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Standardised Chemical Pump

CPK.D

With hydrodynamic shaft sealReinforced bearing assembly

Installation/OperatingManual

Legal information/Copyright Installation/Operating Manual CPK.DOriginal operating manual KSB Aktiengesellschaft Pegnitz All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, editedor processed for any other purpose, nor otherwise transmitted, published or made available to a thirdparty without KSB´s express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 24.06.2010

Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3 Transport/Temporary Storage/Disposal ........................................... 11

3.1 Transport ....................................................................................................... 11

3.2 Storage/preservation ..................................................................................... 11

3.3 Return to supplier ......................................................................................... 12

3.4 Disposal .......................................................................................................... 12

4 Description of the Pump (Set) .......................................................... 13

4.1 General description ....................................................................................... 13

4.2 Designation ................................................................................................... 13

4.3 Name plate .................................................................................................... 13

4.4 Design details ................................................................................................ 13

4.5 Configuration and function ......................................................................... 15

4.6 Noise characteristics ..................................................................................... 16

4.7 Scope of supply ............................................................................................. 16

4.8 Dimensions and weights ............................................................................... 16

5 Installation at Site ............................................................................. 17

5.1 Safety regulations ......................................................................................... 17

5.2 Checking the site before installation ........................................................... 17

5.3 Setting up the pump set ............................................................................... 17

5.4 Piping ............................................................................................................. 19

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

Contents

CPK.D 3 of 60

5.6 Checking the coupling alignment ................................................................ 22

5.7 Aligning the pump and motor ..................................................................... 23

5.8 Connection to power supply ........................................................................ 24

5.9 Checking the direction of rotation .............................................................. 25

6 Commissioning/Start-up/Shutdown ................................................. 27

6.1 Commissioning/start-up ................................................................................ 27

6.2 Operating limits ............................................................................................ 32

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

6.4 Returning to service after storage ............................................................... 34

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

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

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

7.3 Drainage/disposal .......................................................................................... 41

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

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

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

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

8 Trouble-shooting ............................................................................... 51

9 Related Documents ........................................................................... 53

9.1 General assembly drawing with list of components ................................... 53

10 EC Declaration of Conformity .......................................................... 55

11 Certificate of Decontamination ....................................................... 56

Index .................................................................................................. 57

Contents

4 of 60 CPK.D

Glossary

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

Back pull-out unitPump without pump casing; partly completedmachinery

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

Discharge lineThe line which is connected to the dischargenozzle

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

PumpMachine without drive, additional componentsor accessories

Pump setComplete pump set consisting of pump, drive,additional components and accessories

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

Glossary

CPK.D 5 of 60

1 General

1.1 Principles

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

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

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

Noise characteristics (⇨ Section 4.6 Page 16)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, refer to the sub-sectionsunder Servicing/Maintenance. (⇨ Section 7.5.6 Page 47)

1.3 Target group

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

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsData sheet Description of the technical data of the pump

(set)General arrangement drawing/Outline drawing

Description of mating and installation dimensionsfor the pump (set)

Drawing of auxiliary connections Description of auxiliary connectionsHydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power inputGeneral assembly drawing1) Sectional drawing of the pump

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

Spare parts lists1) Description of spare parts

Piping layout1) Description of auxiliary piping

List of components1) Description of all pump components

1.5 Symbols

Table 2: Symbols used in this manual

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

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

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

1 General

6 of 60 CPK.D

Symbol Description1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

CPK.D 7 of 60

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

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk situation which, if notavoided, will result in death or serious injury.

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

CAUTION CAUTIONThis signal word indicates a hazardous situation which, if notavoided, could damage the machine and its functions.General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

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

2.2 General

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

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

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

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

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

▪ Arrow indicating the direction of rotation

▪ Markings for connections

▪ Name plate

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

2.3 Intended use

The pump (set) must only be operated within the operating limits which aredescribed in the other applicable documents.

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

▪ Do not operate partially assembled pumps/pump sets.

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

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

! DANGER

2 Safety

8 of 60 CPK.D

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

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

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

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

Prevention of foreseeable misuse

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

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

– Risk of cavitation damage

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

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

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

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

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

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

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

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

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

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

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

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

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2 Safety

CPK.D 9 of 60

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold or moving parts and check thatthe guards function properly.

▪ Do not remove any contact guards while the pump is running.

▪ Connect an earth conductor to the metal jacket if the fluid handled iselectrostatically charged.

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

▪ Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g.explosive, toxic, hot) so as to avoid any danger to persons and the environment.Adhere to all relevant laws.

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

2.8 Safety information for maintenance, inspection and installation work

▪ Modifications or alterations of the pump are only permitted with themanufacturer's prior consent.

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

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

▪ Carry out work on the pump (set) during standstill only.

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

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

▪ When taking the pump set out of service always adhere to the proceduredescribed in the manual.

▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3Page 41)

▪ As soon as the work is completed, re-install and/or re-activate any safety-relevantand protective devices. Before returning the product to service, observe allinstructions on commissioning. (⇨ Section 6.1 Page 27)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in thismanual.

The warranty relating to the operating reliability and safety of the supplied pump(set) is only valid if the equipment is used in accordance with its intended use. (⇨Section 2.3 Page 8)

2 Safety

10 of 60 CPK.D

3 Transport/Temporary Storage/Disposal

3.1 Transport

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

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

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

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

▷ Observe the local accident prevention regulations.

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

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

Fig. 1: Transporting the pump

max. 90 °

Fig. 2: Transporting the complete pump set

max. 90 °

Fig. 3: Transporting the pump on the baseplate

3.2 Storage/preservation

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

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

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


CPK.D 11 of 60

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

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

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

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

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

For storing a pump (set) which has already been operated, observe the relevantinstructions. (⇨ Section 6.3.1 Page 33)

3.3 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 41)

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

3. If the fluids handled by the pump leave residues which might lead to corrosiondamage when coming into contact with atmospheric humidity, or which mightignite when coming into contact with oxygen, the pump set must also beneutralised, and anhydrous inert gas must be blown through the pump fordrying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set). (⇨ Section 11 Page 56)It is imperative to indicate any safety and decontamination measures taken.

NOTEIf required, a blank certificate of decontamination can be downloaded from the KSB website at: www.ksb.com/certificate_of_decontamination

3.4 Disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

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

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

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

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

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

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


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

4 Description of the Pump (Set)

4.1 General description

▪ Standardised chemical pump with hydrodynamic shaft seal

Pump for handling aggressive fluids in the chemical, petrochemical and foodprocessing industries, in refineries and paint shops, in heavy oil and coal upgradingplants. Particularly suitable if double-acting mechanical seals cannot be used becausethere is no appropriate barrier fluid, if no flushing liquid is available to feed thegland packing or if the flushing liquid must not mix with the fluid handled.

4.2 Designation

Example: CPK.D - C 40 - 200

Table 4: Key to the designation

Code DescriptionCPK.D Type seriesD Variant D = hydrodynamic shaft sealC Casing material, e.g. C = stainless steel40 Nominal discharge nozzle diameter [mm]200 Nominal impeller diameter [mm]

4.3 Name plate

CPK.D 080-250

P-No. 997125086300550001Q 90 m3/h H 80 mn 2955 1/min

KSB Aktiengesellschaft67227 Frankenthal

Mat-No. 01 109 223 ZN 3804 - D 52 x 74

20100520-5-P-10000-31

1

2

5

4

3

6

7

Fig. 4: Name plate

1 Type series, size 2 Customer-specific information(optional)

3 KSB order and order item number 4 Flow rate5 Speed 6 Year of construction7 Head

4.4 Design details

Design

▪ Volute casing pump

▪ Horizontal installation

▪ Back pull-out design

▪ Single-stage

▪ Meets technical requirements to ISO 5199

▪ Dimensions and ratings to EN 22 858/ISO 2858complemented by pumps of nominal diameters DN 25, DN 200 and above

Pump cas ing

▪ Single or double volute, depending on the pump size

▪ Radially split volute casing


CPK.D 13 of 60

▪ Volute casing with integrally cast pump feet

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

Impel ler type

▪ Closed radial impeller with multiply curved vanes

▪ Back vanes reduce axial thrust

Shaft seal

▪ Hydrodynamic shaft seal

Bearings

Motor-end bearing:

▪ Fixed bearing

▪ Paired angular contact ball bearing

▪ Axial movement of the rotor limited to maximum 0.5 mm

▪ Oil lubrication

▪ Optional: grease lubrication

Pump-end bearing:

▪ Radial bearing

▪ Cylindrical roller bearing

▪ Absorbs radial loads only

▪ Oil lubrication

▪ Optional: grease lubrication

Example: P10as

Table 5: Bearing bracket designation

Designation DescriptionP Bearing bracket10 Size code (based on dimensions of seal chamber and shaft

end)a Reinforced bearing bracket (next bearing size up)s Paired angular contact ball bearings (motor end)

Refer to the data sheet to find your bearing design.

Table 6: Bearing design

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

Table 7: Reinforced bearing assembly

Bearing bracket Rolling element bearingPump end Motor end

P02s NU305 2 x 7206 B.GP03s NU307 2 x 7307 B.GP04s NU311 2 x 7311 B.G.8P05s NU313 2 x 7313 B.G.8

Table 8: Reinforced bearing assembly with reinforced thrust bearing

Bearing bracket Rolling element bearingsPump end Motor end

P02as NU307 2 x 7307 B.GP03as NU311 2 x 7311 B.G.8P04as NU313 2 x 7313 B.G.8P05as NU413 2 x 7315 B.G.8

Design specifications

Bearing bracketdesignation

Bearings used


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4.5 Configuration and function1 2 3 4 5

6 7 8 9 10

Fig. 5: Sectional drawing

1 Clearance gap 2 Discharge nozzle3 Casing cover 4 Drive shaft5 Bearing bracket 6 Suction nozzle7 Impeller 8 Hydrodynamic shaft seal9 Rolling element bearing, pump end 10 Rolling element bearing, motor

end

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

The fluid enters the pump axially via the suction nozzle (6) and is acceleratedoutward in a cylindrical flow by the rotating impeller (7). In the flow passage of thepump casing the kinetic energy of the fluid is converted into pressure energy. Thefluid is pumped to the discharge nozzle (2), where it leaves the pump. The clearancegap (1) prevents any fluid from flowing back from the casing into the inlet. At therear side of the impeller, the shaft (4) enters the casing via the casing cover (3). Theshaft passage through the cover is sealed towards the atmosphere by a shaft seal (8).The shaft runs in rolling element bearings (9 and 10), which are supported by abearing bracket (5) linked with the pump casing and/or casing cover.

Pump sets with hydrodynamic shaft seal are equipped with two shaft seals: thehydrodynamic shaft seal proper, which seals off the shaft while the pump set isrunning, and a standstill shaft seal required during start-up and shutdown and whenthe pump set is not running. The key element of the hydrodynamic shaft seal is theexpeller with radial vanes on one side. In the expeller, a rotating liquid ring with afree surface towards the atmospheric side ensures that the rotating liquid columnbalances the pressure at the hub on the rear side of the impeller. The latter pressureis composed of the pressure in front of the pump impeller, the pressure risegenerated in the impeller and the pressure drop in the discharge-side clearancebetween impeller and casing, where the impeller back vanes take effect. As with allother rotating vanes, the function of the expeller depends on its circumferentialspeed and gap geometry.

As long as the pump rotor rotates, the rotating liquid level in the expeller will adjustto a specific diameter, depending on the operating conditions. Within givenoperating conditions, this condition is stable enough to prevent both fluid leakagefrom the seal towards the atmosphere and air ingress from the atmosphere into thepump. At the same time, there is no mechanical friction between rotating andstationary components, as the standstill shaft seal is lifted off by centrifugal forces viaangular levers in this condition. Only at low speeds or when the rotor is stationary

Design

Function

Sealing


CPK.D 15 of 60

will the standstill shaft seal close axially by spring force and take over the sealingfunction, as the free liquid level in the expeller can now extend up to the hubdiameter.

4.6 Noise characteristics

Table 9: Surface sound pressure level LpA2) 3)

Ratedpowerinput

PN[kW]

Pump Pump set2900 rpm

[dB]

1450 rpm

[dB]

960 rpm760 rpm

[dB]

2900 rpm

[dB]

1450 rpm

[dB]

960 rpm760 rpm

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

4.7 Scope of supply

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

▪ Pump

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

▪ Flexible coupling with or without spacer

▪ Coupling guard to EN 294

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

▪ Channel section steel or folded steel plate

▪ As required

4.8 Dimensions and weights

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

Drive

Shaft coupling

Contact guard

Baseplate

Special accessories

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

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


16 of 60 CPK.D

5 Installation at Site

5.1 Safety regulations

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

▷ Comply with the applicable local explosion protection regulations.

▷ Observe the information on the data sheet and on the name plates of pumpand motor.

5.2 Checking the site before installation

Place of instal lat ion

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

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

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

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

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

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

5.3 Setting up the pump set

Always install the pump set in horizontal position.

5.3.1 Installation on a foundation

12

43Fig. 6: Fitting the shims

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

800 mm4 Foundation bolt

✓ The foundation has the required strength and characteristics.

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

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


CPK.D 17 of 60

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

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

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

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

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

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

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

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

5.3.2 Foundationless installation

4

1

2

3

Fig. 7: Adjusting the adjusting elements

1, 3 Locknut 2 Adjusting nut4 Adjusting element

✓ The installation surface has the required strength and characteristics.

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

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

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

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


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5.4 Piping

5.4.1 Connecting the piping

DANGERImpermissible loads acting on the pump nozzlesDanger to life from leakage of hot, toxic, corrosive or flammable fluids!

▷ Do not use the pump as an anchorage point for the piping.

▷ Anchor the pipelines in close proximity to the pump and connect them withouttransmitting any stresses or strains.

▷ Observe the permissible forces and moments at the pump nozzles.

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

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

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

▷ Prevent current flowing through the rolling element bearings.

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

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

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

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

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

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

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

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

▷ Free the piping from any impurities.

▷ If necessary, install a filter.

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

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


CPK.D 19 of 60

1

2Fig. 8: Filter in the piping

1 Differential pressure gauge 2 Filter

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

4. Connect the pump nozzles with the piping.

CAUTIONAggressive flushing and pickling agentsDamage to the pump!

▷ Match the cleaning operation mode and duration for flushing and picklingservice to the casing and seal materials used.

5.4.2 Permissible forces and moments at the pump nozzles

[+]Fy

Fz

Fx

Fx

Fz

Fy

Fx

Fz

Fy

My

Mz

Mx

Forces and moments at the pump nozzles

The resulting permissible forces havebeen determined according to thefollowing formulas:

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

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


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Table 10: Forces and moments at the pump nozzles

Size

sSuction nozzle

[N]Discharge nozzle

[N]Suction nozzle

[Nm]Discharge nozzle

[Nm]Fx Fy Fz Fres Fx FyTens

+FyPress- Fz Fres Mx My Mz Mx My Mz

25-200 1050 700 850 1100 500 350 650 450 700 550 450 300 400 300 20032-20032-250

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

40-20040-25040-315

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

50-20050-25050-315

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

65-20065-25065-315

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

80-20080-25080-31580-400

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

100-200100-250100-315100-400

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

125-250125-315125-400

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

150-250150-315150-400150-500

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

200-315200-400

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

250-315 12000 8000 10000 12800 8000 5000 10000 6700 10450 9150 6900 4500 7500 5700 3650

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

1,00JS1025

1.4408

°C100 110 120 130 140 150

0,95

0,90

0,85

0,80

0,75

0,70

0,65

060

0,55

0,50

Fig. 9: Temperature correction coefficients


CPK.D 21 of 60

5.4.3 Auxiliary connections

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

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

▷ Use the auxiliary connections provided.

5.5 Protective equipment

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

▷ Insulate the volute casing.

▷ Fit protective equipment.

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

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

5.6 Checking the coupling alignment

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

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

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

BA

A B

a) b)

B

B

A

A

1

1 2 21

1

Fig. 10: a) Checking the coupling alignment and b) Aligning a spacer-type coupling

1 Straight-edge 2 Wedge gauge

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

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


22 of 60 CPK.D

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

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

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

5.7 Aligning the pump and motor

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

5.7.1 Motors with levelling screw

1

3

2

Fig. 11: Motor with levelling screw

1 Hexagon head bolt 2 Levelling screw3 Lock nut


1. Check the coupling alignment.

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

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

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

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

WARNINGUnprotected rotating couplingRisk of injury by rotating shafts!

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

▷ Observe all relevant regulations for selecting a coupling guard.

6. Reinstall the coupling guard and step guard, if any.

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


CPK.D 23 of 60

5.7.2 Motors without levelling screw

Any differences in shaft centre height between the pump and the motor arecompensated by means of shims.

1Fig. 12: Pump set with shim

1 Shim


1. Check the coupling alignment.

2. Unscrew the hexagon head bolts at the motor.

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

4. Re-tighten the hexagon head bolts.


WARNINGUnprotected rotating couplingRisk of injury by rotating shafts!

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

▷ Observe all relevant regulations for selecting a coupling guard.

6. Reinstall the coupling guard and step guard, if any.


5.8 Connection to power supply

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

▷ Always have the electrical connections installed by a trained electrician.

▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pumpsets, IEC 60079 (DIN VDE 0165).

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

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

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

2. Select an appropriate start-up method.


24 of 60 CPK.D

NOTEIt is recommended to fit a motor protection device.

5.8.1 Setting the time relay

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

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

Table 11: Time relay settings for star-delta starting:

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

5.8.2 Connecting the motor

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

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

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

5.9 Checking the direction of rotation

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

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

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

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

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

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

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

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

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

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


CPK.D 25 of 60

2. Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the directionof rotation on the pump.

3. If the motor runs in the wrong direction of rotation, check the electricalconnection of the motor and the control system, if necessary.


26 of 60 CPK.D

6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

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

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

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

▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 25)

▪ All auxiliary connections required are connected and operational.

▪ The lubricants have been checked.

▪ After prolonged shutdown of the pump (set), the activities described in (⇨Section 6.4 Page 34) have been carried out.

6.1.2 Filling in lubricants

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

Fill the bearing bracket with lubricating oil.Oil quality see (⇨ Section 7.2.3.1.2 Page 38) Oil quantity see (⇨ Section 7.2.3.1.3 Page 38)

Fi l l ing the constant- level oi ler with lubricat ing oi l (oi l - lubr icatedbearings only)

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

NOTEIf no constant-level oiler is provided on the bearing bracket, the oil level can be read inthe middle of the oil level sight glass arranged at the side of the bearing bracket.

CAUTIONInsufficient lubricating oil in the reservoir of the constant-level oilerDamage to the bearings!

▷ Regularly check the oil level.

▷ Always fill the oil reservoir completely.

▷ Keep the oil reservoir properly filled at all times.

1 2

3 4 5Fig. 13: Bearing bracket with constant-level oiler

Grease-lubricated bearings

Oil-lubricated bearings


CPK.D 27 of 60

1 Constant-level oiler 2 Vent plug3 Connection elbow of the constant-

level oiler4 Screwed plug

5 Bearing bracket

1. Pull out the vent plug (2).

2. Hinge down the reservoir of the constant-level oiler (1) from the bearing bracket(5) and hold it in this position.

3. Fill in oil through the hole for the vent plug until the oil reaches the connectionelbow of the constant-level oiler (3).

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

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

6. Fit the vent plug (2) again.

7. After approximately 5 minutes, check the oil level in the glass reservoir of theconstant-level oiler (1). The oil reservoir must be properly filled at all times to provide an optimum oillevel. Repeat steps 1 - 6, if necessary.

8. To check the function of the constant-level oiler (1), slowly drain some oil via thescrewed plug (4) until air bubbles can be seen in the oil reservoir.

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

6.1.3 Shaft seal

Hydrodynamic shaft seals are fitted prior to delivery.Observe the instructions on reassembly (⇨ Section 7.5.3 Page 45) or dismantling (⇨Section 7.4.6 Page 42).

NOTEIf required, e.g. when sticky or abrasive fluids are handled, the pump may have to beflushed before start-up or shutdown of the pump set. (⇨ Section 7.2.2.4 Page 37)

6.1.4 Priming and venting the pump

DANGERShaft seal failure caused by dry runningHot fluid may escape!

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

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

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

6.1.5 Final check

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

2. Check the coupling alignment; re-align the coupling, if required. (⇨ Section 5.6Page 22)


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



28 of 60 CPK.D

6.1.6 Water cooling

CAUTIONDeposit-forming, aggressive cooling waterDamage to the pump!

▷ Observe the cooling water quality.

Observe the following quality data of the cooling water:

▪ Not deposit forming

▪ Not aggressive

▪ Free from suspended solids

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

▪ pH > 8

▪ Conditioned and neutral with regard to mechanical corrosion

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

6.1.7 Heating

CAUTIONLack of heating mediumDamage to the pump!

▷ Provide sufficient quantities of a suitable heating medium.

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

▷ Check that the pump is sufficiently warmed up throughout.

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

▷ Observe the application limits of the heating media.

6.1.8 Heating up/keeping warm the pump (set)

CAUTIONPump blockageDamage to the pump!

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

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

▪ Make sure the temperature is increased continuously.

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

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

Temperature difference


CPK.D 29 of 60

6.1.9 Start-up

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

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

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

DANGERExcessive temperatures due to dry running or excessive gas content in the fluid handledExplosion hazard!Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Prime the pump as specified.

▷ Always operate the pump within the permissible operating range.

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

▷ Switch off the pump (set) immediately.

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


✓ The system piping has been cleaned.

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

✓ The filling and venting lines have been closed.

CAUTIONStart-up against open discharge lineMotor overload!

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

▷ Use a soft starter.

▷ Use speed control.

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

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

3. Start up the motor.

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


30 of 60 CPK.D

DANGERSeal leakage at operating temperatureHot or toxic fluid could escape!

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

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

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

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

6.1.10 Checking the shaft seal

The hydrodynamic shaft seal does not leak during operation.


6.1.11 Shutdown


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

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

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

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

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

For prolonged shutdown periods:

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

2. Close the auxiliary feed lines but do not turn off the cooling liquid supply, if any,until the pump has cooled down.

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

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


CPK.D 31 of 60

6.2 Operating limits

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

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

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

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

6.2.1 Ambient temperature

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

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table 12: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °CMinimum See data sheet.

6.2.2 Frequency of starts

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

Table 13: Frequency of starts

Motor rating [kW]

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

up to 12 15up to 100 10

more than 100 5

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

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

6.2.3 Flow rate

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

▪ Short-time operation: Qmin4) =0.1xQopt

5)

4) Minimum permissible flow rate5) Best efficiency point


32 of 60 CPK.D

▪ Continuous operation: Qmin4) =0.3xQopt 5)

▪ 2-pole operation: Qmax6) =1.1xQopt 5)

▪ 4-pole operation: Qmax6) =1.25xQopt

5)

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

Table 14: Key

Symbol Description Unitc Specific heat capacity J/kg Kg Gravitational constant m/s²H Pump head mTf Temperature of the fluid handled °C

To Temperature at the casing surface °C

Pump efficiency at duty point -Temperature difference °C

6.2.4 Density of the fluid handled

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

CAUTIONImpermissibly high density of the fluid handledMotor overload!

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

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

6.2.5 Abrasive fluids

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

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains instal led

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

1. Start up the pump (set) regularly between once a month and once every threemonths for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pumpintake area.

6) Maximum permissible flow rate


CPK.D 33 of 60

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

✓ The pump has been properly drained (⇨ Section 7.3 Page 41) and the safetyinstructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page41)

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

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

3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil andgrease, food-approved if required) to protect them against corrosion.Observe the additional instructions. (⇨ Section 3.2 Page 11)

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

Observe any additional instructions and information provided. (⇨ Section 3 Page 11)

6.4 Returning to service after storage

For returning the pump to service observe the sections on commissioning/start-up (⇨Section 6.1 Page 27) and the operating limits. (⇨ Section 6.2 Page 32)

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

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

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

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


34 of 60 CPK.D

7 Servicing/Maintenance

7.1 Safety regulations

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

▷ Service the pump set regularly.

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

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

WARNINGPump set started up inadvertentlyRisk of injury by moving parts!

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

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

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

▷ Observe all relevant laws.

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

▷ Decontaminate pumps handling fluids posing a health hazard.

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

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

Never use force when dismantling and reassembling a pump set.

7.2 Servicing/inspection

7.2.1 Supervision of operation

CAUTIONExcessive temperatures as a result of bearings running hot or defective bearing sealsDamage to the pump set!

▷ Regularly check the lubricant level.

▷ Regularly check the rolling element bearings for running noises.


CPK.D 35 of 60

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

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

CAUTIONIncreased wear due to dry runningDamage to the pump set!

▷ Never operate the pump set without liquid fill.

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

CAUTIONImpermissibly high temperature of fluid handledDamage to the pump!

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

▷ Observe the temperature limits in the data sheet and in the section onoperating limits. (⇨ Section 6.2 Page 32)

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

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

▪ In case of oil lubrication, ensure the oil level is correct. (⇨ Section 6.1.2 Page 27)

▪ Check the static seals for leakages.

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

▪ Monitor the correct functioning of any auxiliary connections.

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

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

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

CAUTIONOperation outside the permissible bearing temperatureDamage to the pump!

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

NOTEAfter commissioning, increased temperatures may occur at grease-lubricated rollingelement bearings due to the running-in process. The final bearing temperature is onlyreached after a certain period of operation (up to 48 h depending on the conditions).

7.2.2 Inspection work

CAUTIONExcessive temperatures caused by friction, impact or frictional sparksDamage to the pump set!

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


36 of 60 CPK.D

7.2.2.1 Checking the coupling

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

7.2.2.2 Checking the clearance gaps

To check the clearance gaps, remove the back pull-out unit. (⇨ Section 7.4.4 Page42)If the clearance gap is larger than permitted (see the following table), replace casingwear ring 502.1 with a new one.The clearances given refer to the diameter.

Table 15: Clearance gaps between impeller and casing/between impeller and casingwear ring

Nominal diameter of thedischarge nozzle

CPK.D-S CPK.D-C

up to and including DN 65 0.40 mm + 0.1 0.60 mm + 0.1

DN 80 to DN 200 0.5 mm + 0.1 0.60 mm + 0.1

DN 250 and above 0.65 mm + 0.1 0.75 mm + 0.1

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

7.2.2.3 Cleaning filters

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

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

▷ Clean filter in appropriate intervals.

7.2.2.4 Flushing the pump

If required, the pump can be flushed in the area of expeller 230.02. For this purpose,two flushing connections (A) are provided on discharge cover 163.

A

Fig. 14: Position of flushing connections on the discharge cover

A Flushing connections

Flushing is normally only effected during start-up or shutdown of the pump set.

A solenoid valve is used for flushing the pump from 30 seconds before until 30seconds after the pump set is switched on or off.

Flushing process


CPK.D 37 of 60

The flushing liquid must meet the following criteria:

▪ The flushing liquid must be compatible with the fluid handled.

▪ Flushing pressure: 0.5 bar higher than the pressure at the suction nozzle

▪ Maximum permissible flushing overpressure: 2.0 bar

NOTEA wiring diagram for automatic control of this process is available from KSB on request.(Supplementary sheet for flushing sticky, incrusting or similar fluids)

7.2.3 Lubrication and lubricant change of rolling element bearings

CAUTIONExcessive temperatures as a result of bearings running hot or defective bearing sealsDamage to the pump set!

▷ Regularly check the condition of the lubricant.

7.2.3.1 Oil lubrication

The rolling element bearings are usually lubricated with mineral oil.

7.2.3.1.1 Intervals

Table 16: Oil change intervals

Temperature at thebearing

First oil change All subsequent oilchanges7)

up to 70 ℃ After 300 operating hours After 8500 operating hours70 °C - 80 °C After 300 operating hours After 4200 operating hours80 °C - 90 °C After 300 operating hours After 2000 operating hours

7.2.3.1.2 Oil quality

Table 17: Oil quality

Designation Symbol to DIN51502

Properties

CLP46 lubricating oilto DIN 51517

orHD 20W/20 SAE

□ Kinematic viscosityat 40 °C

46±4 mm²/s

Flash point (toCleveland)

+175 ℃

Solidification point(pour point)

-15 ℃

Applicationtemperature8)

Higher thanpermissible bearing

temperature

7.2.3.1.3 Oil quantity

Table 18: Oil quantity

Bearing bracket Oil quantity [l]P02s 0.2P02as 0.3

P03s/P03as 0.5P04s/P04as 0.5

Flushing liquid

7) At least once a year8) For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.


38 of 60 CPK.D

Bearing bracket Oil quantity [l]P05s 1.5P05as 1.2

7.2.3.1.4 Changing the oil

WARNINGLubricants posing a health hazardHazard to persons and the environment!

▷ When draining the lubricant take appropriate measures to protect persons andthe environment.

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

1 2 3Fig. 15: Bearing bracket with constant-level oiler

1 Constant-level oiler 2 Screwed plug3 Bearing bracket

✓ A suitable container for the used oil is on hand.

1. Place the container underneath the screwed plug.

2. Undo the screwed plug (2) at the bearing bracket (3) and drain the oil.

3. Once the bearing bracket (3) has been drained, re-insert and re-tighten thescrewed plug (2).

4. Re-fill with oil. (⇨ Section 6.1.2 Page 27)

7.2.3.2 Grease lubrication

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

7.2.3.2.1 Intervals

The bearings are re-lubricated via the lubricating nipples, see the following drawing.

1 2

Fig. 16: Position of lubricating nipples


CPK.D 39 of 60

1 Lubricating nipple 2 Lubricating nipple

CAUTIONContaminated lubricating nipplesThe lubricating grease could become contaminated!

▷ Clean the grease lubricating nipples before using them for re-lubrication.

▪ After approx. 5,000 operating hours

▪ At least once a year

▪ Required grease quantity

▪ After 16,000 operating hours

▪ At least every 2 years

▪ Required grease quantity

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

7.2.3.2.2 Grease quality

Table 19: Grease quality to DIN 51825

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

Drop point Temperature range

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

7.2.3.2.3 Grease quantity

Table 20: Grease quantities for re-lubrication and replacing the grease

Bearing bracket Re-lubrication Replacing the greaseBearing, pump end Bearing, drive end Bearing+cover, pump

endBearing+cover, drive

endP02s 5 g / 5.5 cm³ 10 g / 11 cm³ approx. 7 g / 8 cm³ approx. 21 g / 24 cm³P02as 7.5 g / 8.5 cm³ 15 g / 17 cm³ approx. 10 g / 11 cm³ approx. 30 g / 33 cm³

P03s/P03as 12.5 g / 14 cm³ 25 g / 28 cm³ approx. 25 g / 28 cm³ approx. 60 g / 67 cm³P04s/P04as 12.5 g / 14 cm³ 25 g / 28 cm³ approx. 25 g / 28 cm³ approx. 60 g / 67 cm³

P05s 17.5 g / 20 cm³ 35 g / 40 cm³ approx. 40 g / 45 cm³ approx. 80 g / 90 cm³P05as 22 g / 25 cm³ 44 g / 50 cm³ approx. 50 g / 56 cm³ approx. 100 g / 112

cm³

7.2.3.2.4 Changing the grease

CAUTIONMixing greases of differing soap basesChanged lubricating qualities!

▷ Thoroughly clean the bearings.

▷ Adjust the re-lubrication intervals to the grease used.

✓ The pump has been dismantled for changing the grease. (⇨ Section 7.4 Page41)

1. Only half-fill the bearing cavities with grease.

2. Fill the bearing cavities in the bearing cover until they are about 1/3 full.

Re-lubrication

Grease change


40 of 60 CPK.D

7.3 Drainage/disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

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

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

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

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

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

7.4 Dismantling the pump set

7.4.1 General notes/Safety regulations

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

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

WARNINGHot surfaceRisk of personal injury!

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

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

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

For dismantling and reassembly refer to the general assembly drawing.

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

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

▷ Properly shut down the pump set.

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

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

▷ Close any auxiliary connections.

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

7.4.2 Preparing the pump set

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

2. Disconnect and remove all auxiliary pipework.

3. Remove the coupling guard.

4. Remove the coupling spacer, if any.

5. Drain the oil fill of oil-lubricated bearings. (⇨ Section 7.2.3.1.4 Page 39)


CPK.D 41 of 60

7.4.3 Dismantling the motor

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

1. Disconnect the motor from the power supply.

2. Unbolt the motor from the baseplate.

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

WARNINGMotor tipping overRisk of squashing hands and feet!

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

7.4.4 Removing the back pull-out unit

✓ Pumps without spacer-type coupling: the motor has been removed.

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

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

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

2. Unbolt support foot 183 from the baseplate.

3. Undo hexagon nut 920.01 at the volute casing.

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

5. Remove and dispose of joint ring 411.10.

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

7.4.5 Removing the impeller with expeller

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 41) to (⇨ Section 7.4.4 Page42) have been observed/carried out.

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

1. Undo impeller nut 922 (right-hand thread).

2. Pull off impeller 230.01 with expeller 230.02 as well as intermediate cover 160.09(loose!).

3. Place impeller 230.01 with expeller 230.02 and intermediate cover 160.09 on aclean and level surface.

4. Remove keys 940.1 from shaft 210.

5. Remove and dispose of joint rings 411.31/411.32.

7.4.6 Dismantling the hydrodynamic shaft seal

1. Remove plug 400.64 and undo socket head cap screw 914.26.Note: If screws 914.26 have been secured by a weld spot, knock off the weld spot.

2. Remove expeller 230.02. Watch gasket 400.63.

3. Remove intermediate cover 160.09.

4. Remove discharge cover 163 together with sleeve 520.01 and shaft seal rings421.06.


42 of 60 CPK.D

5. Pull off sleeve 520.10 and push out shaft seal rings 421.06 (if necessary) as well asspacer ring 504.04.Note: The shaft seal rings cannot be removed without being damaged. Makesure they need replacing before pulling them off.

6. Pull shaft protecting sleeve 524.01 off the shaft with the centrifugal mechanismengaged.

7. Loosen grub screws 904.29/.40 to disengage the centrifugal mechanism (onlyrequired if the latter is to be dismantled or O-ring 412.37 needs replacing). Note: The centrifugal mechanism has to be re-adjusted each time it has beendisengaged.

Dismantl ing the centr ifugal mechanism

1. Pull the centrifugal mechanism off the shaft protecting sleeve. Note position ofO-ring 412.37!

2. Remove thrower 507.05.

3. Take out guide piece 897.01 and spring washer 930.10 with ring 500.13.

4. Push out parallel pins 562.09 with a mandrel and remove levers 570.01.Note: Guide piece 897.01 is spring-loaded!

7.4.7 Dismantling the bearings

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

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

1. Unscrew hex. nuts 920.04 at the flange of bearing bracket lantern 344.

2. Remove bearing bracket lantern 344.

3. Unscrew the socket head cap screw in the coupling hub.

4. Pull the coupling half off the pump shaft with a puller.

5. Remove key 940.02.

6. Undo screws 914.02 and remove motor-end bearing cover 360.02 and joint ring400.02.

7. Undo screws 914.01 and remove pump-end bearing cover 360.01 and joint ring400.01.

8. Carefully drive shaft 210 together with angular contact ball bearing 320.02 andthe inner ring of cylindrical roller bearing 322.01 out of the bearing brackettowards the drive end.

9. In case of grease lubrication, remove disc 550.25.

10. Remove support disc 550.23 of angular contact ball bearing 320.02 from bearingbracket 330.

11. Remove cylindrical roller bearing 322.01 (roller cage) from bearing bracket 330.

12. In case of grease lubrication, remove disc 550.24.

13. Bend open lockwasher 931.01 behind keywayed nut 920.21 on shaft 210.

14. Unscrew keywayed nut 920.21 (right-hand thread) and remove lockwasher931.01.

15. Heat up angular contact ball bearing 320.02 and the inner ring of cylindricalroller bearing 322.01 to 80 °C, and pull them off shaft 210.

16. Dispose of joint rings 400.01/.02.


CPK.D 43 of 60

7.5 Reassembling the pump set

7.5.1 General notes/Safety regulations

CAUTIONImproper reassemblyDamage to the pump!

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

▷ Use original spare parts only.

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

▪ Gaskets

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

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

▪ O-rings

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

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

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

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

▪ Assembly adhesives

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

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

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

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

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

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

7.5.2 Installing the bearings

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

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

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

✓ The sealing surfaces have been cleaned.

1. Heat up angular contact ball bearing 320.02 and the inner ring of cylindricalrolling element bearing 322.01 to approx. 80 ℃ in an oil bath.

2. Push the angular contact ball bearing and the inner ring of cylindrical rollerbearing 322.01 onto shaft 210 until they will not go any further.

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

Sequence

Seal elements

Tightening torques


44 of 60 CPK.D

3. Use a spanner wrench to tighten keywayed nut 920.21 without lockwasher931.01.

4. Let angular contact ball bearing 320.01 cool down to approximately 5 °C aboveambient temperature.

5. Re-tighten keywayed nut 920.21, then unscrew it again.

6. Apply a few spots of a suitable lubricant (e.g. Molykote) to the contact faces oflockwasher 931.01 and keywayed nut 920.21.

7. Fit lockwasher 931.01.

8. Tighten keywayed nut 920.21.

9. Bend back lockwasher 931.01.

10. Insert circlip 932.01/932.02 into the bearing bracket.

11. In case of grease lubrication, insert disc 550.24.

12. Fit cylindrical roller bearing 322.01 (roller cage) in the bearing bracket.

13. Insert support disc 550.23 of the angular contact ball bearing 320.02 into bearingbracket 330.

14. In case of grease lubrication, insert disc 550.25.

15. In case of grease lubrication, fill bearing and bearing cover with grease.Grease lubrication (⇨ Section 7.2.3.2 Page 39)

16. Carefully push pre-assembled shaft 210 with angular contact ball bearing 320.02and the inner ring of cylindrical roller bearing 322.01 from the drive end intobearing bracket 330.

17. Fit pump-end bearing cover 360.01 with joint ring 400.01; take care not todamage lip seal 421.01.

18. Fit motor-end bearing cover 360.02 with joint ring 400.02; take care not todamage lip seal 421.02.

19. Fit bearing bracket lantern 344.

20. Tighten hex. nuts 920.04 at the flange of bearing bracket lantern 330.

21. Fit keys 940.02.

22. Pull the coupling hub onto the shaft end.

23. Secure the coupling hub with a set screw.

24. Fit thrower 507.01, if any.

7.5.3 Fitting the standstill shaft seal

Fig. 17: Dimensions of shaft seal rings


CPK.D 45 of 60

Table 21: Dimensions of shaft seal rings

Bearingbracket

L Ød1 Ød2 Ød3 Cross-section

P02s 26 45 45 62 8.5x8P02asP03s 35 54 65 85 10x8P03asP04sP04asP05s 35 80 90 110 10x10P05as

1. Place disc 550.10 in discharge cover 163.

2. Use suitable round stock to press in shaft seal ring 421.06. The shaft seal ring lipmust point towards the impeller.

3. Push in spacer ring 504.04.

4. Press in the second shaft seal ring, proceeding analogously with the first one.

5. Insert sleeve 520.10 with fitted O-ring 412.15 into discharge cover 163.

6. Slip pre-assembled centrifugal mechanism loosely onto shaft protecting sleeve524.01.

7. Insert O-ring 412.37 into the circular gap between the shaft protecting sleeveand the centrifugal mechanismMake sure that the O-ring is not twisted and "rolls" easily when levers 570.01 aremoved.

8. Slip on thrower 507.05.

7.5.4 Fitting the impeller


✓ The assembled bearing/standstill heater as well as the individual parts are kept ina clean and level assembly area.

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



✓ Impeller bore, shaft and keyways are clean and free from burrs.

1. Insert keys 940.01 into the shaft keyway.

2. Insert joint ring 411.32.

3. Coat the impeller seat with a suitable lubricant.

NOTESecure socket head cap screws 914.26 in material variants 9.4460 and 1.4408 with aweld spot. This also applies to special materials.

4. Pre-assemble impeller 230.01 and expeller 230.02 with loosely insertedintermediate cover 160.09 and gasket 400.63 using socket head cap screws914.26.

5. Insert plug 400.64.

6. Insert joint ring 411.31.

7. Slip the pre-assembled impeller unit onto shaft 210.

8. Screw impeller nut 922 to shaft 210. (⇨ Section 7.6.2 Page 48)


46 of 60 CPK.D

7.5.5 Adjusting the centrifugal mechanism (for assembled pump sets only)

160.02

904.40904.39

897.01412.15

A

Fig. 18: Adjusting the centrifugal mechanism

1. Pull two opposite levers slightly outward (overcoming the spring force), so thatthe adjusting segments (A) can be pushed into position via cover 160.02.

2. Push the centrifugal mechanism towards the impeller until guide piece 897.01touches O-ring 412.15.

3. Apply Loctite 242 to the threads of grub screws 904.40 (hexagon socket setscrews with cup point). Tighten the two grub screws 904.40 (hexagon socket setscrews with cup point).

4. Before fitting the third grub screw 904.39 (hexagon socket set screw with fulldog point), drill a hole into the shaft protecting sleeve the pin end of the grubscrew can engage in.

5. Apply Loctite 242 to the thread of grub screw 904.39 (hexagon socket set screwwith full dog point). Tighten grub screw 904.39 (hexagon socket set screw withfull dog point).

6. Remove the adjusting segment (A).

7. Evenly pull at the levers to check the function of the centrifugal mechanism. Make sure thrower 507.05 does not restrict the movement of guide piece 897.01.

Table 22: Dimensions of the adjusting segment (in mm)

Bearingbracket

A B C D E F Seg-ment

P02s 92 82 20 2 77 98 45 13.5P02asP03s 128.8 117 20 2 112 137 45 12P03asP04sP04asP05s 163.6 149 20 2 144 169 45 10P05as

7.5.6 Fitting the back pull-out unit

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

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




✓ For back pull-out units without coupling, fit the coupling in accordance with themanufacturer's instructions.

1. If required, suspend or support the back pull-out unit to prevent it from tippingover. Then push it into volute casing 102 with a new gasket 411.10.

Fig. 19: Dimensions of theadjusting segment


CPK.D 47 of 60

2. Tighten nut 920.01 at the volute casing.

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

7.5.7 Mounting the motor

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

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

2. Fasten the motor to the baseplate.

3. Align the pump. (⇨ Section 5.7 Page 23)

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

7.6 Tightening torques

7.6.1 Tightening torques

Use torque wrench to tighten the screwed connections (902.02/920.01) between thevolute casing and the bearing bracket lantern.

Table 23: Tightening torques for screwed connections

Materialstud/hex. nut

C35E+Qt/C 35 A4-70/A4-70 1.7709+QT/1.7258+QT1.6772/1.6722

Stamp markstud/hex.nut9)

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

Bearingbracketlantern10)

A B A B A B

Newthreads11)

-15%12)

-20%12)

Newthreads11)

-15%12)

-20%12)

Newthreads11)

-15 %12) -20 %12)

M10 - - - 30 25.5 24 47 30 39.9 25,5 37.6 24M12 40 34 32 55 46.7 44 80 55 68 46.7 64 44M16 100 85 80 155 131.7 124 190 155 161.5 131.7 152 124M20 - - - 200 170 160 330 200 280.5 170 264 160

7.6.2 Tightening torques for the impeller nut

Observe the following tightening torques for impeller nut (922):

Table 24: Tightening torques for the impeller nut

Bearing bracket Tightening torque [Nm]

Width across flats [mm]

P02s, P02as 55 22P03s, P03as 125 27P04s, P04as 200 32P05s, P05as 300 41

Re-tighten the impeller nut some 20 to 30 minutes after assembly.

9) Treat unstamped screwed connections like material pair C35/E+QT/C35.10) A: made of toughened material - except for JL 1040; B: made of material JL 104011) These values are determined on the basis of a friction coefficient μ = 0.12.12) After repeated tightening of the threads and in case of good lubrication, reduce the values by 15 to 20 %.


48 of 60 CPK.D

7.7 Spare parts stock

7.7.1 Ordering spare parts

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

▪ Type series

▪ Size

▪ KSB order number

▪ Material variant

▪ Year of construction

Refer to the name plate for all data. (⇨ Section 4.3 Page 13)

Also supply the following data:

▪ Description

▪ Part No.

▪ Quantity of spare parts

▪ Shipping address

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

Refer to the general assembly drawing for part numbers and descriptions. (⇨ Section9.1 Page 53)

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

Table 25: Quantity of spare parts for recommended spare parts stock

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

more210 Shaft 1 1 1 2 2 2 20 %230 Impeller 1 1 1 2 2 2 20 %320.02 Angular contact ball bearing

(set)1 1 2 2 2 3 25 %

322.01 Cylindrical roller bearing 1 1 2 2 2 3 25 %330 Bearing bracket - - - - - 1 2400.63 Gasket 2 2 2 3 3 3 30 %412.15 O-ring 1 1 2 2 3 4 40 %412.37 O-ring 1 1 2 2 3 4 40 %421.06 Shaft seal ring (set) 1 1 2 2 3 4 40 %502.01 Casing wear ring 2 2 2 3 3 4 50 %520.10 Sleeve 2 2 2 3 3 4 50 %524.01 Shaft protecting sleeve 2 2 2 3 3 4 50 %550.10 Disc 2 2 2 2 3 4 50 %- Seal elements for pump casing

(set)4 6 8 8 9 12 150 %

- Torque-transmitting couplingelements (set)

1 1 2 2 3 4 30 %

7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

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


CPK.D 49 of 60

Table 26: Interchangeability of pump components

Size

Bea

rin

g b

rack

et

Part description

Inte

rmed

iate

co

ver

Dis

char

ge

cove

r

Sup

po

rt f

oo

t

Shaf

t

Exp

elle

r

An

gu

lar

con

tact

bal

l bea

rin

g

Cyl

ind

rica

l ro

ller

bea

rin

g

Bea

rin

g b

rack

et

Bea

rin

g b

rack

et la

nte

rn

O-r

ing

Shaf

t se

al r

ing

Cas

ing

wea

r ri

ng

13)

Thro

wer

Thro

wer

Slee

ve

Shaf

t p

rote

ctin

g s

leev

e

Dis

c

Gu

ard

Imp

elle

r n

ut

Cen

trif

ug

al m

ech

anis

m

Part No.

160.

9

163

183

210

230.

02

320.

02

322.

01

330

344

412.

15

421.

06

502.

01

507.

01

507.

05

520.

10

524.

01

550.

10

680

922

14)

25-200 P02s 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 140-200 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 150-200 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 132-250 P03s 2 2 2 2 2 2 2 2 2 2 2 7 2 2 2 2 2 2 2 240-250 2 2 2 2 2 2 2 2 2 2 2 8 2 2 2 2 2 2 2 240-315 3 3 3 2 3 2 2 2 3 2 2 8 2 2 2 2 2 3 2 250-250 2 2 2 2 2 2 2 2 2 2 2 9 2 2 2 2 2 2 2 250-315 3 3 4 2 3 2 2 2 3 2 2 10 2 2 2 2 2 3 2 265-200 2 1 2 2 1 2 2 2 1 2 2 5 2 2 2 2 2 1 2 265-250 2 2 3 2 2 2 2 2 2 2 2 5 2 2 2 2 2 2 2 280-200 2 1 2 2 1 2 2 2 1 2 2 1 2 2 2 2 2 1 2 280-250 2 2 4 2 2 2 2 2 2 2 2 6 2 2 2 2 2 2 2 2100-200 2 1 3 2 1 2 2 2 1 2 2 6 2 2 2 2 2 1 2 265-315 P04s 5 3 5 3 5 3 3 3 3 2 2 14 3 2 2 3 2 3 3 280-315 5 3 6 3 5 3 3 3 3 2 2 15 3 2 2 3 2 3 3 280-400 6 4 7 3 6 3 3 3 4 2 2 14 3 2 2 3 2 4 3 2100-250 4 2 5 3 4 3 3 3 2 2 2 11 3 2 2 3 2 2 3 2100-315 5 3 6 3 5 3 3 3 3 2 2 16 3 2 2 3 2 3 3 2100-400 6 4 7 3 6 3 3 3 4 2 2 16 3 2 2 3 2 4 3 2125-250 4 2 6 3 4 3 3 3 2 2 2 12 3 2 2 3 2 2 3 2125-315 5 3 7 3 5 3 3 3 3 2 2 13 3 2 2 3 2 3 3 2125-400 6 4 8 3 6 3 3 3 4 2 2 12 3 2 2 3 2 4 3 2150-250 4 2 7 3 4 3 3 3 2 2 2 13 3 2 2 3 2 2 3 2150-315 P05s 7 5 9 4 7 4 4 4 5 3 3 17 4 3 3 4 3 5 4 3150-400 8 6 9 4 8 4 4 4 6 3 3 17 4 3 3 4 3 6 4 3150-500 9 7 12 4 9 4 4 4 7 3 3 21 4 3 3 4 3 6 4 3200-315 7 5 10 4 7 4 4 4 5 3 3 18 4 3 3 4 3 5 4 3200-400 8 6 10 4 8 4 4 4 6 3 3 20 4 3 3 4 3 6 4 3250-315 7 5 11 5 7 4 4 4 5 3 3 19 4 3 3 4 3 5 4 3

13) For CPK.D-S only14) Centrifugal mechanism consisting of: cover 160.02, guide piece 897.01, O-ring 412.37, lever 570.01, parallel pin 562.09,

grub screw 904.39/.40, spring washer 930.10, ring 500.13, thrower 507.05


50 of 60 CPK.D

8 Trouble-shootingPump delivers insufficient flow rate

Motor is overloaded

Excessive pump discharge pressure

Increased bearing temperature

Leakage at the pump

Excessive leakage at the shaft seal

Vibrations during pump operation

Impermissible rise of temperature inside the pump

Leakage during pump operation

Table 27: Trouble-shooting

A B C D E F G H I Possible cause Remedy 15)

X X Pump delivers against an excessivelyhigh discharge pressure.

Re-adjust to duty point.Check system for impurities.Fit a larger impeller. 16)

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

vented or primed.Vent and/or prime.

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

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

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

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

X X Speed is too low. 16)

- Operation with frequency inverter- Operation without frequency inverter

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

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

specified in purchase orderRe-adjust to duty point.In the case of persistent overloading, turndown impeller. 16)

X Density or viscosity of fluid handledhigher than stated in purchase order

Contact KSB.

X X Speed is too high. Reduce speed. 16)

X Use of unsuitable materials. Change the material combination. X Tie bolts/seal elements Re-tighten the bolts.

Replace seal elements. X Vibrations during pump operation. Correct suction conditions.

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

X X X The pump set is misaligned. Re-align.

A

B

C

D

E

F

G

H

I

15) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.16) Contact KSB.

8 Trouble-shooting

CPK.D 51 of 60

A B C D E F G H I Possible cause Remedy 15)

X X X Pump warped or resonant vibrations inpiping

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

X X Insufficient or excessive quantity oflubricant or unsuitable lubricant.

Top up, reduce or change lubricant.

X Non-compliance with specifiedcoupling distance

Correct distance according to generalarrangement drawing.

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

X Supply voltage is too low. Increase the voltage. X Rotor out of balance Clean the impeller.

Re-balance the impeller. X Defective bearing Fit new bearing. X X X Insufficient flow rate Increase minimum flow rate.X Suction lift is too high. Clean suction strainer and suction line.

Correct/alter fluid level.Change suction line.

X Standstill seal defective Check O-rings.Check shaft seal rings, sealing lips.Check whether centrifugal mechanism isblocked.Check centrifugal mechanism for smoothoperation.Check spring.

X Inlet pressure in the suction nozzlehigher than specified in the purchaseorder.

Reduce inflow. Increase speed.

X Back vanes or expeller vanes cloggedor worn.

Clean. Replace expeller.

X Wrong diametral clearance Check clearances at back vanes or expeller. X Expeller has worked loose. Verify that expeller is firmly mounted. X Pre-load of centrifugal mechanism too

lowCheck setting.

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

8 Trouble-shooting

52 of 60 CPK.D

9 Related Documents

9.1 General assembly drawing with list of components

Fig. 20: General assembly drawing

Table 28: List of components

Part No. Description Scope of supply102 Volute casing with joint ring 411.01/.10, casing wear ring 502.0117) , grooved pin

561.0117) , stud 902.01, screwed plug 903.01, hexagon nut 920.01160.02 Cover with O-ring 412.15/.37, ring 500.13, thrower 507.05, parallel pin

562.09, lever 570.01, guide piece 897.01, grub screw 904.39/.40,spring washer 930.10

160.09 Intermediate cover with joint ring 411.10/.11163 Discharge cover with joint ring 411.10/.11183 Support foot with hexagon head bolt 901.04, spring washer 930.01210 Shaft with joint ring 411.31, impeller nut 922, keywayed nut 920.21,

lockwasher 931.01, key 940.01/.02230.01 Impeller with gasket 400.63/.64, joint ring 411.32, socket head cap screw

914.26230.02 Expeller with gasket 400.63/.64, socket head cap screw 914.26320.02 Angular contact ball bearing 322.01 Cylindrical roller bearing 330 Bearing bracket with joint ring 411.46, vent plug 672, screwed plug 903.46

17) On CPK-SD only

9 Related Documents

CPK.D 53 of 60

Part No. Description Scope of supply330 Bearing bracket, complete as above, with support foot 183, bearing cover 360.01/.02, gasket

400.01/.02, shaft seal ring 421.01/.02, constant-level oiler 638,hexagon head bolt 901.04, socket head cap screw 914.01/.02,support disc 550.23, circlip 932.01/.02, spring washer 930.01

344 Bearing bracket lantern with guard 680.11, stud 902.04, hexagon head bolt 901.14/.31,hexagon nut 920.04

360.01/02 Bearing cover with gasket 400.01/.02, socket head cap screw 914.01/.02412.15/.37 O-ring 421.01/02 Lip seal 421.06 Lip seal with disc 550.10502.0117) Casing wear ring 504.04 Spacer ring 507.01 Thrower 520.10 Sleeve 524.01 Shaft protecting sleeve with joint ring 411.32638 Constant-level oiler

9 Related Documents

54 of 60 CPK.D

10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

CPK.D

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

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

– EC Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100-1/A1, ISO 12100-2/A1,

– ISO 14121-1,

– EN 809/A1

Pegnitz, 29 December 2009

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

Name

Function

Responsible for compiling the technical documentationKSB Aktiengesellschaft

Bahnhofplatz 1

91257 Pegnitz (Germany)

10 EC Declaration of Conformity

CPK.D 55 of 60

11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number18) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled18) : ................................................................................................................................

Please tick where applicable18) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return18) : ................................................................................................................................ Comments: ................................................................................................................................ ................................................................................................................................ The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placingat your disposal.

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

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

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

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

18) Required fields

11 Certificate of Decontamination

56 of 60 CPK.D

Index

AAbrasive fluids 33

BBearing temperature 36Bearings 14

CCertificate of decontamination 56Clearance gaps 37Commissioning/start-up 27Configuration 15Constant-level oiler 27Coupling 37Coupling alignment 22

DDesign 13Designation 13Direction of rotation 25Dismantling 41Disposal 12

EExplosion protection 17, 30, 35

FFilter 19, 37Final check 28Flow rate 32Frequency of starts 32Function 15

GGeneral assembly drawing 53Grease lubrication

Grease quality 40Intervals 39

HHeating 29Heating speed 29Heating up 29Hydrodynamic shaft seal 15

IImpeller type 14

InstallationInstallation on a foundation 17Installation without foundation 18

Installation at site 17Intended use 8Interchangeability of pump components 49

KKeeping warm 29

MMisuse 9

NName plate 13Noise characteristics 16

OOil lubrication

Intervals 38Oil quality 38Oil quantity 38

Operating limits 8Order number 6Ordering spare parts 49Other applicable documents 6

PPartly completed machinery 6Permissible forces and moments at the pump nozzles20Piping 19Preservation 12, 34

RReturn to supplier 12Returning to service 34Running noises 36

SSafety 8Safety awareness 9Scope of supply 16Servicing 35Shaft seal 14Shutdown 31, 34Spare parts stock 49Start-up 30Storage 12, 34

Index

CPK.D 57 of 60

TTemperature difference 29Tightening torques 48Transport 11Trouble-shooting 51

WWater cooling 29

Index

58 of 60 CPK.D

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

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