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Operating instructions

1384.8/4--10 Omega
Volute casing pump
with radial impeller

Pump set
Horizontal installation -- 3 E

These operating instructions contain fundamental information and precautionary notes.


Please read the manual thoroughly prior to installation of unit, electrical connection and
commissioning. It is imperative to comply with all other operating instructions referring to
components of individual units.

Any work on the unit must only be carried out with the electrical connections (incl. control cable)
disconnected (or unplugged). Make sure that the pump set cannot be switched on accidentally.

Ident--No.: 01 059 616


Omega

For usage in hazardous locations


refer to supplementary operating
instructions 1387.81.

2
Omega

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

3
Omega

1 General The word

This KSB pump has been developed in accordance with


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

safety sign in accordance with DIN 4844 -- W9.


The electrical danger warning sign is

safety sign in accordance with DIN 4844 -- W8.

4
Omega

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

2.7 Unauthorized Modification and Manufacture


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

2.8 Unauthorized Modes of Operation


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

Fig.2: Transport of motor

The motor eyebolts must only be used for lifting the mo-
tor alone, never for lifting the complete unit.

5
Omega

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

-- motor sizes 315 and above


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

Safe transport in horizontal position must be ensured by


suitable transport facilities. Make sure the pump cannot
slip out of the transport arrangement.

3.2 Interim Storage / Preservation


When the unit is temporarily put into storage, only the wetted
low alloy components, e.g. JL1040 (GG--25) must be preser-
ved. Commercially available preservatives can be used for this
purpose. Please observe the manufacturers instructions for
application / removal.
Fig.4a: Transport of complete unit
(horizontal installation type 3E) 4 Description of the Product and
-- up to motor size 280 (IEC standard)
Accesories
-- or up to a total weight of 1500 kg
4.1 Technical Specification
Observe angles of pull when lifting.
Angle of pull > 90_ not permitted. Design
Use two separate sets of lifting slings!
The KSB pump of the Omega series is a horizontally installed,
single--stage, axially split volute casing pump with double--en-
try radial impeller. Connection flanges are manufactured accor-
ding to EN, DIN, ISO, BS or ASME, as preferred.

Fields of application
In waterworks, irrigation and drainage pumping stations, power
stations, for industrial water supply, dock installations, fire ex-
tinguishing systems, refineries, pipelines and tank farms, also
for handling crude oil and refinery intermediates

Fig.4b: Transport of complete unit

-- up to motor size 280 (IEC standard)


-- or up to a total weight of 1500 kg

6
Omega

4.2 Designation 4.5 Accessories (optional)


Omega XXX XXX X The following accessories are available:

Type series Configuration


g Omega
Discharge nozzle DN mm Accessories Fig.0 3E
Nominal impeller dia. Motor ---- x 1)
Impeller type (A,B,C) Baseplate/baseframe ---- x 1)
Coupling and coupling guard ---- x 1)
4.3 Design Details Sealing and flushing water pi- x x
ping
4.3.1 Pump Casing
Set of pressure gauges x x
Axially split volute casing with replaceable casing wear rings. Cyclone separator with pipework x x
Suction and discharge nozzles in lower half of casing are at the Vent valve (manual or automatic) x x
same level (inline version). Temperature sensor for rolling x x
element bearings (PT 100)
4.3.2 Impeller Signal transmitter for PT 100 x x
The double--entry radial impeller is manufactured for the opera- Drain line x x
ting data provided in each case. Also with impeller wear rings, 2) included in standard scope of supply
if requested.
4.6 Dimensions and Weights
In double--entry radial impellers the axial thrust is largely balan-
ced. For dimensions and weights please refer to the tables in the ap-
pendix.
4.3.3 Pump Shaft
The shaft is fully sealed against the liquid being pumped. Shaft-- 5 Installation at Site
protecting sleeves are fitted in the seal area.
5.1 Safety Regulations
4.3.4 Shaft Seal
Electrical equipment operated in zone 1 hazardous
The shaft seals at the drive end and non--drive end are gland locations must comply with the explosion protection
packings or mechanical seals, as requested. regulations. This is indicated on the motor rating pla-
te.
4.3.5 Bearings and Lubrication
If the equipment is installed in hazardous locations, the applica-
The pump is fitted with covered deep--groove ball bearings ble local explosion protection regulations and the regulations of
which are grease--lubricated for life. the test certificate supplied with the equipment and issued by
The fixed bearing at the non--drive end is located on a bush to the responsible approval authorities must be observed and
permit rapid changing without removing the rotor or upper half. complied with.
The test certificate must be kept close to the location of opera-
4.4 Types of Installation tion for easy access (e.g. foremans office).
The pump set is installed in configuration 3E -- horizontal instal- 5.2 Checks to Be Carried out Prior to
lation, direct--coupled (see appendix). Installation
All structural work required must have been prepared in accor-
dance with the dimensions and loads stated in the dimension
table / installation plan.
The concrete foundations shall have sufficient strength
(min. BN 25) to ensure safe and functional installation in
accordance with DIN 1045 or equivalent standards.
Make sure that the concrete foundation has set firmly before
placing the unit on it. Its surface shall be truly horizontal and
even.

7
Omega

5.3 Installing the Pump / Unit 5.4 Connecting the Piping


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

straight edge gauge

Fig.6: Coupling alignment, using gauge and straight edge


Special instructions see appendix

8
Omega

6 Commissioning, Start--up / Correct direction of rotation:


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

6.2 Shaft Seal 1. Part load operating limit for low flow rate
For commissioning the shaft seal please refer to section 8.1 / This limit is indicated in the H--Q characteristic by Qmin or by the
8.2. If the pump has been out of service for a prolonged period, discontinuation of the characteristic curve.
the measures specified in section 6.6 must be carried out.
Caution It is not permissible to operate the pump in the
6.3 Venting range from Q=0 to Qmin. Prolonged operation
Before start--up, the pump and the pipes must be vented and in this range causes greatly increased mechanical loads which
filled with the liquid to be pumped. This is done at the vent plug the components cannot withstand.
on the casing (903). For suction lift operation, the pump must
also be evacuated, i.e. a vacuum must be produced. Brief passage through the critical range is permissible, e.g. du-
ring start--up
6.4 Commissioning
2. NPSH--related limits in the part load and overload ranges
6.4.1 Checking the Direction of Rotation
These two limits are determined by the ratio of NPSHrequired to
Caution For trouble--free operation of the pump, the NPSHavailable. They are determined as follows:
correct direction of rotation of the impeller is of
paramount importance.

If running in the wrong direction of rotation, the pump cannot re-


ach its duty point; vibrations and overheating will be the conse-
quence. The unit or the shaft seal might be damaged.

9
Omega

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

6.6 Returning to Service after Storage


Before returning the pump to service carry out all checks and
maintenance work specified in sections 5.1 and 5.2.
In addition, the instructions laid down in section 6.1
Commissioning and section 6.4.3 Operating limits
must be observed.
6.4.4 Shutdown
Upon completion of the work, all safety--related and pro-
Close the shut--off element in the discharge line. If the di- tective equipment must be properly refitted and / or re-
scharge line is equipped with a check valve, the shut--off ele- activated before starting the pump set.
ment may remain open, provided there is back pressure in the
line.
7 Maintenance / Repair
The shut--off element in the suction line must not be clo-
sed when switching off the pump. Switch off the motor,
making sure that the unit runs smoothly down to a standstill. 7.1 General Instructions
The operator is responsible for ensuring that all maintenance,
Depending on the system the pump shall have an adequate af-
inspection and installation work is carried out by authorized,
ter--run period -- with the heat source switched off -- to allow the
duly qualified staff who are thouroughly familiar with these ope-
medium handled to cool down sufficiently to avoid any heat
rating instructions.
build--up within the pump.
A regular maintenance schedule will help avoid expensive re-
In the case of prolonged shutdown, the shut--off element in the
pairs and contribute to trouble--free, reliable operation of the
suction line has to be closed.
pump with a minimum of maintenance expenditure and work.
Close the auxiliary connections.
In the event of frost and / or prolonged shutdowns, the pump Work on the pump and the motor must only be car-
must be drained or otherwise protected against freezing. ried out with the electrical connections disconnec-
ted. Make sure that the pump set cannot be switched on ac-
6.5 Shutdown / Storage / Preservation cidentally (danger of life!).

Each KSB pump leaves the factory carefully assembled. If com- Pumps handling liquids posing health hazards must be
missioning is to take place some time after delivery, we recom- decontaminated. When draining the medium see to it
mend that the following measures be taken for pump storage. that there is no risk to persons or the environment. All relevant
laws must be adhered to (danger of life!).
6.5.1 Storage of New Pumps
New pumps are supplied by our factory duly prepared for
storage.
Maximum protection for up to 12 months, if the pump is pro-
perly stored indoors.
Store the pump in a dry location.

10
Omega

7.2 Maintenance / Inspection Dismantling and reassembly must always be carried out in ac-
cordance with the relevant general drawing. The general dra-
7.2.1 Supervision of Operation wing and other relevant documents are found in the annex. The
The pump shall run quietly and free from dismantling sequence can be derived from the general dra-
Caution wing.
vibrations at all times. The pump must never be
allowed to run dry. In case of damage you can always contact our nearest custo-
Prolonged operation against a closed shut--off element mer service centre.
is not permitted in order to prevent the medium handled
from heating up. 7.3.2 Preparations for Dismantling
The pump is designed so that the complete rotor can be remo-
At room temperatures of up to 30 _C (86 _F) the bearing tempe- ved in the sequence described below without removing the suc-
rature shall be below 90 _C (194 _F). At higher room tempera- tion or discharge pipe or disturbing the alignment of the pump
tures, the bearing temperature shall be below 100 _C (212 _F). unit:
During pump operation the shut--off element in the inlet Close the suction and discharge--side gate valves and drain
line must not be closed. the pump by opening the drain plug (903.01 bottom) and
vent plug (903.01 top).
Any stand--by pumps installed shall be switched on and then
immediately off again once a week to keep them operational. Remove any pipes between additional equipment and the
Attention shall be paid to the correct functioning of the auxiliary pump.
connections. Remove the coupling guard. Decouple pump--side coupling
If the flexible coupling elements begin to show half as described in the appendix.
Caution
signs of wear, they must be replaced in due Loosen and push back the seal cover (471), if a mechanical
time. See section Coupling. seal is fitted.

If an external supply of sealing, flushing or lubricating liquid is Undo the flange screws (901.01 / 901.02) and separate the
used, make sure supply pressure is 1.0 to 2.0 bar higher than upper casing half (105.02) from the lower casing half
pressure at the suction nozzle. (105.01) with the aid of the forcing screws. Remove with lif-
ting gear. The interior of the pump (impeller with casing
On pumps fitted with a gland packing the packing must drip wear rings, shaft seal) is now accessible for inspection.
slightly during operation. The gland cover should therefore only
Remove the screwed connection (901.04) between bearing
be gently tightened. (See section 8 Special instructions for
housing (350.01) and bearing brackets. Also undo the nuts
subassemblies, shaft seal variants).
(920.05) and bolts (901.07) which secure the bearing cover
7.2.2 Shaft Seal Maintenance (360).
Press the bearing housing out of the recesses and lift the
For required maintenance work on gland packings please refer
rotor out of the lower casing half. For further disassembly,
to section 8.1. Shaft seal. Mechanical seals are mainte-
place securely in horizontal position.
nance--free.
Pull off the bearing housing of the fixed bearing (opposite
7.2.3 Bearing Maintenance the drive end).
The bearings are maintenance--free and greased for life. No Undo and remove the keywayed nuts (920.03).
re--lubrication is required. Remove the deep--groove ball bearing (312) with bush
(520) from the shaft.
7.3 Dismantling
Remove the bearing cover (360).
Before dismantling, secure the pump so as to make sure
it cannot be switched on accidentally. The shut--off ele- Remove the V--ring (412.02) from the shaft--protecting
ments in the suction and discharge lines must be closed. The sleeve (524.01).
pump must have cooled down to ambient temperature, pump Pull off the shaft--protecting sleeve (524.01).
pressure must be released and the pump must be drained.
Remove the shaft seal housing (441).
Dismantling and reassembly must always be carried out in ac- The impeller (234) is located with a sliding fit on the shaft
cordance with the relevant sectional drawing. and can normally be removed easily. In case of difficulty, it
can be loosened by gently tapping the hub with a wooden
7.3.1 Fundamental Instructions and hammer.
Recommendations
Remove the second shaft protection sleeve (524.01) com-
Repair and maintenance work to the pump must only be carried plete with the shaft seal housing (441), if fitted.
out by specially trained personnel, using original spare parts.
Remove the coupling half.
Observe the safety regulations laid down. Any work on the mo- Pull off the bearing housing (350.01).
tor shall be governed by the specifications and regulations of
the respective motor supplier. Remove the circlip (932) and pull off the deep--groove ball
bearing (321).

11
Omega

7.4 Reassembly
Reassembly is effected in reverse order to dismantling. For all
work on the pump unit refer to the general drawing, in conjunc-
tion with the list of components, for orientation.
The rules of sound engineering practice and also the instruc-
tions for removal and installation of shaft seal, bearings, impel-
ler wear rings and casing wear rings (sections 7.5.1 and 7.5.2)
must be observed.
The tightening torques indicated for nuts and bolts shall be ob-
served. The table below indicates the tightening torques for
threads depending on the materials used.
Property class (Material) 8.8 10.9 A.-50 A.-70 1.4462
0,2% yield stress 640 900 210 450
Rp 02 in N/mm2 1) 250 450
Metric ISO threads Tightening torque
coarse--pitch- fine--pitch- MA in Nm
M4 3,1 4,4 1,0 2,15
M5 6,1 8,7 2,00 4,25
M6 10,4 14,9 3,40 7,30
M8 25,2 36,1 8,30 17,7
M8x1 27,2 39,0 8,90 19,1
M10 49,5 71,0 16,2 34,8
M10x1,25 52,5 75,4 17,3 36,9
M12 85,2 122,2 28,0 59,9
M12x1,5 89,5 128,5 29,4 62,9
M12x1,25 93,9 134,7 30,8 66,0
M16 211 302,7 69,2 148
M16x1,5 226 324,7 74,3 159
M20 412 591,9 135 290
M20x1,5 461 661,0 151 324
M24 710 1019,6 233 276 500
M24x2 780 1118,6 256 305 548
M27 1050 1501,3 343 409 736
M27x2 1130 1627,1 372 443 797
M30 1420 2036,4 466 554 1000
M30x2 1580 2269,9 519 618 1110
M33 1940 2779,4 636 ---- 1360
M33x2 2130 3062,6 700 ---- 1500
M36 2480 3552,3 812 ---- 1740
M36x3 2630 3775,4 863 ---- 1850
1) Nominal values to DIN ISO 898 Part 1, DIN 267 Part 11 and DIN 267 Part 18

ALTEMP Q NB 50 grease
It is imperative to lock and seal the screwed connections spe-
cially marked in the general drawings.
Symbols for screwed connections to be locked and sealed:
Sealed with Loctite 574

12
Omega

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

13
Omega

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

Impeller clearances and trim dimensions for impeller wear rings

Clearance (as--new) Dimensions of impeller wear ring


No. Pump Shaft Nominal clea- Min. Max.
size unit rance clearance clearance
(max. perm.) S min S max

D2 - D1
DW 2 D5 b
[mm] [mm] [mm] [mm] [mm]
1 80-210 0,3 0,15 0,2 134 r6 18
2 80-270 0,3 0,15 0,2 134 r6 18
3 80-370 0,3 0,15 0,2 134 r6 18
40
4 100-250 0,35 0,17 0,2 163 r6 22
5 100-310 0,35 0,17 0,2 163 r6 22
6 100-375 0,35 0,17 0,2 163 r6 22
7 125-230 0,35 0,18 0,23 178 r6 22
8 125-290 0,35 0,18 0,23 178 r6 22
9 125-365 0,35 0,18 0,23 178 r6 22
10 125-500 50 0,35 0,18 0,23 178 r6 22
11 150-290 0,45 0,22 0,26 210 r6 30
12 150-360 0,45 0,22 0,26 210 r6 30
13 150-460 0,45 0,22 0,26 210 r6 30
14 150-605 0,45 0,22 0,26 210 r6 30
60
15 200-320 0,5 0,24 0,28 243 r6 30
16 200-420 0,5 0,24 0,28 243 r6 30
17 200-520 0,5 0,24 0,28 243 r6 30
18 200-670 70 0,5 0,24 0,28 243 r6 30
19 250-370 0,5 0,24 0,28 276 r6 30
20 250-480 0,5 0,24 0,28 276 r6 30
80
21 250-600 0,5 0,24 0,28 276 r6 30
22 300-300 70 0,5 0,24 0,28 259 r6 30
23 300-435 80 0,6 0,29 0,35 313 r6 35
24 300-560 0,6 0,29 0,35 313 r6 35
90
25 300-700 0,6 0,29 0,35 313 r6 35
26 350-360 80 0,5 0,24 0,28 294 r6 35
27 350-430 0,6 0,32 0,37 333 r6 35
90
28 350-510 0,6 0,32 0,37 353 r6 35

b
S (min - max)

14
Omega

7.6 Monitoring schedule


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

Component monitored Action Value required

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

* see list of measuring points (if applicable) in section 13,


Annex.

In the event of deviations proceed as described in the table gi-


ven in section 11.2 (Trouble--shooting).

15
Omega

8 Special Instructions for Also note the following:


Subassemblies (Shaft Seal Variants) Leakage and temperature rise: If necessary, shut down the
pump. After a short cooling period (approx. 10 to 15 minutes)
The shaft seal variant supplied is shown in the purchase order the pump can be restarted. The necessary minimum leakage
and order--processing documents. depends on the liquid being pumped, the pressure, sliding velo-
city and temperature. It is approx. 10 to 120 drops per minute
8.1 Gland packing (20 drops of water correspond to approx. 1 ml).
The gland packings used by KSB are asbestos--free and suita-
ble for drinking water applications. Disassembly
A packing puller must be used for pulling out the packing rings.
Installation and commissioning
Before installation, ensure that the gland space is clean (no Maintenance
packing remnants or corrosion). The shaft protecting sleeve Gland packings must be repacked in accordance with the sec-
must be bright and have no scoring. Otherwise a new shaft pro- tion Installation and commissioning after prolonged stand-
tecting sleeve must be used. still, repair work or heavy leakage. Therefore, the leakage rate
must be observed during operation, also to avoid possible over-
Cutting the packing rings to size heating.
If moulded packing rings are not available, the rings can best
be cut to size using a special cutting gauge. If no cutting gauge
is available, take a tube with the same diameter as the shaft,
wind the packing around the tube in a spiral and cut the rings
from the spiral. We recommend a straight cut.

Installing the packing rings


Push the packing rings with the stuffing box insert into the gland
space one by one. The joints of the packing rings must be offset
by 90_. The number of rings and the arrangement of the lantern
ring are shown in the general drawing (see appendix). After fit-
ting all the packing rings, put on the stuffing box insert and gland
cover and tighten them so that the packing rings adapt to the
gland space. Then loosen the gland cover again to relieve the
load on the packing. This procedure is not necessary if moulded
packing rings are used.

Commissioning
When the pump is started up, the gland must only be gently tigh-
tened (by hand). A high leakage rate (approx. 50 to 200 drops
per minute), depending on the liquid being pumped, must be ac-
cepted until the packing material has settled and has adapted
to the temperature conditions (approx. 10 to 15 minutes).
Then the gland cover must be carefully and evenly tightened to
reduce the leakage to a minimum. If there is no leakage, there
is a risk that the packing will run hot.

16
Omega

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

Mechanical seal variants


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

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

17
Omega

8.2.1 Mechanical Seal Type H7N4


(Shaft unit dw 40 to 80 mm)
The mechanical seal type H 7 N 4 used is a single--acting, bi--ro-
tational, non--balanced seal which does not require circulation
pipework in cold water applications, due to the pump design.
Caution Dry--running of the seal must be avoided at
all costs!

Installation
For the installation of the total seal assembly (mechanical seal,
seal housing) see operating instructions for the pump.

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

18
Omega

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

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

19
Omega

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

Preparations for installation


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

20
Omega

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

Reliable seal operation Repair


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

Should the mechanical seal fail, the liquid to be sealed


off may spurt out. Take suitable precautions to pre-
vent hazards to persons and the environment, e.g. install
splash guards, wear safety goggles, etc. Proper disposal of
leakage shall be arranged for and supervised by the operator.

21
Omega

Mechanical seal removal 8.2.3 Mechanical Seal Type HJ92 N


Shut down the pump in accordance with the operating (Shaft unit dw = 40 to 80 mm)
manual, allow to cool down and release pump pressure. Note:
There must be no pumped product at the Refer to sections 8.2.1 and 8.2.2 for general recommendations
mechanical seal The pump must be drained. and instructions for handling this seal type.
Secure the pump to prevent inadvertent start--up. For detailed information please refer to the operating manual
for seal type HJ92 N.
Follow the safety instructions
(safety data sheets)!

Make sure to comply with the applicable accident preven-


tion regulations when removing a mechanical seal. Also ob-
serve the instructions for handling hazardous substances
if the mechanical seal has already been in operation. If you
have any queries about the applicable regulations please in-
form yourself before commencing any repair work.
Any work on the mechanical seal is only permitted with the
pump shut down and pump pressure released.
Removal of the mechanical seal shall be performed analo-
gously with mechanical seal installation, but in reverse order.

Removing the subassembly


See section 7.3.
Grub screw (7) und Dichtringe (2+9) nach jeder Demontage
erneuern.

Spare parts
Only genuine spare parts shall be used. Non--compliance
with this requirement entails the risk of seal malfunctions
which may jeopardize the safety of personnel and the environ-
ment.
It will also lead to forfeiture of all warranty claims.To keep a
complete spare seal on stock.

22
OPERATING MANUAL
MECHANICAL SEAL (MS)
HJ92N
PLEASE READ this manual carefully and OBSERVE the information contained as to:
H Safety H Storage H Installation H Start up H Maintenance H Repair

J SAFETY J OPERATING LIMITS


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

In addition to the instructions contained in this manual, the ge- J DRAWINGS


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

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

Operating maual mechanical seal 23


Rev. 0, 13.02.2004
Due to their protected spring (1.5), mechanical seals of this type The mechanical seals need not be preserved.
are particularly suitable for fluids containing solids and/or highly D Do not apply anti--corrosives.
viscous fluids, for ex. in sugar, paper or waste water applica- ' Risk of deposits and possible chemical attacks on ela-
tions. The seal design is rugged and reliable. The spring neither stomer secondary seals.
clogs nor sticks. Max. axial end play between shaft and hou-
sing: 0.5 mm in any direction. When applying preservatives to entire systems where mecha-
nical seals are installed please check the following:
For operation at negative pressures (down to --0.2 bar), no seat
lock is required for the seat ring (2). D Verify the compatibility of the preservatives chosen with the
Torque transmission between the shaft and the seal is normally materials of construction and the elastomer components of
effected by grub screws(1.6); or by special drive elements (1.2) the mechanical seal.
on individual models. D Verify that mechanical seal movement is not restricted by re-
sin deposits or sticking.
During storage, seal face materials and elastomers will un-
J LIQUID SUPPLY TO MECHANICAL dergo material specific time dependent changes (distortion,
SEAL ageing), which can impair the perfect function of the mechanical
seal. The specified storage period must therefore be complied
To ensure trouble--free operation of the mechanical seal, a sui-
with.
table circulation process has been selected on the pump, see
The manufacturer cannot be held responsible for damage re-
section 9 of the pumps operating manual. This process avoids
sulting from improper storage.
product deposits in the seal chamber.
The room where mechanical seals are kept must be dust--free
and moderately ventilated, with an even temperature. We re-
J EMISSIONS commend: relative humidity below 65%, temperature between
Mechanical seals are dynamic seals which for physical and 15 C and 25 C.
technical reasons cannot be completely leak--free. The amount
The mechanical seal shall be protected from:
of leakage largely depends on the seal selection, production to-
lerances, operating conditions, smooth running of the machine, D direct heat from sun, heating
etc. Compared with other dynamic sealing systems, however, D ozone and ultraviolet light from halogen lamps, fluorescent
mechanical seals have little leakage. lamps, sunlight, arc welding
' danger of embrittlement of elastomer materials
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine, The seals shall be stored in their original packaging on a level
safety goggles worn by the operating staff, etc. may prevent ha- surface.
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi- The mechanical seal needs to be checked:
ronment. D after a storage period of approx. 2--3 years
D if the packaging has been damaged
Leakage may be liquid or gaseous, its aggressiveness corres-
D after a shock load (e.g. if the mechanical seal package has
ponding to that of the fluid to be sealed off.
been dropped)
Any mechanical seal leakage must be drained off in a controlled
' at the manufacturers workshop or nearest service centre.
way and safely disposed of.
. Components which may come into contact with the seal lea- J BEFORE INSTALLATION
kage shall either be corrosion resistant or must be adequately
protected. Checks to be carried out on the pump components:
Shaft surface in the area of the dynamically loaded seal ring:
J STORAGE roughness depth Rmax 5 mm.
Unless otherwise agreed in the contract, mechanical seals are Checks to be carried out on the pump:
delivered in standard packaging suitable for dry transport by
D Check contact surfaces between the pump and the mecha-
truck, train or plane. The symbols or handling instructions given
nical seal for damage.
on the packaging must be adhered to.
D Connecting dimensions, squareness and concentricity to
For incoming goods inspection: shaft.
D Check packaging for external damage. D Shaft run--out as per DIN ISO 5199: between 50 mm and
D Carefully open packaging, making sure not to damage or 100 mm, depending on the diameter.
lose any components packed separately. D Apply a thin coat of suitable grease to the shaft in the
D Check consignment for completeness (delivery note). The mech.seal area.
supplier shall be notified immediately of any damaged ' Never use mineral oil base lubricants on sealing elements
goods or missing parts. made of ethylene propylene rubber (swelling, possibly de-
The instructions given below shall apply both to mechanical composition).
seals delivered and stored in their undamaged, original packa- ' Grease recommended for elastomer sealing elements
ging, and to mechanical seals already installed in a pump, (O--rings, etc.): type TURMOPOLGREASE SH2, produ-
which have not been in operation yet. cer: Lubricant Consult (LUBCON).

24 Operating maual mechanical seal


Rev. 0, 13.02.2004
' Double PTFE encapsulated O--rings must be fitted so that
the joint of the outer sheath points in opposite direction to
the mounting direction, so that the friction force generated
when sliding on the O--ring closes the joint. Kinks in the foil
will result in leakage.

J INSTALLATION TOOLS / EQUIPMENT


D Propyl alcohol + paper tissue (no cleaning rags)
D Lubricating grease for elastomer seals: type TURMOPOLGREASE
SH2, producer: Lubricant Consult (LUBCON)
D Thread--locking compound, e.g. type LoctiteR Nr. 243,
producer: Loctite Corporation
D O--ring extractor Possible installation sequence:
D Set of hex. keys (WAF 2 mm -- 6 mm) D Slide the degreased O--ring onto the seat ring.
D Cardboard washers to protect the contact faces during in- D Cover the contact face of the seat ring with a cardboard
stallation washer. Generously lubricate the seat ring with water or al-
D Manual screw press (compulsory from DN 80 mm). cohol and press it slowly and evenly into its seat. Use a spa-
cer, if necessary. Check squareness of seat ring to the shaft
J INSTALLATION axis.
Refer to the general pump assembly drawing when installing D Apply a thin coat of grease to the shaft protecting sleeve in
the mechanical seal. the mechanical seal area.
Mechanical seals are precision--machined machinery compo- ' Never use mineral oil base lubricants on sealing ele-
nents which have been inspected several times. They must be ments made of ethylene propylene rubber (swelling,
installed with due care and in compliance with certain procedu- possibly decomposition).
res, particularly regarding the contact faces and elastomer D Slide the rotating seal assembly with greased O--rings onto
seals. the shaft protecting sleeve.
D Fit the degreased grub screws, having applied one drop of
Utmost cleanliness must be ensured in the immediate vicinity
thread--locking compound (e.g. Loctite R No. 243) to each
of the location where a mechanical seal is to be installed.
screw.
Never use force when installing a mechanical seal. D Tighten the grub screws to lock the torque--transmitting
D Unpack the seal and inspect the spring--loaded ring, seat sleeve into place.
ring, O--rings and contact faces for damage. D Clean the contact faces with propyl alcohol and paper tissue
' Never place the spring--loaded ring and the seat ring on (no cloth, no cleaning rags!) to remove any smears. Do
the table facing down without protecting the contact fa- not touch the contact faces with bare fingers after that.
ces. ' Do not apply lubricants to the contact faces. The contact
faces must be installed in clean and dry condition.
D Thoroughly clean all parts with alcohol and paper tissue.
D Fit the seal cover with pre--assembled seat ring.
The sequence of operations required to install the mechanical
seal in the machine depends on the design of the machine in J COMMISSIONING
question, which is described in the pumps operating manual. Prime the pump and the seal chamber with the fluid handled
Unless otherwise stated, apply a very thin coat of grease to and vent thoroughly. The seal is now ready for operation.
O--rings which will slide into or onto other components during J SAFE OPERATION
mechanical seal installation.
For single mechanical seals, the pressure in the seal chamber
of the pump must always exceed ambient pressure, to prevent
any air intake at the seal faces, which would result in dry running
and thus failure of the mechanical seal.
In all operating conditions, the product to be sealed off must be
available in liquid state at the mechanical seal, particularly du-
ring pump start--up and shutdown.
If the operating conditions indicated are observed and the in-
structions given in this operating manual are complied with, the
mechanical seal can be expected to give trouble--free opera-
tion.
J HEALTH AND SAFETY
Mechanical seals are often used for sealing off hazardous sub-
stances (chemicals, pharmaceuticals, etc.). The applicable in-
structions and regulations for handling hazardous materials
must absolutely be adhered to.
Operating maual mechanical seal 25
Rev. 0, 13.02.2004
Should the mechanical seal fail, the hot liquid or steam to be J REMOVING THE SEAL FROM
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent ha-
THE PUMP
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-
ronment..
D Shut down the pump, allow to cool down and release pres-
sure as per operating instructions
J FAULTS/MALFUNCTIONS D No product should contact the mechanical seal Drain the
Determine and document the nature of the fault/malfunction. pump, if necessary!
In the event of a fault as evidenced by excessive leakage, ob- D Secure the pump against inadvertent start--up!
serve the tendency of the leakage amount. Changes in opera- D Follow the safety instructions (safety data sheets)!
ting conditions must be documented. If an excessive tempera- When removing the mechanical seal make sure to observe the
ture rise is detected, the mechanical seal must be shut down for applicable health and safety regulations, as well as the regula-
safety reasons. tions for handling hazardous substances, if the mechanical seal
A continuous flow of leakage indicates a fault/malfunction at the has already been in operation. If in doubt, the necessary infor-
mechanical seal. mation has to be obtained before starting repair work.
During the warranty period the mechanical seal shall only be re- Any work on the mechanical seal shall only be performed with
moved and dismantled with the manufacturers approval or in the pump shut down and the pump pressure released.
the presence of his representative. The sequence of operations required to remove the mechanical
If the fault/malfunction cannot be remedied by the operator or seal from the pump depends on the design of the pump in ques-
if the cause is unclear, please contact your responsible KSB tion, which is described in the pumps operating manual.
service centre. Removal of the mechanical seal shall be effected in analogy
with, but in reverse order to, installation.

J SERVICING / MAINTENANCE J CUSTOMER SERVICE


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

26 Operating maual mechanical seal


Rev. 0, 13.02.2004
Omega

8.2.4 Mechanical Seal Type H75N


(Shaft unit dw = 90 mm)

General instructions concerning assembly/installation, com-


missioning, maintenance, faults and repair have already been
given in sections 8.2.1 and 8.2.2.

(See Operating manual


S for seal type H75N).

27
OPERATING MANUAL
BURGMANN MECHANICAL (M.S.)
H75N
PLEASE READ this manual carefully and OBSERVE the information contained as to:
H Safety H Storage H Installation H Start up H Maintenance H Repair

J SAFETY J OPERATING LIMITS


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

In addition to the instructions contained in this manual, the ge- J DRAWINGS


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

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

28 Operating maual mechanical seal


Rev. 0, 13.02.2004
H Multiple springs in guide sleeves During storage, seal face materials and elastomers will un-
H axial mobility/play up to dw 55 = 2 mm, and 3 mm dergo material specific time dependent changes (distortion,
H Torque transmission by grub screws ageing), which can impair the perfect function of the mechanical
H Connecting dimensions to DIN 24960 KB seal. The specified storage period must therefore be complied
H Installation dimensions l1K with.
The manufacturer cannot be held responsible for damage re-
sulting from improper storage.
J LIQUID SUPPLY TO MECHANICAL The room where mechanical seals are kept must be dust--free
SEAL and moderately ventilated, with an even temperature. We re-
commend: relative humidity below 65%, temperature between
To ensure trouble--free operation of the mechanical seal, a sui- 15 C and 25 C.
table circulation process has been selected on the pump, see
The mechanical seal shall be protected from:
section 9 of the pumps operating manual. This process avoids
product deposits in the seal chamber. D direct heat from sun, heating
D ozone and ultraviolet light from halogen lamps, fluorescent
lamps, sunlight, arc welding
J EMISSIONS ' danger of embrittlement of elastomer materials.
The seals shall be stored in their original packaging on a level
Mechanical seals are dynamic seals which for physical and surface.
technical reasons cannot be completely leak--free. The amount
of leakage largely depends on the seal selection, production to- The mechanical seal needs to be checked:
lerances, operating conditions, smooth running of the machine, D after a storage period of approx. 2--3 years
etc. Compared with other dynamic sealing systems, however, D if the packaging has been damaged
mechanical seals have little leakage. D after a shock load (e.g. if the mechanical seal package has
been dropped)
Leakage may be liquid or gaseous, its aggressiveness corres-
' at the manufacturers workshop or nearest service centre.
ponding to that of the fluid to be sealed off.
Any mechanical seal leakage must be drained off in a controlled J BEFORE INSTALLATION
way and safely disposed of. Checks to be carried out on the pump components:
Shaft surface in the area of the dynamically loaded seal ring:
. Components which may come into contact with the seal lea-
roughness depth Rmax 5 mm.
kage shall either be corrosion resistant or must be adequately
protected. Checks to be carried out on the pump:
D Check contact surfaces between the pump and the mecha-
nical seal for damage.
J STORAGE D Connecting dimensions, squareness and concentricity to
shaft
Unless otherwise agreed in the contract, mechanical seals are D Shaft run--out as per DIN ISO 5199: between 50 mm and
delivered in standard packaging suitable for dry transport by 100 mm, depending on the diameter.
truck, train or plane. The symbols or handling instructions given D Apply a thin coat of a suitable grease to the shaft in the
on the packaging must be adhered to. mech. seal area.
' Never use mineral oil base lubricants on sealing elements
For incoming goods inspection: made of ethylene propylene rubber (swelling, possibly de-
D Check packaging for external damage. composition).
D Carefully open packaging, making sure not to damage or ' Grease recommended for elastomer sealing elements
lose any components packed separately. (O--rings, etc.): type TURMOPOLGREASE SH2, produ-
D Check consignment for completeness (delivery note). The cer: Lubricant Consult (LUBCON).
supplier shall be notified immediately of any damaged
goods or missing parts.
The instructions given below shall apply both to mechanical
seals delivered and stored in their undamaged, original packa-
ging, and to mechanical seals already installed in a pump,
which have not been in operation yet.
The mechanical seals need not be preserved.
D Do not apply anti--corrosives. ' Double PTFE encapsulated O--rings must be fitted so that
' Risk of deposits and possibly chemical attack of the ela- the joint of the outer sheath points in opposite direction to
stomer secondary sealing elements. the mounting direction, so that the friction force generated
When applying preservatives to entire systems where mecha- when sliding on the O--ring closes the joint. Kinks in the foil
nical seals are installed please check the following: will result in leakage.
D Verify the compatibility of the preservatives chosen with the
materials of construction and the elastomer components of J INSTALLATION TOOLS / EQUIPMENT
the mechanical seal. D Propyl alcohol + paper tissue (no cleaning rags)
D Verify that mechanical seal movement is not restricted by re- D lubricant for elastomer--sealing rings: Type TURMOPOL-
sin deposits or sticking. GREASE SH2, make Lubricant Consult (LUBCON)

Operating maual mechanical seal 29


Rev. 0, 13.02.2004
D Thread--locking compound, e.g. type LoctiteR Nr. 243, Primary seal components
producer: Loctite Corporation 1.1 Spring--loaded ring
D O--ring extractor 2 Seat ring
D Set of hex. keys (WAF 2 mm -- 6 mm) Secondary seal elements
D Cardboard washers to protect the contact faces during in- 1.4 O--ring (dynamic)
stallation 3 O--ring (static)
D Manual screw press (compulsory from DN 80 mm)
Spring components
1.5 Guide sleeve
J INSTALLATION 1.6 Spring
Refer to the general pump assembly drawing when installing Torque transmission and housing components
the mechanical seal. 1.2 Torque--transmitting sleeve
1.3 Thrust ring
Mechanical seals are precision--machined machinery compo- 1.7 Grub screw
nents which have been inspected several times. They must be
Possible installation sequence:
installed with due care and in compliance with certain procedu-
res, particularly regarding the contact faces and elastomer D Slide the degreased O--ring onto the seat ring.
seals. D Cover the contact face of the seat ring with a cardboard
Utmost cleanliness must be ensured in the immediate vicinity washer. Generously lubricate the seat ring with water or al-
of the location where a mechanical seal is to be installed. cohol and press it slowly and evenly into its seat. Use a spa-
Never use force when installing a mechanical seal. cer, if necessary. Check squareness of seat ring to the shaft
Unpack the seal and inspect the spring--loaded ring, seat ring, axis.
O--rings and contact faces for damage. D Apply a thin coat of grease to the shaft protecting sleeve in
D Never place the spring--loaded ring and the seat ring on the the mechanical seal area.
table facing down without protecting the contact faces. ' Never use mineral oil base lubricants on sealing ele-
D Thoroughly clean all parts with alcohol and paper tissue. ments made of ethylene propylene rubber (swelling,
possibly decomposition).
The sequence of operations required to install the mechanical D Slide the rotating seal assembly with greased O--rings onto
seal in the machine depends on the design of the machine in the shaft protecting sleeve.
question, which is described in the pumps operating manual. D Fit the degreased grub screws, having applied one drop of
Unless otherwise stated, apply a very thin coat of grease to thread--locking compound (e.g. Loctite R No. 243) to each
O--rings which will slide into or onto other components during screw.
mechanical seal installation. D Tighten the grub screws to lock the torque--transmitting
sleeve in place.
D Clean the contact faces with propyl alcohol and paper tissue
(no cloth, no cleaning rags!) to remove any smears. Do
not touch the contact faces with bare fingers after that.
' Do not apply lubricants to the contact faces. The contact
faces must be installed in clean and dry condition.
D Fit the seal cover with pre--assembled seat ring.

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

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

J HEALTH AND SAFETY


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

30 Operating maual mechanical seal


Rev. 0, 13.02.2004
Should the mechanical seal fail, the hot liquid or steam to be J REMOVING THE SEAL FROM
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent ha-
THE PUMP
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-
ronment.
D Shut down the pump, allow to cool down and release pres-
sure as per operating instructions.
J FAULTS/MALFUNCTIONS D No product should contact the mechanical seal Drain the
Determine and document the nature of the fault/malfunction. pump, if necessary!
D Secure the pump against inadvertent start--up!
In the event of a fault as evidenced by excessive leakage, ob-
serve the tendency of the leakage amount. Changes in opera- D Follow the safety instructions (safety data sheets)!
ting conditions must be documented. If an excessive tempera- When removing the mechanical seal make sure to observe the
ture rise is detected, the mechanical seal must be shut down for applicable health and safety regulations, as well as the regula-
safety reasons. tions for handling hazardous substances, if the mechanical seal
have already been in operation. If in doubt, the necessary infor-
A continuous flow of leakage indicates a fault/malfunction at the
mation has to be obtained before starting repair work.
mechanical seal.
Any work on the mechanical seal shall only be performed with
During the warranty period the mechanical seal shall only be re- the pump shut down and the pump pressure released.
moved and dismantled with the manufacturers approval or in
the presence of his representative. The sequence of operations required to remove the mechanical
seal from the pump depends on the design of the pump in ques-
If the fault/malfunction cannot be remedied by the operator or tion, which is described in the pumps operating manual.
if the cause is unclear, please contact your responsible KSB
service centre. Removal of the mechanical seal shall be effected in analogy
with, but in reverse order to, installation.
J SERVICING / MAINTENANCE J CUSTOMER SERVICE
Mechanical seals operated in compliance with manual are Services provided by the seal manufacturer range from plan-
maintenance--free. Wear parts, however, must be replaced as ning advice to product support after commissioning.
required.
For this purpose, the manufacturer has established a worldwide
The mechanical seal shall be inspected in accordance with the network of subsidiaries abroad, partner companies, sales offi-
plant inspection schedule. We recommend to have the mecha- ces and service stations, to handle any problems.
nical seal inspected by competent KSB service staff.
If the mechanical seal is removed during plant inspection, the J PURCHASE ORDERS
contact faces shall be re--worked and all elastomer seals and For enquiries and purchase orders, the following details are re-
springs shall be replaced. quired:
D KSB order No.
J REPAIR D No. of general pump assembly drawing
If the seal needs to be repaired, always return the complete seal D Part item No., description, material, quantity as per drawing
to the manufacturer. The manufacturers service personnel will
know best which parts can be re--worked and which parts have J DISPOSAL
to be replaced to ensure an optimum sealing effect. Usually, mechanical seals can easily be disposed of after a tho-
If repair on the spot is absolutely necessary (e.g. no spare seal rough cleaning.
available, long transport distances, problems with customs pro- D Metal parts (steel, stainless steel, non--ferrous metals),
cedures), skilled operator staff may carry out the repair work in shall be sorted and disposed of in the appropriate waste me-
a clean workshop to the directions of the seal manufacturers fit- tal collection facility.
ters. D Plastics (elastomers, PTFE) are special waste. After sor-
ting, some of them can be recycled.
J SPARE PARTS ' CAUTION! Material containing fluorine must not be inci-
nerated.
Use only genuine spare parts, to prevent
D Ceramic contact face materials (carbon, ceramics, carbide)
D the risk of mechanical seal malfunction, involving hazards can be separated from their carrier materials and -- being
to persons and the environment. physiologically harmless -- disposed of as residual waste.
D forfeiture of any and all warranty claims. We reserve the right to technical modifications designed to
To ensure quick mechanical seal replacement, we recommend improve the product, even if they are not mentioned in this ma-
to stock a complete spare seal. nual yet.

Operating maual mechanical seal 31


Rev. 0, 13.02.2004
Omega

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

Part no. Description Number of pumps (incl. stand--by pumps)


2 3 4 5 6 8 10
and more
Number of spare parts *
234 Impeller 1 1 1 2 2 3 30 %
502 Casing wear ring 4 4 4 6 6 8 50 %
503 Impeller wear ring 4 4 4 6 6 8 50 %
211,940 Shaft with keys and 1 1 2 2 2 3 30 %
920,932 shaft nuts
321 Rolling element 2 2 4 4 6 8 100 %
bearing
524 Shaft protecting 4 4 4 6 6 8 50 %
sleeve
461 Packing ring 32 32 48 48 48 64 40 %
411,412 Set of sealing ele- 4 6 8 8 9 12 150 %
421 ments
433 Mechanical seal Spring--loaded 4 6 8 8 8 12 90 %
ring
Seat ring 4 6 8 8 8 12 90 %
O--rings 4 6 12 16 16 20 150 %
Seals on 4 6 12 16 16 20 150 %
seat ring

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

32
Omega

Interchangeability of rotor components

Pump sizes Pump shaft diameter

40 50 60 70 80 90

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

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

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

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

250 - 480 *
250 - 600 *

300 - 300 *

300 - 435 *

300 - 560 *
300 - 700 *

350 - 360 *

350 - 430 *
350 - 450 *

33
Omega

10 Forces and Moments


Fz
Mz

Fy

My

Mx
Fx

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

Dimensions in mm
Pump Impeller dimensions in mm Permissible nozzle Mass moments of Permissi- Permissi-
sizes inertia J ble opera- ble test
ting pressure
pressure
free passage max. diameter Clearances forces moments (without coupling) in bar in bar
10 % in N in Nm in kgm2
A B C A B C A B C Fx, Fy, Fz Mx, My, Mz without with 1) 2) 1) 2)
1); 3) 1); 3) water water
80-210 15 11 -- 215 215 -- 0.30 0.30 -- 800 500 0.023 0.028 16 25 28 37.5
80-270 13 9 -- 275 275 -- 0.30 0.30 -- 800 500 0.037 0.044 16 25 28 37.5
80-370 11 8 -- 345 345 -- 0.30 0.30 -- 800 500 0.027 0.032 16 25 28 37.5
100-250 19 14 -- 254 254 -- 0.35 0.35 -- 1000 700 0.048 0.058 16 25 28 37.5
100-310 15 11 -- 325 325 -- 0.35 0.35 -- 1000 700 0.092 0.110 16 25 28 37.5
100-375 13 10 -- 408 408 -- 0.35 0,35 -- 1000 700 0.229 0.275 16 25 28 37.5
125-230 23 17 -- 245 245 -- 0.35 0.35 -- 1500 1000 0.161 0.193 16 25 28 37.5
125-290 19 12 -- 301 301 -- 0.35 0.35 -- 1500 1000 0.125 0.150 16 25 28 37.5
125-365 14 10 -- 392 392 -- 0.35 0.35 -- 2000 1500 0.261 0.313 16 25 28 37.5
125-500 14 10 -- 482 482 -- 0.35 0.35 -- 2000 1500 0.688 0.825 16 25 28 37.5
150-290 27 20 14 289 289 289 0.45 0.45 0,45 2500 1500 0.169 0.288 16 25 28 37.5
150-360 22 15 -- 355 355 -- 0.45 0.45 -- 2500 2000 0.199 0.338 16 25 28 37.5
150-460 17 12 -- 462 462 -- 0.45 0.45 -- 2500 2000 0.456 0.775 16 25 28 37.5
150-605 16 11 -- 569 569 -- 0.45 0.45 -- 3000 2000 1.074 1.825 24 25 28 37.5
200-320 30 22 17 338 338 338 0.50 0.50 0,50 4000 2750 0.442 0.575 16 25 24 37.5
200-420 26 18 -- 415 415 -- 0.50 0.50 -- 4000 2750 0.588 0.725 16 25 24 37.5
200-520 20 14 -- 540 540 -- 0.50 0.50 -- 4000 2750 1.288 1.675 16 25 24 37.5
200-670 18 12 -- 665 665 -- 0.50 0.50 -- 4000 2750 3.654 4.750 24 25 28 37.5
1) see next page
2) see next page
3) see next page

34
Omega

Dimensions in mm
Pump Impeller dimensions in mm Permissible nozzle Mass moments of Permissi- Permissi-
sizes inertia ble opera- ble test
J ting pressure
pressure

free passage max. diameter Clearances forces moments (without coupling) in bar in bar
10 % in N in Nm in kgm2
A B C A B C A B C Fx, Fy, Fz Mx, My, Mz without with 1) 2) 1) 2)
water water
1); 3) 1); 3)
250-370 39 27 20 390 390 390 0.5 0.5 0,5 4000 2750 0.721 1.225 10 25 15 37.5
250-480 30 20 -- 478 478 -- 0.5 0.5 -- 4000 2750 0.956 1.625 16 25 24 37.5
250-600 23 16 -- 622 622 -- 0.5 0.5 -- 4000 2750 2.206 3.750 24 25 28 37.5
300-300 39 27 -- 323 323 -- 0.5 0.5 -- 4000 3000 0.571 0.800 10 25 15 37.5
300-435 45 32 30 450 450 450 0.6 0.6 0,6 4000 3000 1.785 2.500 10 25 15 37.5
300-560 35 23 -- 553 553 -- 0.6 0.6 -- 5000 3000 2.411 3.375 16 25 24 37.5
300-700 26 18 -- 719 719 -- 0.6 0.6 -- 5000 3000 6.346 8.250 24 25 28 37.5
350-360 39 27 -- 373 373 -- 0.5 0.5 -- 5000 3000 1.116 1.563 10 25 15 37.5
350-430 57 40 -- 430 430 -- 0.6 0.6 -- 5000 3000 2.232 3.125 10 25 15 37.5
350-510 52 36 35 518 518 518 0.6 0,6 0,6 5000 3000 3.393 4.750 10 25 15 37.5
1) Casing material JL 1040 and GGG-NiCrNb 20 2
2) Casing material JS 1030 and 1.4517
3) Casing material JS 1030; 1,4--times the given value
4) Casing material 1.4517; 1,9--times the given value

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

Capacity

35
Omega

11.2 Trouble--shooting Table

Pump does not run smoothly (noise, vibrations)


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

Exessive leakage at shaft seal


Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid


Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

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

36
Omega

Trouble--shooting Table

Pump does not run smoothly (noise, vibrations)


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

Exessive leakage at shaft seal


Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid


Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

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

37
Omega

Trouble--shooting Table

Pump does not run smoothly (noise, vibrations)


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

Exessive leakage at shaft seal


Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid


Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

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

38
Omega

Trouble--shooting Table

Pump does not run smoothly (noise, vibrations)

Inadmissible temperature increase at pump /


Pump fails to pump liquid after being switched on

Exessive leakage at shaft seal


Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid


Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

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

F F F F Impeller rubs against ca- Check rotor


sing components Check impeller position
Check that the piping is connected wi-
thout transmitting any stresses or
strains.
1) Consult KSB

39
Omega

12 Routine Maintenance and Inspection Intervals

Interval Number of per- Time Maintenance job


sonnel required [h]

Check leakage on mechanical seal or lea-


kage of packed gland
Daily 1 1/10 (see section 8.1 Gland packing).

Check pump operation (positive suction pres-


Weekly 1 1/4 sure, total head, bearing temperature, noises
and vibrations)

Check torsional play of coupling


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

General inspection and overhaul of pump in


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

40
Omega

13 Appendix
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

Types of installation ....................................................................... 42

Type of Installation 3E -- Motor Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43


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

Sealing water pipe for gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Sealing water pipe for mechanical seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Coupling (N--EUPEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Correlation between tightening torques, dimension P and clearance S1 49
- Trouble--shooting 50

General drawing of pump with parts list Shaft seal: Gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

General drawing of pump with parts list Shaft seal: Mechanical seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Mechanical seals, standard design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Shaft seal -- mechanical seals -- Type Crane 58U and 58B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Dimension table Omega 80 -- 210 up to 150 -- 605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Dimension tables Omega 200 -- 320 up to 350 -- 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

General arrangement drawing Omega 80 -- 210 up to 100 -- 375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

General arrangement drawing Omega 250 -- 480 up to 250 -- 600; 300 -- 435 and 350 -- 360 . . . 70

General arrangement drawing Omega 300 -- 560 up to 300 -- 700; 350 -- 430 and 350 -- 510 . . . . . 72

Table of Connections and Measuring Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

41
Omega

Types of installation
Horizontal

Type of installation 3E

Pump set with close--coupled motor (type IM B3) 1)


Baseplate, baseframe, coupling guard and motor height adjustment
Vertical

Type of installation DB 2) Type of installation DK 2) Type of installation DJ 2)


2) Depending of motor size Version with intermediate bearing

Direction of rotation / flow direction


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

1) General arrangement drawing Pump set 3 E -- Baseplate/baseframe with motor height adjustment shows the main variants available
42
Omega

Type of Installation 3E -- Motor Height Adjustment


Baseplate with adjusting screw or shims under the motor feet

901.54

550.54

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

909.54
550.56 (Adjusting screw)

890

901.05

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

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

901.54

550.54

550.55

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

550.57
550.56
890 180.54
(891) (Pedestal)

901.05

89--4.03
920.10 550.10 900.01 ,

43
Omega

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

901.54
(902.54) 2)
(920.54)

550.54
901.06

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

891

901.05

1) optional, depending on height required


2) for long lengths, instead of hex. head bolts
89--4.03
920.10 550.10 900.01

Part no. Description


89-4 Shim
180 Pedestal
550 Washer
592 Base
890 Baseplate
900 Screw
901 Hex. head bolt
902 Stud
909 Adjusting screw
920 Nut

44
Omega

Sealing / flushing water piping


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

Arrangement of sealing water and flush pipes

45
Omega

Sealing water pipe for gland packing

903.01 731.03 731.04 719.01

731.02

(731.12)
(731.11)

731.05

Part no. Description


719.01 Flexible tube
731.02 Nipple joint
731.03 Cross
731.04 Nipple joint
731.05 Pipe bend
731.12 Socket
903.01 Screwed plug

Sealing water pipe for mechanical seal

903.01 731.03 731.04 719.01

731.02

Part no. Description


719.01 Flexible tube
731.02 Nipple joint
731.03 Cross
731.04 Nipple joint
903.01 Screwed plug

46
Omega

Coupling (N--EUPEX) Installation


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

D The coupling shall only be used and


operated within the conditions
stipulated in the technical specification
and supply contract.

D Unauthorized modification and removal


of protective equipment is not permitted. -- Mounting the coupling components
Before fitting the coupling components, carefully clean the shaft
D Any work on the coupling shall only be ends and the coupling parts. Make sure to remove the flexible
performed with the machine shut down. coupling blocks before cleaning the coupling parts with a sol-
The driver must be secured against
vent.
inadvertent start--up (e.g. by locking the
key--operated switch or removing the Heed the manufacturers instructions for the use of
power supply fuses). At the switch--on solvents.
point a notice shall be affixed to the
effect that work is being performed on Caution Use appropriate tools when pulling on the
the coupling. coupling parts, to prevent damage to the
shaft bearings due to the axial joining force.
D Immediately switch off the driver when Make sure to use suitable lifting tackle.
changes in coupling behaviour occur,
such as changed running noises. The shaft ends must not protrude from the hub faces. The cou-
pling is locked in axial direction by means of the set screw or
D The coupling must be suitably protected end plate, as applicable / set screw and end plate, respectively.
against accidental contact.
Caution The set screws shall only be tightened by
means of a hexagon socket head wrench to
DIN 911, without extension.
Non--compliance with these instructions may cause
the coupling to burst. Danger of life by flying frag-
ments!

47
Omega

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

Take appropriate precautions to prevent injury by


crushing.

Make sure to observe dimension S1. On types A and ADS, the


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

Straight edge

Feeler gauge

48
Omega

Correlation between tightening torques, dimension P and clearance S1

N-EUPEX N-EUPEX-DS Tightening torque TA and width across flats SW for bolts
to DIN 912 Part 2/3
coupling coupling

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

Commissioning the coupling Operation

Measures to be taken prior to commissioning General operating data


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

49
Omega

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

Trouble--shooting list

Fault Possible causes Remedy


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

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

Check the tightening torques of the screwed connec-


tion between parts 2 and 3.

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

50
Omega

Table: Wear mark on N--EUPEX coupling


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

Table: Wear mark on N--EUPEX--DS coupling


Size 66 76 88 103 118 135 152 172 194 218 245 272 305 340 380 430 472 514 556

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

Replacing wear parts


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

For reassembly carefully follow the instructions in the sections


on Installation and Commissioning.

51
Omega

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

Shaft Axial overhang of shaft protec-


diameter ting sleeve
Sealed with Loctite 574 dW A 0.5
40 2
50 2
60 2
ALTEMP Q NB 50 grease 70 5
80 4
90 4

52
Omega

Part no. Description Part no. Description Part no. Description


102 Volute casing 452 Gland cover 561 Grooved pin
105.01 Lower casing half 455 Gland packing 580 Cap
105.02 Upper casing half 457 Stuffing box insert 901 Hex. head bolt
211 Pump shaft 458 Neck ring 902 Stud
234 Impeller 461 Lantern ring 903 Screwed plug
321 Deep--groove ball bearing 502 Casing wear ring 904 Grub screw
350 Bearing housing 503 Impeller wear ring 920 Nut
360 Bearing cover 520 Sleeve 932 Circlip
411 V--ring 524 Shaft protecting sleeve 940 Key
412 O-ring 550 Washer 950 Cup spring
421 Radial shaft seal ring
441 Housing for shaft seal

53
Omega

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

Shaft Axial overhang of shaft protec-


diameter ting sleeve
Sealed with Loctite 574
dW A 0.5
40 2
50 2
ALTEMP Q NB 50 grease 60 2
70 5
80 4
90 4

54
Omega

Part no. Description Part no. Description Part no. Description


102 Volute casing 421 Radial shaft seal ring 901 Hex. head bolt
105.01 Lower casing half 433 Mechanical seal 903 Screwed plug
105.02 Upper casing half 441 Housing for shaft seal 920 Nut
211 Pump shaft 457.02 Stuffing box insert 932 Circlip
234 Impeller 503 Impeller wear ring 940 Key
321 Deep--groove ball bearing 520 Sleeve 950 Cup spring
350 Bearing housing 524.01 Shaft protecting sleeve
360 Bearing cover 525.02 Spacer sleeve
411 V--ring 550 Washer
412 O-ring 561 Grooved pin
580 Cap

55
Omega

Mechanical seals, standard design


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

211 524.01 457.02 525.02 411 433 471 901.16

Flushing line
connection

dw

Standardized mechanical seal to DIN 24960 -- short design, non--balanced


Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)

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

110

Part no. Description Part no. Description


211 Pump shaft 471 Seal cover
433 Mechanical seal 524.01 Shaft protecting sleeve
441 Housing for shaft seal 525.02 Spacer sleeve
457.02 Neck ring 901.16 Hexagon head bolt

56
Omega

Mechanical seals, standard design


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

457.02 411 433 Flushing line 471 901.16


connection

525.02

524.01

211
dw

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

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

Part no. Description Part no. Description


211 Pump shaft 471 Seal cover
433 Mechanical seal 524.01 Shaft protecting sleeve
441 Housing for shaft seal 525.02 Spacer sleeve
457.02 Neck ring 901.16 Hexagon head bolt

57
Omega

Shaft seal -- mechanical seals -- Type Crane 58U and 58B


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

780 Retainer 578 Balanced face


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

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

58
Omega

Dismantling and assembly of the rotating unit


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

Wing nut

Grub screw

Thrust plate with


glued--on

protective support

Locking nut

Baseplate Assembly is carried out in reverse sequence.


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

At the outer circumference of the retainer (780) there are 2 mar-


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

59
Omega

Dimension table Omega 80 -- 210 up to 150 -- 605


Fig. 0 N.B.: If the pumps direction of rotation is
Direction of rotation: CLOCKWISE ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).

a2 a1 l3
Direction of rotation:
Z

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

h3

d1
h2

1M
DN2

DN1

h1

1M
8B 8B
6B
s

Keyway and key


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

n2 n1

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

Dimensions and weights All dimensions in mm


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

Pump Foot dimensions Shaft Weights [kg]


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

60
Omega

Standard flange connections 1):


Pump JL 1040 / GGG--NiCrNb 202 JS 1030 / 1.4517
Size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
80-210
80-270 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
80-370
100-250
100-310 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
100-375
125-230 d2
125-290
number of
125-365 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250 holes n
125-500
150-290
150-360 PN 16 Table 16/11
150-460 Class 250 PN 25 Table 25/11 Class 250
150-605 PN 25 Table 25/11
k
1) Other flange connections on request
Flange dimensions -- Hole pattern All dimensions in mm
Standard DN 80 DN 100 DN 125 DN 150 DN 200
d2 k n d2 k n d2 k n d2 k n d2 k n
ISO 7005/2
DIN 2501 PN 16 19 160 8 19 180 8 19 210 8 23 240 8 23 295 12

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

BS 4504 Table 16/11 19 160 8 19 180 8 19 210 8 23 240 8 23 295 12


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

61
Omega

Dimension tables Omega 200 -- 320 up to 350 -- 510


Fig. 0 N.B.: If the pumps direction of rotation is
Direction of rotation: CLOCKWISE ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).

a2 a1 l3 Direction of rotation:
CLOCKWISE
Z

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

h3
h2

d1
1M
DN2

DN1

h1

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

Shaft diameter:
m2 Tolerance h6 to DIN 7155
d2 b1

n4 n3 m1
n2 n1

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

Dimensions and weights All dimensions in mm


Pump Flange dimensions Pump dimensions
Size DN1 DN2 s1 s2 a1 a2 d3 f h1 h2 2) h3 l2 l3 z 2)
200-320 450 450 285 570
590 500 240 399 989
200-420 500 310 620
250 200 48 41 500 24 5
24,5
200-520 600 560 300 370 740
655 464 1119
200-670 650 550 600 350 430 860
250-370 33 (51) 1) 32 (48) 1) 500 500 655 320 464 1119 640
600 300
250-480 300 250 550 12,5 355 710
51 48 550 730 515 1245
250-600 650 630 350 415 830
300-300 350 36 (54) 1) 33 550 500 655 630 300 360 464 1119 720
300-435 38 (57) 1) (51) 1) 650 550 730 670 350 365 515 1245 730
300 24 5
24,5
300-560 400 700 710 350 430 860
57 51 650 810 585 1395
300-700 750 750 400 480 960
350-360 400 38 (57) 1) 650 550 730 670 350 410 515 1245 820
350-430 450 350 41 (60) 1) 36 (54) 1) 750 24,5 465 930
650 810 750 400 585 1395
350-510 400 38 (57) 1) 700 420 840

Pump Foot dimensions Shaft Weights [kg]


Size b1 d2 m1 m2 n1 n2 n3 n4 s d1 l1 Pump Water
fill
200-320 450 80
200-420 17 5
17,5 430 315 315 280 280 20 55 125 520 95
70
200-520 480 400 385 385 840 115
22 350 350 26 65 140
200-670 100 400 400 400 990 140
250-370 480 400 65 140 665 125
250-480 100 22 400 400 350 350 26 830 145
600 520 75 160
250-600 1215 180
300-300 480 400 65 140 630 100
400 400 350 350
300-435 75 160 905 190
100 22 26
300-560 600 520 1425 225
525 525 475 475 85 180
300-700 1690 275
350-360 400 400 350 350 75 160 865 160
350-430 100 22 600 520 26 1285 240
525 525 475 475 85 180
350-510 1395 290
1) for casing material GGG--NiCrNb 202, JS 1030, 1.4517
2) z = clearance above casing cover for dismantling of the rotor

62
Omega

Standard flange connections 1):


Pump JL 1040 / GGG--NiCrNb 202 JS 1030 / 1.4517
Size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
200-320
200-420 PN 16 Table 16/11
Class 250 PN 25 Table 25/11 Class 250
200-520
200-670 PN 25 Table 25/11
250-370 PN 10 Table 10/11 Class 125
250-480 PN 16 Table 16/11 PN 25 Table 25/11 Class 250
Class 250 d2
250-600 PN 25 Table 25/11
300-300 number of
PN 10 Table 10/11 Class 125
300-435 holes n
PN 25 Table 25/11 Class 250
300-560 PN 16 Table 16/11
300-700 PN 25 Table 25/11 Class 250
350-360
350-430 PN 10 Table 10/11 Class 125 PN 25 Table 25/11 Class 250
350-510
k
1) Other flange connections on request
Flange dimensions -- Hole pattern All dimensions in mm
Standard DN 200 DN 250 DN 300 DN 350 DN 400 DN 450
d2 k n d2 k n d2 k n d2 k n d2 k n d2 k n
ISO 7005/2
DIN 2501 PN 10 23 295 8 23 350 12 23 400 12 23 460 16 28 515 16 28 565 20

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

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

BS 4504 Table 10/11 23 295 8 23 350 12 23 400 12 23 460 16 28 515 16 28 565 20


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

63
Omega

General arrangement drawing Omega 80 -- 210 up to 100 -- 375


Installation type 3E N.B.: If the pumps direction of rotation is
Direction of rotation: CLOCKWISE ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).

a2 a1 l2 q
f
Z

s2 s1 5
5D
5D 5D

h7
DN2
h5

1M

DN1
1M

h6
8B 8B
6B
h4

h8
50

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

h8
50

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

Dimensions and weights All dimensions in mm


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

64
Omega

Standard flange connections 1):


Pump JL 1040 / GGG--NiCrNb 202 JS 1030 / 1.4517
Size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
80-210
80-270
80-370
PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
100-250
100-310
100-375
1) Other flange connections on request

Flange dimensions -- Hole pattern All dimensions in mm


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

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

Baseplate / motor combinations

Pump Motor Size


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

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

65
Omega

General arrangement drawing Omega 125 -- 230 up to 150 -- 360


Installation type 3E N.B.: If the pumps direction of rotation is
Direction of rotation: CLOCKWISE ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).

a2 a1 l2 q
f
Z

s2 s1 5
5D
5D 5D

h7
DN2
h5

1M

DN1
1M

h6
8B 8B
6B
h4

h8
50

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

h8
50

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

Baseplate-- / base frame and foundation dimensions All dimensions in mm


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

66
Omega

Standard flange connections 1):


Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
Size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
125-230
125-290
125-365
125-500 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
150-290
150-360
1) Other flange connections on request

Flange dimensions -- Hole pattern All dimensions in mm


Standard
Suction flange Discharge flange
DN d2 k n DN d2 k n Mating flange
All flanges designed as plate flanges
Pump sizes 125-230 up to
125-500 200 125

ISO 7005/2 PN 16
DIN 2501 23 (M20) 295 19 (M16) 210 d2
BS 4504 Table 16/11
number of
ISO 7005/2 PN 25 12 8 holes n
DIN 2501 28 (M24) 310 28 (M24) 220
BS 4504 Table 25/11
ANSI B 16.1 Class 250 28 (M24) 330 23 (M20) 235
Pump sizes 150-290 up to
150-360 200 150

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

Baseplate / motor combinations


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

67
Omega

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

a2 a1 l2 q
f
Z

s2 s1 5
5D
5D 5D

h7
DN2
h5

1M

DN1
1M

h6
8B 8B
6B
h4

h8
50

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

h8
50

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

Dimensions and weights All dimensions in mm


Pump Flange dimensions Pump dimensions Weight [kg]
Size Motor- DN1 DN2 s1 s2 a1 a2 f h4 h5 h6 i l2 z 2) Pump Water-
dependet max. fill
up to 250 M 320 520
150-460 280 S up to 315 450 450 610 436 75
200 150 41 37 1050 580 399
L
-- 380
150-605 600 500 680 740 646 90
up to 250 M 590 620 215
200-320 450 450 570 450 80
280 S, M 440 680
up to 250 M 380 620 399
200-420 280 S up to 315 500 500 620 517 95
250 200 48 41 440 1240
L 680
250 M 380
200-520 600 500 740 840 115
up 280 S 440 740
200-670 -- 650 550 430 780 860 990 140
250 M 655 420 720 150 464
250-370 300 250 33 (51)1) 32 (48)1) 500 500 1275 640 665 125
up 280 S 480 780
up to 250 M 450 750
300-300 350 300 36 (54)1) 33 (51)1) 550 500 1430 720 630 100
up 280 S 510 810
1) for casing material GGG--NiCrNb 202, JS 1030, 1.4517
2) z = clearance above casing cover for dismantling of the rotor

68
Omega

Baseplate-- / base frame and foundation dimensions All dimensions in mm


Baseplate Baseplate
Baseplate and foundation dimensions Foundation bolts
Size Size
No. Drawing no. b2 G1 G2 l3 l4 l5 h8 Weight Size VN L
[kg]
7 0W 384 174-00 880 820 960 1660 730 730 120 157
8 1) 0W 384 175-00 1870 835 835 185
9 1) 0W 384 176-00 204
10 1) 0W 384 478-00 700 620 750 1970 885 885 180 208 M 20x320 100 320
14 1) 0W 384 479-00 2170 985 985 210
15 1) 0W 384 480-00 2320 1060 1060 215
1) Base frame
Standard flange connections 2):
Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
Size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
150-460 PN 16 Table 16/11
150-605 PN 25 Table 25/11 Class 250
200-320
200-420 PN 16 Table 16/11
200-520 PN 25 Table 25/11 Class 250
200-670 PN 25 Table 25/11
250-370
PN 10 Table 10/11 Class 125
300-300
2) Other flange connections on request
Flange dimensions -- Hole pattern All dimensions in mm
Standard Suction flange Discharge flange
DN d2 k n DN d2 k n
Pump sizes 150-460 and 150-605 200 150 Mating flange
ISO 7005/2, DIN 2501 PN 16 All flanges designed as plate flanges
BS 4504 Table 16/11 23 (M20) 295 23 (M20) 240
8
ISO 7005/2, DIN 2501 PN 25 12
BS 4504 Table 25/11 28 (M24) 310 28 (M24) 250
ANSI B 16.1 Class 250 28 (M24) 330 23 (M20) 270 12 d2
Pump sizes 200-320 up to 200-670 250 200
ISO 7005/2, DIN 2501 PN 16
number of
BS 4504 Table 16/11 28 (M24) 355 23 (M20) 295 holes n
12
ISO 7005/2, DIN 2501 PN 25 12
BS 4504 Table 25/11 31 (M27) 370 28 (M24) 310
ANSI B 16.1 Class 250 28 (M24) 387 28 (M24) 330
Pump sizes 250-370 300 250
ISO 7005/2, DIN 2501 PN 10
BS 4504 Table 10/11 23 (M20) 400 23 (M20) 350
12 k
ISO 7005/2, DIN 2501 PN 16
BS 4504 Table 16/11 28 (M24) 410 28 (M24) 355
12
ISO 7005/2, DIN 2501 PN 25
BS 4504 Table 25/11 31 (M27) 430 16 31 (M27) 370
ANSI B 16.1 Class 125 28 (M24) 432 12 28 (M24) 362
ANSI B 16.1 Class 250 31 (M27) 451 16 28 (M24) 387 16
Pump sizes 300-300 350 300
ISO 7005/2, DIN 2501 PN 10
BS 4504 Table 10/11 23 (M20) 460 23 (M20) 400
12
ISO 7005/2, DIN 2501 PN 16
BS 4504 Table 16/11 28 (M24) 470 16 28 (M24) 410
ISO 7005/2, DIN 2501 PN 25
BS 4504 Table 25/11 34 (M30) 490 31 (M27) 430 16
ANSI B 16.1 Class 125 28 (M24) 476 12 28 (M24) 432 12
ANSI B 16.1 Class 250 31 (M27) 514 20 31 (M27) 451 16
Baseplate / motor combinations
Pump Motor Size
Si
Size 180L 200L 225S 225M 250M 280S 280M 315S 315M 315L 315 355 400
No of 4 4 4 4 4 4 4 4 4 4 4 4 4
poles
150-460 7 7 7 7 8 8 8 8 8
150-605 8 8 8 8 9 9 14
200-320 7 7 7 7 7 8 8
200-420 7 7 7 7 8 8 8 8 9
200-520 7 8 8 8 8 10 10 15
200-670 8 8 10 10 15 15
250-370 7 8 8 8 8 10
300-300 7 7 7 7 8 8 8
N. B.: - The numbers listed in the table indicate the relevant baseplate numbers.
- The baseplate numbers shown in the boxes also serve to select the correct motor size for the listed pump size.
- Units comprising a motor size 315 and larger are completely assembled for verification and adjustment of the individual components.
Before shipment, the units are dismantled again and the components packed / shipped separately.
69
Omega

General arrangement drawing Omega 250 -- 480 up to 250 -- 600; 300 -- 435 and
350 -- 360
Installation type 3E N.B.: If the pumps direction of rotation is
Direction of rotation: CLOCKWISE ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
a2 a1 l2 reversedf (mirror image). q
Z

s2 s1 5
5D
5D 5D

h7
DN2
h5

1M

DN1
1M

h6
8B 8B
6B

h4

h8
50

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

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

Dimensions and weights All dimensions in mm


Pump Flange dimensions Pump dimensions Weight [kg]
Size DN1 DN2 s1 s2 a1 a2 f h4 h5 h6) i l2 z 2) Pump Water-
max. fill
250-480 550 500 800 710 830 145
300 250 51 48 1275
250-600 480 830 830 1215 180
550 730 210 515
300-435 300 33 (51) 1) 650 1430 730 905 190
400 38 (57) 1) 520 870
350-360 350 36 (54) 1 1415 820 865 160
1) for casing material GGG--NiCrNb 202, JS 1030, 1.4517
2) z = clearance above casing cover for dismantling of the rotor

Baseplate-- / base frame and foundation dimensions All dimensions in mm


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

70
Omega

Standard flange connections 1):


Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
Size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
250-480 PN 16 Table 16/11
Class 250
250-600 PN 25 Table 25/11
PN 25 Table 25/11 Class 250
300-435
PN 10 Table 10/11 Class 125
350-360
1) Other flange connections on request

Flange dimensions -- Hole pattern All dimensions in mm


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

Baseplate / motor combinations


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

71
Omega

General arrangement drawing Omega 300 -- 560 up to 300 -- 700; 350 -- 430 and
350 -- 510
Installation type 3E N.B.: If the pumps direction of rotation is
Direction of rotation: CLOCKWISE ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
a2 a1 l2 reversedf (mirror image). q
Z

s2 s1 5
5D
5D 5D

h7
DN2
h5

1M

DN1
1M

h6
8B 8B
6B

h4

h8
50

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

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

Dimensions and weights All dimensions in mm


Pump Flange dimensions Pump dimensions Weight [kg]
Size DN1 DN2 s1 s2 a1 a2 f h4 h5 h6 i l2 z 2) Pump Water-
max. fill
300-560 700 560 910 860 1425 225
400 300 57 51 1430
300-700 960 1690 275
750 650 810 210 585
350-430 450 41 (60) 1) 550 950 930 1285 240
350 36 (54) 1) 1415
350-510 400 38 (57) 1) 700 840 1395 290
1) for casing material GGG--NiCrNb 202, JS 1030, 1.4517
2) z = clearance above casing cover for dismantling of the rotor

Baseplate-- / base frame and foundation dimensions All dimensions in mm


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

72
Omega

Standard flange connections 1):


Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
Size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
300-560 PN 16 Table 16/11
Class 250
300-700 PN 25 Table 25/11
PN 25 Table 25/11 Class 250
350-430
PN 10 Table 10/11 Class 125
350-510
1) Other flange connections on request
Flange dimensions -- Hole pattern All dimensions in mm
Standard
Suction flange Discharge flange
Mating flange
DN d2 k n DN d2 k n All flanges designed as plate flanges
Pump sizes 300-560 and 300-700 400 300
ISO 7005/2 PN 10
DIN 2501 28 (M24) 515 23 (M20) 400
BS 4504 Table 10/11 d2
12
ISO 7005/2 PN 16
DIN 2501 31 (M27) 525 28 (M24) 410 number of
BS 4504 Table 16/11 16 holes n
ISO 7005/2 PN 25
DIN 2501 37 (M33) 550 31 (M27) 430 16
BS 4504 Table 25/11
ANSI B 16.1 Class 125 28 (M24) 540 28 (M24) 432 12
ANSI B 16.1 Class 250 34 572 20 31 (M27 451 16
Pump size 350-430 450 350 k
ISO 7005/2 PN 10
DIN 2501 28 (M24) 565 23 (M20) 460
BS 4504 Table 10/11
ISO 7005/2 PN 16
DIN 2501 31 (M27) 585 20 28 (M24) 470 16
BS 4504 Table 16/11
ISO 7005/2 PN 25
DIN 2501 37 (M33) 600 34 (M30) 490
BS 4504 Table 25/11
ANSI B 16.1 Class 125 31 (M27) 578 16 28 (M24) 476 12
ANSI B 16.1 Class 250 34 629 24 31 (M27) 514 20
Pump size 350-510 400 350
ISO 7005/2 PN 10
DIN 2501 28 (M24) 515 23 (M20) 460
BS 4504 Table 10/11
ISO 7005/2 PN 16
DIN 2501 31 (M27) 525 28 (M24) 470 16
BS 4504 Table 16/11 16
ISO 7005/2 PN 25
DIN 2501 37 (M33) 550 34 (M30) 490
BS 4504 Table 25/11
ANSI B 16.1 Class 125 28 (M24) 540 28 (M24) 476 12
ANSI B 16.1 Class 250 34 572 20 31 (M27) 514 20

Baseplate / motor combinations


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

73
Omega

Table of Connections and Measuring Points

Item No. Description Connections Value required

5D Venting G 1/2

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

6B Casing drain G 1/2

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

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

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


discharge side

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

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

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

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


non--drive end

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

KSBs competent Spare Parts Service is at your disposal for the products

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

To: KSB Aktiengesellschaft Postfach 200743 Date:


Turmstr. 92 D-06008 Halle/Saale
D-06110 Halle/Saale
Ersatzteilabteilung

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

From:

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

1. Works No. / Item No. enter here

D The works No. is given on the name plate


of your pump
e.g. 2--M01--753328
or KRT-F 100-250/7 4 UG-249
2--M01--753328
9970428626 000100 2

in addition:

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

Sample
2. Required part with part No.
enter
here

D The description of the parts is given


in the operating instructions
e.g. Impeller, Part no. 230

in addition:

for multi--vane impeller:


impeller diameter in mm

for terminal gland:


cable length in mm
Omega

Subject to modification without notice


21.07.2005
1384.8/4-10

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