with the installation dimensions
which are given in the mech. seal drawing, or until it reaches the     Special instructions for mechanical seal assembly
stop on the shaft protection sleeve. Finally the grub screws are       -- The contact faces must only be cleaned with propyl alcohol
tightened and secured with LOCTITE.                                       and paper tissue.
                                                                          -- Never use cleaning rags or cloth.
                                                                          -- Clean carefully to remove any smears.
                                                                       -- Do not touch the contact faces with bare fingers.
                                                                       -- Never use force during mechanical seal assembly.
                                                                       -- Never put the spring--loaded ring and the seat ring face
                                                                          down on the contact faces without the protective wrapping.
                                                                       -- Cover the contact face with a cardboard washer and press
                                                                          the seat ring into its position slowly and evenly, lubricating
                                                                          it with a generous amount of water or alcohol. Use a spacer
                                                                          sleeve, if necessary. Verify that the seat ring position is nor-
                                                                          mal to the shaft axis.
                                                                       -- In the mechanical seal area, the shaft shall be slightly lubri-
                                                                          cated with water, alcohol or silicone grease. Sealing ele-
                                                                          ments made of EP rubber must never come into contact
                                                                          with mineral oil base lubricants (swelling, possibly de-
                                                                          composition).




18
                                                                                                                          Omega

Commissioning                                                       Dismantling
Flood the pump and the seal chamber with the medium to be           For dismantling of the mechanical seal assembly please refer
handled and vent carefully. The seal is operational now.            to section 7.3 ”Dismantling”. Grub screws (7) and joint rings
On single--acting mechanical seals, the pressure in the seal        (2+9) shall be replaced whenever the mechanical seal has
chamber of the pump (stuffing box) must always exceed am-           been dismantled!
bient pressure, to prevent any air intake at the seal faces,
which would result in dry running and thus failure of the me-       Repair
chanical seal.                                                      If the seal needs to be repaired, always return the complete
In all operating conditions, the product to be sealed off must      seal to the manufacturer. The manufacturer will know best
be available in liquid state at the mechanical seal, particularly   which parts can be re--worked and which parts have to be repla-
during pump start--up and shutdown. This must be ensured by         ced to ensure an optimum sealing effect.
appropriate facilities on the pump (e.g. heating).                  If repair on the spot is necessary, it should be carried out in a
Should the mechanical seal fail, the liquid to be sealed off may    clean workshop preferrably by KSB--monteurs or skilled opera-
spurt out. Take suitable precautions to prevent hazards to per-     tor staff. Spring--loaded rings, seat rings, all elastomer materi-
sons and the environment, e.g. install splash guards, wear sa-      als and springs should be replaced in any case.
fety goggles, etc. Proper disposal of leakage shall be arran-       Make sure to comply with the instructions for handling ha-
ged for and supervised by the operator.                             zardous substances and the applicable accident preven-
                                                                    tion regulations when repairing, dismantling and cleaning
Maintenance                                                         used mechanical seals. If you have any queries in this context
Mechanical seals operated in compliance with the manual             please inform yourself before commencing any repair work.
are maintenance- -free in their entire service life.
                                                                    Spare parts
The mechanical seal should be inspected in accordance with
the plant inspection schedule.                                      Only original spare parts shall be used. Non-  -compliance
                                                                    with this requirement entails the risk of seal malfunctions
During planned plant outage periods the spring--loaded rings        which may jeopardize the safety of personnel and the environ-
and the seat rings should be checked for visible damage in in-      ment.
stalled condition.
                                                                    It will also lead to forfeiture of all warranty claims.
If the mechanical seal is inspected during plant outage, the con-
tact faces should be re--worked.

Faults
Determine and document the nature of the fault.
In the event of a fault as evidenced by excessive leakage, ob-
serve the tendency of the leakage amount. Changes in opera-
ting conditions must be documented. If an excessive tempera-
ture rise is detected, the mechanical seal must be shut down for
safety reasons.
During the warranty period the mechanical seal shall only be re-
moved and dismantled with the manufacturer’s approval or un-
der instructions of the mechanical seal manufacturer’s service
engineers.
If the fault cannot be remedied by the operator or if the cause
is unclear, please contact the KSB service center.




                                                                                                                                   19
                                                                                                                            Omega

8.2.2                         -
           Mechanical Seal - ”Type M74N ”                           The seat ring (8) together with the relevant O--ring (9), is fitted
           (Shaft unit dw = 90 mm)                                  into the seal cover (see general drawing). The O--ring can be
This mechanical seal type is a single-
                                     -acting, bi-
                                                -rotational,        lubricated for easy sliding movement. Special attention must
non--balanced mechanical seal with multiple spring arran-           be given to ensure that pressure is applied evenly. The contact
gement.                                                             surfaces are generally fitted dry.
                                                                    In mechanical seals of the M 74 N design, the rotating assembly
     Caution     It is imperative to avoid dry running of the       is supplied as one unit, consisting of a housing and pin ( 1 + 5),
                 mechanical seal!                                   fitted spring loaded ring (6), O--ring (2), spring (3), thrust plate
                                                                    (4) and grub screws (7). The grub screws (7) must be loosened
Special instructions for mechanical seal installation
                                                                    so far as to prevent them from protruding from the housing (1)
                                                                    at the inner diameter. The O--ring (2) can be slightly lubricated
--   Application limits                                             to facilitate assembly.
 Pressure to be sealed off, p max.               25 bar             The complete rotating assembly is pushed onto the shaft pro-
 Product temperature, t                          --40...220 °C      tection sleeve in compliance with the installation dimensions
                                                                    which are given in the mech. seal drawing, or until it reaches the
 Sliding velocity, vg                            20 m/s
                                                                    stop on the shaft protection sleeve. Finally the grub screws are
                                                                    tightened and secured with LOCTITE.
--   Safety
Any work on the mechanical seal shall only be performed af-
                                                                    Degrease the grub
ter the pump has stopped and pump pressure has been relea-
                                                                    screws and insert
sed.
                                                                    with a thread sealant
In addition to the safety instructions contained in this manual,    (e.g. Loctite). Use
the general health and accident prevention regulations              new grub screws
shall be observed.                                                  whenever the me-
                                                                    chanical seal has
Preparations for installation                                       been dismantled!

Check pump components for:
--   chamfered edges (sliding cones 2 mm/ 30_ or to DIN
     24960).                                                             Item   Description        Material                    No. of
--   radiused transitions                                                                                                      items
--   locating surfaces, surfaces for O--rings: fine finished Rz           1     Housing            Cr-Ni-Mo-steel                 1
     10 (DIN 4768)                                                        2     O--ring            Compat. elastomers             1
--   Shaft surface in the area of the dynamically loaded joint            3     Spring             Cr-Ni-Mo-steel                 1
     ring: roughness depth Rmax 5 µm.                                     4     Thrust plate       Cr-Ni-Mo-steel                 1
                                                                          5     Pin                Cr-Ni-Mo-steel                 2
     The shaft must be provided with the requisite recesses for           6     Rotating ring      Buka, Buke, Bume               1
     the housing screws of the mechanical seal.
                                                                          7     Grub screw         Cr-Ni-Mo-steel                 2
Check pump for:                                                           8     Seat ring          Buke, Buko, Buka               1
--   damage at the mating surfaces with the mechanical seal               9     O--ring            Compat. elastomers             1
--   connecting dimensions, rectangularity and concentricity to
     the shaft axis                                                 --    Apply a thin coat of grease to the shaft in the mechanical
                                                                          seal area.
Installation
                                                                          Sealing elements made of EP rubber must never come
For the installation of the total seal assembly (mechanical seal,         into contact with mineral oil base lubricants (swelling,
seal housing) see operating instructions for the pump.                    possibly decomposition).
The shaft protection sleeves and also the surfaces of the casing    --    Unwrap the mechanical seal and inspect for damage to the
are subjected to accurate finishing processes with regard to the          spring--loaded ring and the seat ring, the O--rings and the
O--ring seats, in order to achieve a complete and reliable seal.          mating surfaces.
Care must be taken during installation to keep these parts ab-
solutely clean, to avoid the surfaces from being damaged and              Never put the spring--loaded ring and the seat ring face
prevent entry of foreign particles.                                       down on the contact faces without the protective wrapping.
                                                                    --    Thoroughly clean all components with alcohol and cellulose
                                                                          tissue.




20
                                                                                                                             Omega

Installation                                                           Faults
Never use force during mechanical seal installation.                   Determine and document the nature of the fault.
--   Slip the degreased O--ring onto the seat ring.                    In the event of a fault as evidenced by excessive leakage, ob-
--   Cover the contact face with a cardboard washer.                   serve the tendency of the leakage amount. Changes in opera-
                                                                       ting conditions must be documented. If an excessive tempera-
--   Push the seat ring slowly and evenly into its seat. Use a spa-    ture rise is detected, the mechanical seal must be shut down for
     cer sleeve, if necessary. Lubricate with a generous amount        safety reasons.
     of water or alcohol.
                                                                       A continuous flow of leakage indicates a fault.
--   Verify that the seat ring position is normal to the shaft axis.
                                                                       During the warranty period the mechanical seal shall only be re-
--   Push the rotating assembly with the degreased joint rings
                                                                       moved and dismantled with the manufacturer’s approval or un-
     onto the shaft. Thread in the degreased grub screws with
                                                                       der instructions of the mechanical seal manufacturer’s service
     1 drop of thread sealant each (e.g. Loctite No. 243) and po-
                                                                       engineers.
     sition the mechanical seal by tightening the grub screws.
     The installation dimensions given in the drawing must be          If the fault cannot be remedied by the operator or if the cause
     adhered to.                                                       is unclear, please contact the KSB service centre.
--   The contact faces must only be cleaned with propyl alcohol
     and paper tissue (no cleaning rags or cloth). Clean carefully     Maintenance
     to remove any smears. Do not touch the contact faces with         Mechanical seals operated in compliance with the manual are
     bare fingers afterwards.                                          maintenance--free; however, wear parts will have to be repla-
The contact faces must not be lubricated; they must be clean           ced as required.
and dry.                                                               The mechanical seal should be inspected in accordance with
-- Assemble the seal cover with the installed seat ring.               the plant inspection schedule. We recommend to have the me-
                                                                       chanical seal inspected by KSB service centre.
Commissioning                                                          If the mechanical seal is inspected during plant outage, the con-
Flood the pump and the seal chamber with the medium to be              tact faces should be re--worked and all elastomer seals and
handled and vent carefully. The seal is operational now.               springs should be replaced.

Reliable seal operation                                                Repair
On single--acting mechanical seals, the pressure in the seal           If the seal needs to be repaired, always return the complete
chamber of the pump (stuffing box) must always exceed am-              seal to the manufacturer. The manufacturer will know best
bient pressure, to prevent any air intake at the seal faces,           which parts can be re--worked and which parts have to be repla-
which would result in dry running and thus failure of the me-          ced to ensure an optimum sealing effect.
chanical seal.                                                         If repair on the spot is absolutely necessary (e.g. no spare
In all operating conditions, the product to be sealed off must         seal available, long transport distances, problems with customs
be available in liquid state at the mechanical seal, particularly      procedures), skilled operator staff may carry out the repair
during pump start--up and shutdown. This must be ensured by            work in a clean workshop to the directions of KSB service cen-
appropriate facilities on the pump (e.g. heating).                     tres.
If the operating conditions indicated are observed and the in-
structions given in this operating manual are complied with, the
mechanical seal can be expected to give trouble--free opera-
tion.
        Should the mechanical seal fail, the liquid to be sealed
        off may spurt out. Take suitable precautions to pre-
vent hazards to persons and the environment, e.g. install
splash guards, wear safety goggles, etc. Proper disposal of
leakage shall be arranged for and supervised by the operator.




                                                                                                                                     21
                                                                                                                     Omega

Mechanical seal removal                                            8.2.3    Mechanical Seal ”Type HJ92 N”
     Shut down the pump in accordance with the operating                    (Shaft unit dw = 40 to 80 mm)
     manual, allow to cool down and release pump pressure.         Note:
       There must be no pumped product at the                      Refer to sections 8.2.1 and 8.2.2 for general recommendations
       mechanical seal →The pump must be drained.                  and instructions for handling this seal type.
       Secure the pump to prevent inadvertent start--up.           For detailed information please refer to the operating manual
                                                                   for seal type HJ92 N.
       Follow the safety instructions
       (safety data sheets)!
Make sure to comply with the applicable accident preven-
tion regulations when removing a mechanical seal. Also ob-
serve the instructions for handling hazardous substances
if the mechanical seal has already been in operation. If you
have any queries about the applicable regulations please in-
form yourself before commencing any repair work.
Any work on the mechanical seal is only permitted with the
pump shut down and pump pressure released.
Removal of the mechanical seal shall be performed analo-
gously with mechanical seal installation, but in reverse order.
Removing the subassembly
See section 7.3.
-- Grub screw (7) und Dichtringe (2+9) nach jeder Demontage
   erneuern.
Spare parts
Only genuine spare parts shall be used. Non-   -compliance
with this requirement entails the risk of seal malfunctions
which may jeopardize the safety of personnel and the environ-
ment.
It will also lead to forfeiture of all warranty claims.To keep a
complete spare seal on stock.




22
                                                                                                        Mechanical seal HJ92N


OPERATING MANUAL
MECHANICAL SEAL (MS)
HJ92N
 PLEASE READ this manual carefully and OBSERVE the information contained as to:
 H Safety     H    Storage            H  Installation  H Start up          H    Maintenance                         H          Repair



J SAFETY                                                              J OPERATING LIMITS
                                                                      Shaft diameter dw:                    18 to 100 mm
Any person in the operator’s plant who is involved in the installa-
                                                                      Press. to be sealed off p max.:       25 bar *)
tion, removal, operation, commissioning and maintenance of
the mechanical seal must have read and thoroughly under-              Fluid temperature t:                  --40 to 220 °C
stood these operating instructions, particularly the safety in-       Sliding velocity vg:                  20 m/s
structions contained therein. It is advisable for the operator to     *) depending on the seal face materials
have this confirmed.                                                  The mechanical seal shall not be operated at several applica-
                                                                      tion limits at the same time.
The mechanical seal is a precision product (ISO 9001) and safe        Higher loads (pressure, temperature, speed) may lead to in-
to operate. However, it may constitute a hazard if it is not used     creased wear and damage the contact faces or the elastomer
in accordance with its designated use, or if operated improperly      elements.
by unskilled personnel.                                               Such operating conditions would shorten the useful life of the
                                                                      seal but also entail the risk of sudden seal failure with hazards
The operator has to determine the consequences of any me-             to personnel and the environment.
chanical seal failure and decide whether safety precautions
need to be taken to protect personnel or the environment.             J OPERATING DATA
                                                                      The operating data for the application in question, such as fluid
The pump shall be installed in such a way that any fluid spurting     to be sealed off, operating pressure, operating temperature, ro-
out cannot cause personal injury and that leakage can be pro-         tational speed, etc., are indicated on the respective pump data
perly disposed of.                                                    sheets.
Any operating mode liable to impair the safe and reliable func-       J DESIGNATED USE
tion of the mechanical seal is not permitted.
Mechanical seals shall only be installed, operated, removed or        Any operation outside the operating conditions stated in the
                                                                      ”Operating Limits” section is deemed to be non--conforming
repaired by authorized, qualified and appropriately instructed
personnel.                                                            with the designated use.
                                                                      To ensure safe operation of the mechanical seal, check with the
Any work on the mechanical seal shall only be performed with          seal manufacturer before using the seal for other operating
the pump shut down and the pump pressure released.                    conditions or in a different location of operation.
Staff responsibilities for the work involved must be clearly defi-
ned and complied with, to prevent unclear competencies with
                                                                      J MATERIALS
regard to safety aspects.                                             Materials as per drawing and/or order.

In addition to the instructions contained in this manual, the ge-     J DRAWINGS
neral occupational health and safety regulations must be adhe-        General assembly drawing of pump.
red to.                                                               The applicable design is shown on the general pump drawing
                                                                      in the original scale and latest revision, see section 9 of the
Unauthorized modifications and alterations liable to jeopardize       pump’s operating manual, which shall be used in conjunction
the safe operation of the mechanical seal are not permitted.          with this document.

                                                                      J SPECIFICATION
J DECLARATION                                                         H   Single mechanical seal
                                                                      H   Balanced
within the meaning of EC Directive ”Machinery” 98/37/EC.              H   Bi--rotational
                                                                      H   Connecting dimensions to DIN 24960 KB
A mechanical seal does not function independently. It is inten-       H   Installation dimensions l1K
ded to be incorporated into or assembled with machinery.




Operating maual mechanical seal                                                                                                     23
Rev. 0, 13.02.2004
                                                                                                  Mechanical seal HJ92N

Due to their protected spring (1.5), mechanical seals of this type     The mechanical seals need not be preserved.
are particularly suitable for fluids containing solids and/or highly   D Do not apply anti--corrosives.
viscous fluids, for ex. in sugar, paper or waste water applica-          ' Risk of deposits and possible chemical attacks on ela-
tions. The seal design is rugged and reliable. The spring neither           stomer secondary seals.
clogs nor sticks. Max. axial end play between shaft and hou-
sing: 0.5 mm in any direction.                                         When applying preservatives to entire systems where mecha-
                                                                       nical seals are installed please check the following:
For operation at negative pressures (down to --0.2 bar), no seat
lock is required for the seat ring (2).                                D Verify the compatibility of the preservatives chosen with the
Torque transmission between the shaft and the seal is normally           materials of construction and the elastomer components of
effected by grub screws(1.6); or by special drive elements (1.2)         the mechanical seal.
on individual models.                                                  D Verify that mechanical seal movement is not restricted by re-
                                                                         sin deposits or sticking.
                                                                       During storage, seal face materials and elastomers will un-
J LIQUID            SUPPLY           TO      MECHANICAL                dergo material specific time dependent changes (distortion,
  SEAL                                                                 ageing), which can impair the perfect function of the mechanical
                                                                       seal. The specified storage period must therefore be complied
To ensure trouble--free operation of the mechanical seal, a sui-
                                                                       with.
table circulation process has been selected on the pump, see
                                                                       The manufacturer cannot be held responsible for damage re-
section 9 of the pump’s operating manual. This process avoids
                                                                       sulting from improper storage.
product deposits in the seal chamber.
                                                                       The room where mechanical seals are kept must be dust--free
                                                                       and moderately ventilated, with an even temperature. We re-
J EMISSIONS                                                            commend: relative humidity below 65%, temperature between
Mechanical seals are dynamic seals which for physical and              15 °C and 25 °C.
technical reasons cannot be completely leak--free. The amount
                                                                       The mechanical seal shall be protected from:
of leakage largely depends on the seal selection, production to-
lerances, operating conditions, smooth running of the machine,         D direct heat from sun, heating
etc. Compared with other dynamic sealing systems, however,             D ozone and ultraviolet light from halogen lamps, fluorescent
mechanical seals have little leakage.                                    lamps, sunlight, arc welding
                                                                       ' danger of embrittlement of elastomer materials
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine,         The seals shall be stored in their original packaging on a level
safety goggles worn by the operating staff, etc. may prevent ha-       surface.
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-      The mechanical seal needs to be checked:
ronment.                                                               D after a storage period of approx. 2--3 years
                                                                       D if the packaging has been damaged
Leakage may be liquid or gaseous, its aggressiveness corres-
                                                                       D after a shock load (e.g. if the mechanical seal package has
ponding to that of the fluid to be sealed off.
                                                                          been dropped)
Any mechanical seal leakage must be drained off in a controlled
                                                                       ' at the manufacturer’s workshop or nearest service centre.
way and safely disposed of.
. Components which may come into contact with the seal lea-            J BEFORE INSTALLATION
kage shall either be corrosion resistant or must be adequately
protected.                                                             Checks to be carried out on the pump components:
                                                                       Shaft surface in the area of the dynamically loaded seal ring:
J STORAGE                                                              roughness depth Rmax 5 µm.
Unless otherwise agreed in the contract, mechanical seals are          Checks to be carried out on the pump:
delivered in standard packaging suitable for dry transport by
                                                                       D Check contact surfaces between the pump and the mecha-
truck, train or plane. The symbols or handling instructions given
                                                                         nical seal for damage.
on the packaging must be adhered to.
                                                                       D Connecting dimensions, squareness and concentricity to
For incoming goods inspection:                                           shaft.
D Check packaging for external damage.                                 D Shaft run--out as per DIN ISO 5199: between 50 µm and
D Carefully open packaging, making sure not to damage or                 100 µm, depending on the diameter.
    lose any components packed separately.                             D Apply a thin coat of suitable grease to the shaft in the
D Check consignment for completeness (delivery note). The                mech.seal area.
    supplier shall be notified immediately of any damaged              ' Never use mineral oil base lubricants on sealing elements
    goods or missing parts.                                              made of ethylene propylene rubber (swelling, possibly de-
The instructions given below shall apply both to mechanical              composition).
seals delivered and stored in their undamaged, original packa-         ' Grease recommended for elastomer sealing elements
ging, and to mechanical seals already installed in a pump,               (O--rings, etc.): type ”TURMOPOLGREASE SH2”, produ-
which have not been in operation yet.                                    cer: Lubricant Consult (LUBCON).




24                                                                                                        Operating maual mechanical seal
                                                                                                          Rev. 0, 13.02.2004
                                                                                                   Mechanical seal HJ92N




'   Double PTFE encapsulated O--rings must be fitted so that
    the joint of the outer sheath points in opposite direction to
    the mounting direction, so that the friction force generated
    when sliding on the O--ring closes the joint. Kinks in the foil
    will result in leakage.

J INSTALLATION TOOLS / EQUIPMENT
D Propyl alcohol + paper tissue (no cleaning rags)
D Lubricating grease for elastomer seals: type ”TURMOPOLGREASE
    SH2”, producer: Lubricant Consult (LUBCON)
D Thread--locking compound, e.g. type ”LoctiteR Nr. 243”,
  producer: Loctite Corporation
D O--ring extractor                                                   Possible installation sequence:
D Set of hex. keys (WAF 2 mm -- 6 mm)                                 D Slide the degreased O--ring onto the seat ring.
D Cardboard washers to protect the contact faces during in-           D Cover the contact face of the seat ring with a cardboard
  stallation                                                             washer. Generously lubricate the seat ring with water or al-
D Manual screw press (compulsory from DN 80 mm).                         cohol and press it slowly and evenly into its seat. Use a spa-
                                                                         cer, if necessary. Check squareness of seat ring to the shaft
J INSTALLATION                                                           axis.
Refer to the general pump assembly drawing when installing            D Apply a thin coat of grease to the shaft protecting sleeve in
the mechanical seal.                                                     the mechanical seal area.
Mechanical seals are precision--machined machinery compo-                ' Never use mineral oil base lubricants on sealing ele-
nents which have been inspected several times. They must be                  ments made of ethylene propylene rubber (swelling,
installed with due care and in compliance with certain procedu-              possibly decomposition).
res, particularly regarding the contact faces and elastomer           D Slide the rotating seal assembly with greased O--rings onto
seals.                                                                   the shaft protecting sleeve.
                                                                      D Fit the degreased grub screws, having applied one drop of
Utmost cleanliness must be ensured in the immediate vicinity
                                                                         thread--locking compound (e.g. Loctite R No. 243) to each
of the location where a mechanical seal is to be installed.
                                                                         screw.
Never use force when installing a mechanical seal.                    D Tighten the grub screws to lock the torque--transmitting
D Unpack the seal and inspect the spring--loaded ring, seat              sleeve into place.
    ring, O--rings and contact faces for damage.                      D Clean the contact faces with propyl alcohol and paper tissue
    ' Never place the spring--loaded ring and the seat ring on           (no cloth, no cleaning rags!) to remove any smears. Do
        the table facing down without protecting the contact fa-         not touch the contact faces with bare fingers after that.
        ces.                                                             ' Do not apply lubricants to the contact faces. The contact
                                                                             faces must be installed in clean and dry condition.
D Thoroughly clean all parts with alcohol and paper tissue.
                                                                      D Fit the seal cover with pre--assembled seat ring.
The sequence of operations required to install the mechanical
seal in the machine depends on the design of the machine in           J COMMISSIONING
question, which is described in the pump’s operating manual.          Prime the pump and the seal chamber with the fluid handled
Unless otherwise stated, apply a very thin coat of grease to          and vent thoroughly. The seal is now ready for operation.
O--rings which will slide into or onto other components during        J SAFE OPERATION
mechanical seal installation.
                                                                      For single mechanical seals, the pressure in the seal chamber
                                                                      of the pump must always exceed ambient pressure, to prevent
                                                                      any air intake at the seal faces, which would result in dry running
                                                                      and thus failure of the mechanical seal.
                                                                      In all operating conditions, the product to be sealed off must be
                                                                      available in liquid state at the mechanical seal, particularly du-
                                                                      ring pump start--up and shutdown.
                                                                      If the operating conditions indicated are observed and the in-
                                                                      structions given in this operating manual are complied with, the
                                                                      mechanical seal can be expected to give trouble--free opera-
                                                                      tion.
                                                                      J HEALTH AND SAFETY
                                                                      Mechanical seals are often used for sealing off hazardous sub-
                                                                      stances (chemicals, pharmaceuticals, etc.). The applicable in-
                                                                      structions and regulations for handling hazardous materials
                                                                      must absolutely be adhered to.
Operating maual mechanical seal                                                                                                       25
Rev. 0, 13.02.2004
                                                                                                Mechanical seal HJ92N

Should the mechanical seal fail, the hot liquid or steam to be       J REMOVING THE SEAL FROM
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent ha-
                                                                       THE PUMP
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-
ronment..
                                                                     D Shut down the pump, allow to cool down and release pres-
                                                                         sure as per operating instructions
J FAULTS/MALFUNCTIONS                                                D No product should contact the mechanical seal Drain the
Determine and document the nature of the fault/malfunction.              pump, if necessary!
In the event of a fault as evidenced by excessive leakage, ob-       D Secure the pump against inadvertent start--up!
serve the tendency of the leakage amount. Changes in opera-          D Follow the safety instructions (safety data sheets)!
ting conditions must be documented. If an excessive tempera-         When removing the mechanical seal make sure to observe the
ture rise is detected, the mechanical seal must be shut down for     applicable health and safety regulations, as well as the regula-
safety reasons.                                                      tions for handling hazardous substances, if the mechanical seal
A continuous flow of leakage indicates a fault/malfunction at the    has already been in operation. If in doubt, the necessary infor-
mechanical seal.                                                     mation has to be obtained before starting repair work.
During the warranty period the mechanical seal shall only be re-     Any work on the mechanical seal shall only be performed with
moved and dismantled with the manufacturer’s approval or in          the pump shut down and the pump pressure released.
the presence of his representative.                                  The sequence of operations required to remove the mechanical
If the fault/malfunction cannot be remedied by the operator or       seal from the pump depends on the design of the pump in ques-
if the cause is unclear, please contact your responsible KSB         tion, which is described in the pump’s operating manual.
service centre.                                                      Removal of the mechanical seal shall be effected in analogy
                                                                     with, but in reverse order to, installation.

J SERVICING / MAINTENANCE                                            J CUSTOMER SERVICE
Mechanical seals operated in compliance with manual are              Services provided by the seal manufacturer range from plan-
maintenance--free. Wear parts, however, must be replaced as          ning advice to product support after commissioning.
required.                                                            For this purpose, the manufacturer has established a worldwide
The mechanical seal shall be inspected in accordance with the        network of subsidiaries abroad, partner companies, sales offi-
plant inspection schedule. We recommend to have the mecha-           ces and service centres, to handle any problems.
nical seal inspected by competent KSB service staff.
If the mechanical seal is removed during plant inspection, the       J PURCHASE ORDERS
contact faces shall be re--worked and all elastomer seals and        For enquiries and purchase orders, the following details are re-
springs shall be replaced.                                           quired:
                                                                     D KSB order No.
J REPAIR                                                             D No. of general pump assembly drawing
If the seal needs to be repaired, always return the complete seal    D Part item No., description, material, quantity as per drawing.
to the manufacturer. The manufacturer’s service personnel will
know best which parts can be re--worked and which parts have         J DISPOSAL
to be replaced to ensure an optimum sealing effect.                  Usually, mechanical seals can easily be disposed of after a tho-
If repair on the spot is absolutely necessary (e.g. no spare seal    rough cleaning.
available, long transport distances, problems with customs pro-      D Metal parts (steel, stainless steel, non--ferrous metals),
cedures), skilled operator staff may carry out the repair work in       shall be sorted and disposed of in the appropriate waste me-
a clean workshop to the directions of the seal manufacturer’s fit-      tal collection facility.
ters.                                                                D Plastics (elastomers, PTFE) are special waste. After sor-
                                                                        ting, some of them can be recycled.
                                                                        ' CAUTION! Material containing fluorine must not be inci-
J SPARE PARTS                                                                nerated.
Use only genuine spare parts, to prevent                             D Ceramic contact face materials (carbon, ceramics, carbide)
D the risk of mechanical seal malfunction, involving hazards            can be separated from their carrier materials and -- being
    to persons and the environment.                                     physiologically harmless -- disposed of as residual waste.
D forfeiture of any and all warranty claims.                         We reserve the right to technical modifications designed to
To ensure quick mechanical seal replacement, we recommend            improve the product, even if they are not mentioned in this ma-
to stock a complete spare seal.                                      nual yet.




26                                                                                                      Operating maual mechanical seal
                                                                                                        Rev. 0, 13.02.2004
                                                               Omega

8.2.4    Mechanical Seal –“Type H75N“
         (Shaft unit dw = 90 mm)

General instructions concerning assembly/installation, com-
missioning, maintenance, faults and repair have already been
given in sections 8.2.1 and 8.2.2.

(See Operating manual
S   for seal type H75N).




                                                                  27
                                                                                                   Mechanical seal H75N


OPERATING MANUAL
BURGMANN MECHANICAL (M.S.)
H75N
 PLEASE READ this manual carefully and OBSERVE the information contained as to:
 H Safety     H    Storage            H  Installation  H Start up          H    Maintenance                         H       Repair




J SAFETY                                                              J OPERATING LIMITS
                                                                      Shaft diameter dw:                    28 to 100 mm
Any person in the operator’s plant who is involved in the installa-
                                                                      Press. to be sealed off p max.:       40 bar *)
tion, removal, operation, commissioning and maintenance of
                                                                      Fluid temperature t:                  --40 to 220 °C
the mechanical seal must have read and thoroughly under-
                                                                      Sliding velocity vg:                  20 m/s
stood these operating instructions, particularly the safety in-
                                                                      *) depending on the seal face materials
structions contained therein. It is advisable for the operator to
have this confirmed.                                                  The mechanical seal shall not be operated at several applica-
                                                                      tion limits at the same time.
The mechanical seal is a precision product (ISO 9001) and safe        Higher loads (pressure, temperature, speed) may lead to in-
to operate. However, they may constitute a hazard if they are         creased wear and damage the contact faces or the elastomer
not used in accordance with their designated use, or if operated      elements.
improperly by unskilled personnel.
                                                                      Such operating conditions would shorten the useful life of the
The operator has to determine the consequences of any me-             seal but also entail the risk of sudden seal failure with hazards
chanical seal failure and decide whether safety precautions           to personnel and the environment.
need to be taken to protect personnel or the environment.
                                                                      J SPECIFICATION
The pump shall be installed in such a way that any fluid spurting     The operating data for the application in question, such as fluid
out cannot cause personal injury and that leakage can be pro-         to be sealed off, operating pressure, operating temperature, ro-
perly disposed of.                                                    tational speed, etc., are indicated on the respective pump data
                                                                      sheets.
Any operating mode liable to impair the safe and reliable func-
tion of the mechanical seal is not permitted.
                                                                      J DESIGNATED USE
Mechanical seals shall only be installed, operated, removed or        Any operation outside the operating conditions stated in the
repaired by authorized, qualified and appropriately instructed        ”Operating Limits” section is deemed to be non--conforming
personnel.                                                            with the designated use.
                                                                      To ensure safe operation of the mechanical seal, check with the
Any work on the mechanical seal shall only be performed with
                                                                      seal manufacturer before using the seal for other operating
the pump shut down and the pump pressure released.
                                                                      conditions or in a different location of operation.
Staff responsibilities for the work involved must be clearly defi-
ned and complied with, to prevent unclear competencies with           J MATERIALS
regard to safety aspects..                                            Materials as per drawing and/or order.

In addition to the instructions contained in this manual, the ge-     J DRAWINGS
neral occupational health and safety regulations must be adhe-
red to.                                                               General assembly drawing of pump.
                                                                      The applicable design is shown on the general pump drawing
Unauthorized modifications and alterations liable to jeopardize       in the original scale and latest revision, see section 9 of the
the safe operation of the mechanical seal are not permitted.          pump’s operating manual, which shall be used in conjunction
                                                                      with this document.

                                                                      J SPECIFICATION
J DECLARATION
                                                                      H   Single mechanical seal
within the meaning of EC Directive ”Machinery” 98/37/EC.              H   Balanced
                                                                      H   Bi--rotational
A mechanical seal does not function independently. It is inten-       H   Rotating spring--loaded ring
ded to be incorporated into or assembled with machinery.              H   Stationary seat ring




28                                                                                                       Operating maual mechanical seal
                                                                                                         Rev. 0, 13.02.2004
                                                                                                  Mechanical seal H75N

H   Multiple springs in guide sleeves                               During storage, seal face materials and elastomers will un-
H   axial mobility/play up to dw 55 = ± 2 mm, and ± 3 mm            dergo material specific time dependent changes (distortion,
H   Torque transmission by grub screws                              ageing), which can impair the perfect function of the mechanical
H   Connecting dimensions to DIN 24960 KB                           seal. The specified storage period must therefore be complied
H   Installation dimensions l1K                                     with.
                                                                    The manufacturer cannot be held responsible for damage re-
                                                                    sulting from improper storage.
J LIQUID           SUPPLY          TO      MECHANICAL               The room where mechanical seals are kept must be dust--free
  SEAL                                                              and moderately ventilated, with an even temperature. We re-
                                                                    commend: relative humidity below 65%, temperature between
To ensure trouble--free operation of the mechanical seal, a sui-    15 °C and 25 °C.
table circulation process has been selected on the pump, see
                                                                    The mechanical seal shall be protected from:
section 9 of the pump’s operating manual. This process avoids
product deposits in the seal chamber.                               D direct heat from sun, heating
                                                                    D ozone and ultraviolet light from halogen lamps, fluorescent
                                                                        lamps, sunlight, arc welding
J EMISSIONS                                                         ' danger of embrittlement of elastomer materials.
                                                                    The seals shall be stored in their original packaging on a level
Mechanical seals are dynamic seals which for physical and           surface.
technical reasons cannot be completely leak--free. The amount
of leakage largely depends on the seal selection, production to-    The mechanical seal needs to be checked:
lerances, operating conditions, smooth running of the machine,      D after a storage period of approx. 2--3 years
etc. Compared with other dynamic sealing systems, however,          D if the packaging has been damaged
mechanical seals have little leakage.                               D after a shock load (e.g. if the mechanical seal package has
                                                                       been dropped)
Leakage may be liquid or gaseous, its aggressiveness corres-
                                                                    ' at the manufacturer’s workshop or nearest service centre.
ponding to that of the fluid to be sealed off.
Any mechanical seal leakage must be drained off in a controlled     J BEFORE INSTALLATION
way and safely disposed of.                                         Checks to be carried out on the pump components:
                                                                    Shaft surface in the area of the dynamically loaded seal ring:
. Components which may come into contact with the seal lea-
                                                                    roughness depth Rmax 5 µm.
kage shall either be corrosion resistant or must be adequately
protected.                                                          Checks to be carried out on the pump:
                                                                    D Check contact surfaces between the pump and the mecha-
                                                                       nical seal for damage.
J STORAGE                                                           D Connecting dimensions, squareness and concentricity to
                                                                       shaft
Unless otherwise agreed in the contract, mechanical seals are       D Shaft run--out as per DIN ISO 5199: between 50 µm and
delivered in standard packaging suitable for dry transport by          100 µm, depending on the diameter.
truck, train or plane. The symbols or handling instructions given   D Apply a thin coat of a suitable grease to the shaft in the
on the packaging must be adhered to.                                   mech. seal area.
                                                                    ' Never use mineral oil base lubricants on sealing elements
For incoming goods inspection:                                         made of ethylene propylene rubber (swelling, possibly de-
D Check packaging for external damage.                                 composition).
D Carefully open packaging, making sure not to damage or            ' Grease recommended for elastomer sealing elements
  lose any components packed separately.                               (O--rings, etc.): type ”TURMOPOLGREASE SH2”, produ-
D Check consignment for completeness (delivery note). The              cer: Lubricant Consult (LUBCON).
  supplier shall be notified immediately of any damaged
  goods or missing parts.
The instructions given below shall apply both to mechanical
seals delivered and stored in their undamaged, original packa-
ging, and to mechanical seals already installed in a pump,
which have not been in operation yet.
The mechanical seals need not be preserved.
D Do not apply anti--corrosives.                                    '   Double PTFE encapsulated O--rings must be fitted so that
   ' Risk of deposits and possibly chemical attack of the ela-          the joint of the outer sheath points in opposite direction to
      stomer secondary sealing elements.                                the mounting direction, so that the friction force generated
When applying preservatives to entire systems where mecha-              when sliding on the O--ring closes the joint. Kinks in the foil
nical seals are installed please check the following:                   will result in leakage.
D Verify the compatibility of the preservatives chosen with the
    materials of construction and the elastomer components of       J INSTALLATION TOOLS / EQUIPMENT
    the mechanical seal.                                            D Propyl alcohol + paper tissue (no cleaning rags)
D Verify that mechanical seal movement is not restricted by re-     D lubricant for elastomer--sealing rings: Type ”TURMOPOL-
    sin deposits or sticking.                                         GREASE SH2”, make Lubricant Consult (LUBCON)



Operating maual mechanical seal                                                                                                     29
Rev. 0, 13.02.2004
                                                                                                Mechanical seal H75N

D Thread--locking compound, e.g. type ”LoctiteR Nr. 243”,         Primary seal components
  producer: Loctite Corporation                                      1.1                 Spring--loaded ring
D O--ring extractor                                                  2                   Seat ring
D Set of hex. keys (WAF 2 mm -- 6 mm)                             Secondary seal elements
D Cardboard washers to protect the contact faces during in-          1.4                 O--ring (dynamic)
  stallation                                                         3                   O--ring (static)
D Manual screw press (compulsory from DN 80 mm)
                                                                  Spring components
                                                                     1.5                 Guide sleeve
J INSTALLATION                                                       1.6                 Spring
Refer to the general pump assembly drawing when installing        Torque transmission and housing components
the mechanical seal.                                                 1.2                 Torque--transmitting sleeve
                                                                     1.3                 Thrust ring
Mechanical seals are precision--machined machinery compo-            1.7                 Grub screw
nents which have been inspected several times. They must be
                                                                  Possible installation sequence:
installed with due care and in compliance with certain procedu-
res, particularly regarding the contact faces and elastomer       D Slide the degreased O--ring onto the seat ring.
seals.                                                            D Cover the contact face of the seat ring with a cardboard
Utmost cleanliness must be ensured in the immediate vicinity         washer. Generously lubricate the seat ring with water or al-
of the location where a mechanical seal is to be installed.          cohol and press it slowly and evenly into its seat. Use a spa-
Never use force when installing a mechanical seal.                   cer, if necessary. Check squareness of seat ring to the shaft
Unpack the seal and inspect the spring--loaded ring, seat ring,      axis.
O--rings and contact faces for damage.                            D Apply a thin coat of grease to the shaft protecting sleeve in
D Never place the spring--loaded ring and the seat ring on the       the mechanical seal area.
    table facing down without protecting the contact faces.          ' Never use mineral oil base lubricants on sealing ele-
D Thoroughly clean all parts with alcohol and paper tissue.              ments made of ethylene propylene rubber (swelling,
                                                                         possibly decomposition).
The sequence of operations required to install the mechanical     D Slide the rotating seal assembly with greased O--rings onto
seal in the machine depends on the design of the machine in          the shaft protecting sleeve.
question, which is described in the pump’s operating manual.      D Fit the degreased grub screws, having applied one drop of
Unless otherwise stated, apply a very thin coat of grease to         thread--locking compound (e.g. Loctite R No. 243) to each
O--rings which will slide into or onto other components during       screw.
mechanical seal installation.                                     D Tighten the grub screws to lock the torque--transmitting
                                                                     sleeve in place.
                                                                  D Clean the contact faces with propyl alcohol and paper tissue
                                                                     (no cloth, no cleaning rags!) to remove any smears. Do
                                                                     not touch the contact faces with bare fingers after that.
                                                                     ' Do not apply lubricants to the contact faces. The contact
                                                                         faces must be installed in clean and dry condition.
                                                                  D Fit the seal cover with pre--assembled seat ring.

                                                                  J COMMISSIONING
                                                                  Prime the pump and the seal chamber with the fluid handled
                                                                  and vent thoroughly. The seal is now ready for operation.

                                                                  J SAFE OPERATION
                                                                  For single mechanical seals, the pressure in the seal chamber
                                                                  of the pump must always exceed ambient pressure, to prevent
                                                                  any air intake at the seal faces, which would result in dry running
                                                                  and thus failure of the mechanical seal.
                                                                  In all operating conditions, the product to be sealed off must be
                                                                  available in liquid state at the mechanical seal, particularly du-
                                                                  ring pump start--up and shutdown.
                                                                  If the operating conditions indicated are observed and the in-
                                                                  structions given in this operating manual are complied with, the
                                                                  mechanical seal can be expected to give trouble--free opera-
                                                                  tion.

                                                                  J HEALTH AND SAFETY
                                                                  Mechanical seals are often used for sealing off hazardous sub-
                                                                  stances (chemicals, pharmaceuticals, etc.). The applicable in-
                                                                  structions and regulations for handling hazardous materials
Fig. 1: General mech. seal design                                 must absolutely be adhered to.




30                                                                                                    Operating maual mechanical seal
                                                                                                      Rev. 0, 13.02.2004
                                                                                                  Mechanical seal H75N

Should the mechanical seal fail, the hot liquid or steam to be       J REMOVING THE SEAL FROM
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent ha-
                                                                       THE PUMP
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-
ronment.
                                                                     D Shut down the pump, allow to cool down and release pres-
                                                                         sure as per operating instructions.
J FAULTS/MALFUNCTIONS                                                D No product should contact the mechanical seal ⇒ Drain the
Determine and document the nature of the fault/malfunction.              pump, if necessary!
                                                                     D Secure the pump against inadvertent start--up!
In the event of a fault as evidenced by excessive leakage, ob-
serve the tendency of the leakage amount. Changes in opera-          D Follow the safety instructions (safety data sheets)!
ting conditions must be documented. If an excessive tempera-         When removing the mechanical seal make sure to observe the
ture rise is detected, the mechanical seal must be shut down for     applicable health and safety regulations, as well as the regula-
safety reasons.                                                      tions for handling hazardous substances, if the mechanical seal
                                                                     have already been in operation. If in doubt, the necessary infor-
A continuous flow of leakage indicates a fault/malfunction at the
                                                                     mation has to be obtained before starting repair work.
mechanical seal.
                                                                     Any work on the mechanical seal shall only be performed with
During the warranty period the mechanical seal shall only be re-     the pump shut down and the pump pressure released.
moved and dismantled with the manufacturer’s approval or in
the presence of his representative.                                  The sequence of operations required to remove the mechanical
                                                                     seal from the pump depends on the design of the pump in ques-
If the fault/malfunction cannot be remedied by the operator or       tion, which is described in the pump’s operating manual.
if the cause is unclear, please contact your responsible KSB
service centre.                                                      Removal of the mechanical seal shall be effected in analogy
                                                                     with, but in reverse order to, installation.
J SERVICING / MAINTENANCE                                            J CUSTOMER SERVICE
Mechanical seals operated in compliance with manual are              Services provided by the seal manufacturer range from plan-
maintenance--free. Wear parts, however, must be replaced as          ning advice to product support after commissioning.
required.
                                                                     For this purpose, the manufacturer has established a worldwide
The mechanical seal shall be inspected in accordance with the        network of subsidiaries abroad, partner companies, sales offi-
plant inspection schedule. We recommend to have the mecha-           ces and service stations, to handle any problems.
nical seal inspected by competent KSB service staff.
If the mechanical seal is removed during plant inspection, the       J PURCHASE ORDERS
contact faces shall be re--worked and all elastomer seals and        For enquiries and purchase orders, the following details are re-
springs shall be replaced.                                           quired:
                                                                     D KSB order No.
J REPAIR                                                             D No. of general pump assembly drawing
If the seal needs to be repaired, always return the complete seal    D Part item No., description, material, quantity as per drawing
to the manufacturer. The manufacturer’s service personnel will
know best which parts can be re--worked and which parts have         J DISPOSAL
to be replaced to ensure an optimum sealing effect.                  Usually, mechanical seals can easily be disposed of after a tho-
If repair on the spot is absolutely necessary (e.g. no spare seal    rough cleaning.
available, long transport distances, problems with customs pro-      D Metal parts (steel, stainless steel, non--ferrous metals),
cedures), skilled operator staff may carry out the repair work in       shall be sorted and disposed of in the appropriate waste me-
a clean workshop to the directions of the seal manufacturer’s fit-      tal collection facility.
ters.                                                                D Plastics (elastomers, PTFE) are special waste. After sor-
                                                                        ting, some of them can be recycled.
J SPARE PARTS                                                           ' CAUTION! Material containing fluorine must not be inci-
                                                                             nerated.
Use only genuine spare parts, to prevent
                                                                     D Ceramic contact face materials (carbon, ceramics, carbide)
D the risk of mechanical seal malfunction, involving hazards            can be separated from their carrier materials and -- being
  to persons and the environment.                                       physiologically harmless -- disposed of as residual waste.
D forfeiture of any and all warranty claims.                         We reserve the right to technical modifications designed to
To ensure quick mechanical seal replacement, we recommend            improve the product, even if they are not mentioned in this ma-
to stock a complete spare seal.                                      nual yet.




Operating maual mechanical seal                                                                                                    31
Rev. 0, 13.02.2004
                                                                                                          Omega

9           Spare Parts
Recommended Spare Parts
Recommended spare parts stock for 2 years’ operation to VDMA 24296 (also for continuous operation)


 Part no.       Description                         Number of pumps (incl. stand--by pumps)
                                                       2         3            4    5          6      8       10
                                                                                                          and more
                                                    Number of spare parts *
     234     Impeller                                  1         1            1    2          2      3     30 %
     502     Casing wear ring                          4         4            4    6          6      8     50 %
     503     Impeller wear ring                        4         4            4    6          6      8     50 %
 211,940     Shaft with keys and                       1         1            2    2          2      3     30 %
 920,932     shaft nuts
     321     Rolling element                           2         2            4    4          6      8     100 %
             bearing
     524     Shaft protecting                          4         4            4    6          6      8     50 %
             sleeve
     461     Packing ring                             32        32        48      48          48     64    40 %
 411,412     Set of sealing ele-                       4         6            8    8          9      12    150 %
   421       ments
     433     Mechanical seal       Spring--loaded      4         6            8    8          8      12    90 %
                                   ring
                                   Seat ring           4         6            8    8          8      12    90 %
                                   O--rings            4         6        12      16          16     20    150 %
                                   Seals on            4         6        12      16          16     20    150 %
                                   seat ring

                                   Set of springs      1         2            2    2          2      4       %
* These figures already allow for components required twice for replacement




32
                                                                         Omega

Interchangeability of rotor components

  Pump sizes                             Pump shaft diameter

                   40           50        60           70      80   90

    80 - 210        *
    80 - 270        *
    80 - 370        *
   100 - 250        *
   100 - 310        *
   100 - 375        *

   125 - 230                    *
   125 - 290                    *
   125 - 365                    *
   125 - 500                    *
   150 - 290                    *
   150 - 360                    *

   150 - 460                               *
   150 - 605                               *
   200 - 320                               *
   200 - 420                               *

   200 - 520                                            *
   200 - 670                                            *
   250 - 370                                            *

   250 - 480                                                   *
   250 - 600                                                   *

   250 - 800                                                        *

   300 - 300                                            *

   300 - 435                                                   *

   300 - 560                                                        *
   300 - 700                                                        *

   350 - 360                                                   *

   350 - 430                                                        *
   350 - 510                                                        *




                                                                            33
                                                                                                                                                 Omega

10          Forces and Moments
                                                      Fz
                                                                   Mz



                                                                                                     Fy

                                                                                                           My

                                                                                             Mx
                                                                                                     Fx




The given forces and moments are mean values for simulta-                                   The values given in the table do not apply to the re-
neous loading in the three planes. If the forces and moments in                             action forces of braceless expansion joints.
one particular direction are larger than given in the table, con-
sult KSB.

                                                                                                                                          Dimensions in mm
 Pump                          Impeller dimensions in mm                        Permissible nozzle              Mass moments of      Permissi-    Permissi-
 sizes                                                                                                              inertia J        ble opera-    ble test
                                                                                                                                        ting      pressure
                                                                                                                                      pressure
             free passage          max. diameter           Clearances           forces        moments           (without coupling)     in bar       in bar
                 ± 10 %                                                          in N          in Nm                 in kgm2
             A       B    C        A     B      C     A        B         C     Fx, Fy, Fz     Mx, My, Mz        without    with      1)     2)    1)    2)
                                                                                 3); 4)           3); 4)        water      water

80-210      15       11   --      215   215     --   0.30     0.30       --      800              500           0.023      0.028     16    25     28   37.5
80-270      13       9    --      275   275     --   0.30     0.30       --      800              500           0.037      0.044     16    25     28   37.5
80-370      11       8    --      345   345     --   0.30     0.30       --      800              500           0.027      0.032     16    25     28   37.5
100-250     19       14   --      254   254     --   0.35     0.35       --      1000             700           0.048      0.058     16    25     28   37.5
100-310     15       11   --      325   325     --   0.35     0.35       --      1000             700           0.092      0.110     16    25     28   37.5
100-375     13       10   --      408   408     --   0.35     0,35       --      1000             700           0.229      0.275     16    25     28   37.5
125-230     23       17   --      245   245     --   0.35     0.35       --      1500             1000          0.161      0.193     16    25     28   37.5
125-290     19       12   --      301   301     --   0.35     0.35       --      1500             1000          0.125      0.150     16    25     28   37.5
125-365     14       10   --      392   392     --   0.35     0.35       --      2000             1500          0.261      0.313     16    25     28   37.5
125-500     14       10   --      482   482     --   0.35     0.35       --      2000             1500          0.688      0.825     16    25     28   37.5
150-290     27       20   14      289   289    289   0.45     0.45      0.45     2500             1500          0.169      0.288     16    25     28   37.5
150-360     22       15   --      355   355     --   0.45     0.45       --      2500             2000          0.199      0.338     16    25     28   37.5
150-460     17       12   --      462   462     --   0.45     0.45       --      2500             2000          0.456      0.775     16    25     28   37.5
150-605     16       11   --      569   569     --   0.45     0.45       --      3000             2000          1.074      1.825     24    25     28   37.5
200-320     30       22   17      338   338    338   0.50     0.50      0.50     4000             2750          0.442      0.575     16    25     24   37.5
200-420     26       18   --      415   415     --   0.50     0.50       --      4000             2750          0.588      0.725     16    25     24   37.5
200-520     20       14   --      540   540     --   0.50     0.50       --      4000             2750          1.288      1.675     16    25     24   37.5
200-670     18       12   --      665   665     --   0.50     0.50       --      4000             2750          3.654      4.750     24    25     28   37.5
1)   see next page
2)   see next page
3)   see next page
4)   see next page




34
                                                                                                                                       Omega


                                                                                                                               Dimensions in mm
     Pump                    Impeller dimensions in mm                   Permissible nozzle         Mass moments        Permissible   Permissible
     sizes                                                                                            of inertia         operating       test
                                                                                                           J             pressure      pressure

              free passage        max. diameter      Clearances         forces      moments        (without coupling)     in bar        in bar
                   ± 10 %                                                in N        in Nm              in kgm2
              A      B      C     A     B     C     A      B     C     Fx, Fy, Fz   Mx, My, Mz     without    with       1)    2)      1)    2)
                                                                         3); 4)        3); 4)       water     water
 250-370      39     27     20   390   390   390   0.5     0.5   0.5     4000         2750         0.721      1.225      10    25     15    37.5
 250-480      30     20     --   478   478    --   0.5     0.5    --     4000         2750         0.956      1.625      16    25     24    37.5
 250-600      23     16     --   622   622    --   0.5     0.5    --     4000         2750         2.206      3.750      24    25     28    37.5
 250-800      33     31     --   770   730    --   0.5     0.5    --     4000         2750         17.313     22.506     24    25     28    37.5
 300-300      39     27     --   323   323    --   0.5     0.5    --     4000         3000         0.571      0.800      10    25     15    37.5
 300-435      45     32     30   450   450   450   0.6     0.6   0.6     4000         3000         1.785      2.500      10    25     15    37.5
 300-560      35     23     --   553   553    --   0.6     0.6    --     5000         3000         2.411      3.375      16    25     24    37.5
 300-700      26     18     --   719   719    --   0.6     0.6    --     5000         3000         6.346      8.250      24    25     28    37.5
 350-360      39     27     --   373   373    --   0.5     0.5    --     5000         3000         1.116      1.563      10    25     15    37.5
 350-430      57     40     --   430   430    --   0.6     0.6    --     5000         3000         2.232      3.125      10    25     15    37.5
 350-510      52     36     35   518   518   518   0.6     0.6   0.6     5000         3000         3.393      4.750      10    25     15    37.5
1)   Casing material JL 1040
2)   Casing material JS 1030 and 1.4517
3)   Casing material JS 1030; 1.4--times the given value
4)   Casing material 1.4517; 1.9--times the given value




11                  -Shooting
             Trouble-
11.1         General                                                                             Power
                                                                                                 Head
The diagram opposite is to facilitate understanding of the cau-                                  Efficiency
ses of faults and their remedies as indicated in the trouble--
shooting table.
The cause of many operating faults on pumps is often hydrau-
lic. The hydraulic behavior of a pump is illustrated by its charac-
teristic curves H, P, Eta and NPSH in combination with the plant                                       Operating Limit
characteristic curves HA and NPSHA.The operating point B is
where the system curve HA and the characteristic curve H inter-
sect. Consult the manufacturer if the cause of a fault is unclear.




                                                                                                           Capacity




                                                                                                                                                 35
                                                                                                                                                                                                                                                                                                                                                                                                                                     Omega


11.2                                                 -shooting Table
                                              Trouble-



                                                                                                                                                                                Pump does not run smoothly (noise, vibrations)
                                                                                                                                                                                                                                 Inadmissible temperature increase at pump /
                                                                                               Pump fails to pump liquid after being switched on




                                                                                                                                                                                                                                                                                                              Exessive leakage at shaft seal
                                                                                                                                                                                                                                                                               Bearing temperature too high
                                                                  Power consumption too high


                                                                                                                                                   Pump ceases to pump liquid
Pump pressure too high
Pump pressure too low


                         Flow rate too high




                                                                                                                                                                                                                                                                                                                                               Leakage at pump
                                              Flow rate too low




                                                                                                                                                                                                                                                                                                              Drive overloaded
                                                                                                                                                                                                                                 seal casing




                                                                                                                                                                                                                                                                                                                                                                 Cause                           Remedy1)
 F             F              F                   F                      F                          F                                                                                        F                                                  F                                                                                 F                              Operating point B does not      Re--adjust operating point
                                                                                                                                                                                                                                                                                                                                                                 lie at the calculated inter-
                                                                                                                                                                                                                                                                                                                                                                 sections of Q and H
                                                                                                    F                                                                                                                                                                                                                                                            Pump or piping incomple-        Vent.
                                                                                                                                                                                                                                                                                                                                                                 tely vented or not primed
 F                                                F                                                 F                                                     F                                  F                                                  F                                                                                                                Suction pipe or impeller        Clean impeller
                                                                                                                                                                                                                                                                                                                                                                 blocked                         Check plant for impurities
                                                                                                                                                                                                                                                                                                                                                                                                 Remove deposits in pump and / or piping
                                                                                                                                                                                                                                                                                                                                                                                                 Check strainer / suction opening
                                                                                                    F                                                     F                                  F                                                                                                                                                                   Formation of air pockets in     Correct suction conditions
                                                                                                                                                                                                                                                                                                                                                                 the piping                      Alter piping
 F                                                F                                                 F                                                     F                                  F                                                                                                                                                                   Suction head too high           Check mode of operation
                                                                                                                                                                                                                                                                                                                                                                 (NPSHavailable too low) /       Correct suction conditions
                                                                                                                                                                                                                                                                                                                                                                 water level too low             Increase positive suction head
                                                                                                                                                                                                                                                                                                                                                                                                 Increase back pressure by throttling
                                                                                                                                                                                                                                                                                                                                                                                                 Install pump at a lower level
                                                                                                                                                                                                                                                                                                                                                                                                 Alter intake pipe if resistances are too high
 F                                                F                                                 F                                                     F                                                                                                                                                                                                      Air is drawn in at shaft seal   Clean sealing liquid line, possibly introduce
                                                                                                                                                                                                                                                                                                                                                                                                 sealing liquid from an external source or
                                                                                                                                                                                                                                                                                                                                                                                                 increase pressure
                                                                                                                                                                                                                                                                                                                                                                                                 Check level of liquid in feed tank
                                                                                                                                                                                                                                                                                                                                                                                                 Replace shaft seal
                                                                                                                                                                                                                                                                                                                                                                                                 Replace shaft protecting sleeve
 F                                                F                      F                                                                                                                   F                                                                                                                                    F                              Wrong direction of rotation     Interchange two phases of the power cable
                                                                                                                                                                                                                                                                                                                                                                                                 Check electrical connections
                                                                                                                                                                                                                                                                                                                                                                                                 Check impeller position, correct if neces-
                                                                                                                                                                                                                                                                                                                                                                                                 sary
 F                                                F                                                                                                                                          F                                                                                                                                                                   Speed too low                   Increase speed 1),
                                                                                                                                                                                                                                                                                                                                                                                                 Check switchgear,
                                                                                                                                                                                                                                                                                                                                                                                                 Fit larger impeller 1).
 F                                                F                                                 F                                                     F                                                                                                                                                                                                      Internals worn                  Check duty point / pump selection
                                                                                                                                                                                                                                                                                                                                                                                                 Increase back pressure by throttling
                                                                                                                                                                                                                                                                                                                                                                                                 Check medium handled for contamination
                                                                                                                                                                                                                                                                                                                                                                                                 by chemicals and solids content
                                                                                                                                                                                                                                                                                                                                                                                                 Replace worn components
                                                                         F                                                                                                                                                                                                                                                        F                              Pump pressure is lower          Re--adjust operating point
                                                                                                                                                                                                                                                                                                                                                                 than specified in the order     Increase back pressure by throttling.




36
                                                                                                                                                                                                                                                                                                                                                                                                                                   Omega

       -shooting Table
Trouble-




                                                                                                                                                                                Pump does not run smoothly (noise, vibrations)
                                                                                                                                                                                                                                 Inadmissible temperature increase at pump /
                                                                                               Pump fails to pump liquid after being switched on




                                                                                                                                                                                                                                                                                                              Exessive leakage at shaft seal
                                                                                                                                                                                                                                                                               Bearing temperature too high
                                                                  Power consumption too high


                                                                                                                                                   Pump ceases to pump liquid
Pump pressure too high
Pump pressure too low


                         Flow rate too high




                                                                                                                                                                                                                                                                                                                                               Leakage at pump
                                              Flow rate too low




                                                                                                                                                                                                                                                                                                              Drive overloaded
                                                                                                                                                                                                                                 seal casing




                                                                                                                                                                                                                                                                                                                                                                 Cause                         Remedy 1)
                                                                         F                                                                                                                                                                                                                                                        F                              Higher density or viscosity   Reduce speed
                                                                                                                                                                                                                                                                                                                                                                 of medium handled than        In the case of persistent overloading, turn
                                                                                                                                                                                                                                                                                                                                                                 specified in the order        down impeller, if necessary 1).
               F              F                                          F                                                                                                                   F                                                                                                                                    F                              Speed too high                Reduce speed
                                                                                                                                                                                                                                                                                                                                                                                               In the case of persistent overloading, turn
                                                                                                                                                                                                                                                                                                                                                                                               down impeller, if necessary 1).
                                                                                                                                                                                                                                                                                                                                                  F              Tie bolts / seals             Check
                                                                                                                                                                                                                                                                                                                                                                                               Tighten tie bolts
                                                                                                                                                                                                                                                                                                                                                                                               Replace gaskets
                                                                                                                                                                                                                                                                                                                                                                                               Check pipe connections and pump moun-
                                                                                                                                                                                                                                                                                                                                                                                               ting, if necessary, improve mounting of pi-
                                                                                                                                                                                                                                                                                                                                                                                               ping.
                                                                                                                                                                                                                                                                                                                F                                                Worn shaft seal               Check flushing / sealing liquid pressure
                                                                                                                                                                                                                                                                                                                                                                                               clean sealing liquid line, possibly introduce
                                                                                                                                                                                                                                                                                                                                                                                               sealing liquid from an external source or
                                                                                                                                                                                                                                                                                                                                                                                               increase pressure
                                                                                                                                                                                                                                                                                                                                                                                               Replace shaft seal
                                                                                                                                                                                                                                                                                                                                                                                               Replace worn components
                                                                                                                                                                                                                                                                                                                                                                                               Replace shaft protecting sleeve.
 F                                                F                                                                                                                                          F                                                                                         F                                                                         Unfavourable flow to suc-     Alter piping
                                                                                                                                                                                                                                                                                                                                                                 tion nozzle of pump           If necessary, alter intake pipe if resistances
                                                                                                                                                                                                                                                                                                                                                                                               are too high
                                                                                                                                                                                                                                                                                                                                                                                               Check whether pipe routing results in twi-
                                                                                                                                                                                                                                                                                                                                                                                               sted or irregular flow (e.g. downstream of
                                                                                                                                                                                                                                                                                                                                                                                               an elbow) and correct, if necessary.
1)     Consult KSB




                                                                                                                                                                                                                                                                                                                                                                                                                                           37
                                                                                                                                                                                                                                                                                                                                                                                                                                                                            Omega

       -shooting Table
Trouble-




                                                                                                                                                                                                        Pump does not run smoothly (noise, vibrations)
                                                                                                                                                                                                                                                         Inadmissible temperature increase at pump /
                                                                                                                       Pump fails to pump liquid after being switched on




                                                                                                                                                                                                                                                                                                                                      Exessive leakage at shaft seal
                                                                                                                                                                                                                                                                                                       Bearing temperature too high
                                                                                          Power consumption too high


                                                                                                                                                                           Pump ceases to pump liquid
                        Pump pressure too high
Pump pressure too low


                                                 Flow rate too high




                                                                                                                                                                                                                                                                                                                                                                                          Leakage at pump
                                                                      Flow rate too low




                                                                                                                                                                                                                                                                                                                                                                       Drive overloaded
                                                                                                                                                                                                                                                         seal casing




                                                                                                                                                                                                                                                                                                                                                                                                            Cause                       Remedy 1)
                                                                                                                                                                                                                                                                        F                                                                  F                                                                Gland cover, seal cover     Alter
                                                                                                                                                                                                                                                                                                                                                                                                            tightened incorrectly,      Replace
                                                                                                                                                                                                                                                                                                                                                                                                            wrong packing material      Correct
                                                                                                                                                                                                                                                                                                                                                                                                                                        Replace gland packing
                                                                                                                                                                                                                                                                                                                                                                                                                                        Replace worn components
                                                                                                                                                                                                                                                                        F                                                                  F                                                                Lack of cooling liquid or   Check flushing / sealing liquid pressure
                                                                                                                                                                                                                                                                                                                                                                                                            cooling liquid chamber con- Clean sealing liquid line, possibly introduce
                                                                                                                                                                                                                                                                                                                                                                                                            taminated                   sealing liquid from an external source or
                                                                                                                                                                                                                                                                                                                                                                                                                                        increase its pressure
                                                                                                                                                                                                                                                                                                                                                                                                                                        Increase cooling liquid flow
                                                                                                                                                                                                                                                                                                                                                                                                                                        Clean cooling liquid line.
                                                                                                                                                                                                                     F                                                                                         F                                                                                            Pump mis--aligned or reso- Re--align pump / drive
                                                                                                                                                                                                                                                                                                                                                                                                            nance vibrations in the pi- Check piping connections and pump
                                                                                                                                                                                                                                                                                                                                                                                                            ping                        mounting, if necessary, improve mounting
                                                                                                                                                                                                                                                                                                                                                                                                                                        of piping
                                                                                                                                                                                                                                                                                                                                                                                                                                        Apply vibration--damping measures
                                                                                                                                                                                                                                                                                                               F                                                                                            Excessive axial thrust      Check duty point / pump selection
                                                                                                                                                                                                                                                                                                                                                                                                                                        Check mode of operation
                                                                                                                                                                                                                                                                                                                                                                                                                                        Check suction -- side flow.
                                                                                                                                                                                                                                                                                                               F                                                                                            Too little, too much or un- Clean bearing
                                                                                                                                                                                                                                                                                                                                                                                                            suitable lubricant          Replace lubricant
                                                                                                                                                                                                                                                                                                                                                                                                                                        Top up, reduce or change lubricant
   F                                                                      F                      F                                                                                                                                                                                                                                                                         F                                Motor is running on two     Replace defective fuses
                                                                                                                                                                                                                                                                                                                                                                                                            phases only                 Check electrical connections
                                                                                                                                                                                                                                                                                                                                                                                                                                        Check switchgear.
                                                                                                                                                                                                                     F                                                                                         F                           F                                                                Rotor is out of balance     Clean rotor
                                                                                                                                                                                                                                                                                                                                                                                                                                        Check run--out, straighten if necessary
                                                                                                                                                                                                                                                                                                                                                                                                                                        Re--balance rotor.
                                                                                                                                                                                                                     F                                                                                         F                           F                                                                Bearings damaged            Replace / change
                                                                                                                                                                                                                     F                                                  F                                                                                                                                   Flow rate too low            Re--adjust operating point
                                                                                                                                                                                                                                                                                                                                                                                                                                         Fully open shut--off valve in the intake pipe
                                                                                                                                                                                                                                                                                                                                                                                                                                         Fully open shut--off valve in the discharge
                                                                                                                                                                                                                                                                                                                                                                                                                                         pipe
                                                                                                                                                                                                                                                                                                                                                                                                                                         Recalculate or measure the hydraulic los-
                                                                                                                                                                                                                                                                                                                                                                                                                                         ses HV.
1)               Consult KSB




38
                                                                                                                                                                                                                                                                                                                                                                                                                                 Omega

       -shooting Table
Trouble-




                                                                                                                                                                Pump does not run smoothly (noise, vibrations)

                                                                                                                                                                                                                 Inadmissible temperature increase at pump /
                                                                           Pump fails to pump liquid after being switched on




                                                                                                                                                                                                                                                                                              Exessive leakage at shaft seal
                                                                                                                                                                                                                                                               Bearing temperature too high
                                              Power consumption too high



                                                                                                                                   Pump ceases to pump liquid
Pump pressure too high
Pump pressure too low

                         Flow rate too high




                                                                                                                                                                                                                                                                                                                                                  Leakage at pump
                                              Flow rate too low




                                                                                                                                                                                                                                                                                                                               Drive overloaded
                                                                                                                                                                                                                 seal casing




                                                                                                                                                                                                                                                                                                                                                                    Cause                         Remedy 1)
 F                                              F                                                                                                                                                                                                                                                                                                                   In star / delta operation     Check electrical connections
                                                                                                                                                                                                                                                                                                                                                                    motor hangs at star sta-      Check switchgear.
                                                                                                                                                                                                                                                                                                                                                                    ge
 F                                              F                                                                                                                                         F                                                                                                                                                                         Inadmissible air or gas       Vent
                                                                                                                                                                                                                                                                                                                                                                    content in liquid             Check integrity of suction pipe, seal if
                                                                                                                                                                                                                                                                                                                                                                                                  necessary
 F                                              F                                                                              F         F                                                F                                                                                                                                                                         Air drawn in at pump in-      Correct suction conditions
                                                                                                                                                                                                                                                                                                                                                                    let                           Reduce flow velocity at suction pipe en-
                                                                                                                                                                                                                                                                                                                                                                                                  try
                                                                                                                                                                                                                                                                                                                                                                                                  Increase suction head
                                                                                                                                                                                                                                                                                                                                                                                                  Check integrity of suction pipe and seal,
                                                                                                                                                                                                                                                                                                                                                                                                  if necessary
                                                                                                                                                                                                                                                                                                                                                                                                  Replace defective pipes.
                                                                                                                                                                                          F                                                                                                                                                                         Cavitation (rattling noise)   Correct suction conditions
                                                                                                                                                                                                                                                                                                                                                                                                  Check mode of operation
                                                                                                                                                                                                                                                                                                                                                                                                  Increase suction head
                                                                                                                                                                                                                                                                                                                                                                                                  Install pump at a lower level
                                                                                                                                                                                          F                                                                           F                                                                                             Foundation not rigid          Check
                                                                                                                                                                                                                                                                                                                                                                    enough                        Alter
 F                                              F                                                                              F         F                                                F                                                                                                                                                                         Inadmissible parallel         Re--adjust operating point
                                                                                                                                                                                                                                                                                                                                                                    operation                     Alter pump characteristic H 1).
                                                                                                                                                                                          F                                                                                                        F                                                                Shaft is out of true          Renew / Replace

                                                               F                                                                                                                          F                                    F                                      F                                                                                             Impeller rubs against ca-     Check rotor
                                                                                                                                                                                                                                                                                                                                                                    sing components               Check impeller position
                                                                                                                                                                                                                                                                                                                                                                                                  Check that the piping is connected wi-
                                                                                                                                                                                                                                                                                                                                                                                                  thout transmitting any stresses or
                                                                                                                                                                                                                                                                                                                                                                                                  strains.
1)      Consult KSB




                                                                                                                                                                                                                                                                                                                                                                                                                                           39
                                                                                                Omega



12       Routine Maintenance and Inspection Intervals
             Interval            Number of per-    Time                 Maintenance job
                                 sonnel required    [h]

                                                          Check leakage on mechanical seal or lea-
                                                          kage of packed gland
               Daily                   1           1/10   (see section 8.1 ”Gland packing”).

                                                          Check pump operation (positive suction pres-
             Weekly                    1           1/4    sure, total head, bearing temperature, noises
                                                          and vibrations)

                                                          Check torsional play of coupling
                                       1           1/4    (see section ”Coupling”),
             Monthly                                      If available, switch to stand--by pump or carry
                                                          out a test run (for 5 min.)
                                       1           1/4
                                                          Replace deep--groove ball bearings
          every 20.000                 2            3     (see section 7.3 ”Dismantling” and
         operating hours                                  7.4 ”Reassembly”).



                                                          General inspection and overhaul of pump in
                                                          accordance with the operating instructions.
     every 4 years or if total
      head of pump drops                                  Check and renew, if required:
                                       2            6     -- wear parts such as: bearings, casing wear
                                                             ring (impeller wear ring, if any), shaft
                                                             protecting sleeve
                                                          -- impeller and shaft
                                                          -- Replace sealing elements




40
                                                                                                                                                                     Omega

13            Appendix
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Types of installation                  .......................................................................                                                                42
                        -
Type of Installation 3E - Motor Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                    43
- Type of Installation 3E -- Motor Height Adjustment -- Baseplate with adjusting screw and pedestal                                                                            43
- Type of Installation 3E -- Motor Height Adjustment -- Baseframe with Base / Shims under the Motor Feet                                                                       44
- Sealing / flushing water piping                                                                                                                                              45
- Arrangement of sealing water and flush pipe                                                                                                                                  45

Sealing water pipe for gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                         46
Sealing water pipe for mechanical seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                         46
           -EUPEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling (N-                                                                                                                                                                  47
- Correlation between tightening torques, dimension P and clearance S1                                                                                                         49
- Trouble--shooting                                                                                                                                                            50

General drawing of pump with parts list                                Shaft seal: Gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . .                       52
General drawing of pump with parts list Shaft seal: Mechanical seal . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                    54
Mechanical seals, standard design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                       56
           -                  -
Shaft seal - mechanical seals - Type Crane 58U and 58B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                          58
                         -               -
Dimension table Omega 80 - 210 up to 150 - 605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                         60
                           -               -
Dimension tables Omega 200 - 320 up to 350 - 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                           62
                                     -               -
General arrangement drawing Omega 80 - 210 up to 100 - 375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                       64
                                      -               -          -          -
General arrangement drawing Omega 250 - 480 up to 250 - 600; 300 - 435; 350 - 360 . . . . . . . .                                                                             70
                                      -          -               -          -          -
General arrangement drawing Omega 250 - 800; 300 - 560 up to 300 - 700; 350 - 430; 350 - 510 .                                                                                72
Table of Connections and Measuring Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                74




                                                                                                                                                                                41
                                                                                                                               Omega

Types of installation
Horizontal




                                                          Type of installation 3E

                                              -coupled motor (type IM B3) 1)
                           Pump set with close-
                           Baseplate, baseframe, coupling guard and motor height adjustment
     Vertical




                Type of installation DB 2)                  Type of installation DK 2)               Type of installation DJ 2)
                2)   Depending of motor size                                                         Version with intermediate bearing

 Direction of rotation / flow direction
                                 Horizontal                                                          Vertical
       Direction of rotation                   Direction of rotation         Direction of rotation           Direction of rotation
       anticlockwise,                          clockwise, viewed from the    anticlockwise,                  clockwise, viewed from the
       viewed from the drive end               drive end                     viewed from the drive end       drive end




1)    General arrangement drawing ”Pump set 3 E -- Baseplate/baseframe with motor height adjustment” shows the main variants available

42
                                                                                                          Omega


                        -
Type of Installation 3E - Motor Height Adjustment
Baseplate with adjusting screw or shims under the motor feet




                                                                                  901.54

                                                                                  550.54

                                                                                  89-4.54 1)
                                                                                  (Shims)
                                (840)       (681)
901.06                                                                            550.55

                                                                                  909.54
550.56                                                                            (Adjusting screw)

                                                                                  890


                                   901.05


 920.10    550.10     900.01     89--4.03                       1) for   screw set without adjusting screw (909.54)


                        -                         -
Type of Installation 3E - Motor Height Adjustment - Baseplate with adjusting screw and pedestal




                                                                                            901.54

                                                                                            550.54

                                                                                            550.55

                                                                                            909.54
                                                                                  (Adjusting screw)
                                    (840)        (681)
 901.06                                                                                     901.57

                                                                                            550.57
550.56
    890                                                                                     180.54
  (891)                                                                                 (Pedestal)


                                        901.05


                                    89--4.03
 920.10     550.10    900.01                                                                          ,




                                                                                                                43
                                                                                                                   Omega

                        -                         -
Type of Installation 3E - Motor Height Adjustment - Baseframe with Base / Shims under the Motor Feet




                                                                                                        901.54
                                                                                                        (902.54)    2)
                                                                                                        (920.54)

                                                                                                        550.54
     901.06

                                                                                    (Shim)              89-4.54
     550.56                                                                          (Base)             (592.54)    1)

                                                                                                     891


                                          901.05

                                                           1) optional, depending on height required
                                                           2) for long lengths, instead of hex. head bolts
                                       89--4.03
     920.10      550.10    900.01




      Part no.       Description
       89-4          Shim
        180          Pedestal
        550          Washer
        592          Base
        890          Baseplate
        900          Screw
        901          Hex. head bolt
        902          Stud
        909          Adjusting screw
        920          Nut




44
                                                                   Omega

Sealing / flushing water piping
The pump is equipped with sealing / flushing water piping.
These pipes are sheathed PTFE hoses which are flexible, tem-
perature and highly pressure resistant.
Another favourable property of PTFE (polytetrafluorethylene)
is the extremely low friction coefficient which prevents pipe
clogging.
Normally we supply this assembly ready mounted to the pump.
If this is not the case, mount the hoses and fittings as per the
attached drawings (see appendix).
Arrangement of sealing water and flush pipes




                                                                      45
                                                                                  Omega


Sealing water pipe for gland packing

                                 903.01     731.03     731.04     719.01




                                                                             731.02

                                                                             (731.12)
                      (731.11)

                                                                             731.05




     Part no.   Description
      719.01    Flexible tube
      731.02    Nipple joint
      731.03    Cross
      731.04    Nipple joint
      731.05    Pipe bend
      731.12    Socket
      903.01    Screwed plug



Sealing water pipe for mechanical seal

                                   903.01     731.03     731.04     719.01




                                                                                731.02




     Part no.   Description
      719.01    Flexible tube
      731.02    Nipple joint
      731.03    Cross
      731.04    Nipple joint
      903.01    Screwed plug


46
                                                                                                                       Omega

           -EUPEX)
Coupling (N-                                                     Installation
                                                                 -
                                                                 - Design of types A / ADS
(Flexible couplings N-     -EUPEX and N-    -EUPEX- -DS,
types A and ADS)                                                 The N--EUPEX coupling types A / ADS consist of a coupling
-- N--EUPEX couplings provide radial, angular, axial and tor-    part 1 which houses the flexible coupling blocks (12), the finger
    sional flexibility. They are positive--locking.              part 3 and the coupling part 2, which bolts onto part 3.
-- Torque is transmitted by flexible coupling elements (flexi-   The bolted connection between part 2 and part 3 makes it possi-
    bles).                                                       ble to separate the coupled machines without axial displace-
                                                                 ment (if clearance P is observed).
-- The non--linear spring characteristic and the favourable
    damping properties of the N--EUPEX coupling effectively
                                                                           Part 1      Part 12    Part 13         Part 2
    counteract any dangerous increase in vibrations.
                                                                                             S1
General instructions and safety notes
When fitting and removing N--EUPEX couplings please note
the following requirements:
                  D The coupling shall only be operated,
                    serviced or repaired by authorized,
                    skilled and duly qualified staff.

                  D The coupling shall only be used and
                    operated     within    the    conditions
                    stipulated in the technical specification
                    and supply contract.

                  D Unauthorized modification and removal
                    of protective equipment is not permitted.
                                                                 -
                                                                 - Mounting the coupling components
                  D Any work on the coupling shall only be
                                                                 Before fitting the coupling components, carefully clean the shaft
                    performed with the machine shut down.
                                                                 ends and the coupling parts. Make sure to remove the flexible
                    The driver must be secured against
                                                                 coupling blocks before cleaning the coupling parts with a sol-
                    inadvertent start--up (e.g. by locking the
                                                                 vent.
                    key--operated switch or removing the
                    power supply fuses). At the switch--on              Heed the manufacturer’s instructions for the use of
                    point a notice shall be affixed to the              solvents.
                    effect that work is being performed on
                    the coupling.                                  Caution     Use appropriate tools when pulling on the
                                                                               coupling parts, to prevent damage to the
                  D Immediately switch off the driver when       shaft bearings due to the axial joining force.
                    changes in coupling behaviour occur,
                                                                 Make sure to use suitable lifting tackle.
                    such as changed running noises.
                                                                 The shaft ends must not protrude from the hub faces. The cou-
                  D The coupling must be suitably protected      pling is locked in axial direction by means of the set screw or
                    against accidental contact.                  end plate, as applicable / set screw and end plate, respectively.

                                                                   Caution       The set screws shall only be tightened by
                                                                                 means of a hexagon socket head wrench to
                                                                                 DIN 911, without extension.
                                                                        Non- -compliance with these instructions may cause
                                                                        the coupling to burst. Danger of life by flying frag-
                                                                        ments!




                                                                                                                               47
                                                                                                                            Omega

Heating up the coupling parts (to max. +150 °C) may facilitate         Using a dial micrometer will make for increased measuring ac-
pulling on the coupling parts. If temperatures exceed +80 °C,          curacy.
the flexible coupling blocks must be removed from the coupling         To allow one shaft end to rotate freely, the driving section can
parts before the heating process.                                      be separated on types A and ADS by loosening the screwed
                                                                       connection between parts 2 and 3 and pulling part 3 out of the
       Protect against burns from contact with hot compo-              recesses in part 1.
       nents!
                                                                         Caution       After   the    connection has   been
                                                                                         -established, check the tightening
                                                                                       re-
If the coupling blocks have been removed, they shall be re--in-                        torque of the bolts.
stalled after the coupling parts have been pulled on. Make sure
the heated coupling parts have cooled down to under 80 _C be-
fore doing so. All coupling blocks used must be of identical size
and marking.
Push the machines to be coupled together.

       Take appropriate precautions to prevent injury by
       crushing.


Make sure to observe dimension S1. On types A and ADS, the
connection between parts 2 and 3 shall be re--established be-
fore aligning the coupling, and the tightening torque of the scre-
wed connection between parts 2 and 3 shall be checked (for
tightening torques and clearance S1 please refer to point 6.6).
Aligning the coupling
(Also refer to section 5.3.2).
The couplings will only tolerate misalignment of the shaft ends
to be coupled to a certain extent.
When aligning the coupling, the radial and angular misalign-
ment of the shaft ends should therefore be minimized. With
identical operating conditions, the useful life of the flexible cou-
pling blocks will be increased as a result.
Coupling alignment shall be effected in two planes which are
normal to each other. Use a straight--edge (radial misalign-
ment) and feeler gauge (angular misalignment) as shown be-
low to verify.

                                     Straight edge




                                    Feeler gauge




48
                                                                                                                      Omega

Correlation between tightening torques, dimension P and clearance S1
     N-EUPEX             N-EUPEX-DS          Tightening torque TA and width across flats SW for bolts
                                                               to DIN 912 Part 2/3
     coupling              coupling

        Size                  Size                   TA                   SW                    P                   S1
                                                     Nm                  [mm]                 [mm]                 [mm]
        110                   118                    14                    6                    33                  2-4
        125                   135                   17,5                   6                    38                  2-4
        140                   152                    29                    8                    43                  2-4
        160                   172                    35                    8                    47                  2-5
        180                   194                    44                    8                    50                  2-6
        200                   218                   67,5                  10                    53                  2-6
        225                   245                    89                   10                    61                  2-6
        250                   272                    145                  14                    69                  3-8
        280                   305                    185                  14                    73                  3-8
        315                   340                    200                  14                    78                  3-8
        350                   350                    260                  17                    83                  3-8
        400                   430                    340                  17                    88                  3-8
        440                   472                    420                  17                    99                  5-10
        480                   514                    550                  19                   104                  5-10
        520                   556                    670                  19                   115                  5-10
        560                    ----                  710                  19                   125                  6-12
        610                    ----                 1450                  22                   135                  6-12
        660                    ----                 1450                  22                   145                  6-12
        710                    ----                 1450                  22                   155                  6-12

Commissioning the coupling                                          Operation

Measures to be taken prior to commissioning                         General operating data
Before commissioning the coupling check the proper installa-        During coupling operation, watch out for
tion of the flexible coupling elements, i.e. make sure the flexi-   -- changed running noises,
bles are flush with the hub face, and check whether the set
                                                                    -- sudden vibrations.
screws are properly tightened. Also verify coupling alignment
and clearance S1 and correct, if necessary. Check whether all         Caution       If any irregularities occur during operation,
screwed connections have been tightening with the tightening                        switch off the driver immediately and refer
torques specified. Finally, fit the coupling guard against acci-                  -shooting table to determine the cause.
                                                                    to the trouble-
dental contact.
                                                                    The trouble--shooting table lists possible faults, causes and
                                                                    suggested remedies.




                                                                                                                              49
                                                                                                                         Omega

       -shooting
Trouble-
General                                                                   Before commencing any maintenance, repair or
The faults listed below shall serve as orientation only when de-          other work on the coupling, the operator must shut
termining failure causes.                                          down the entire driving mechanism. The drivers, in parti-
                                                                   cular, must be secured against inadvertent start--up.
In a complex plant system, all other components will have to be
included in the search for possible failure causes.                Also, the accident prevention regulations in force at the in-
                                                                   stallation site shall be complied with.
The coupling shall give low--noise and vibration--free operation
in all phases of operation. Any other operating behaviour shall
be considered a fault which must be remedied immediately.
       -shooting list
Trouble-

 Fault                                      Possible causes               Remedy
 Sudden change in noise level and/or        Misalignment                  Shut down the unit.
 sudden vibrations
                                                                          Eliminate cause for misalignment, if any.
                                                                          (E.g. re--tighten the foundation bolts).
                                                                          Inspect for wear, proceed as described
                                                                          in section ”Coupling -- Maintenance and Repair”
                                            Flexibles are worn            Shut down the unit.


                                            Torque transmission by        Dismantle the coupling and remove what is left of the
                                            metal--to--metal contact      flexible coupling blocks.
                                                                          Inspect the coupling parts and replace
                                                                          any damaged components.
                                                                          Coupling blocks shall always be replaced by complete
                                                                          sets of new coupling blocks; only use.
                                                                          coupling blocks with identical markings.
                                                                          Verify alignment and correct, if necessary.


                                                                          Check the tightening torques of the screwed connec-
                                                                          tion between parts 2 and 3.

Maintenance and repair                                             To determine the chord dimension ∆SV, rotate one coupling part
General                                                            by hand up to the stop and mark the coupling parts (see illustra-
                                                                   tion). Hand--rotate one coupling part into the opposite direction
The torsional play between the two coupling parts shall be         up to the stop. The two marks will diverge. The distance bet-
checked in acc. with the maintenance schedule of the plant, but    ween the marks is the chord dimension ∆SV. If ∆SV exceeds the
at least once a year.                                              value given in the table, the flexible coupling blocks have to be
If torsional play must not be limited for extremely smooth cou-    replaced.
pling operation, the plastic flexibles can be allowed to wear                       Coupling blocks shall always be replaced
                                                                      Caution
down to approx. of their original thickness before they have                        by complete sets of new coupling blocks;
to be replaced. To assess the wear condition of the coupling       only use coupling blocks with identical identification
blocks, the table below indicates the permissible torsional play   numbers.
as indicated by the chord dimension ∆SV on the outside cou-
pling diameter.




50
                                                                                                                                                         Omega




Table: Wear mark on N-
                     -EUPEX coupling
  Size   58    68    80    95    110   125    140    160    180    200    225    250     280     315     350   400    440    480    520     560   610    660    710
Wear
mark     5.5   5.5   5.0   6.0   7.0   8.0    8.0    8.0    8.0    8.5    9.0    10.0    11.5    10.5   11.5   13.0   14.0   15.5   17.5   17.5   19.5   21.0   22.5
∆SV


Table: Wear mark on N-     -DS coupling
                     -EUPEX-
  Size   66    76    88    103   118   135    152     172    194    218    245     272     305     340     380    430    472    514       556


wear
mark     6.0   7.0   5.0   7.0   9.0   10.5   11.5    9.0    8.0    7.0    6.5     7.0     8.0 6.5         7.0 10.0      12.0   14.0   16.0
∆SV


Replacing wear parts
Use only genuine N- -EUPEX flexible blocks as spare parts, to                    After the screwed connection between parts 2 and 3 has been
ensure correct torque transmission and trouble--free operation.                  undone, part 3 can be shifted in axial direction. By rotating part
Please note:                                                                     3, the flexible coupling blocks are freely accessible. To facilitate
                                                                                 axial displacement, sizes 225--430 are provided with forcing
On types A and ADS, the flexibles can be replaced without axial                  threads in part 1. From size 440, the forcing threads are located
displacement of the coupled machines.                                            in part 3 (see illustrations).




For reassembly carefully follow the instructions in the sections
on ”Installation” and ”Commissioning”.




                                                                                                                                                                  51
                                                                              Omega


General drawing of pump with parts list   Shaft seal: Gland packing




                                           Shaft       Axial overhang of shaft protec-
                                          diameter               ting sleeve
           Sealed with Loctite 574          dW                     A ± 0.5
                                             40                      2
                                             50                      2
                                             60                      2
           ALTEMP Q NB 50 grease             70                      5
                                             80                      4
                                             90                      4




52
                                                                                                        Omega


Part no.   Description                 Part no.   Description               Part no.   Description
102        Volute casing               452        Gland cover               561        Grooved pin
105.01     Lower casing half           455        Gland packing             580        Cap
105.02     Upper casing half           457        Stuffing box insert       901        Hex. head bolt
211        Pump shaft                  458        Neck ring                 902        Stud
234        Impeller                    461        Lantern ring              903        Screwed plug
321        Deep--groove ball bearing   502        Casing wear ring          904        Grub screw
350        Bearing housing             503        Impeller wear ring        920        Nut
360        Bearing cover               520        Sleeve                    932        Circlip
411        V--ring                     524        Shaft protecting sleeve   940        Key
412        O-ring                      550        Washer                    950        Cup spring
421        Radial shaft seal ring
441        Housing for shaft seal




                                                                                                           53
                                                                              Omega


General drawing of pump with parts list   Shaft seal: Mechanical seal




                                            Shaft      Axial overhang of shaft protec-
                                          diameter               ting sleeve
           Sealed with Loctite 574
                                            dW                     A ± 0.5
                                             40                      2
                                             50                      2
           ALTEMP Q NB 50 grease             60                      2
                                             70                      5
                                             80                      4
                                             90                      4




54
                                                                                                        Omega


Part no.   Description                 Part no.   Description               Part no.   Description
102        Volute casing               421        Radial shaft seal ring    901        Hex. head bolt
105.01     Lower casing half           433        Mechanical seal           903        Screwed plug
105.02     Upper casing half           441        Housing for shaft seal    920        Nut
211        Pump shaft                  457.02     Stuffing box insert       932        Circlip
234        Impeller                    503        Impeller wear ring        940        Key
321        Deep--groove ball bearing   520        Sleeve                    950        Cup spring
350        Bearing housing             524.01     Shaft protecting sleeve
360        Bearing cover               525.02     Spacer sleeve
411        V--ring                     550        Washer
412        O-ring                      561        Grooved pin
                                       580        Cap




                                                                                                           55
                                                                                                                                    Omega


Mechanical seals, standard design
                                            -
Standardized mechanical seal to DIN 24960 - short design, non- -balanced
Sizes for shaft diameter dw = 40 to 80 mm (with single spring)

                  211      524.01     457.02   525.02                         411                 433              471     901.16

                                                                                                       Flushing line
                                                                                                       connection




                                                                 Ø dw




                                           -
Standardized mechanical seal to DIN 24960 - short design, non- -balanced
Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)

                211       524.01      457.02   525.02                   411           433 Flushing line     471        901.16
                                                                                          connection
                                                        dw =90




                                                                              ∅ 110




Part no.     Description                       Part no.                  Description
211          Pump shaft                        471                       Seal cover
433          Mechanical seal                   524.01                    Shaft protecting sleeve
441          Housing for shaft seal            525.02                    Spacer sleeve
457.02       Neck ring                         901.16                    Hexagon head bolt




56
                                                                                                                 Omega


Mechanical seals, standard design
Balanced mechanical seal (for operating pressures > 16 bar) to DIN 24960
Sizes for shaft diameter dw = 40 to 80 mm (with covered spring)

                                457.02     411                433            Flushing line     471      901.16
                                                                             connection




           525.02



           524.01



               211
                                               dw




Balanced mechanical seal (for operating pressures p > 16 bar) to DIN 24960
Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)

                     211       524.01 457.02    525.02          411    433 Flushing line 471   901.16
                                                                             connection
                                                                               ∅ 110
                                                    dw = 90




Part no.     Description                   Part no.             Description
211          Pump shaft                    471                  Seal cover
433          Mechanical seal               524.01               Shaft protecting sleeve
441          Housing for shaft seal        525.02               Spacer sleeve
457.02       Neck ring                     901.16               Hexagon head bolt




                                                                                                                    57
                                                                                                                          Omega


           -                  -
Shaft seal - mechanical seals - Type Crane 58U and 58B
Description                                                         Preparation for installation
The mechanical seals, 58U and 58B, are precision--made and          1. The installation dimensions and tolerances must comply
must be treated accordingly. The contact faces are lapped to           with those outlined in the relevant literature.
a high degree of accuracy and prior to despatch they are cove-      2. The cover which will accept the seat ring must be checked
red in a protective sleeve to prevent damage. If the protective        with regard to depth and installation dimensions.
sleeve is removed for installation purposes, then great care
must be taken to avoid any damage to the finely finished, lap-
ped surfaces.
Whenever replacing worn out or damaged mechanical seals,
the section of the shaft or sleeve which will accept the new seal
must be cleaned and oiled.




     780              Retainer                578            Balanced face
     305              Grub screw              096            Snap ring
     582 (092)        Spring                  500            Seat type BP
     583              Thust ring              501            Seat ring
     123              O-ring                  902            Seat type BO
     574              Rotating face           123 (R)        O-ring
     564              Support ring


Installation and operation                                          3. Push the seat ring together with the joint ring into the cover
1. Clean and lightly lubricate the shaft / sleeve with a suitable      applying even manual pressure. The joint ring shall also be
   lubricant.                                                          lubricated using a suitable lubricant.
Caution:                                                            4. The contact faces must be cleaned prior to installation into
  Sealing elements manufactured in EP--Elastomer materials             the machine. Tighten the cover bolts evenly. Overtightening
  must not come in contact with mineral oil and grease.                can affect the true running of the rubbing faces and there-
                                                                       fore have an adverse effect on the functioning of the mecha-
2. Push on the rotating unit applying light manual pressure.           nical seal.
                                                                    5. Manually turn the shaft. Fill the machine whilst simulta-
                                                                       neously monitoring the venting equipment within the seal
                                                                       area. Check the circulation pipe.




58
                                                                                                                           Omega

Dismantling and assembly of the rotating unit
The first step is to remove the snap ring (096) from the retainer
(780). The springs are compressed to achieve this. This can
be done by using a simple tool, as illustrated.
  Caution         Lapped surfaces of the rotating face must
                  be protected.



                                      Wing nut



                                      Grub screw




                                       Thrust plate with
                                       glued--on

                                      protective support

                                      Locking nut



                                      Baseplate                     Assembly is carried out in reverse sequence.
                                                                    The following must be noted during assembly:
1. The rotating face (574 / 578) is pushed down and the snap        The drive cams in the retainer (780) must engage into the groo-
   ring (096) is removed from the groove using a pointed tool.      ves of the thrust ring (583) or the rotating face (574 / 578) .
                                                                    Fit the snap ring (096) into the groove of the retainer (780), lea-
                                                                    ving one end of the snap ring protruding by approx 6 -- 12 mm
                                                                    to the side of the drilled hole.




                                                                    At the outer circumference of the retainer (780) there are 2 mar-
2. Now remove in the following sequence: the rotating face          ker grooves. The lower one runs precisely through the centre
   (574 / 578), the O--ring (123), the thrust ring (583) and the    of the drilled hole for the internal socket head screws, which in-
   springs (582 / 092).                                             dicates that the thread of the screws is metric.
                                                                    The upper groove assists during installation. If the initial ten-
                                                                    sion of the mechanical seal is set correctly to the installation
                                                                    length, then the thrust ring shall be in alignment (be flush) with
                                                                    this groove.




                                                                                                                                    59
                                                                                                                                                                       Omega

                         -               -
Dimension table Omega 80 - 210 up to 150 - 605
Fig. 0                                                                                          N.B.:                   If the pump’s direction of rotation is
Direction of rotation: CLOCKWISE                                                                                        ANTI--CLOCKWISE, the position of
                                                                                                                        the suction and discharge nozzle is
                                                                                                                        reversed (mirror image).

                          a2                         a1                                                                 l3
                                                                                                                                                        Direction of rotation:
          Z




                                                     d3                                                   l2                         f                  CLOCKWISE
                                5D
                                                                                                     5D                                  5D
                     s2
                                                               s1
                                                                                                                                                        l1




                                                                      h3




                                                                                                                                                             d1
 h2




                                                1M
         DN 2




                                                               DN 1

                                                                      h1

                          1M
                                                                                                8B                                            8B
                                     6B
                                s




                                                                                                                                               Keyway and key
                                d2                        b1                                                            m2                     DIN 6885 sheet 1
                                                                                                                                               Shaft diameter:
                                n4          n3                                                                          m1                     Tolerance h6 to DIN 7155

                                n2          n1


                                                                                                                                     Connections:
Flanges:                                                                                                                             - 1M  Pressure gauge               G 1/2
- All flanges designed as plate flanges                                                                                              - 5D  Vent                         G 1/2
- flange thickness to ANSI                                                                                                           - 6B  Drainage                     G 1/2
- Connect pipes without transmitting stresses or strains                                                                             - 8B  Leakage liq. drain           G 3/4


Dimensions and weights                                                                                                                                   All dimensions in mm
     Pump                            Flange dimensions                                                            Pump dimensions
     Size       DN1        DN2             s1                   s2              a1     a2            d3         f   h1     h2     h3                     l2       l3      z 1)
      80-210                                                                                                                                  168                         340
      80-270                                                                    300    300                                                    190                         380
                125        80              34                   29                                   19        415       315     140                    300       715
      80-370                                                                    330    330                                                    225                         450
     100-250                                                                                                                                  195                         390
                                                                                330    330
     100-310    150        100             37                   32                                   19        415       355     170          225       300       715     450
     100-375                                                                    370    370                                                    260                         520
     125-230                                                                                                                                  210                         420
     125-290                                                                    370    370                                                    230                         460
                200        125             41                   35                                   19        515       400     200                    366       881
     125-365                                                                                                                                  260                         520
     125-500                                                                    450    450                                                    305                         610
     150-290                                                                                                                                  245                         490
                                                                                400    400                     515                                      366       881
     150-360                                                                                                             400     200          265                         530
                200        150             41                   37                                   19
     150-460                                                                    450    450                                                    305                         610
                                                                                                               590                                      399       989
     150-605                                                                    600    500                               500     300          370                         740

     Pump                                    Foot dimensions                                               Shaft               Weights [kg]
     Size       b1             d2     m1     m2     n1    n2               n3    n4         s         d1           l1        Pump      Water
                                                                                                                                         fill
    80-210                                                                                                                     185                 10
    80-270     70    17,5    320     270    205     205      170                 170     20           35        80             195                 15
    80-370                                                                                                                     205                 20
   100-250                                                                                                                     210                 20
   100-310     70    17,5    320     270    235     235      200                 200     20           35        80             225                 25
   100-375                                                                                                                     245                 30
   125-230                                                                                                                     250                 35
   125-290                                  260     260      225                 225                                           275                 40
               70    17 5
                     17,5    390     340                                                 20           45        100
   125-365                                                                                                                     300                 45
   125-500                                  315     315      280                 280                                           335                 55
   150-290                                                                                                                     350                 50
                             390     340    260     260      225                 225                  45        100
   150-360                                                                                                                     360                 60
               70    17 5
                     17,5                                                                20
   150-460                                  315     315      280                 280                                           440                 75
                             480     430                                                              55        125
   150-605                                  385     385      350                 350                                           650                 90
1) z = clearance above casing cover for dismantling of the rotor




60
                                                                                                                                            Omega

Standard flange connections 1):
     Pump                       JL 1040                                        JS 1030 / 1.4517
     Size               Nominal pressure acc. to:                          Nominal pressure acc. to:
                  DIN 2501    BS 4504      ANSI B 16.1               DIN 2501     BS 4504      ANSI B 16.1
                 ISO 7005/2                                         ISO 7005/2
      80-210
      80-270       PN 16        Table 16/11        Class 250          PN 25       Table 25/11      Class 250
      80-370
     100-250
     100-310       PN 16        Table 16/11        Class 250          PN 25       Table 25/11      Class 250
     100-375
     125-230                                                                                                                  d2
     125-290
                                                                                                                                        number of
     125-365       PN 16        Table 16/11        Class 250          PN 25       Table 25/11      Class 250                            holes n
     125-500
     150-290
     150-360       PN 16        Table 16/11
     150-460                                       Class 250          PN 25       Table 25/11      Class 250
     150-605       PN 25        Table 25/11
                                                                                                                             k
1)   Other flange connections on request
                  -
Flange dimensions - Hole pattern                                                                                                 All dimensions in mm
 Standard                                  DN 80                    DN 100                DN 125               DN 150                   DN 200
                                     d2        k       n       d2      k      n      d2     k        n    d2     k      n          d2      k    n
 ISO 7005/2
 DIN 2501           PN 16            19       160      8       19     180     8      19    210       8    23    240     8          23     295   12

 ISO 7005/2
 DIN 2501           PN 25            19       160      8       23     190     8      28    220       8    28    250     8          28     310   12

 BS 4504            Table 16/11      19       160      8       19     180     8      19    210       8    23    240     8          23     295   12
 BS 4504            Table 25/11      19       160      8       23     190     8      28    220       8    28    250     8          28     310   12
 ANSI B 16.1        Class 250        23       168      8       23     200     8      23    235       8    23    270     12         28     330   12




                                                                                                                                                     61
                                                                                                                                                                                Omega

                           -               -
Dimension tables Omega 200 - 320 up to 350 - 510
Fig. 0                                                                                                         N.B.:               If the pump’s direction of rotation is
Direction of rotation: CLOCKWISE                                                                                                   ANTI--CLOCKWISE, the position of
                                                                                                                                   the suction and discharge nozzle is
                                                                                                                                   reversed (mirror image).

                     a2                              a1                                                                       l3                                    Direction of rotation:
                                                                                                                                                                    CLOCKWISE
       Z




                                                     d3                                                         l2                          f
                           5D
                                                                                                          5D                                    5D
                s2
                                                                s1
                                                                                                                                                              l1




                                                                        h3
h2




                                                                                                                                                                   d1
                                               1M
      DN 2




                                                                 DN 1

                                                                          h1


                     1M
                                                                                                     8B                                              8B
                                                                                                                                                          Keyway and key
                                6B                                                                                                                        DIN 6885 sheet 1
                          s




                                                                                                                                                          Shaft diameter:
                                                                                                                                  m2                      Tolerance h6 to DIN 7155
                          d2                               b1

                           n4             n3                                                                                      m1                 Connections:
                           n2             n1                                                                                                         - 1M  Pressure gauge           G 1/2
                                                                                                                                                     - 5D  Vent                     G 1/2
Flanges:                                                                                                                                             - 6B  Drainage                 G 1/2
- All flanges designed as plate flanges                                                                                                              - 8B  Leakage liq. drain       G 3/4
- flange thickness to ANSI
- Connect pipes without transmitting stresses or strains
Dimensions and weights                                                                                                                                             All dimensions in mm
     Pump                       Flange dimensions                                                                          Pump dimensions
     Size     DN1         DN2         s1                             s2              a1         a2         d3            f    h1   h2 2)   h3                      l2      l3      z 2)
  200-320                                                                            450        450                                                     285                        570
                                                                                                                       590         500     240                 399        989
  200-420                                                                            500                                                                310                        620
              250         200             48                         41                         500       24,5
                                                                                                          24 5
  200-520                                                                            600                                           560     300          370                        740
                                                                                                                       655                                     464       1119
  200-670                                                                            650        550                                600     350          430                        860
  250-370                            33 (51) 1)                 32 (48) 1)           500        500                    655                              320    464       1119      640
                                                                                                                                   600     300
  250-480                                                                            550                  12,5                                          355                        710
              300         250                                                                   550                    730                                     515       1245
  250-600                                 51                         48              650                                           630     350          415                        830
  250-800                                                                            800        700        30          810         710     400          520    585       1395     1040
  300-300     350                    36 (54) 1)                    33                550        500                    655         630     300          360    464       1119      720
  300-435                            38 (57) 1)                  (51) 1)             650        550       24,5         730         670     350          365    515       1245      730
                          300
  300-560     400                                                                    700        650                    810         710     350          430    585       1395      860
                                          57                         51
  300-700                                                                            750        650       24,5         810         750     400          480    585       1395      960
  350-360     400                    38 (57)    1)                                   650        550                    730         670     350          410    515       1245      820
  350-430     450         350        41 (60) 1)                 36 (54) 1)           750                  24,5                                          465                        930
                                                                                                650                    810         750     400                 585       1395
  350-510     400                    38 (57) 1)                                      700                                                                420                        840

     Pump                                      Foot dimensions                                                       Shaft                Weights [kg]
     Size      b1          d2        m1        m2     n1     n2                n3     n4             s         d1            l1        Pump     Water fill
    200-320                                                                                                              450            80
                        17,5
                        17 5           430                315     315          280    280         20           55        125
    200-420     70                                                                                                       520            95
                                480
    200-520                            400                385     385                                                    840           115
                         22                                                    350    350         26      65    140
    200-670    100                     400                400     400                                                    990           140
    250-370                     480    400                                                                65    140      665           125
    250-480              22                               400     400          350    350                                830           145
               100                                                                                26      75    160
    250-600                     600    520                                                                              1215           180
    250-800              23                               525     525          475    475                 85    180     1500           240
    300-300                     480    400                                                                65    140      630           100
                                                          400     400          350    350
    300-435                                                                                               75    160      905           190
               100       22                                                                       26
    300-560                     600    520                                                                              1425           225
                                                          525     525          475    475                 85    180
    300-700                                                                                                             1690           275
    350-360                                               400     400          350    350                 75    160      865           160
    350-430    100       22     600    520                                                        26                    1285           240
                                                          525     525          475    475                 85    180
    350-510                                                                                                             1395           290
1) for casing material JS 1030, 1.4517                                                     2)   z = clearance above casing cover for dismantling of the rotor


62
                                                                                                                                                 Omega

Standard flange connections 1):
     Pump                       JL 1040                                       JS 1030 / 1.4517
     Size               Nominal pressure acc. to:                         Nominal pressure acc. to:
                  DIN 2501    BS 4504      ANSI B 16.1              DIN 2501      BS 4504     ANSI B 16.1
                 ISO 7005/2                                        ISO 7005/2
     200-320
     200-420       PN 16        Table 16/11
                                                   Class 250         PN 25       Table 25/11        Class 250
     200-520
     200-670       PN 25        Table 25/11
     250-370       PN 10        Table 10/11        Class 125
     250-480       PN 16        Table 16/11
                                                                     PN 25       Table 25/11        Class 250
     250-600                                       Class 250
                   PN 25        Table 25/11
     250-800
     300-300
                   PN 10        Table 10/11        Class 125                                                                          d2
     300-435
                                                                     PN 25       Table 25/11        Class 250
     300-560       PN 16        Table 16/11                                                                                                   number of
                                                   Class 250
     300-700       PN 25        Table 25/11                                                                                                   holes n
     350-360
     350-430       PN 10        Table 10/11        Class 125         PN 25       Table 25/11        Class 250
     350-510
1)   Other flange connections on request
                                                                                                                                     k

                  -
Flange dimensions - Hole pattern                                                                                                     All dimensions in mm
 Standard                             DN 200               DN 250              DN 300               DN 350             DN 400                DN 450
                                 d2     k      n      d2       k    n     d2     k      n      d2     k      n    d2     k      n        d2      k    n
 ISO 7005/2
 DIN 2501         PN 10          23    295     8      23    350     12   23     400     12     23    460     16   28    515     16       28     565   20

 ISO 7005/2
 DIN 2501         PN 16          23    295     12     28    355     12   28     410     12     28    470     16   31    525     16       31     585   20

 ISO 7005/2
 DIN 2501         PN 25          28    310     12     31    370     12   31     430     16     34    490     16   37    550     16       37     600   20

 BS 4504          Table 10/11    23    295     8      23    350     12   23     400     12     23    460     16   28    515     16       28     565   20
 BS 4504          Table 16/11    23    295     12     28    355     12   28     410     12     28    470     16   31    525     16       31     585   20
 BS 4504          Table 25/11    28    310     12     31    370     12   31     430     16     34    490     16   37    550     16       37     600   20
 ANSI B 16.1      Class 125      23    299     8      28    362     12   28     432     12     28    476     12   28    540     16       31     578   16
 ANSI B 16.1      Class 250      28    330     12     28    387     16   31     451     16     31    514     20   34    572     20       34     629   24




                                                                                                                                                          63
                                                                                                                                                                                             Omega

                                     -               -
General arrangement drawing Omega 80 - 210 up to 100 - 375
Installation type 3E                                                                                                 N.B.:              If the pump’s direction of rotation is
Direction of rotation: CLOCKWISE                                                                                                        ANTI--CLOCKWISE, the position of
                                                                                                                                        the suction and discharge nozzle is
                                                                                                                                        reversed (mirror image).


                                                          a2              a1                                                       l2                                               q
                                                                                                                                                    f
                                Z




                                               s2                                         s1                                                                        5
                                                           5D
                                                                                                                            5D                      5D




                                                                                                                                                                                                         h7
                                      DN2
                              h5




                                                                          1M




                                                                                                     DN1
                                                         1M




                                                                                                                                                                                                         h6
                                                                                                                           8B                            8B
                                                               6B
                                                                                           h4




                                                                                                                                                                                                    h8
                                    50




                                                                                                   L



                                                                                                             Grouting
                                V   N (øN)                                                200                                                                  100
                                                                     G1                                                                        l4                              l5
                                                                                                                                  100                                                        100
                                                                     b2
                                                                     G2                                                                                        l3




                                                                                                                                                                                                    h8
                                      50




                                                                                               L




 Connections:                                                        b2                                                                                        100
 - 1M  Pressure gauge                G 1/2 100                                  200                                               100          l4                              l5            100
 - 5D  Vent                          G 1/2
                                                                                                                                                              l3
 - 6B  Drainage                      G 1/2
 - 8B  Leakage liq. drain            G 3/4
 Ground baseplate / base frame with low--shrinkage concrete                                                  The motor--dependt dimensions refer to KSB standard motors
Dimensions and weights                                                                                                                                                     All dimensions in mm
        Pump                          Flange dimensions                                                     Pump dimensions                                                     Masse [kg]
         Size
                    Motor--         DN1       DN2         s1         s2        a1         a2          f      h4      h5      h6          i      l2           z 1)         Pump                Water
                   dependet                                                                                         max.                                                                       fill
       80-210           --                                                                                                                                   340           185                     10
                                                                                                            295             435         70
                  up to 280 M                                                  300        300
       80-270                       125        80         36         29                            415              660                        300           380           195                     15
                     up 315 S                                                                               320             460         85
       80-370           --                                                     330        330               295             435         70                   450           205                     20
                  up to 280 M                                                                               305             475         70
   100-250                                                                                                                                                   390           210                     20
                     up 315 S                                                                               330             500         85
                                                                               330        330
                  up to 280 M       150        100        37         32                            415      305     760     475         70     300
   100-310                                                                                                                                                   450           225                     25
                     up 315 S                                                                               330             500         85
   100-375              --                                                     370        370               305             475         70                   520           245                     30
1) z   = clearance above casing cover for rotor removal
Baseplate / base frame and foundation dimensions                                                                                                                           All dimensions in mm
        Baseplate-                          Baseplate-and foundation dimensions                                             Foundation bolts                                Ancor bolts
           Size
           No.                b2         G1         G2          l3        l4         l5         h8         Weight         Size           VN              L              Size            øN          L
        Drawing no.                                                                                         [kg]
             1
                              530        475        590        1190       495        495        120         74
       0W 384 167-00
             2
                              640        580        700        1400       600        600        120         97       M 16x250            100            250         M 12/25             18         110
       0W 384 169-00
            3 2)
                              670        610        720        1630       715        715        145         105
       0W 384 170-00
2) Base frame
64
                                                                                                                                                                 Omega

Standard flange connections 1):
      Pump                       JL 1040                                                    JS 1030 / 1.4517
      Size               Nominal pressure acc. to:                                       Nominal pressure acc. to:
                  DIN 2501          BS 4504       ANSI B 16.1                DIN 2501             BS 4504           ANSI B 16.1
                 ISO 7005/2                                                 ISO 7005/2
      80-210
      80-270
      80-370
                    PN 16         Table 16/11        Class 250                  PN 25            Table 25/11         Class 250
     100-250
     100-310
     100-375
1)   Other flange connections on request



                  -
Flange dimensions - Hole pattern                                                          All dimensions in mm
 Standard
                                                Suction flange                            Discharge flange
                                       DN            d2            k        n       DN           d2         k       n
 Pump sizes 80-210 up to 80-370        125                                          80                                                Mating flange
 ISO 7005/2           PN 16                                                                                                           All flanges designed as plate flanges
 DIN 2501                                       19 (M16)          210
 BS 4504              Table 16/11
                                                                                           19 (M16)     160
 ISO 7005/2           PN 25                                                 8                                       8
 DIN 2501                                       28 (M24)          220                                                                                  d2
 BS 4504              Table 25/11
 ANSI B 16.1          Class 250                 23 (M20)          235                      23 (M20)     168                                                 number of
                                                                                                                                                            holes n
 Pump sizes 100-250 up to
 100-375                               150                                          100

 ISO 7005/2           PN 16
 DIN 2501                                       23 (M20)          240                      19 (M16)     180
 BS 4504              Table 16/11
                                                                            8
 ISO 7005/2           PN 25                                                                                         8
 DIN 2501                                       28 (M24)          250                      23 (M20)     190                                        k
 BS 4504              Table 25/11
 ANSI B 16.1          Class 250                 23 (M20)          270   12                 23 (M20)     200



Baseplate / motor combinations

     Pump                                                                                     Motor Size
     Size      100L    112M   132S     132M      160M         160L      180M        180L     200L     225S      225M        250M    280S   280M   315S      315M   315L    315
     No of      4        4        4      4       2        4   2    4    2       4    4       2    4     4       2       4   2   4    2      2       2        2      2          2
     poles
     80-210     1        1        1      1       1            1         1                    1                  2           2
     80-270     1        1        1      1       1        1   1    1    1                    1                  2           2        2      2       3
     80-370                       1      1                1        1            1    1            1
 100-250        1        1        1      1                1   1    1    1                    1                  2           2        2      2       3        3
 100-310                          1      1                1        1            1    1       1    1             2           2        2      2       3        3      3          3
 100-375                                                  1        1            1    1            1     2               2       2

N.B.:     - The numbers listed in the table indicate the relevant baseplate numbers.
          - The baseplate numbers shown in the boxes also serve to select the correct motor size for the listed pump size.
          - Units comprising a motor size 315 and larger are completely assembled for verification and adjustment of the individual
            components. Before shipment, the units are dismantled again and the components packed / shipped separately




                                                                                                                                                                          65
                                                                                                                                                                                           Omega

                                      -               -
General arrangement drawing Omega 125 - 230 up to 150 - 360
Installation type 3E                                                                                               N.B.:              If the pump’s direction of rotation is
Direction of rotation: CLOCKWISE                                                                                                      ANTI--CLOCKWISE, the position of
                                                                                                                                      the suction and discharge nozzle is
                                                                                                                                      reversed (mirror image).


                                                         a2              a1                                                      l2                                               q
                                                                                                                                                   f
                               Z




                                              s2                                         s1                                                                        5
                                                          5D
                                                                                                                           5D                     5D




                                                                                                                                                                                                       h7
                                      DN2
                              h5




                                                                        1M




                                                                                                   DN1
                                                        1M




                                                                                                                                                                                                       h6
                                                                                                                         8B                             8B
                                                              6B
                                                                                          h4




                                                                                                                                                                                                  h8
                                    50




                                                                                                   L



                                                                                                            Grouting
                                V   N (øN)                                              200                                                                   100
                                                                   G1                                                                        l4                              l5
                                                                                                                                100                                                        100
                                                                   b2
                                                                   G2                                                                                         l3




                                                                                                                                                                                                  h8
                                      50




                                                                                              L




Connections:                                                       b2                                                                                         100
- 1M  Pressure gauge                 G 1/2
                                           100                                200                                               100          l4                              l5            100
- 5D  Vent                           G 1/2
- 6B  Drainage                       G 1/2                                                                                                                   l3
- 8B  Leakage liq. drain             G 3/4
 Ground baseplate / base frame with low--shrinkage concrete                                                The motor--dependt dimensions refer to KSB standard motors
Dimensions and weights                                                                                                                                                  All dimensions in mm
 Pump size                            Flange dimensions                                                   Pump dimensions                                                   Weight [kg]
                    Motor-          DN1 DN2     s1    s2                      a1         a2         f      h4   h5    h6               i      l2            z 1)       Pump          Water
                   dependet                                                                                    max.                                                                    fill
                  up to 280 M                                                                             320             520
       125-230
       125 230                                                                                                                                              420         250                      35
                     up 315 S                                                                             345             545
                  up to 280 M                                                370        370               320             520
       125-290                                                                                                                                              460         275                      40
                     up 315 S       200       125        41        35                                     345     825     545
       125-365          --                                                                         515    320             520         120    366            520         300                      45
                  up to 280 M                                                                             320             520
       125-500                                                               450        450                                                                 610         335                      55
                     up 315 S                                                                             345             545
       150-290          --                                                                                                                                  490         347                      50
                                    200       150        41        37        400        400               320     1050    520
       150-360          --                                                                                                                                  530         359                      60
1) z   = clearance above casing cover for rotor removal

         -
Baseplate- / base frame and foundation dimensions                                                                                                                      All dimensions in mm
 Baseplate                                  Baseplate and foundation dimensions                                           Foundation bolts                              Ancor bolts
 Size
         No.                  b2         G1        G2         l3        l4         l5         h8         Weight         Size           VN               L           Size              øN          L
     Drawing no.                                                                                          [kg]
             4
                             695      635          750    1330          565        565        120         92
       0W 384 171-00
             5
                             695      635          750    1540          670        670        120         106      M 16x250            100             250         M 12/25            18         110
       0W 384 172-00
            6 2)
                             560      500          610    1820          810        810        145         110
       0W 384 173-00
2) Base frame

66
                                                                                                                                                              Omega

Standard flange connections 1):
Pump                         JL 1040                                             JS 1030 / 1.4517
Size                 Nominal pressure acc. to:                               Nominal pressure acc. to:
               DIN 2501    BS 4504      ANSI B 16.1                    DIN 2501     BS 4504      ANSI B 16.1
              ISO 7005/2                                              ISO 7005/2
 125-230
 125-290
 125-365
 125-500         PN 16      Table 16/11             Class 250              PN 25           Table 25/11          Class 250
 150-290
 150-360
1) Other flange connections on request




                  -
Flange dimensions - Hole pattern                                                     All dimensions in mm
Standard
                                                  Suction flange                     Discharge flange
                                        DN          d2        k       n        DN          d2           k       n
Pump sizes 125-230 up to
125-500                                 200                                    125                                               Mating flange
                                                                                                                                 All flanges designed as plate flanges
ISO 7005/2           PN 16
DIN 2501                                      23 (M20)       295                      19 (M16)      210
BS 4504              Table 16/11
ISO 7005/2           PN 25                                            12                                        8                                    d2
DIN 2501                                      28 (M24)       310                      28 (M24)      220
BS 4504              Table 25/11                                                                                                                          number of
ANSI B 16.1          Class 250                28 (M24)       330                      23 (M20)      235                                                   holes n
Pump sizes 150-290 up to
150-360                                 200                                    150

ISO 7005/2           PN 16
DIN 2501                                      23 (M20)       295                           23       240
BS 4504              Table 16/11
                                                                                                                8
ISO 7005/2           PN 25                                            12                                                                         k
DIN 2501                                      28 (M24)       310                           28       250
BS 4504              Table 25/11
ANSI B 16.1          Class 250                28 (M24)       330                           23       270         12



Baseplate / motor combinations
  Pump                                                                                Motor Size
  Size        132S     132M      160M     160L        180M    180L         200L      225S       225M        250M     280S    280M    315S    315M         315L    315
 No of po-     4         4         4          4          4        4        2   4       4        2   4       2   4    2   4   2   4   2   4   2        4   2   4   2
   les
 125-230       4         4         4          4          4                 4                    5           5        5       5       6       6
 125-290                 4         4          4          4        4            4       5        5           5        5       5       6       6            6       6
 125-365                                      4          4        4            4       5            5           5        5       5
 125-500                                                                       4       5            5           5        5       5       6            6
 150-290                                      4          4        4            4       5            5
 150-360                                      4          4        4            4       5            5           5        5       5
N.B.:   - The numbers listed in the table indicate the relevant baseplate numbers.
        - The baseplate numbers shown in the boxes also serve to select the correct motor size for the listed pump size.
        - Units comprising a motor size 315 and larger are completely assembled for verification and adjustment of the individual
          components. Before shipment, the units are dismantled again and the components packed / shipped separately.




                                                                                                                                                                        67
                                                                                                                                                                       Omega

                                      -               -                   -
General arrangement drawing Omega 150 - 460 up to 250 - 370 and Omega 300 - 300
Installation type 3E                                                                                      N.B.:          If the pump’s direction of rotation is
Direction of rotation: CLOCKWISE                                                                                         ANTI--CLOCKWISE, the position of
                                                                                                                         the suction and discharge nozzle is
                                                                                                                         reversed (mirror image).


                                                  a2             a1                                                 l2                                           q
                                                                                                                                     f
                            Z




                                          s2                                    s1                                                                  5
                                                   5D
                                                                                                              5D                     5D




                                                                                                                                                                                 h7
                                   DN2
                           h5




                                                                 1M




                                                                                         DN1
                                                 1M




                                                                                                                                                                                 h6
                                                                                                            8B                            8B
                                                       6B
                                                                                 h4




                                                                                                                                                                            h8
                                 50




                                                                                         L


                                                                                                Grouting
                             V   N (øN)                                         200                                                            100
                                                            G1                                                                  l4                          l5
                                                                                                                   100                                                100
                                                            b2
                                                            G2                                                                                 l3




                                                                                                                                                                            h8
                                   50




                                                                                     L




                                                            b2                                                                                 100
Connections:                              100                         200                                          100          l4                           l5       100
- 1M  Pressure gauge              G 1/2
- 5D  Vent                        G 1/2                                                                                                        l3
- 6B  Drainage                    G 1/2
- 8B  Leakage liq. drain          G 3/4
Ground baseplate / base frame with low--shrinkage concrete                                      The motor--dependt dimensions refer to KSB standard motors



Dimensions and weights                                                                                                                                    All dimensions in mm
     Pump                                 Flange dimensions                                                 Pump dimensions                                           Weight [kg]
      Size         Motor-             DN1 DN2      s1       s2                           a1    a2     f      h4    h5    h6                i         l2    z 2)      Pump Water-
                  dependet                                                                                       max.                                                          fill
                  up to 250 M                                                                               320               520
 150 460
 150-460                                                                              450      450                                                        610        436         75
             280 S up to 315 L          200     150         41             37                                      1050       580                   399
 150-605            --                                                                600      500          380               680                         740        646         90
                  up to 250 M                                                                        590                      620         215
 200-320                                                                              450      450                                                        570        450         80
                     280 S, M                                                                               440               680
                                                                                                                                                    399
                  up to 250 M                                                                               380               620
 200-420                                                                              500      500                                                        620        517         95
             280 S up to 315 L          250     200         48             41                               440    1240
                                                                                                                              680
                        250 M                                                                               380
 200-520                                                                              600      500                                                        740        840      115
                     up 280 S                                                                               440               740
 200-670            --                                                                650      550          430               780                         860        990      140
                        250 M                                                                        655    420               720         150       464
 250-370                                300     250    33   (51)1)    32   (48)1)     500      500                 1275                                   640        665      125
                     up 280 S                                                                               480               780
                  up to 250 M                                                                               450               750
 300-300                                350     300    36 (54)1)      33 (51)1)       550      500                 1430                                   720        630      100
                     up 280 S                                                                               510               810
1) for casing material JS 1030, 1.4517
2) z = clearance above casing cover for    dismantling of the rotor




68
                                                                                                                                                             Omega

         -
Baseplate- / base frame and foundation dimensions                                                                                             All dimensions in mm
 Baseplate                   Baseplate
                                                                    Baseplate and foundation dimensions                                  Foundation bolts
 Size                        Size
         No.                      Drawing no.         b2      G1      G2          l3        l4      l5         h8        Weight        Size            VN      L
                                                                                                                          [kg]
               7                0W 384 174-00         880     820     960        1660     730      730     120            157
             8 1)               0W 384 175-00                                    1870     835      835                    185
              9 1)              0W 384 176-00                                                                             204
             10 1)              0W 384 478-00         700     620     750        1970     885      885     180            208     M 20x320             100    320
             14 1)              0W 384 479-00                                    2170      985     985                    210
             15 1)              0W 384 480-00                                    2320     1060    1060                    215
1)   Base frame
Standard flange connections 2):
      Pump                                JL 1040                                                        JS 1030 / 1.4517
      Size                        Nominal pressure acc. to:                                          Nominal pressure acc. to:
                     DIN 2501 / ISO 7005/2     BS 4504      ANSI B 16.1                 DIN 2501 / ISO 7005/2      BS 4504     ANSI B 16.1
     150-460                PN 16             Table 16/11
     150-605                PN 25             Table 25/11    Class 250
     200-320
     200-420                 PN 16              Table 16/11
     200-520                                                                                     PN 25                   Table 25/11     Class 250
     200-670                 PN 25              Table 25/11
     250-370
                             PN 10              Table 10/11        Class 125
     300-300
2)   Other flange connections on request
                  -
Flange dimensions - Hole pattern                                                     All dimensions in mm
 Standard                                             Suction flange                     Discharge flange
                                                DN      d2        k         n      DN        d2       k   n
 Pump sizes 150-460 and 150-605                 200                                150
 ISO 7005/2, DIN 2501 PN 16                                                                                                  Mating flange
 BS 4504              Table 16/11                     23 (M20)      295                    23 (M20)      240                 All flanges designed as plate flanges
                                                                                                                    8
 ISO 7005/2, DIN 2501 PN 25                                                 12
 BS 4504              Table 25/11                     28 (M24)      310                    28 (M24)      250
 ANSI B 16.1          Class 250                       28 (M24)      330                    23 (M20)      270        12                            d2
 Pump sizes 200-320 up to 200-670               250                                200
 ISO 7005/2, DIN 2501 PN 16                                                                                                                            number of
 BS 4504              Table 16/11                     28 (M24)      355                    23 (M20)      295                                           holes n
                                                                                                                    12
 ISO 7005/2, DIN 2501 PN 25                                                 12
 BS 4504              Table 25/11                     31 (M27)      370                    28 (M24)      310
 ANSI B 16.1          Class 250                       28 (M24)      387                    28 (M24)      330
 Pump sizes 250-370                             300                                250
 ISO 7005/2, DIN 2501 PN 10
 BS 4504              Table 10/11                     23 (M20)      400                    23 (M20)      350
                                                                            12                                                                k
 ISO 7005/2, DIN 2501 PN 16
 BS 4504              Table 16/11                     28 (M24)      410                    28 (M24)      355
                                                                                                                    12
 ISO 7005/2, DIN 2501 PN 25
 BS 4504              Table 25/11                     31 (M27)      430     16             31 (M27)      370
 ANSI B 16.1          Class 125                       28 (M24)      432     12             28 (M24)      362
 ANSI B 16.1          Class 250                       31 (M27)      451     16             28 (M24)      387        16
 Pump sizes 300-300                             350                                300
 ISO 7005/2, DIN 2501 PN 10
 BS 4504              Table 10/11                     23 (M20)      460                    23 (M20)      400
                                                                                                                    12
 ISO 7005/2, DIN 2501 PN 16
 BS 4504              Table 16/11                     28 (M24)      470     16             28 (M24)      410
 ISO 7005/2, DIN 2501 PN 25
 BS 4504              Table 25/11                     34 (M30)      490                    31 (M27)      430        16
 ANSI B 16.1          Class 125                       28 (M24)      476     12             28 (M24)      432        12
 ANSI B 16.1          Class 250                       31 (M27)      514     20             31 (M27)      451        16

Baseplate / motor combinations
   Pump                                                 Motor Size
   Si
   Size      180L 200L 225S 225M 250M 280S 280M 315S 315M 315L                           315     355    400
   No of       4      4       4       4       4      4       4      4      4       4       4       4      4
   poles
 150-460              7       7       7       7      8       8      8      8       8
 150-605                                             8       8      8      8       9       9      14
 200-320       7      7       7       7       7      8       8
 200-420              7       7       7       7      8       8      8      8       9
 200-520                                      7      8       8      8      8      10      10      15
 200-670                                                            8      8      10      10      15     15
 250-370                                      7      8       8      8      8      10
 300-300              7       7       7       7      8       8      8
N. B.: - The numbers listed in the table indicate the relevant baseplate numbers.
        - The baseplate numbers shown in the boxes also serve to select the correct motor size for the listed pump size.
        - Units comprising a motor size 315 and larger are completely assembled for verification and adjustment of the individual components.
          Before shipment, the units are dismantled again and the components packed / shipped separately.
                                                                                                                                                                    69
                                                                                                                                                                                       Omega


                                      -               -          -
General arrangement drawing Omega 250 - 480 up to 250 - 600; 300 - 435 and
    -
350 - 360
Installation type 3E                                                                                        N.B.:           If the pump’s direction of rotation is
Direction of rotation: CLOCKWISE                                                                                            ANTI--CLOCKWISE, the position of
                                                                                                                            the suction and discharge nozzle is
                                                                                                                            reversed (mirror image).

                                                    a2             a1                                                l2                                                      q
                                                                                                                                            f
                              Z




                                            s2                                 s1                                                                               5
                                                        5D
                                                                                                                5D                          5D




                                                                                                                                                                                                  h7
                                     DN2
                             h5




                                                                   1M



                                                                                      DN1
                                                   1M




                                                                                                                                                                                                  h6
                                                                                                              8B                                     8B
                                                         6B
                                                                                 h4




                                                                                                                                                                                             h8
                                   50




                                                                                      L




                                                                                                 Grouting
                               V   N (øN)                                      200                                                                        100
                                                              G1                                                                       l4                               l5
                                                                                                                     100                                                              100
                                                              b2
                                                              G2                                                                                          l3




     Connections:
     - 1M  Pressure gauge               G 1/2                                                                      100            l4                            l5               l6    100
     - 5D  Vent                         G 1/2
     - 6B  Drainage                     G 1/2                                                                                                                   l3
     - 8B  Leakage liq. drain           G 3/4
     Ground baseplate / base frame with low--shrinkage concrete                                   The motor--dependt dimensions refer to KSB standard motors


Dimensions and weights                                                                                                                                                 All dimensions in mm
        Pump              Flange dimensions                                                      Pump dimensions                                                         Weight [kg]
         Size     DN1     DN2      s1                    s2         a1         a2           f    h4     h5    h6)             i                 l2             z 2)    Pump     Water-
                                                                                                      max.                                                                        fill
     250-480                                                       550                           500                800                                        710      830                 145
                  300     250            51              48                                             1275
     250-600                                                                                     480                830                                        830     1215                 180
                                                                               550     730                                  210             515
     300-435              300                       33 (51) 1)     650                                  1430                                                   730      905                 190
                  400                38 (57) 1)                                                  520                870
     350-360              350                       36 (54) 1                                           1415                                                   820      865                 160
1)   for casing material JS 1030, 1.4517
2)    z = clearance above casing cover for dismantling of the rotor

         -
Baseplate- / base frame and foundation dimensions                                                                             All dimensions in mm
 Baseplate Size                                   Baseplate and foundation dimensions                                        Foundation bolts
         No.                    b2       G1        G2     l3     l4     l5    l6    h8                 Weight             Size       VN       L
    Drawing no.                                                                                         [kg]
          11 3)
                                                          1950           875           --               215
      0W 384 177-00
          12 3)
                              700        620      760     2100           950           --       200     228          M 20x320                   100              320
      0W 384 178-00
          16 3)
                                                          2450           750          750               240
      0W 384 481-00
3) Base frame

70
                                                                                                                                                      Omega

Standard flange connections 1):
      Pump                        JL 1040                                            JS 1030 / 1.4517
      Size                Nominal pressure acc. to:                               Nominal pressure acc. to:
                  DIN 2501         BS 4504        ANSI B 16.1            DIN 2501             BS 4504          ANSI B 16.1
                 ISO 7005/2                                             ISO 7005/2
     250-480       PN 16          Table 16/11
                                                   Class 250
     250-600       PN 25          Table 25/11
                                                                          PN 25              Table 25/11        Class 250
     300-435
                   PN 10          Table 10/11      Class 125
     350-360
1)   Other flange connections on request

                  -
Flange dimensions - Hole pattern                                                           All dimensions in mm
 Standard
                                                 Suction flange                         Discharge flange
                                            DN        d2           k     n       DN           d2          k        n         Mating flange
 Pump sizes 250-480 and 250-600            300                                   250                                         All flanges designed as plate flanges
 ISO 7005/2            PN 10
 DIN 2501                                        23 (M20)      400                      23 (M20)         350
 BS 4504               Table 10/11                                                                                                            d2
                                                                        12
 ISO 7005/2            PN 16
 DIN 2501                                        28 (M24)      410                      28 (M24)         355                                       number of
 BS 4504               Table 16/11                                                                              12                                 holes n
 ISO 7005/2            PN 25
 DIN 2501                                        31 (M27)      430      16              31 (M27)         370
 BS 4504               Table 25/11
 ANSI B 16.1           Class 125                 28 (M24)      432      12              28 (M24)         362
 ANSI B 16.1           Class 250                 31 (M27)      451      16              28 (M24)         387    16
 Pump size 300-435                         400                                   300                                                      k
 ISO 7005/2            PN 10
 DIN 2501                                        28 (M24)      515                      23 (M20)         400
 BS 4504               Table 10/11
                                                                                                                12
 ISO 7005/2            PN 16
 DIN 2501                                        31 (M27)      525                      28 (M24)         410
 BS 4504               Table 16/11                                      16
 ISO 7005/2            PN 25
 DIN 2501                                        37 (M33)      550                      31 (M27)         430    16
 BS 4504               Table 25/11
 ANSI B 16.1           Class 125                 28 (M24)      540                      28 (M24)         432    12
 ANSI B 16.1           Class 250                      34       572      20              31 (M27)         451    16
 Pump size 350-360                         400                                   350
 ISO 7005/2            PN 10
 DIN 2501                                        28 (M24)      515      16              23 (M20)         460
 BS 4504               Table 10/11
 ISO 7005/2            PN 16
 DIN 2501                                        31 (M27)      525      16              28 (M24)         470    16
 BS 4504               Table 16/11
 ISO 7005/2            PN 25
 DIN 2501                                        37 (M33)      550      16              34 (M30)         490
 BS 4504               Table 25/11
 ANSI B 16.1           Class 125                 28 (M24)      540      16              28 (M24)         476    12
 ANSI B 16.1           Class 250                      34       572      20              31 (M27)         514    20

Baseplate / motor combinations
      Pump                                                 Motor Size
      Size       250M      280S      280M        315S        315M       315L           315         355         400
      No of        4        4          4          4            4             4         4           4           4
      poles
     250-480      11        11         11         11          11         12            12          16
     250-600                                                  11         12            12          16          16
     300-435                           11         11          11         12            12
     350-360      11        11         11         11          11         12            12
N.B.:     - The numbers listed in the table indicate the relevant baseplate numbers.
          - The baseplate numbers shown in the boxes also serve to select the correct motor size for the listed pump size.
          - Units comprising a motor size 315 and larger are completely assembled for verification and adjustment of the individual
            components. Before shipment, the units are dismantled again and the components packed / shipped separately.


                                                                                                                                                               71
                                                                                                                                                                                       Omega


                                      -          -               -          -
General arrangement drawing Omega 250 - 800; 300 - 560 up to 300 - 700; 350 - 430;
    -
350 - 510
Installation type 3E                                                                                      N.B.:          If the pump’s direction of rotation is
Direction of rotation: CLOCKWISE                                                                                         ANTI--CLOCKWISE, the position of
                                                                                                                         the suction and discharge nozzle is
                                                                                                                         reversed (mirror image).

                                                     a2             a1                                             l2                                                        q
                                                                                                                                             f
                           Z




                                         s2                                   s1                                                                             5
                                                        5D
                                                                                                              5D                             5D




                                                                                                                                                                                                   h7
                                   DN2
                           h5




                                                                    1M



                                                                                        DN1
                                                    1M




                                                                                                                                                                                                   h6
                                                                                                            8B                                    8B
                                                          6B
                                                                                   h4




                                                                                                                                                                                             h8
                                50




                                                                                        L




                                                                                               Grouting
                            V   N (øN)                                        200                                                                      100
                                                               G1                                                  100                  l4                              l5            100
                                                               b2
                                                               G2                                                                                      l3




 Connections:
 - 1M  Pressure gauge                G 1/2
 - 5D  Vent                          G 1/2                                                                       100               l4                        l5                  l6    100
 - 6B  Drainage                      G 1/2
 - 8B  Leakage liq. drain            G 3/4                                                                                                                   l3

 Ground baseplate / base frame with low--shrinkage concrete                                     The motor--dependt dimensions refer to KSB standard motors
Dimensions and weights                                                                                                                   All dimensions in mm
      Pump               Flange dimensions                                                     Pump dimensions                                                                   Weight [kg]
       Size     DN1     DN2            s1                 s2         a1       a2         f     h4      h5         h6           i                 l2         z 2)        Pump            Water-
                                                                                                      max.                                                                                  fill
  250-800       300     250            51                 48        800       700              510               1030                                       1040        1500                240
  300-560                                                           700                        560   1430         910                                       860         1425                225
                400     300            57                 51
  300-700                                                                               810                               210                    585        960         1690                275
                                              1)
                                                                    750       650
  350-430       450                41 (60)                                                     550                950                                       930         1285                240
                        350                         36 (54) 1)                                       1415
  350-510       400                38 (57) 1)                       700                                                                                     840         1395                290
1) for casing material JS 1030,   1.4517
2) z = clearance above casing     cover for dismantling of the rotor

         -
Baseplate- / base frame and foundation dimensions                                                                              All dimensions in mm
Baseplate                                          Baseplate and foundation dimensions                                    Foundation bolts
Size
        No.                   b2       G1          G2          l3        l4   l5        l6    h8     Weight             Size                      VN               L
    Drawing no.                                                                                       [kg]
         13 3)
                                                             2195             665                     290
     0W 384 179-00
         17 3)
                            950       870      1010          2540             780             200     322          M 20x320                      100              320
     0W 384 482-00
         18 3)
                                                             2390             730                     309
     0W 384 483-00
3) Base frame
72
                                                                                                                                               Omega

Standard flange connections 1):
      Pump                          JL 1040                                        JS 1030 / 1.4517
      Size                  Nominal pressure acc. to:                           Nominal pressure acc. to:
                    DIN 2501          BS 4504     ANSI B 16.1             DIN 2501       BS 4504         ANSI B 16.1
                   ISO 7005/2                                            ISO 7005/2
     250-800         PN 25        Table 25/11
     300-560         PN 16        Table 16/11        Class 250
     300-700         PN 25        Table 25/11                              PN 25                /
                                                                                        Table 25/11       Class 250
     350-430
                     PN 10        Table 10/11        Class 125
     350-510
1)   Other flange connections on request
                  -
Flange dimensions - Hole pattern                                                       All dimensions in mm
 Standard
                                                 Suction flange                       Discharge flange
                                                                                                                       Mating flange
                                           DN        d2          k        n    DN        d2        k       n           All flanges designed as plate flanges
 Pump sizes 300-560 and 300-700           400                                  300
 ISO 7005/2            PN 10
 DIN 2501                                        28 (M24)    515                      23 (M20)   400
 BS 4504               Table 10/11                                                                                                     d2
                                                                                                          12
 ISO 7005/2            PN 16
 DIN 2501                                        31 (M27)    525                      28 (M24)   410                                        number of
 BS 4504               Table 16/11                                       16                                                                 holes n
 ISO 7005/2            PN 25
 DIN 2501                                        37 (M33)    550                      31 (M27)   430      16
 BS 4504               Table 25/11
 ANSI B 16.1           Class 125                 28 (M24)    540                      28 (M24)   432      12
 ANSI B 16.1           Class 250                     34      572         20            31 (M27   451      16
 Pump size 350-430                        450                                  350                                                 k
 ISO 7005/2            PN 10
 DIN 2501                                        28 (M24)    565                      23 (M20)   460
 BS 4504               Table 10/11
 ISO 7005/2            PN 16
 DIN 2501                                        31 (M27)    585         20           28 (M24)   470      16
 BS 4504               Table 16/11
 ISO 7005/2            PN 25
 DIN 2501                                        37 (M33)    600                      34 (M30)   490
 BS 4504               Table 25/11
 ANSI B 16.1           Class 125                 31 (M27)    578         16           28 (M24)   476      12
 ANSI B 16.1           Class 250                     34      629         24           31 (M27)   514      20
 Pump size 350-510                        400                                  350
 ISO 7005/2            PN 10
 DIN 2501                                        28 (M24)    515                      23 (M20)   460
 BS 4504               Table 10/11
 ISO 7005/2            PN 16
 DIN 2501                                        31 (M27)    525                      28 (M24)   470      16
 BS 4504               Table 16/11                                       16
 ISO 7005/2            PN 25
 DIN 2501                                        37 (M33)    550                      34 (M30)   490
 BS 4504               Table 25/11
 ANSI B 16.1           Class 125                 28 (M24)    540                      28 (M24)   476      12
 ANSI B 16.1           Class 250                     34      572         20           31 (M27)   514      20

Baseplate / motor combinations
       Pump                             Motor Size
       Size          315M       315L       315        355        400
     No of poles       4          4         4          4             4
      250-801                              13         17         17
      300-560          13        13        13         17         17
      300-700                              13         18         17
      350-430          13        13        13         18
      350-510                    13        13         18         17
N.B.:     - The numbers listed in the table indicate the relevant baseplate numbers.
          - The baseplate numbers shown in the boxes also serve to select the correct motor size for the listed pump size.
          - Units comprising a motor size 315 and larger are completely assembled for verification and adjustment of the individual
            components. Before shipment, the units are dismantled again and the components packed / shipped separately.

                                                                                                                                                        73
                                                                                                            Omega


Table of Connections and Measuring Points




Item No.                     Description                            Connections   Value required

5D                           Venting                                   G 1/2

9D         (if applicable)   Venting of barrier liquid                 G 1/2

6B                           Casing drain                              G 1/2

8B                           Leakage drain                             G 3/4      Enter order--specific data !

1 M.1      (if applicable)   Pressure gauge connection, suction        G 1/2      Enter order--specific data !
                             side

1 M.2                        Pressure gauge connection,                G 1/2      Enter order--specific data !
                             discharge side

4 M.1      (if applicable)   Temperature measuring point, bearing      G 3/8      See section 7.2
                             Drive end

4 M.2      (if applicable)   Temperature measuring point,              G 3/8      See section 7.2
                              non--drive end

26 M.1 (if applicable)       Thread for SPM measurement,               M8         Enter order--specific data !
                             drive end

26 M.2                       Thread for SPM measurement,               M8         Enter order--specific data !
                             non--drive end




74
. . . and should something have to be replaced,

KSB’s competent Spare Parts Service is at your disposal for the products

         D   Amarex/KRT                    D Amamix/Amaprop
         D   Sewatec                       D Amajet
         D   Amacan                        D Omega
         D   Amaline




To:       KSB Aktiengesellschaft                       Postfach 200743                        Date:
          Turmstr. 92                                  D-06008 Halle/Saale
          D-06110 Halle/Saale
          Ersatzteilabteilung

Fax:      (+49) 345/48 26 4691                                Tel:   (+49) 345/48 26--0

From:


In order to ensure the smooth processing of your spare parts inquiry, we request that you let us have the following data:


1. Works No. / Item No.              enter here

D The works No. is given on the name plate
  of your pump
  e.g. 2-  -M01--753328
         or                                                             KRT-F 100-250/7 4 UG-249
                                                                         -M01-
                                                                        2-    -753328
             9970428626 000100 2

in addition:

Pump type
   e.g. KRT-F 100-250/7 4 UG-249




                                                                                        Sample
2. Required part with part No.
enter
here


D The description of the parts is given
  in the operating instructions
  e.g. Impeller, Part no. 230

in addition:

for multi--vane impeller:
   impeller diameter in mm

for terminal gland:
   cable length in mm
                                                                                Omega




                                                                                         Subject to modification without notice
                                                                                        01/2009
                                                                                        1384.8/5 -- 10




KSB Aktiengesellschaft
P.O. Box 200743 • 06008 Halle (Saale) • Turmstraße 92 • 06110 Halle (Germany)
Tel. +49 (345) 48 26 0 • Fax +49 (345) 48 26 46 99 • www.ksb.com

				
DOCUMENT INFO