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
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Marking of Instructions in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personnel Qualification and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non--Compliance with Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions for the Operator / User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions for Maintenance, Inspection and Installation Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unauthorized Modification and Manufacture of Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unauthorized Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
4
5
5
5
5
Transport and Interim Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
3.1
3.2
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interim Storage / Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
Description of the Product and Accesories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
4.1
4.2
4.3
4.4
4.5
4.6
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7
7
7
7
7
Installation at Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
5.1
5.2
5.3
5.4
5.5
Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks to Be Carried out Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Pump / Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
8
8
8
Commissioning, Start--up / Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3
4
5
6
6.1
6.2
6.3
6.4
6.5
6.6
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown / Storage / Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Returning to Service after Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
9
10
10
Maintenance / Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
7.1
7.2
7.3
7.4
7.5
7.6
General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions for Replacing Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
11
12
14
15
Special Instructions for Subassemblies (Shaft Seal Variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
8.1
8.2
Gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations) . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
17
9
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
10
Forces and Moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
11
Trouble--Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
11.1
11.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trouble--shooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
36
12
Routine Maintenance and Inspection Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
13
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
7
8
3
Omega
1
General
The word
This KSB pump has been developed in accordance with
state--of--the--art technology; it is manufactured with utmost care and subject to continuous quality control.
Caution
These operating instructions are intended to facilitate familiarization with the pump and its designated use.
The manual contains important information for reliable, proper
and efficient operation. Compliance with the operating instructions is of vital importance to ensure reliability and a long service life of the pump and to avoid any risks.
is used to introduce safety instructions whose non--observance
may lead to damage to the machine and its functions.
These operating instructions do not take into account local regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for installation.
must always be complied with and be kept in perfectly legible
condition at all times.
This pump / unit must not be operated beyond the limit values
specified in the technical documentation for the medium handled, capacity, speed, density, pressure, temperature and motor
rating. Make sure that operation is in accordance with the instructions laid down in this manual or in the contract documentation.
The name plate indicates the type series / size, main operating
data and works / series number; please quote this information
in all queries, repeat orders and particularly when ordering
spare parts.
If you need any additional information or instructions exceeding
the scope of this manual or in case of damage please contact
KSB’s nearest customer service centre.
2
Safety
These operating instructions contain fundamental information
which must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read
and understood both by the installing personnel and the responsible trained personnel / operators prior to installation and
commissioning, and it must always be kept close to the location
of operation of the machine / unit for easy access.
Not only must the general safety instructions laid down in this
chapter on ”Safety” be complied with, but also the safety instructions outlined under specific headings.
2.1
Marking of Instructions in the Manual
The safety instructions contained in this manual whose non-observance might cause hazards to persons are specially marked with the general hazard sign, namely
safety sign in accordance with DIN 4844 -- W9.
The electrical danger warning sign is
safety sign in accordance with DIN 4844 -- W8.
4
Instructions attached directly to the machine, e.g.
· arrow indicating the direction of rotation
· markings for fluid connections
2.2
Personnel Qualification and Training
All personnel involved in the operation, maintenance, inspection and installation of the machine must be fully qualified to
carry out the work involved.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question
is not already in possession of the requisite know--how, appropriate training and instruction must be provided. If required, the
operator may commission the manufacturer / supplier to take
care of such training. In addition, the operator is responsible for
ensuring that the contents of the operating instructions are fully
understood by the responsible personnel.
2.3
Non--Compliance with Safety Instructions
Non--compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine itself. Non-compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
In particular, non--compliance can, for example, result in:
· failure of important machine / unit functions
· failure of prescribed maintenance and servicing practices
· hazard to persons by electrical, mechanical and chemical
effects
· hazard to the environment due to leakage of hazardous
substances
2.4
Safety Awareness
It is imperative to comply with the safety instructions contained
in this manual, the relevant national health and safety regulations and the operator’s own internal work, operation and safety
regulations.
Omega
2.5
Safety Instructions for the Operator / User
· Any hot or cold components that could pose a hazard must
be equipped with a guard by the operator.
· Guards which are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed whilst the
machine is operating.
· Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot) must be contained so as to
avoid any danger to persons and the environment. Pertinent legal provisions must be adhered to.
· Electrical hazards must be eliminated. (In this respect refer
to the relevant safety regulations applicable to different
countries and/or the local energy supply companies.)
2.6
Safety Instructions for Maintenance,
Inspection and Installation Work
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the manual.
3
Transport and Interim Storage
3.1
Transport
Transport of the unit requires proper preparation and handling.
Always make sure that the pump or the unit remains in horizontal position during transport and cannot slip out of the transport
suspension arrangement. Do not use lifting slings on the free
shaft end of the pump or on the motor eyebolt.
Also make sure that the coupling guard is not damaged
by the sling arrangement.If the pump / unit slips out of
the suspension arrangement, it may cause personal injury and damage to property.
Transport in horizontal position is recommended in all cases,
since this ensures stable positioning of the unit without any risk
of accident, whatever the method of transport, e.g. road, rail or
ship, etc.
For transport purposes the unit shall be secured on suitable pallets or sleds. All loose and movable parts must be secured.
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--relevant and protective devices must be re--installed and/or re--activated.
Please observe all instructions set out in the chapter on ”Commissioning” before returning the machine to service.
2.7
Unauthorized Modification and Manufacture
of Spare Parts
Modifications or alterations of the machine are only permitted
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 manufacturer for consequential damage.
2.8
Fig.1:
Transport of pump
Fig.2:
Transport of motor
(Fig.0)
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.
The motor eyebolts must only be used for lifting the motor 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
Fig.4a:
Transport of complete unit
(horizontal installation type 3E)
-- up to motor size 280 (IEC standard)
-- or up to a total weight of 1500 kg
Observe angles of pull when lifting.
Angle of pull > 90_ not permitted.
Use two separate sets of lifting slings!
Interim Storage / Preservation
When the unit is temporarily put into storage, only the wetted
low alloy components, e.g. JL1040 (GG--25) must be preserved. Commercially available preservatives can be used for this
purpose. Please observe the manufacturer’s instructions for
application / removal.
4
Description of the Product and
Accesories
4.1
Technical Specification
Design
The KSB pump of the Omega series is a horizontally installed,
single--stage, axially split volute casing pump with double--entry radial impeller. Connection flanges are manufactured according 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 extinguishing 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
Omega
XXX
XXX
X
Type series
Discharge nozzle DN mm
Nominal impeller dia.
Impeller type (A,B,C)
4.3
Design Details
4.3.1
Pump Casing
Axially split volute casing with replaceable casing wear rings.
Suction and discharge nozzles in lower half of casing are at the
same level (inline version).
4.3.2
Impeller
The double--entry radial impeller is manufactured for the operating data provided in each case. Also with impeller wear rings,
if requested.
In double--entry radial impellers the axial thrust is largely balanced.
4.3.3
Pump Shaft
The shaft is fully sealed against the liquid being pumped. Shaft-protecting sleeves are fitted in the seal area.
4.3.4
Shaft Seal
The following accessories are available:
Configuration
g
Accessories
Motor
Baseplate/baseframe
Coupling and coupling guard
Sealing and flushing water piping
Set of pressure gauges
Cyclone separator with pipework
Vent valve (manual or automatic)
Temperature sensor for rolling
element bearings (PT 100)
Signal transmitter for PT 100
Drain line
2)
Bearings and Lubrication
The pump is fitted with covered deep--groove ball bearings
which are grease--lubricated for life.
The fixed bearing at the non--drive end is located on a bush to
permit rapid changing without removing the rotor or upper half.
4.4
Types of Installation
The pump set is installed in configuration 3E -- horizontal installation, direct--coupled (see appendix).
Omega
Fig.0
---------x
3E
x 1)
x 1)
x 1)
x
x
x
x
x
x
x
x
x
x
x
x
x
included in standard scope of supply
4.6
Dimensions and Weights
For dimensions and weights please refer to the tables in the appendix.
5
5.1
Installation at Site
Safety Regulations
Electrical equipment operated in ”zone 1” hazardous
locations must comply with the explosion protection
regulations. This is indicated on the motor rating plate.
The shaft seals at the drive end and non--drive end are gland
packings or mechanical seals, as requested.
4.3.5
Accessories (optional)
If the equipment is installed in hazardous locations, the applicable local explosion protection regulations and the regulations of
the test certificate supplied with the equipment and issued by
the responsible approval authorities must be observed and
complied with.
The test certificate must be kept close to the location of operation for easy access (e.g. foreman’s office).
5.2
Checks to Be Carried out Prior to
Installation
All structural work required must have been prepared in accordance 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
Before setting up the pump, check the
operating data. Ensure that the data on the
name plate matches the data in the order and the system data,
e.g. operating voltage, frequency, pumped liquid temperature
etc.
Caution
After placing the pump on the foundation, align it with the help
of a spirit level. Shims shall be fitted between the baseplate and
the foundation itself; they shall always be inserted to the left and
right of the foundation bolts and in close proximity to these
bolts. For a bolt--to--bolt clearance of more than 1000 mm, additional shims shall be inserted halfway between the adjoining
holes. All shims must lie perfectly flush.
Shim
Shim
Shim
1000
Foundation bolts
1000
Connecting the Piping
Caution
Never use the pump itself as an anchorage
point for the piping.
Suction lift lines shall be laid with a rising slope towards the
pump and suction head lines with a downward slope towards
the pump. The pipelines shall be anchored in close proximity to
the pump and connected without transmitting any stresses or
strains. Their weight must not exert any load on the pump. With
short pipelines, the nominal diameters shall be at least equal to
the nominal diameters of the pump nozzles. For long pipelines
the most economical nominal diameter has to be determined
from case to case.
Any additional loads on the discharge and suction nozzles, e.g. caused by:
Weight of the water--filled pipes, changes in the length of pipes
owing to temperature fluctuations, reaction forces due to unbraced 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!
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
Insert the foundation bolts and set them into the foundation
using concrete. When the concrete has set, align the baseplate
as described in section 5.3.2 and tighten the foundation bolts
evenly and firmly. Then grout the baseplate using low shrinkage
concrete, making sure no cavities remain.
The locations of the auxiliary connections (sealing liquid, flushing liquid, etc.) are indicated on the installation plan or piping
layout (see appendix).
5.3.1
Removing Rotor Lock
This is not necessary for a horizontally installed pump, since no
locking device is fitted.
5.3.2
Aligning the Pump / Drive
Improper alignment of the unit can cause damage to
both the coupling and the unit itself!
A pump set in horizontal installation type 3E is correctly aligned,
if a straight--edge placed axially on both coupling halves is the
same distance from each shaft at all points around the circumference. In addition, the distance between the two coupling halves must remain the same all around the circumference. Use
a feeler gauge, a wedge gauge or a dial micrometer to verify
(see fig. 6).
straight edge
straight edge
Fig.6:
8
gauge
Coupling alignment, using gauge and straight edge
Special instructions see appendix
Auxiliary Connections
Please refer to the appendix for detailed assembly instructions.
These connections are required for proper
Caution
functioning of the pump and are therefore of
vital importance!
5.4.2
Coupling Guard
In compliance with the accident prevention regulations
the pump must not be operated without a coupling
guard. If the customer specifically requests not to include a coupling guard in our delivery, then the operator must supply one.
5.5
Final Check
Re--check the alignment as described in section 5.3.2.
It must be easy to rotate the shaft by hand at the coupling.
Check the integrity and proper functioning of all
Caution
connections.
Omega
6
Commissioning, Start--up /
Shutdown
Compliance with the following requirements is
of paramount importance. Damage resulting
from non--compliance shall not be covered by the scope of
warranty.
Caution
6.1
Commissioning
Before starting up the pump make sure that the following requirements have been checked and fulfilled:
Correct direction of rotation:
The direction of rotation must correspond to the direction indicated by the arrow on the pump. This can be verified by switching the pump on and then off again immediately.
Before checking the direction of rotation make sure that
there is no foreign matter in the pump casing.
Never put your hands or any other objects into the pump!
6.4.2
Start--up
Caution
If a non--return valve is not fitted at the di-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.
· Can the unit be easily rotated by hand at the coupling?
All additional connections for flushing or sealing liquid etc., if fitted, must be opened fully and the flow must be checked.
fied?
(Carry out at least one full rotation)
· Are the pipes properly fitted?
· Has the coupling guard been fitted?
· Have staff been informed about sources of danger and
measures been taken to comply with the accident prevention regulations?
· Correct start--up procedure for suction lift operation.
· Is the unit protected against overload (appropriate safety
valve)?
· Have the seals been fitted as described in the appendix?
· Have any additional devices been prepared and fitted as
Switch on the motor.
As soon as the pump starts to deliver -- this can be recognised
by the rising gauge pressure -- slowly open the discharge--side
gate valve fully.
The pump may operate against the closed gate
Caution
valve only during start--up and shutdown, as
otherwise inadmissible temperature rise occurs resulting in
damage.
6.4.3
Pump Operating Range
· Has the pump been vented as specified in section 6.3.?
The flow rate ”Q” adjusts itself automatically to the delivery
head according to the H--Q characteristic. The pump’s permitted operating range is subject to limits, which have separate
causes.
6.2
1. Part load operating limit for low flow rate
specified in the appendix?
Shaft Seal
For commissioning the shaft seal please refer to section 8.1 /
8.2. If the pump has been out of service for a prolonged period,
the measures specified in section 6.6 must be carried out.
6.3
Venting
Before start--up, the pump and the pipes must be vented and
filled with the liquid to be pumped. This is done at the vent plug
on the casing (903). For suction lift operation, the pump must
also be evacuated, i.e. a vacuum must be produced.
6.4
Commissioning
6.4.1
Checking the Direction of Rotation
For trouble--free operation of the pump, the
Caution
correct direction of rotation of the impeller is of
paramount importance.
This limit is indicated in the H--Q characteristic by Qmin or by the
discontinuation of the characteristic curve.
It is not permissible to operate the pump in the
range from Q=0 to Qmin. Prolonged operation
in this range causes greatly increased mechanical loads which
the components cannot withstand.
Caution
Brief passage through the critical range is permissible, e.g. during start--up
2. NPSH--related limits in the part load and overload ranges
These two limits are determined by the ratio of NPSHrequired to
NPSHavailable. They are determined as follows:
If running in the wrong direction of rotation, the pump cannot reach its duty point; vibrations and overheating will be the consequence. The unit or the shaft seal might be damaged.
9
Omega
The intersections of NPSHrequired and NPSHavailable are projected onto the H--Q characteristic, where they indicate the operating limits (refer to the diagram below). Checking of the
NPSH--related operating limit is not necessary for operating the
pump under design conditions. If system--related changes occur, an NPSH check must be carried out. If necessary, consult
the nearest after--sales service centre.
6.5.2
Measures to be Taken for Prolonged Shutdown
1. The pump remains installed; periodic check of operation
In order to make sure that the pump is always ready for instant
start--up and to prevent the formation of deposits within the
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 operation check run ensure that there is sufficient liquid available
for operating the pump.
2. The pump is removed from the pipe and stored
Qmin
NPSHrequired
NPSHavailable
Before putting the pump into storage carry out all checks specified in sections 7.1 to 7.4. Then apply appropriate preservatives:
· Spray--coat the inside wall of the pump casing, and in particular the impeller clearance areas, with a preservative.
Spray the preservative through the suction and discharge
nozzles. It is advisable to close the nozzles (for ex. with plastic caps or similar).
6.6
6.4.4
Shutdown
Close the shut--off element in the discharge line. If the discharge line is equipped with a check valve, the shut--off element may remain open, provided there is back pressure in the
line.
The shut--off element in the suction line must not be closed when switching off the pump. Switch off the motor,
making sure that the unit runs smoothly down to a standstill.
Depending on the system the pump shall have an adequate after--run period -- with the heat source switched off -- to allow the
medium handled to cool down sufficiently to avoid any heat
build--up within the pump.
In the case of prolonged shutdown, the shut--off element in the
suction line has to be closed.
Close the auxiliary connections.
In the event of frost and / or prolonged shutdowns, the pump
must be drained or otherwise protected against freezing.
6.5
Shutdown / Storage / Preservation
Each KSB pump leaves the factory carefully assembled. If commissioning is to take place some time after delivery, we recommend that the following measures be taken for pump storage.
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 properly stored indoors.
· Store the pump in a dry location.
10
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.
Upon completion of the work, all safety--related and protective equipment must be properly refitted and / or reactivated before starting the pump set.
7
Maintenance / Repair
7.1
General Instructions
The operator is responsible for ensuring that all maintenance,
inspection and installation work is carried out by authorized,
duly qualified staff who are thouroughly familiar with these operating instructions.
A regular maintenance schedule will help avoid expensive repairs and contribute to trouble--free, reliable operation of the
pump with a minimum of maintenance expenditure and work.
Work on the pump and the motor must only be carried out with the electrical connections disconnected. Make sure that the pump set cannot be switched on accidentally (danger of life!).
Pumps handling liquids posing health hazards must be
decontaminated. When draining the medium see to it
that there is no risk to persons or the environment. All relevant
laws must be adhered to (danger of life!).
Omega
7.2
Maintenance / Inspection
7.2.1
Supervision of Operation
The pump shall run quietly and free from
Caution
vibrations at all times. The pump must never be
allowed to run dry.
Prolonged operation against a closed shut--off element
is not permitted in order to prevent the medium handled
from heating up.
At room temperatures of up to 30 _C (86 _F) the bearing temperature shall be below 90 _C (194 _F). At higher room temperatures, the bearing temperature shall be below 100 _C (212 _F).
During pump operation the shut--off element in the inlet
line must not be closed.
Any stand--by pumps installed shall be switched on and then
immediately off again once a week to keep them operational.
Attention shall be paid to the correct functioning of the auxiliary
connections.
If the flexible coupling elements begin to show
Caution
signs of wear, they must be replaced in due
time. See section ”Coupling”.
If an external supply of sealing, flushing or lubricating liquid is
used, make sure supply pressure is 1.0 to 2.0 bar higher than
pressure at the suction nozzle.
On pumps fitted with a gland packing the packing must drip
slightly during operation. The gland cover should therefore only
be gently tightened. (See section 8 ”Special instructions for
subassemblies, shaft seal variants”).
7.2.2
Shaft Seal Maintenance
For required maintenance work on gland packings please refer
to section 8.1. ”Shaft seal”. Mechanical seals are maintenance--free.
7.2.3
Bearing Maintenance
The bearings are maintenance--free and greased for life. No
re--lubrication is required.
7.3
Dismantling
Before dismantling, secure the pump so as to make sure
it cannot be switched on accidentally. The shut--off elements in the suction and discharge lines must be closed. The
pump must have cooled down to ambient temperature, pump
pressure must be released and the pump must be drained.
Dismantling and reassembly must always be carried out in accordance with the relevant sectional drawing.
7.3.1
Fundamental Instructions and
Recommendations
Repair and maintenance work to the pump must only be carried
out by specially trained personnel, using original spare parts.
Observe the safety regulations laid down. Any work on the motor shall be governed by the specifications and regulations of
the respective motor supplier.
Dismantling and reassembly must always be carried out in accordance with the relevant general drawing. The general drawing and other relevant documents are found in the annex. The
dismantling sequence can be derived from the general drawing.
In case of damage you can always contact our nearest customer service centre.
7.3.2
Preparations for Dismantling
The pump is designed so that the complete rotor can be removed in the sequence described below without removing the suction or discharge pipe or disturbing the alignment of the pump
unit:
· Close the suction and discharge--side gate valves and drain
the pump by opening the drain plug (903.01 bottom) and
vent plug (903.01 top).
· Remove any pipes between additional equipment and the
pump.
· Remove the coupling guard. Decouple pump--side coupling
half as described in the appendix.
· Loosen and push back the seal cover (471), if a mechanical
seal is fitted.
· Undo the flange screws (901.01 / 901.02) and separate the
upper casing half (105.02) from the lower casing half
(105.01) with the aid of the forcing screws. Remove with lifting gear. The interior of the pump (impeller with casing
wear rings, shaft seal) is now accessible for inspection.
· Remove the screwed connection (901.04) between bearing
housing (350.01) and bearing brackets. Also undo the nuts
(920.05) and bolts (901.07) which secure the bearing cover
(360).
· Press the bearing housing out of the recesses and lift the
rotor out of the lower casing half. For further disassembly,
place securely in horizontal position.
· Pull off the bearing housing of the fixed bearing (opposite
the drive end).
· Undo and remove the keywayed nuts (920.03).
· Remove the deep--groove ball bearing (312) with bush
(520) from the shaft.
· Remove the bearing cover (360).
· Remove the V--ring (412.02) from the shaft--protecting
sleeve (524.01).
· Pull off the shaft--protecting sleeve (524.01).
· Remove the shaft seal housing (441).
· The impeller (234) is located with a sliding fit on the shaft
and can normally be removed easily. In case of difficulty, it
can be loosened by gently tapping the hub with a wooden
hammer.
· Remove the second shaft protection sleeve (524.01) complete with the shaft seal housing (441), if fitted.
· Remove the coupling half.
· Pull off the bearing housing (350.01).
· 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 conjunction with the list of components, for orientation.
The rules of sound engineering practice and also the instructions for removal and installation of shaft seal, bearings, impeller 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 observed. The table below indicates the tightening torques for
threads depending on the materials used.
Property class
(Material)
0,2% yield stress
1)
Rp 02 in N/mm2
Metric ISO threads
coarse--pitchfine--pitchM4
M5
M6
M8
M8x1
M10
M10x1,25
M12
M12x1,5
M12x1,25
M16
M16x1,5
M20
M20x1,5
M24
M24x2
M27
M27x2
M30
M30x2
M33
M33x2
M36
M36x3
1)
8.8
640
3,1
6,1
10,4
25,2
27,2
49,5
52,5
85,2
89,5
93,9
211
226
412
461
710
780
1050
1130
1420
1580
1940
2130
2480
2630
10.9
900
4,4
8,7
14,9
36,1
39,0
71,0
75,4
122,2
128,5
134,7
302,7
324,7
591,9
661,0
1019,6
1118,6
1501,3
1627,1
2036,4
2269,9
2779,4
3062,6
3552,3
3775,4
A.-50
210
Tightening torque
MA in Nm
1,0
2,00
3,40
8,30
8,90
16,2
17,3
28,0
29,4
30,8
69,2
74,3
135
151
233
256
343
372
466
519
636
700
812
863
A.-70
250
276
305
409
443
554
618
-------------
Nominal values to DIN ISO 898 Part 1, DIN 267 Part 11 and DIN 267 Part 18
It is imperative to lock and seal the screwed connections specially marked in the general drawings.
ALTEMP Q NB 50 grease
Symbols for screwed connections to be locked and sealed:
Sealed with Loctite 574
12
1.4462
450
450
2,15
4,25
7,30
17,7
19,1
34,8
36,9
59,9
62,9
66,0
148
159
290
324
500
548
736
797
1000
1110
1360
1500
1740
1850
Omega
O--rings and V--rings must be replaced and their seats on the
shaft must be cleaned. In addition, all the sealing elements
must be fitted into the respective components before installation.
For assembling the rotor, position the pump shaft (211) securely. All fits, threads and sliding fits of the shaft must be cleaned
and coated with assembly paste.
Insert the keys required for assembly into the pump shaft (211).
Mount the impeller (234), which has a sliding fit. When fitting the
impeller, observe the direction of rotation (see diagram below).
Push the sleeve (520) with deep--groove ball bearing (321) onto
the pump shaft (211) with key (940.01) inserted.
Tension the rotor parts elastically with keywayed nut (920) and
cup spring (950). For this purpose tension the cup spring (950)
to blocking point and then undo the keywayed nut (920) again
by half a turn (180_).
This measure is essential to compensate for
differences in thermal expansion between the
pump shaft (211) and the components fitted on it.
Caution
Rotor assembly is now complete.
Insert the rotor into the pump casing.
Apply Loctite 574 to the casing wear ring surfaces and the sealing surfaces of the casing.
Install the rotor, making sure that the direction of rotation is correct.
Align the rotor and ensure that the fixing pins are correctly seated in the casing.
For assembling the casing wear rings (502), observe section
7.5.2 ”Replacing the casing wear rings”.
Put the casing wear rings onto the running surfaces of the impeller. Ensure that the bezels of the rings are on the outside (towards the bearing). Insert the pins required for fixing the casing
wear rings.
The remaining components are fitted first on the movable bearing side (i.e. the drive side) of the pump shaft.
Push the shaft protecting sleeve (524.01) onto the pump shaft
(211). Ensure that the groove provided engages in the key of
the impeller.
Push the shaft seal housing (441) onto the shaft and install
the shaft seal as described in section 8.1, ”Gland packing”.
Slip on V--ring (411.01).
The pins (561.01) must be positioned as shown in the diagram
below.
The bearing housings (350.01) must be fastened to the bearing
brackets by means of the screwed connections (901.04), with
the sealing cap (580) inserted at the non--drive end. The seating
positions are determined by the recesses.
Fit the bearing covers.
To assemble the casing cover, apply Loctite 574 to the casing
joint surface of the lower casing half.
Tighten the flange bolts diagonally from the inside towards the
outside.
Insert the key for fitting the coupling into the pump shaft (211).
When fitting the coupling and accessories, refer to the relevant
section of the operating instructions.
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
(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
sleeve (520).
Casing wear rings (502)
561.01
13
Omega
7.5
Instructions for Replacing Subassemblies
7.5.1
Replacing the Shaft Seal
After dismantling as described in section 7.3.2, the casing wear
rings (502) can be removed. When fitting the rings, ensure that
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.
7.5.2
Replacing Casing Wear Rings and / or Impeller
Wear Rings
The impeller clearance 1) clearance between impeller 234 and
casing wear ring 502 is given in the table below.
For impeller removal proceed as described in section 7.3,
”Dismantling”.
If the impeller has not been fitted with a wear ring at the factory,
and changing the casing wear ring alone does not achieve anything close to the required impeller clearance (the impeller
neck is badly worn by clearance flows), the impeller neck must
be turned off on a lathe (contact KSB before doing so) and an
impeller wear ring fitted in addition (available as spare part).
Alternatively, a new impeller can be supplied at short notice.
Impeller clearances and trim dimensions for impeller wear rings
No.
Pump
size
Shaft
unit
DW
Nominal clearance
(max. perm.)
Clearance (as--new)
Min.
Max.
clearance
clearance
S min
S max
D2 - D1
2
[mm]
[mm]
[mm]
D5
[mm]
b
[mm]
0,3
0,3
0,3
0,15
0,15
0,15
0,2
0,2
0,2
134 r6
134 r6
134 r6
18
18
18
0,35
0,35
0,35
0,17
0,17
0,17
0,2
0,2
0,2
163 r6
163 r6
163 r6
22
22
22
0,35
0,35
0,35
0,35
0,18
0,18
0,18
0,18
0,23
0,23
0,23
0,23
178 r6
178 r6
178 r6
178 r6
22
22
22
22
1
2
3
80-210
80-270
80-370
4
5
6
100-250
100-310
100-375
7
8
9
10
125-230
125-290
125-365
125-500
11
12
150-290
150-360
0,45
0,45
0,22
0,22
0,26
0,26
210 r6
210 r6
30
30
13
14
150-460
150-605
0,45
0,45
0,22
0,22
0,26
0,26
210 r6
210 r6
30
30
15
16
200-320
200-420
0,5
0,5
0,24
0,24
0,28
0,28
243 r6
243 r6
30
30
17
18
200-520
200-670
0,5
0,5
0,24
0,24
0,28
0,28
243 r6
243 r6
30
30
19
250-370
0,5
0,24
0,28
276 r6
30
20
21
250-480
250-600
0,5
0,5
0,24
0,24
0,28
0,28
276 r6
276 r6
30
30
22
23
24
25
300-300
300-435
300-560
300-700
70
80
0,5
0,6
0,6
0,6
0,24
0,29
0,29
0,29
0,28
0,35
0,35
0,35
259 r6
313 r6
313 r6
313 r6
30
35
35
35
26
27
28
350-360
350-430
350-510
80
0,5
0,6
0,6
0,24
0,32
0,32
0,28
0,37
0,37
294 r6
333 r6
353 r6
35
35
35
40
50
60
70
80
90
90
b
S (min - max)
14
Dimensions of impeller wear ring
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
(if applicable)
Check for leakage (daily)
see section 8.2 and *
Gland packing
(if applicable)
Check for leakage (daily)
10 to 120 drops / min.
Suction side measuring instrument, ps
(if applicable)
Check pressure (daily)
*
Discharge side measuring instrument, pd
Check pressure (daily)
(if applicable)
*
Thermometer
(suction / discharge nozzle)
(if applicable)
Check temperature (weekly)
*
Flushing line sight glass
(if applicable)
Check flushing water flow
(weekly)
Water flows
Vibration measurement
(if applicable)
Check weekly
*
Bearing temperature
(if applicable)
Check weekly
Section 7.2
Coupling
Check weekly
Annex from p. 47, detailed manufacturer
information
Drive
(if applicable)
See manufacturer’s documentation
Ensure contact--free installation
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 given in section 11.2 (Trouble--shooting).
15
Omega
8
Special Instructions for
Subassemblies (Shaft Seal Variants)
The shaft seal variant supplied is shown in the purchase order
and order--processing documents.
8.1
Gland packing
The gland packings used by KSB are asbestos--free and suitable for drinking water applications.
Installation and commissioning
Before installation, ensure that the gland space is clean (no
packing remnants or corrosion). The shaft protecting sleeve
must be bright and have no scoring. Otherwise a new shaft protecting sleeve must be used.
Cutting the packing rings to size
If moulded packing rings are not available, the rings can best
be cut to size using a special cutting gauge. If no cutting gauge
is available, take a tube with the same diameter as the shaft,
wind the packing around the tube in a spiral and cut the rings
from the spiral. We recommend a straight cut.
Installing the packing rings
Push the packing rings with the stuffing box insert into the gland
space one by one. The joints of the packing rings must be offset
by 90_. The number of rings and the arrangement of the lantern
ring are shown in the general drawing (see appendix). After fitting 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 tightened (by hand). A high leakage rate (approx. 50 to 200 drops
per minute), depending on the liquid being pumped, must be accepted 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
Also note the following:
Leakage and temperature rise: If necessary, shut down the
pump. After a short cooling period (approx. 10 to 15 minutes)
the pump can be restarted. The necessary minimum leakage
depends on the liquid being pumped, the pressure, sliding velocity and temperature. It is approx. 10 to 120 drops per minute
(20 drops of water correspond to approx. 1 ml).
Disassembly
A packing puller must be used for pulling out the packing rings.
Maintenance
Gland packings must be repacked in accordance with the section ”Installation and commissioning” after prolonged standstill, repair work or heavy leakage. Therefore, the leakage rate
must be observed during operation, also to avoid possible overheating.
Omega
8.2
Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations)
Mechanical seal variants
No.
Pump size
Shaft unit
Nom. mech. seal
size
Non--balanced
Balanced
dw
d
for operating pres-sures up to 16 bar
for operating pressures
> 16 bar
40
50
M 7 N 4 / 50
HJ 92 N / 50
50
60
M 7 N 4/ 60
HJ 92 N / 60
60
70
M 7 N 4/ 70
HJ 92 N / 70
70
80
M 7 N 4/ 80
HJ 92 N / 80
80
90
M 7 N 4/ 90
HJ 92 N / 90
1
80 - 210
2
80 - 270
3
80 - 370
4
100 - 250
5
100 - 310
6
100 - 375
7
125 - 230
8
125 - 290
9
125 - 365
10
125 - 500
11
150 - 290
12
150 - 360
13
150 - 460
14
150 - 605
15
200 - 320
16
200 - 420
17
200 - 520
18
200 - 670
19
250 - 370
20
250 - 480
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
25
300 - 700
90
110
M 74 N / 110
H 75 N / 110
26
350 - 360
80
90
M 7 N 4/ 90
HJ 92 N / 90
27
350 - 430
28
350 - 510
90
110
M 74 N / 110
H 75 N / 110
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--rotational, non--balanced seal which does not require circulation
pipework in cold water applications, due to the pump design.
Dry--running of the seal must be avoided at
Caution
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 absolutely clean, to avoid the surfaces from being damaged and
prevent entry of foreign particles.
Item
The seat ring (8) together with the relevant O--ring (9), is fitted
into the seal cover (see general drawing). The O--ring can be
lubricated for easy sliding movement. Special attention must be
given to ensure that pressure is applied evenly. The contact
surfaces are generally fitted dry.
In mechanical seals of the M7N4 design, the rotating assembly
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
(4) and grub screws (7). The grub screws (7) must be loosened
so far as to prevent them from protruding from the housing (1)
at the inner diameter. The O--ring (2) can be slightly lubricated
to facilitate assembly.
The complete rotating assembly is pushed onto the shaft protection sleeve in compliance with the installation dimensions
which are given in the mech. seal drawing, or until it reaches the
stop on the shaft protection sleeve. Finally the grub screws are
tightened and secured with LOCTITE.
1
2
3
4
5
6
7
8
9
Description
Material
Housing
O--ring
Spring
Thrust plate
Pin
Spring--loaded ring
Grub screw
Seat ring
O--ring
Cr-Ni-Mo-steel
Viton
Cr-Ni-Mo-steel
Cr-Ni-Mo-steel
Cr-Ni-Mo-steel
Si-SiC
Cr-Ni-Mo-steel
Si-SiC
Viton
No. of
items
1
1
1
1
2
1
2
1
1
Special instructions for mechanical seal assembly
· The contact faces must only be cleaned with propyl alcohol
and paper tissue.
-- Never use cleaning rags or cloth.
-- Clean carefully to remove any smears.
· Do not touch the contact faces with bare fingers.
· Never use force during mechanical seal assembly.
· Never put the spring--loaded ring and the seat ring face
down on the contact faces without the protective wrapping.
· Cover the contact face with a cardboard washer and press
the seat ring into its position slowly and evenly, lubricating
it with a generous amount of water or alcohol. Use a spacer
sleeve, if necessary. Verify that the seat ring position is normal to the shaft axis.
· In the mechanical seal area, the shaft shall be slightly lubri-
cated with water, alcohol or silicone grease. Sealing elements made of EP rubber must never come into contact
with mineral oil base lubricants (swelling, possibly decomposition).
18
Omega
Commissioning
Dismantling
Flood the pump and the seal chamber with the medium to be
handled and vent carefully. The seal is operational now.
For dismantling of the mechanical seal assembly please refer
to section 7.3 ”Dismantling”. Grub screws (7) and joint rings
(2+9) shall be replaced whenever the mechanical seal has
been dismantled!
On single--acting mechanical seals, the pressure in the seal
chamber of the pump (stuffing box) 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
during pump start--up and shutdown. This must be ensured by
appropriate facilities on the pump (e.g. heating).
Should the mechanical seal fail, the liquid to be sealed off may
spurt out. Take suitable precautions to prevent 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.
Maintenance
Mechanical seals operated in compliance with the manual
are maintenance--free in their entire service life.
The mechanical seal should be inspected in accordance with
the plant inspection schedule.
During planned plant outage periods the spring--loaded rings
and the seat rings should be checked for visible damage in installed condition.
Repair
If the seal needs to be repaired, always return the complete
seal to the manufacturer. The manufacturer will know best
which parts can be re--worked and which parts have to be replaced to ensure an optimum sealing effect.
If repair on the spot is necessary, it should be carried out in a
clean workshop preferrably by KSB--monteurs or skilled operator staff. Spring--loaded rings, seat rings, all elastomer materials and springs should be replaced in any case.
Make sure to comply with the instructions for handling hazardous substances and the applicable accident prevention regulations when repairing, dismantling and cleaning
used mechanical seals. If you have any queries in this context
please inform yourself before commencing any repair work.
Spare parts
Only original 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 environment.
It will also lead to forfeiture of all warranty claims.
If the mechanical seal is inspected during plant outage, the contact 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, observe the tendency of the leakage amount. Changes in operating conditions must be documented. If an excessive temperature rise is detected, the mechanical seal must be shut down for
safety reasons.
During the warranty period the mechanical seal shall only be removed and dismantled with the manufacturer’s approval or under instructions of the mechanical seal manufacturer’s service
engineers.
If the fault cannot be remedied by the operator or if the cause
is unclear, please contact the KSB service center.
19
Omega
8.2.2
Mechanical Seal -- ”Type M74N ”
(Shaft unit dw = 90 mm)
This mechanical seal type is a single--acting, bi--rotational,
non--balanced mechanical seal with multiple spring arrangement.
Caution
It is imperative to avoid dry running of the
mechanical seal!
Special instructions for mechanical seal installation
· Application limits
Pressure to be sealed off, p max.
25 bar
Product temperature, t
--40...220 °C
Sliding velocity, vg
20 m/s
The seat ring (8) together with the relevant O--ring (9), is fitted
into the seal cover (see general drawing). The O--ring can be
lubricated for easy sliding movement. Special attention must
be given to ensure that pressure is applied evenly. The contact
surfaces are generally fitted dry.
In mechanical seals of the M 74 N design, the rotating assembly
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
(4) and grub screws (7). The grub screws (7) must be loosened
so far as to prevent them from protruding from the housing (1)
at the inner diameter. The O--ring (2) can be slightly lubricated
to facilitate assembly.
The complete rotating assembly is pushed onto the shaft protection sleeve in compliance with the installation dimensions
which are given in the mech. seal drawing, or until it reaches the
stop on the shaft protection sleeve. Finally the grub screws are
tightened and secured with LOCTITE.
· Safety
Any work on the mechanical seal shall only be performed after the pump has stopped and pump pressure has been released.
In addition to the safety instructions contained in this manual,
the general health and accident prevention regulations
shall be observed.
Degrease the grub
screws and insert
with a thread sealant
(e.g. Loctite). Use
new grub screws
whenever the mechanical seal has
been dismantled!
Preparations for installation
Check pump components for:
· chamfered edges (sliding cones 2 mm/ 30_ or to DIN
24960).
· radiused transitions
· locating surfaces, surfaces for O--rings: fine finished Rz
10 (DIN 4768)
· Shaft surface in the area of the dynamically loaded joint
ring: roughness depth Rmax 5 mm.
The shaft must be provided with the requisite recesses for
the housing screws of the mechanical seal.
Check pump for:
· damage at the mating surfaces with the mechanical seal
· connecting dimensions, rectangularity and concentricity to
the shaft axis
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 absolutely clean, to avoid the surfaces from being damaged and
prevent entry of foreign particles.
20
Item
Description
Material
1
2
3
4
5
6
7
8
9
Housing
O--ring
Spring
Thrust plate
Pin
Rotating ring
Grub screw
Seat ring
O--ring
Cr-Ni-Mo-steel
Compat. elastomers
Cr-Ni-Mo-steel
Cr-Ni-Mo-steel
Cr-Ni-Mo-steel
Buka, Buke, Bume
Cr-Ni-Mo-steel
Buke, Buko, Buka
Compat. elastomers
No. of
items
1
1
1
1
2
1
2
1
1
· Apply a thin coat of grease to the shaft in the mechanical
seal area.
Sealing elements made of EP rubber must never come
into contact with mineral oil base lubricants (swelling,
possibly decomposition).
· Unwrap the mechanical seal and inspect for damage to the
spring--loaded ring and the seat ring, the O--rings and the
mating surfaces.
Never put the spring--loaded ring and the seat ring face
down on the contact faces without the protective wrapping.
· Thoroughly clean all components with alcohol and cellulose
tissue.
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.
· Cover the contact face with a cardboard washer.
· Push the seat ring slowly and evenly into its seat. Use a spa-
In the event of a fault as evidenced by excessive leakage, observe the tendency of the leakage amount. Changes in operating conditions must be documented. If an excessive temperature rise is detected, the mechanical seal must be shut down for
safety reasons.
· Verify that the seat ring position is normal to the shaft axis.
· Push the rotating assembly with the degreased joint rings
A continuous flow of leakage indicates a fault.
cer sleeve, if necessary. Lubricate with a generous amount
of water or alcohol.
onto the shaft. Thread in the degreased grub screws with
1 drop of thread sealant each (e.g. Loctite No. 243) and position the mechanical seal by tightening the grub screws.
The installation dimensions given in the drawing must be
adhered to.
· The contact faces must only be cleaned with propyl alcohol
and paper tissue (no cleaning rags or cloth). Clean carefully
to remove any smears. Do not touch the contact faces with
bare fingers afterwards.
The contact faces must not be lubricated; they must be clean
and dry.
· Assemble the seal cover with the installed seat ring.
Commissioning
During the warranty period the mechanical seal shall only be removed and dismantled with the manufacturer’s approval or under instructions of the mechanical seal manufacturer’s service
engineers.
If the fault cannot be remedied by the operator or if the cause
is unclear, please contact the KSB service centre.
Maintenance
Mechanical seals operated in compliance with the manual are
maintenance--free; however, wear parts will have to be replaced as required.
The mechanical seal should be inspected in accordance with
the plant inspection schedule. We recommend to have the mechanical seal inspected by KSB service centre.
Flood the pump and the seal chamber with the medium to be
handled and vent carefully. The seal is operational now.
If the mechanical seal is inspected during plant outage, the contact faces should be re--worked and all elastomer seals and
springs should be replaced.
Reliable seal operation
Repair
On single--acting mechanical seals, the pressure in the seal
chamber of the pump (stuffing box) 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.
If the seal needs to be repaired, always return the complete
seal to the manufacturer. The manufacturer will know best
which parts can be re--worked and which parts have to be replaced to ensure an optimum sealing effect.
In all operating conditions, the product to be sealed off must
be available in liquid state at the mechanical seal, particularly
during pump start--up and shutdown. This must be ensured by
appropriate facilities on the pump (e.g. heating).
If repair on the spot is absolutely necessary (e.g. no spare
seal available, long transport distances, problems with customs
procedures), skilled operator staff may carry out the repair
work in a clean workshop to the directions of KSB service centres.
If the operating conditions indicated are observed and the instructions given in this operating manual are complied with, the
mechanical seal can be expected to give trouble--free operation.
Should the mechanical seal fail, the liquid to be sealed
off may spurt out. Take suitable precautions to prevent 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
Shut down the pump in accordance with the operating
manual, allow to cool down and release pump pressure.
Mechanical Seal ”Type HJ92 N”
(Shaft unit dw = 40 to 80 mm)
Note:
There must be no pumped product at the
mechanical seal ®The pump must be drained.
Refer to sections 8.2.1 and 8.2.2 for general recommendations
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 prevention regulations when removing a mechanical seal. Also observe 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 inform 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 analogously 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 environment.
It will also lead to forfeiture of all warranty claims.To keep a
complete spare seal on stock.
22
8.2.3
OPERATING MANUAL
MECHANICAL SEAL (MS)
HJ92N
PLEASE READ this manual carefully and OBSERVE the information contained as to:
Storage
H
Installation
H Start up
H
Maintenance
H Safety
H
J SAFETY
Any person in the operator’s plant who is involved in the installation, removal, operation, commissioning and maintenance of
the mechanical seal must have read and thoroughly understood these operating instructions, particularly the safety instructions contained therein. It is advisable for the operator to
have this confirmed.
The mechanical seal is a precision product (ISO 9001) and safe
to operate. However, it may constitute a hazard if it is not used
in accordance with its designated use, or if operated improperly
by unskilled personnel.
The operator has to determine the consequences of any mechanical seal failure and decide whether safety precautions
need to be taken to protect personnel or the environment.
The pump shall be installed in such a way that any fluid spurting
out cannot cause personal injury and that leakage can be properly disposed of.
Any operating mode liable to impair the safe and reliable function of the mechanical seal is not permitted.
Mechanical seals shall only be installed, operated, removed or
repaired by authorized, qualified and appropriately instructed
personnel.
Any work on the mechanical seal shall only be performed with
the pump shut down and the pump pressure released.
Staff responsibilities for the work involved must be clearly defined and complied with, to prevent unclear competencies with
regard to safety aspects.
In addition to the instructions contained in this manual, the general occupational health and safety regulations must be adhered to.
Unauthorized modifications and alterations liable to jeopardize
the safe operation of the mechanical seal are not permitted.
H
Repair
J OPERATING LIMITS
Shaft diameter dw:
18 to 100 mm
25 bar *)
Fluid temperature t:
--40 to 220 °C
Sliding velocity vg:
20 m/s
*) depending on the seal face materials
The mechanical seal shall not be operated at several application limits at the same time.
Higher loads (pressure, temperature, speed) may lead to increased wear and damage the contact faces or the elastomer
elements.
Such operating conditions would shorten the useful life of the
seal but also entail the risk of sudden seal failure with hazards
to personnel and the environment.
Press. to be sealed off p max.:
J OPERATING DATA
The operating data for the application in question, such as fluid
to be sealed off, operating pressure, operating temperature, rotational speed, etc., are indicated on the respective pump data
sheets.
J DESIGNATED USE
Any operation outside the operating conditions stated in the
”Operating Limits” section is deemed to be non--conforming
with the designated use.
To ensure safe operation of the mechanical seal, check with the
seal manufacturer before using the seal for other operating
conditions or in a different location of operation.
J MATERIALS
Materials as per drawing and/or order.
J DRAWINGS
General assembly drawing of pump.
The applicable design is shown on the general pump drawing
in the original scale and latest revision, see section 9 of the
pump’s operating manual, which shall be used in conjunction
with this document.
J SPECIFICATION
J DECLARATION
within the meaning of EC Directive ”Machinery” 98/37/EC.
A mechanical seal does not function independently. It is intended to be incorporated into or assembled with machinery.
Operating maual mechanical seal
Rev. 0, 13.02.2004
H
H
H
H
H
Single mechanical seal
Balanced
Bi--rotational
Connecting dimensions to DIN 24960 KB
Installation dimensions l1K
23
Due to their protected spring (1.5), mechanical seals of this type
are particularly suitable for fluids containing solids and/or highly
viscous fluids, for ex. in sugar, paper or waste water applications. The seal design is rugged and reliable. The spring neither
clogs nor sticks. Max. axial end play between shaft and housing: 0.5 mm in any direction.
For operation at negative pressures (down to --0.2 bar), no seat
lock is required for the seat ring (2).
Torque transmission between the shaft and the seal is normally
effected by grub screws(1.6); or by special drive elements (1.2)
on individual models.
J LIQUID
SEAL
SUPPLY
TO
MECHANICAL
To ensure trouble--free operation of the mechanical seal, a suitable circulation process has been selected on the pump, see
section 9 of the pump’s operating manual. This process avoids
product deposits in the seal chamber.
J EMISSIONS
Mechanical seals are dynamic seals which for physical and
technical reasons cannot be completely leak--free. The amount
of leakage largely depends on the seal selection, production tolerances, operating conditions, smooth running of the machine,
etc. Compared with other dynamic sealing systems, however,
mechanical seals have little leakage.
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent hazards to persons. The operator/owner is responsible for the proper disposal of leakage, in order to prevent hazards to the environment.
Leakage may be liquid or gaseous, its aggressiveness corresponding to that of the fluid to be sealed off.
Any mechanical seal leakage must be drained off in a controlled
way and safely disposed of.
. Components which may come into contact with the seal leakage shall either be corrosion resistant or must be adequately
protected.
The mechanical seals need not be preserved.
D Do not apply anti--corrosives.
' Risk of deposits and possible chemical attacks on elastomer secondary seals.
When applying preservatives to entire systems where mechanical seals are installed please check the following:
D Verify the compatibility of the preservatives chosen with the
materials of construction and the elastomer components of
the mechanical seal.
D Verify that mechanical seal movement is not restricted by resin deposits or sticking.
During storage, seal face materials and elastomers will undergo material specific time dependent changes (distortion,
ageing), which can impair the perfect function of the mechanical
seal. The specified storage period must therefore be complied
with.
The manufacturer cannot be held responsible for damage resulting from improper storage.
The room where mechanical seals are kept must be dust--free
and moderately ventilated, with an even temperature. We recommend: relative humidity below 65%, temperature between
15 °C and 25 °C.
The mechanical seal shall be protected from:
D direct heat from sun, heating
D ozone and ultraviolet light from halogen lamps, fluorescent
lamps, sunlight, arc welding
' danger of embrittlement of elastomer materials
The seals shall be stored in their original packaging on a level
surface.
The mechanical seal needs to be checked:
D after a storage period of approx. 2--3 years
D if the packaging has been damaged
D after a shock load (e.g. if the mechanical seal package has
been dropped)
' at the manufacturer’s workshop or nearest service centre.
J BEFORE INSTALLATION
Checks to be carried out on the pump components:
J STORAGE
Shaft surface in the area of the dynamically loaded seal ring:
roughness depth Rmax 5 mm.
Unless otherwise agreed in the contract, mechanical seals are
delivered in standard packaging suitable for dry transport by
truck, train or plane. The symbols or handling instructions given
on the packaging must be adhered to.
For incoming goods inspection:
D Check packaging for external damage.
D Carefully open packaging, making sure not to damage or
lose any components packed separately.
D Check consignment for completeness (delivery note). The
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 packaging, and to mechanical seals already installed in a pump,
which have not been in operation yet.
D Check contact surfaces between the pump and the mechanical seal for damage.
D Connecting dimensions, squareness and concentricity to
shaft.
D Shaft run--out as per DIN ISO 5199: between 50 mm and
100 mm, depending on the diameter.
D Apply a thin coat of suitable grease to the shaft in the
mech.seal area.
' Never use mineral oil base lubricants on sealing elements
made of ethylene propylene rubber (swelling, possibly decomposition).
' Grease recommended for elastomer sealing elements
(O--rings, etc.): type ”TURMOPOLGREASE SH2”, producer: Lubricant Consult (LUBCON).
24
Checks to be carried out on the pump:
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
D Set of hex. keys (WAF 2 mm -- 6 mm)
D Cardboard washers to protect the contact faces during installation
D Manual screw press (compulsory from DN 80 mm).
J INSTALLATION
Refer to the general pump assembly drawing when installing
the mechanical seal.
Mechanical seals are precision--machined machinery components which have been inspected several times. They must be
installed with due care and in compliance with certain procedures, particularly regarding the contact faces and elastomer
seals.
Utmost cleanliness must be ensured in the immediate vicinity
of the location where a mechanical seal is to be installed.
Never use force when installing a mechanical seal.
D Unpack the seal and inspect the spring--loaded ring, seat
ring, O--rings and contact faces for damage.
' Never place the spring--loaded ring and the seat ring on
the table facing down without protecting the contact faces.
D Thoroughly clean all parts with alcohol and paper tissue.
The sequence of operations required to install the mechanical
seal in the machine depends on the design of the machine in
question, which is described in the pump’s operating manual.
Unless otherwise stated, apply a very thin coat of grease to
O--rings which will slide into or onto other components during
mechanical seal installation.
Possible installation sequence:
D Slide the degreased O--ring onto the seat ring.
D Cover the contact face of the seat ring with a cardboard
washer. Generously lubricate the seat ring with water or alcohol and press it slowly and evenly into its seat. Use a spacer, if necessary. Check squareness of seat ring to the shaft
axis.
D Apply a thin coat of grease to the shaft protecting sleeve in
the mechanical seal area.
' Never use mineral oil base lubricants on sealing elements made of ethylene propylene rubber (swelling,
possibly decomposition).
D Slide the rotating seal assembly with greased O--rings onto
the shaft protecting sleeve.
D Fit the degreased grub screws, having applied one drop of
thread--locking compound (e.g. Loctite R No. 243) to each
screw.
D Tighten the grub screws to lock the torque--transmitting
sleeve into 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 during pump start--up and shutdown.
If the operating conditions indicated are observed and the instructions given in this operating manual are complied with, the
mechanical seal can be expected to give trouble--free operation.
J HEALTH AND SAFETY
Mechanical seals are often used for sealing off hazardous substances (chemicals, pharmaceuticals, etc.). The applicable instructions and regulations for handling hazardous materials
must absolutely be adhered to.
Operating maual mechanical seal
Rev. 0, 13.02.2004
25
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent hazards to persons. The operator/owner is responsible for the proper disposal of leakage, in order to prevent hazards to the environment..
J FAULTS/MALFUNCTIONS
Determine and document the nature of the fault/malfunction.
In the event of a fault as evidenced by excessive leakage, observe the tendency of the leakage amount. Changes in operating conditions must be documented. If an excessive temperature rise is detected, the mechanical seal must be shut down for
safety reasons.
A continuous flow of leakage indicates a fault/malfunction at the
mechanical seal.
During the warranty period the mechanical seal shall only be removed and dismantled with the manufacturer’s approval or in
the presence of his representative.
If the fault/malfunction cannot be remedied by the operator or
if the cause is unclear, please contact your responsible KSB
service centre.
J SERVICING / MAINTENANCE
Mechanical seals operated in compliance with manual are
maintenance--free. Wear parts, however, must be replaced as
required.
The mechanical seal shall be inspected in accordance with the
plant inspection schedule. We recommend to have the mechanical seal inspected by competent KSB service staff.
If the mechanical seal is removed during plant inspection, the
contact faces shall be re--worked and all elastomer seals and
springs shall be replaced.
J REPAIR
If the seal needs to be repaired, always return the complete seal
to the manufacturer. The manufacturer’s service personnel will
know best which parts can be re--worked and which parts have
to be replaced to ensure an optimum sealing effect.
If repair on the spot is absolutely necessary (e.g. no spare seal
available, long transport distances, problems with customs procedures), skilled operator staff may carry out the repair work in
a clean workshop to the directions of the seal manufacturer’s fitters.
J SPARE PARTS
Use only genuine spare parts, to prevent
D the risk of mechanical seal malfunction, involving hazards
to persons and the environment.
D forfeiture of any and all warranty claims.
To ensure quick mechanical seal replacement, we recommend
to stock a complete spare seal.
26
J REMOVING THE SEAL FROM
THE PUMP
D Shut down the pump, allow to cool down and release pressure as per operating instructions
D No product should contact the mechanical seal Drain the
pump, if necessary!
D Secure the pump against inadvertent start--up!
D Follow the safety instructions (safety data sheets)!
When removing the mechanical seal make sure to observe the
applicable health and safety regulations, as well as the regulations for handling hazardous substances, if the mechanical seal
has already been in operation. If in doubt, the necessary information has to be obtained before starting repair work.
Any work on the mechanical seal shall only be performed with
the pump shut down and the pump pressure released.
The sequence of operations required to remove the mechanical
seal from the pump depends on the design of the pump in question, which is described in the pump’s operating manual.
Removal of the mechanical seal shall be effected in analogy
with, but in reverse order to, installation.
J CUSTOMER SERVICE
Services provided by the seal manufacturer range from planning advice to product support after commissioning.
For this purpose, the manufacturer has established a worldwide
network of subsidiaries abroad, partner companies, sales offices and service centres, to handle any problems.
J PURCHASE ORDERS
For enquiries and purchase orders, the following details are required:
D KSB order No.
D No. of general pump assembly drawing
D Part item No., description, material, quantity as per drawing.
J DISPOSAL
Usually, mechanical seals can easily be disposed of after a thorough cleaning.
D Metal parts (steel, stainless steel, non--ferrous metals),
shall be sorted and disposed of in the appropriate waste metal collection facility.
D Plastics (elastomers, PTFE) are special waste. After sorting, some of them can be recycled.
' CAUTION! Material containing fluorine must not be incinerated.
D Ceramic contact face materials (carbon, ceramics, carbide)
can be separated from their carrier materials and -- being
physiologically harmless -- disposed of as residual waste.
We reserve the right to technical modifications designed to
improve the product, even if they are not mentioned in this manual yet.
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, commissioning, maintenance, faults and repair have already been
given in sections 8.2.1 and 8.2.2.
(See Operating manual
for seal type H75N).
S
27
OPERATING MANUAL
BURGMANN MECHANICAL (M.S.)
H75N
PLEASE READ this manual carefully and OBSERVE the information contained as to:
Storage
H
Installation
H Start up
H
Maintenance
H Safety
H
J SAFETY
Any person in the operator’s plant who is involved in the installation, removal, operation, commissioning and maintenance of
the mechanical seal must have read and thoroughly understood these operating instructions, particularly the safety instructions contained therein. It is advisable for the operator to
have this confirmed.
The mechanical seal is a precision product (ISO 9001) and safe
to operate. However, they may constitute a hazard if they are
not used in accordance with their designated use, or if operated
improperly by unskilled personnel.
The operator has to determine the consequences of any mechanical seal failure and decide whether safety precautions
need to be taken to protect personnel or the environment.
The pump shall be installed in such a way that any fluid spurting
out cannot cause personal injury and that leakage can be properly disposed of.
Any operating mode liable to impair the safe and reliable function of the mechanical seal is not permitted.
Mechanical seals shall only be installed, operated, removed or
repaired by authorized, qualified and appropriately instructed
personnel.
Any work on the mechanical seal shall only be performed with
the pump shut down and the pump pressure released.
Staff responsibilities for the work involved must be clearly defined and complied with, to prevent unclear competencies with
regard to safety aspects..
In addition to the instructions contained in this manual, the general occupational health and safety regulations must be adhered to.
Unauthorized modifications and alterations liable to jeopardize
the safe operation of the mechanical seal are not permitted.
J DECLARATION
within the meaning of EC Directive ”Machinery” 98/37/EC.
A mechanical seal does not function independently. It is intended to be incorporated into or assembled with machinery.
28
H
Repair
J OPERATING LIMITS
Shaft diameter dw:
28 to 100 mm
Press. to be sealed off p max.:
40 bar *)
Fluid temperature t:
--40 to 220 °C
Sliding velocity vg:
20 m/s
*) depending on the seal face materials
The mechanical seal shall not be operated at several application limits at the same time.
Higher loads (pressure, temperature, speed) may lead to increased wear and damage the contact faces or the elastomer
elements.
Such operating conditions would shorten the useful life of the
seal but also entail the risk of sudden seal failure with hazards
to personnel and the environment.
J SPECIFICATION
The operating data for the application in question, such as fluid
to be sealed off, operating pressure, operating temperature, rotational speed, etc., are indicated on the respective pump data
sheets.
J DESIGNATED USE
Any operation outside the operating conditions stated in the
”Operating Limits” section is deemed to be non--conforming
with the designated use.
To ensure safe operation of the mechanical seal, check with the
seal manufacturer before using the seal for other operating
conditions or in a different location of operation.
J MATERIALS
Materials as per drawing and/or order.
J DRAWINGS
General assembly drawing of pump.
The applicable design is shown on the general pump drawing
in the original scale and latest revision, see section 9 of the
pump’s operating manual, which shall be used in conjunction
with this document.
J SPECIFICATION
H
H
H
H
H
Single mechanical seal
Balanced
Bi--rotational
Rotating spring--loaded ring
Stationary seat ring
Operating maual mechanical seal
Rev. 0, 13.02.2004
H
H
H
H
H
Multiple springs in guide sleeves
axial mobility/play up to dw 55 = ± 2 mm, and ± 3 mm
Torque transmission by grub screws
Connecting dimensions to DIN 24960 KB
Installation dimensions l1K
J LIQUID
SEAL
SUPPLY
TO
MECHANICAL
To ensure trouble--free operation of the mechanical seal, a suitable circulation process has been selected on the pump, see
section 9 of the pump’s operating manual. This process avoids
product deposits in the seal chamber.
J EMISSIONS
Mechanical seals are dynamic seals which for physical and
technical reasons cannot be completely leak--free. The amount
of leakage largely depends on the seal selection, production tolerances, operating conditions, smooth running of the machine,
etc. Compared with other dynamic sealing systems, however,
mechanical seals have little leakage.
Leakage may be liquid or gaseous, its aggressiveness corresponding to that of the fluid to be sealed off.
Any mechanical seal leakage must be drained off in a controlled
way and safely disposed of.
. Components which may come into contact with the seal leakage shall either be corrosion resistant or must be adequately
protected.
J STORAGE
Unless otherwise agreed in the contract, mechanical seals are
delivered in standard packaging suitable for dry transport by
truck, train or plane. The symbols or handling instructions given
on the packaging must be adhered to.
For incoming goods inspection:
D Check packaging for external damage.
D Carefully open packaging, making sure not to damage or
lose any components packed separately.
D Check consignment for completeness (delivery note). The
supplier shall be notified immediately of any damaged
goods or missing parts.
During storage, seal face materials and elastomers will undergo material specific time dependent changes (distortion,
ageing), which can impair the perfect function of the mechanical
seal. The specified storage period must therefore be complied
with.
The manufacturer cannot be held responsible for damage resulting from improper storage.
The room where mechanical seals are kept must be dust--free
and moderately ventilated, with an even temperature. We recommend: relative humidity below 65%, temperature between
15 °C and 25 °C.
The mechanical seal shall be protected from:
D direct heat from sun, heating
D ozone and ultraviolet light from halogen lamps, fluorescent
lamps, sunlight, arc welding
' danger of embrittlement of elastomer materials.
The seals shall be stored in their original packaging on a level
surface.
The mechanical seal needs to be checked:
D after a storage period of approx. 2--3 years
D if the packaging has been damaged
D after a shock load (e.g. if the mechanical seal package has
been dropped)
' at the manufacturer’s workshop or nearest service centre.
J BEFORE INSTALLATION
Checks to be carried out on the pump components:
Shaft surface in the area of the dynamically loaded seal ring:
roughness depth Rmax 5 mm.
Checks to be carried out on the pump:
D Check contact surfaces between the pump and the mechanical seal for damage.
D Connecting dimensions, squareness and concentricity to
shaft
D Shaft run--out as per DIN ISO 5199: between 50 mm and
100 mm, depending on the diameter.
D Apply a thin coat of a suitable grease to the shaft in the
mech. seal area.
' Never use mineral oil base lubricants on sealing elements
made of ethylene propylene rubber (swelling, possibly decomposition).
' Grease recommended for elastomer sealing elements
(O--rings, etc.): type ”TURMOPOLGREASE SH2”, producer: Lubricant Consult (LUBCON).
The instructions given below shall apply both to mechanical
seals delivered and stored in their undamaged, original packaging, 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.
' Risk of deposits and possibly chemical attack of the elastomer secondary sealing elements.
'
When applying preservatives to entire systems where mechanical seals are installed please check the following:
D Verify the compatibility of the preservatives chosen with the
materials of construction and the elastomer components of
the mechanical seal.
D Verify that mechanical seal movement is not restricted by resin deposits or sticking.
J INSTALLATION TOOLS / EQUIPMENT
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.
D Propyl alcohol + paper tissue (no cleaning rags)
D lubricant for elastomer--sealing rings: Type ”TURMOPOLGREASE SH2”, make Lubricant Consult (LUBCON)
29
D Thread--locking compound, e.g. type ”LoctiteR Nr. 243”,
producer: Loctite Corporation
D O--ring extractor
D Set of hex. keys (WAF 2 mm -- 6 mm)
D Cardboard washers to protect the contact faces during installation
D Manual screw press (compulsory from DN 80 mm)
J INSTALLATION
Refer to the general pump assembly drawing when installing
the mechanical seal.
Mechanical seals are precision--machined machinery components which have been inspected several times. They must be
installed with due care and in compliance with certain procedures, particularly regarding the contact faces and elastomer
seals.
Utmost cleanliness must be ensured in the immediate vicinity
of the location where a mechanical seal is to be installed.
Never use force when installing a mechanical seal.
Unpack the seal and inspect the spring--loaded ring, seat ring,
O--rings and contact faces for damage.
D Never place the spring--loaded ring and the seat ring on the
table facing down without protecting the contact faces.
D Thoroughly clean all parts with alcohol and paper tissue.
The sequence of operations required to install the mechanical
seal in the machine depends on the design of the machine in
question, which is described in the pump’s operating manual.
Unless otherwise stated, apply a very thin coat of grease to
O--rings which will slide into or onto other components during
mechanical seal installation.
Primary seal components
1.1
Spring--loaded ring
2
Seat ring
Secondary seal elements
1.4
O--ring (dynamic)
3
O--ring (static)
Spring components
1.5
Guide sleeve
1.6
Spring
Torque transmission and housing components
1.2
Torque--transmitting sleeve
1.3
Thrust ring
1.7
Grub screw
Possible installation sequence:
D Slide the degreased O--ring onto the seat ring.
D Cover the contact face of the seat ring with a cardboard
washer. Generously lubricate the seat ring with water or alcohol and press it slowly and evenly into its seat. Use a spacer, if necessary. Check squareness of seat ring to the shaft
axis.
D Apply a thin coat of grease to the shaft protecting sleeve in
the mechanical seal area.
' Never use mineral oil base lubricants on sealing elements made of ethylene propylene rubber (swelling,
possibly decomposition).
D Slide the rotating seal assembly with greased O--rings onto
the shaft protecting sleeve.
D Fit the degreased grub screws, having applied one drop of
thread--locking compound (e.g. Loctite R No. 243) to each
screw.
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 during pump start--up and shutdown.
If the operating conditions indicated are observed and the instructions given in this operating manual are complied with, the
mechanical seal can be expected to give trouble--free operation.
J HEALTH AND SAFETY
Fig. 1: General mech. seal design
30
Mechanical seals are often used for sealing off hazardous substances (chemicals, pharmaceuticals, etc.). The applicable instructions and regulations for handling hazardous materials
must absolutely be adhered to.
Operating maual mechanical seal
Rev. 0, 13.02.2004
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent hazards to persons. The operator/owner is responsible for the proper disposal of leakage, in order to prevent hazards to the environment.
J FAULTS/MALFUNCTIONS
Determine and document the nature of the fault/malfunction.
In the event of a fault as evidenced by excessive leakage, observe the tendency of the leakage amount. Changes in operating conditions must be documented. If an excessive temperature rise is detected, the mechanical seal must be shut down for
safety reasons.
A continuous flow of leakage indicates a fault/malfunction at the
mechanical seal.
During the warranty period the mechanical seal shall only be removed and dismantled with the manufacturer’s approval or in
the presence of his representative.
If the fault/malfunction cannot be remedied by the operator or
if the cause is unclear, please contact your responsible KSB
service centre.
J SERVICING / MAINTENANCE
Mechanical seals operated in compliance with manual are
maintenance--free. Wear parts, however, must be replaced as
required.
The mechanical seal shall be inspected in accordance with the
plant inspection schedule. We recommend to have the mechanical seal inspected by competent KSB service staff.
If the mechanical seal is removed during plant inspection, the
contact faces shall be re--worked and all elastomer seals and
springs shall be replaced.
J REPAIR
If the seal needs to be repaired, always return the complete seal
to the manufacturer. The manufacturer’s service personnel will
know best which parts can be re--worked and which parts have
to be replaced to ensure an optimum sealing effect.
If repair on the spot is absolutely necessary (e.g. no spare seal
available, long transport distances, problems with customs procedures), skilled operator staff may carry out the repair work in
a clean workshop to the directions of the seal manufacturer’s fitters.
J SPARE PARTS
Use only genuine spare parts, to prevent
D the risk of mechanical seal malfunction, involving hazards
to persons and the environment.
D forfeiture of any and all warranty claims.
To ensure quick mechanical seal replacement, we recommend
to stock a complete spare seal.
Operating maual mechanical seal
Rev. 0, 13.02.2004
J REMOVING THE SEAL FROM
THE PUMP
D Shut down the pump, allow to cool down and release pressure as per operating instructions.
D No product should contact the mechanical seal Þ Drain the
pump, if necessary!
D Secure the pump against inadvertent start--up!
D Follow the safety instructions (safety data sheets)!
When removing the mechanical seal make sure to observe the
applicable health and safety regulations, as well as the regulations for handling hazardous substances, if the mechanical seal
have already been in operation. If in doubt, the necessary information has to be obtained before starting repair work.
Any work on the mechanical seal shall only be performed with
the pump shut down and the pump pressure released.
The sequence of operations required to remove the mechanical
seal from the pump depends on the design of the pump in question, which is described in the pump’s operating manual.
Removal of the mechanical seal shall be effected in analogy
with, but in reverse order to, installation.
J CUSTOMER SERVICE
Services provided by the seal manufacturer range from planning advice to product support after commissioning.
For this purpose, the manufacturer has established a worldwide
network of subsidiaries abroad, partner companies, sales offices and service stations, to handle any problems.
J PURCHASE ORDERS
For enquiries and purchase orders, the following details are required:
D KSB order No.
D No. of general pump assembly drawing
D Part item No., description, material, quantity as per drawing
J DISPOSAL
Usually, mechanical seals can easily be disposed of after a thorough cleaning.
D Metal parts (steel, stainless steel, non--ferrous metals),
shall be sorted and disposed of in the appropriate waste metal collection facility.
D Plastics (elastomers, PTFE) are special waste. After sorting, some of them can be recycled.
' CAUTION! Material containing fluorine must not be incinerated.
D Ceramic contact face materials (carbon, ceramics, carbide)
can be separated from their carrier materials and -- being
physiologically harmless -- disposed of as residual waste.
We reserve the right to technical modifications designed to
improve the product, even if they are not mentioned in this manual yet.
31
Omega
9
Spare Parts
Recommended Spare Parts
Recommended spare parts stock for 2 years’ operation to VDMA 24296 (also for continuous operation)
Part no.
Number of pumps (incl. stand--by pumps)
Description
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 %
Shaft with keys and
shaft nuts
1
1
2
2
2
3
30 %
321
Rolling element
bearing
2
2
4
4
6
8
100 %
524
Shaft protecting
sleeve
4
4
4
6
6
8
50 %
461
Packing ring
32
32
48
48
48
64
40 %
Set of sealing elements
4
6
8
8
9
12
150 %
Spring--loaded
ring
4
6
8
8
8
12
90 %
Seat ring
4
6
8
8
8
12
90 %
O--rings
4
6
12
16
16
20
150 %
Seals on
seat ring
4
6
12
16
16
20
150 %
Set of springs
1
2
2
* These figures already allow for components required twice for replacement
2
2
4
%
211,940
920,932
411,412
421
433
32
Mechanical seal
Omega
Interchangeability of rotor components
Pump shaft diameter
Pump sizes
40
80 - 210
*
80 - 270
*
80 - 370
*
100 - 250
*
100 - 310
*
100 - 375
*
50
125 - 230
*
125 - 290
*
125 - 365
*
125 - 500
*
150 - 290
*
150 - 360
*
60
150 - 460
*
150 - 605
*
200 - 320
*
200 - 420
*
70
200 - 520
*
200 - 670
*
250 - 370
*
80
250 - 480
*
250 - 600
*
300 - 300
300 - 435
90
*
*
300 - 560
*
300 - 700
*
350 - 360
*
350 - 430
*
350 - 450
*
33
Omega
10
Forces and Moments
Fz
Mz
Fy
My
Mx
The given forces and moments are mean values for simultaneous loading in the three planes. If the forces and moments in
one particular direction are larger than given in the table, consult KSB.
Impeller dimensions in mm
Pump
sizes
free passage
max. diameter
A
A
± 10 %
B
C
B
C
Clearances
A
B
C
Fx
The values given in the table do not apply to the reaction forces of braceless expansion joints.
Dimensions in mm
PermissiPermissible operable test
ting
pressure
pressure
in bar
in bar
Permissible nozzle
Mass moments of
inertia J
forces
in N
moments
in Nm
(without coupling)
in kgm2
Fx, Fy, Fz
Mx, My, Mz
with
water
2)
1)
2)
1); 3)
without
water
1)
1); 3)
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)
2)
3)
34
see next page
see next page
see next page
Omega
Dimensions in mm
Pump
sizes
Impeller dimensions in mm
free passage
max. diameter
A
A
± 10 %
B
C
B
C
Permissible nozzle
Mass moments of
inertia
J
Permissible operating
pressure
Permissible test
pressure
forces
in N
moments
in Nm
(without coupling)
in kgm2
in bar
in bar
Fx, Fy, Fz
Mx, My, Mz
1); 3)
1); 3)
Clearances
A
B
C
without
water
with
water
1)
2)
1)
2)
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)
2)
3)
4)
Casing material JL 1040 and GGG-NiCrNb 20 2
Casing material JS 1030 and 1.4517
Casing material JS 1030; 1,4--times the given value
Casing material 1.4517; 1,9--times the given value
11
Trouble--Shooting
11.1
General
The diagram opposite is to facilitate understanding of the causes of faults and their remedies as indicated in the trouble-shooting table.
The cause of many operating faults on pumps is often hydraulic. The hydraulic behavior of a pump is illustrated by its characteristic curves H, P, Eta and NPSH in combination with the plant
characteristic curves HA and NPSHA.The operating point B is
where the system curve HA and the characteristic curve H intersect. Consult the manufacturer if the cause of a fault is unclear.
Power
Head
Efficiency
Operating Limit
Capacity
35
Omega
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
36
F
F
F
F
Leakage at pump
F
Drive overloaded
F
Exessive leakage at shaft seal
Pump fails to pump liquid after being switched on
F
Bearing temperature too high
Power consumption too high
F
Inadmissible temperature increase at pump /
seal casing
Flow rate too low
F
Pump does not run smoothly (noise, vibrations)
Flow rate too high
F
Pump ceases to pump liquid
Pump pressure too high
Trouble--shooting Table
Pump pressure too low
11.2
Cause
Operating point B does not
lie at the calculated intersections of Q and H
Pump or piping incompletely vented or not primed
Suction pipe or impeller
blocked
Remedy1)
Re--adjust operating point
Vent.
Clean impeller
Check plant for impurities
Remove deposits in pump and / or piping
Check strainer / suction opening
Formation of air pockets in Correct suction conditions
the piping
Alter piping
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
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
Wrong direction of rotation Interchange two phases of the power cable
Check electrical connections
Check impeller position, correct if necessary
Speed too low
Increase speed 1),
Check switchgear,
Fit larger impeller 1).
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
Pump pressure is lower
Re--adjust operating point
than specified in the order Increase back pressure by throttling.
Omega
F
F
F
F
Leakage at pump
Drive overloaded
Exessive leakage at shaft seal
Bearing temperature too high
Inadmissible temperature increase at pump /
seal casing
Pump does not run smoothly (noise, vibrations)
Pump ceases to pump liquid
Pump fails to pump liquid after being switched on
Power consumption too high
Flow rate too low
Flow rate too high
Pump pressure too high
Pump pressure too low
Trouble--shooting Table
F
F
F
F
F
F
1)
F
F
F
Cause
Higher density or viscosity
of medium handled than
specified in the order
Speed too high
Tie bolts / seals
Worn shaft seal
Unfavourable flow to suction nozzle of pump
Remedy 1)
Reduce speed
In the case of persistent overloading, turn
down impeller, if necessary 1).
Reduce speed
In the case of persistent overloading, turn
down impeller, if necessary 1).
Check
Tighten tie bolts
Replace gaskets
Check pipe connections and pump mounting, if necessary, improve mounting of piping.
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.
Alter piping
If necessary, alter intake pipe if resistances
are too high
Check whether pipe routing results in twisted or irregular flow (e.g. downstream of
an elbow) and correct, if necessary.
Consult KSB
37
Omega
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
1)
38
Consult KSB
F
Leakage at pump
Drive overloaded
Exessive leakage at shaft seal
Bearing temperature too high
Inadmissible temperature increase at pump /
seal casing
Pump does not run smoothly (noise, vibrations)
Pump ceases to pump liquid
Pump fails to pump liquid after being switched on
Power consumption too high
Flow rate too low
Flow rate too high
Pump pressure too high
Pump pressure too low
Trouble--shooting Table
Remedy 1)
Alter
Replace
Correct
Replace gland packing
Replace worn components
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.
Pump mis--aligned or reso- Re--align pump / drive
nance vibrations in the piCheck piping connections and pump
ping
mounting, if necessary, improve mounting
of piping
Apply vibration--damping measures
Excessive axial thrust
Check duty point / pump selection
Check mode of operation
Check suction -- side flow.
Too little, too much or unClean bearing
suitable lubricant
Replace lubricant
Top up, reduce or change lubricant
Motor is running on two
Replace defective fuses
phases only
Check electrical connections
Check switchgear.
Rotor is out of balance
Clean rotor
Check run--out, straighten if necessary
Re--balance rotor.
Bearings damaged
Replace / change
Cause
Gland cover, seal cover
tightened incorrectly,
wrong packing material
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 losses HV.
Omega
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
1)
F
Leakage at pump
Cavitation (rattling noise)
F
F
Cause
In star / delta operation
motor hangs at star stage
Inadmissible air or gas
content in liquid
Air drawn in at pump inlet
F
F
F
Drive overloaded
Exessive leakage at shaft seal
Inadmissible temperature increase at pump /
seal casing
Bearing temperature too high
Pump does not run smoothly (noise, vibrations)
Pump ceases to pump liquid
Pump fails to pump liquid after being switched on
Flow rate too low
Power consumption too high
Flow rate too high
Pump pressure too low
Pump pressure too high
Trouble--shooting Table
F
F
F
Foundation not rigid
enough
Inadmissible parallel
operation
Shaft is out of true
Impeller rubs against casing components
Remedy 1)
Check electrical connections
Check switchgear.
Vent
Check integrity of suction pipe, seal if
necessary
Correct suction conditions
Reduce flow velocity at suction pipe entry
Increase suction head
Check integrity of suction pipe and seal,
if necessary
Replace defective pipes.
Correct suction conditions
Check mode of operation
Increase suction head
Install pump at a lower level
Check
Alter
Re--adjust operating point
Alter pump characteristic H 1).
Renew / Replace
Check rotor
Check impeller position
Check that the piping is connected without transmitting any stresses or
strains.
Consult KSB
39
Omega
12
Routine Maintenance and Inspection Intervals
Interval
Time
[h]
Daily
1
1/10
Weekly
1
1/4
1
1/4
1
1/4
2
3
Monthly
every 20.000
operating hours
every 4 years or if total
head of pump drops
40
Number of personnel required
Maintenance job
Check leakage on mechanical seal or leakage of packed gland
(see section 8.1 ”Gland packing”).
Check pump operation (positive suction pressure, total head, bearing temperature, noises
and vibrations)
Check torsional play of coupling
(see section ”Coupling”),
If available, switch to stand--by pump or carry
out a test run (for 5 min.)
Replace deep--groove ball bearings
(see section 7.3 ”Dismantling” and
7.4 ”Reassembly”).
General inspection and overhaul of pump in
accordance with the operating instructions.
2
6
Check and renew, if required:
-- wear parts such as: bearings, casing wear
ring (impeller wear ring, if any), shaft
protecting sleeve
-- impeller and shaft
-- Replace sealing elements
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)
2)
Type of installation DK 2)
Depending of motor size
Type of installation DJ 2)
Version with intermediate bearing
Direction of rotation / flow direction
Horizontal
Direction of rotation
anticlockwise,
viewed from the drive end
1)
42
Direction of rotation
clockwise, viewed from the
drive end
Vertical
Direction of rotation
anticlockwise,
viewed from the drive end
Direction of rotation
clockwise, viewed from the
drive end
General arrangement drawing ”Pump set 3 E -- Baseplate/baseframe with motor height adjustment” shows the main variants available
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)
(840)
901.06
(681)
(Shims)
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
(840)
901.06
(681)
(Adjusting screw)
901.57
550.57
550.56
180.54
890
(891)
(Pedestal)
901.05
920.10
550.10
900.01
89--4.03
,
43
Omega
Type of Installation 3E -- Motor Height Adjustment -- Baseframe with Base / Shims under the Motor Feet
901.54
(902.54)
(920.54)
550.54
901.06
(Shim)
(Base)
550.56
89-4.54
(592.54)
891
901.05
920.10
Part no.
89-4
180
550
592
890
900
901
902
909
920
44
2)
550.10
900.01
Description
Shim
Pedestal
Washer
Base
Baseplate
Screw
Hex. head bolt
Stud
Adjusting screw
Nut
89--4.03
1) optional, depending on height required
2) for long lengths, instead of hex. head bolts
1)
Omega
Sealing / flushing water piping
The pump is equipped with sealing / flushing water piping.
These pipes are sheathed PTFE hoses which are flexible, temperature 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.
719.01
731.02
731.03
731.04
731.05
731.12
903.01
Description
Flexible tube
Nipple joint
Cross
Nipple joint
Pipe bend
Socket
Screwed plug
Sealing water pipe for mechanical seal
903.01
731.03
731.04
719.01
731.02
Part no.
719.01
731.02
731.03
731.04
903.01
46
Description
Flexible tube
Nipple joint
Cross
Nipple joint
Screwed plug
Omega
Coupling (N--EUPEX)
(Flexible couplings N--EUPEX and N--EUPEX--DS,
types A and ADS)
· N--EUPEX couplings provide radial, angular, axial and torsional flexibility. They are positive--locking.
· Torque is transmitted by flexible coupling elements (flexibles).
· The non--linear spring characteristic and the favourable
damping properties of the N--EUPEX coupling effectively
counteract any dangerous increase in vibrations.
Installation
-- Design of types A / ADS
The N--EUPEX coupling types A / ADS consist of a coupling
part 1 which houses the flexible coupling blocks (12), the finger
part 3 and the coupling part 2, which bolts onto part 3.
The bolted connection between part 2 and part 3 makes it possible to separate the coupled machines without axial displacement (if clearance P is observed).
Part 1
Part 12
Part 13
Part 2
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.
D Any work on the coupling shall only be
performed with the machine shut down.
The driver must be secured against
inadvertent start--up (e.g. by locking the
key--operated switch or removing the
power supply fuses). At the switch--on
point a notice shall be affixed to the
effect that work is being performed on
the coupling.
D Immediately switch off the driver when
changes in coupling behaviour occur,
such as changed running noises.
D The coupling must be suitably protected
against accidental contact.
-- Mounting the coupling components
Before fitting the coupling components, carefully clean the shaft
ends and the coupling parts. Make sure to remove the flexible
coupling blocks before cleaning the coupling parts with a solvent.
Heed the manufacturer’s instructions for the use of
solvents.
Use appropriate tools when pulling on the
coupling parts, to prevent damage to the
shaft bearings due to the axial joining force.
Caution
Make sure to use suitable lifting tackle.
The shaft ends must not protrude from the hub faces. The coupling is locked in axial direction by means of the set screw or
end plate, as applicable / set screw and end plate, respectively.
Caution
The set screws shall only be tightened by
means of a hexagon socket head wrench to
DIN 911, without extension.
Non--compliance with these instructions may cause
the coupling to burst. Danger of life by flying fragments!
47
Omega
Heating up the coupling parts (to max. +150 °C) may facilitate
pulling on the coupling parts. If temperatures exceed +80 °C,
the flexible coupling blocks must be removed from the coupling
parts before the heating process.
Protect against burns from contact with hot components!
Using a dial micrometer will make for increased measuring accuracy.
To allow one shaft end to rotate freely, the driving section can
be separated on types A and ADS by loosening the screwed
connection between parts 2 and 3 and pulling part 3 out of the
recesses in part 1.
Caution
If the coupling blocks have been removed, they shall be re--installed after the coupling parts have been pulled on. Make sure
the heated coupling parts have cooled down to under 80 _C before 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 before aligning the coupling, and the tightening torque of the screwed 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 misalignment of the shaft ends should therefore be minimized. With
identical operating conditions, the useful life of the flexible coupling 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 misalignment) and feeler gauge (angular misalignment) as shown below to verify.
Straight edge
Feeler gauge
48
After
the
connection
has
been
re--established, check the tightening
torque of the bolts.
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
Nm
SW
[mm]
P
[mm]
S1
[mm]
110
125
140
160
180
200
225
250
280
315
350
400
440
480
520
560
610
660
710
118
135
152
172
194
218
245
272
305
340
350
430
472
514
556
-------------
14
17,5
29
35
44
67,5
89
145
185
200
260
340
420
550
670
710
1450
1450
1450
6
6
8
8
8
10
10
14
14
14
17
17
17
19
19
19
22
22
22
33
38
43
47
50
53
61
69
73
78
83
88
99
104
115
125
135
145
155
2-4
2-4
2-4
2-5
2-6
2-6
2-6
3-8
3-8
3-8
3-8
3-8
5-10
5-10
5-10
6-12
6-12
6-12
6-12
Commissioning the coupling
Operation
Measures to be taken prior to commissioning
General operating data
Before commissioning the coupling check the proper installation of the flexible coupling elements, i.e. make sure the flexibles are flush with the hub face, and check whether the set
screws are properly tightened. Also verify coupling alignment
and clearance S1 and correct, if necessary. Check whether all
screwed connections have been tightening with the tightening
torques specified. Finally, fit the coupling guard against accidental contact.
During coupling operation, watch out for
· changed running noises,
· sudden vibrations.
If any irregularities occur during operation,
switch off the driver immediately and refer
to the trouble--shooting table to determine the cause.
Caution
The trouble--shooting table lists possible faults, causes and
suggested remedies.
49
Omega
Trouble--shooting
General
The faults listed below shall serve as orientation only when determining failure causes.
In a complex plant system, all other components will have to be
included in the search for possible failure causes.
The coupling shall give low--noise and vibration--free operation
in all phases of operation. Any other operating behaviour shall
be considered a fault which must be remedied immediately.
Before commencing any maintenance, repair or
other work on the coupling, the operator must shut
down the entire driving mechanism. The drivers, in particular, must be secured against inadvertent start--up.
Also, the accident prevention regulations in force at the installation site shall be complied with.
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 connection between parts 2 and 3.
Maintenance and repair
General
The torsional play between the two coupling parts shall be
checked in acc. with the maintenance schedule of the plant, but
at least once a year.
If torsional play must not be limited for extremely smooth coupling operation, the plastic flexibles can be allowed to wear
down to approx. ¼ of their original thickness before they have
to be replaced. To assess the wear condition of the coupling
blocks, the table below indicates the permissible torsional play
as indicated by the chord dimension DSV on the outside coupling diameter.
50
To determine the chord dimension DSV, rotate one coupling part
by hand up to the stop and mark the coupling parts (see illustration). Hand--rotate one coupling part into the opposite direction
up to the stop. The two marks will diverge. The distance between the marks is the chord dimension DSV. If DSV exceeds the
value given in the table, the flexible coupling blocks have to be
replaced.
Coupling blocks shall always be replaced
Caution
by complete sets of new coupling blocks;
only use coupling blocks with identical identification
numbers.
Omega
Table: Wear mark on N--EUPEX coupling
Size
Wear
mark
DSV
58
68
80
95
110
125
140
160
180
200
225
250
280
315
350
400
440
480
520
560
610
660
710
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
Table: Wear mark on N--EUPEX--DS coupling
Size
wear
mark
DSV
66
76
88
103
118
135
152
172
194
218
245
272
305
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
Replacing wear parts
Use only genuine N--EUPEX flexible blocks as spare parts, to
ensure correct torque transmission and trouble--free operation.
Please note:
On types A and ADS, the flexibles can be replaced without axial
displacement of the coupled machines.
340
6.5
380
430
472
514
556
7.0
10.0
12.0
14.0
16.0
After the screwed connection between parts 2 and 3 has been
undone, part 3 can be shifted in axial direction. By rotating part
3, the flexible coupling blocks are freely accessible. To facilitate
axial displacement, sizes 225--430 are provided with forcing
threads in part 1. From size 440, the forcing threads are located
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
Sealed with Loctite 574
ALTEMP Q NB 50 grease
52
Shaft seal: Gland packing
Shaft
diameter
Axial overhang of shaft protecting sleeve
dW
A ± 0.5
40
50
60
70
80
90
2
2
2
5
4
4
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
Sealed with Loctite 574
ALTEMP Q NB 50 grease
54
Shaft seal: Mechanical seal
Shaft
diameter
Axial overhang of shaft protecting sleeve
dW
A ± 0.5
40
50
60
70
80
90
2
2
2
5
4
4
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
Ø dw
Flushing line
connection
Standardized mechanical seal to DIN 24960 -- short design, non--balanced
Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)
457.02
525.02
411
433 Flushing line
connection
Æ 110
524.01
dw =90
211
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
471
901.16
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
connection
471
901.16
525.02
524.01
dw
211
Balanced mechanical seal (for operating pressures p > 16 bar) to DIN 24960
Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)
525.02
411
433 Flushing line 471
connection
901.16
Æ 110
524.01 457.02
dw = 90
211
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
The mechanical seals, 58U and 58B, are precision--made and
must be treated accordingly. The contact faces are lapped to
a high degree of accuracy and prior to despatch they are covered in a protective sleeve to prevent damage. If the protective
sleeve is removed for installation purposes, then great care
must be taken to avoid any damage to the finely finished, lapped 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
305
582 (092)
583
123
574
564
Retainer
Grub screw
Spring
Thust ring
O-ring
Rotating face
Support ring
578
096
500
501
902
123 (R)
Balanced face
Snap ring
Seat type BP
Seat ring
Seat type BO
O-ring
Installation and operation
1. Clean and lightly lubricate the shaft / sleeve with a suitable
lubricant.
Caution:
Sealing elements manufactured in EP--Elastomer materials
must not come in contact with mineral oil and grease.
2. Push on the rotating unit applying light manual pressure.
58
Preparation for installation
1. The installation dimensions and tolerances must comply
with those outlined in the relevant literature.
2. The cover which will accept the seat ring must be checked
with regard to depth and installation dimensions.
3. Push the seat ring together with the joint ring into the cover
applying even manual pressure. The joint ring shall also be
lubricated using a suitable lubricant.
4. The contact faces must be cleaned prior to installation into
the machine. Tighten the cover bolts evenly. Overtightening
can affect the true running of the rubbing faces and therefore have an adverse effect on the functioning of the mechanical seal.
5. Manually turn the shaft. Fill the machine whilst simultaneously monitoring the venting equipment within the seal
area. Check the circulation pipe.
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.
Lapped surfaces of the rotating face must
Caution
be protected.
Wing nut
Grub screw
Thrust plate with
glued--on
protective support
Locking nut
Baseplate
1. The rotating face (574 / 578) is pushed down and the snap
ring (096) is removed from the groove using a pointed tool.
2. Now remove in the following sequence: the rotating face
(574 / 578), the O--ring (123), the thrust ring (583) and the
springs (582 / 092).
Assembly is carried out in reverse sequence.
The following must be noted during assembly:
The drive cams in the retainer (780) must engage into the grooves of the thrust ring (583) or the rotating face (574 / 578) .
Fit the snap ring (096) into the groove of the retainer (780), leaving 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 marker grooves. The lower one runs precisely through the centre
of the drilled hole for the internal socket head screws, which indicates that the thread of the screws is metric.
The upper groove assists during installation. If the initial tension 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
N.B.:
Fig. 0
If the pump’s direction of rotation is
ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).
Direction of rotation: CLOCKWISE
a2
l3
a1
Z
d3
5D
l2
s2
f
5D
s1
Direction of rotation:
CLOCKWISE
5D
DN1
DN2
1M
1M
h1
h2
d1
h3
l1
8B
8B
s
6B
n4
n3
n2
n1
Keyway and key
DIN 6885 sheet 1
Shaft diameter:
Tolerance h6 to DIN 7155
m2
b1
d2
m1
Connections:
- 1M
Pressure gauge
- 5D
Vent
- 6B
Drainage
- 8B
Leakage liq. drain
Flanges:
- All flanges designed as plate flanges
- flange thickness to ANSI
- Connect pipes without transmitting stresses or strains
Dimensions and weights
Pump
Size
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
Pump
Size
Flange dimensions
s1
DN1
DN2
125
80
34
29
150
100
37
32
200
125
41
35
200
b1
150
d2
41
m1
s2
37
Foot dimensions
m2
n1
n2
n3
80-210
80-270
70
17,5
320
270
205
205
170
80-370
100-250
100-310
70
17,5
320
270
235
235
200
100-375
125-230
125-290
260
260
225
70
17 5
17,5
390
340
125-365
125-500
315
315
280
150-290
390
340
260
260
225
150-360
70
17 5
17,5
150-460
315
315
280
480
430
150-605
385
385
350
1) z = clearance above casing cover for dismantling of the rotor
60
a1
a2
d3
300
300
330
330
330
330
370
370
370
370
450
450
400
400
450
600
450
500
Pump dimensions
f
h1
h2
h3
19
415
315
140
19
415
355
170
19
515
400
200
400
200
500
300
19
515
590
n4
s
Shaft
d1
l1
170
20
35
80
200
20
35
80
20
45
100
45
100
55
125
225
280
225
280
350
20
168
190
225
195
225
260
210
230
260
305
245
265
305
370
Weights [kg]
Pump
Water
fill
185
195
205
210
225
245
250
275
300
335
350
360
440
650
10
15
20
20
25
30
35
40
45
55
50
60
75
90
G 1/2
G 1/2
G 1/2
G 3/4
All dimensions in mm
l2
l3
300
715
300
715
366
881
366
881
399
989
z 1)
340
380
450
390
450
520
420
460
520
610
490
530
610
740
Omega
Standard flange connections 1):
Pump
Size
JL 1040 / GGG--NiCrNb 202
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
JS 1030 / 1.4517
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
80-210
80-270
PN 16
Table 16/11
Class 250
PN 25
Table 25/11
Class 250
PN 16
Table 16/11
Class 250
PN 25
Table 25/11
Class 250
80-370
100-250
100-310
100-375
d2
125-230
125-290
125-365
PN 16
Table 16/11
PN 16
Table 16/11
PN 25
Table 25/11
Class 250
PN 25
Table 25/11
Class 250
Class 250
PN 25
Table 25/11
Class 250
number of
holes n
125-500
150-290
150-360
150-460
150-605
1)
k
Other flange connections on request
Flange dimensions -- Hole pattern
DN 80
Standard
DN 100
DN 125
All dimensions in mm
DN 200
DN 150
d2
k
n
d2
k
n
d2
k
n
d2
k
n
d2
k
n
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
ISO 7005/2
DIN 2501
61
Omega
Dimension tables Omega 200 -- 320 up to 350 -- 510
N.B.:
Fig. 0
If the pump’s direction of rotation is
ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).
Direction of rotation: CLOCKWISE
a2
l3
a1
Z
d3
5D
l2
s2
f
5D
s1
Direction of rotation:
CLOCKWISE
5D
DN1
DN2
1M
1M
h1
d1
h2
h3
l1
8B
8B
s
6B
m2
b1
d2
n4
n3
n2
n1
Keyway and key
DIN 6885 sheet 1
Shaft diameter:
Tolerance h6 to DIN 7155
m1
Connections:
- 1M
Pressure gauge
- 5D
Vent
- 6B
Drainage
- 8B
Leakage liq. drain
Flanges:
- All flanges designed as plate flanges
- flange thickness to ANSI
- Connect pipes without transmitting stresses or strains
Dimensions and weights
Pump
Size
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
350-510
Pump
Size
DN1
250
DN2
All dimensions in mm
Flange dimensions
s1
200
48
250
350
400
300
s2
41
33 (51) 1)
300
32 (48) 1)
51
48
36 (54) 1)
38 (57) 1)
33
(51) 1)
57
51
1)
400
450
400
350
b1
d2
38 (57)
41 (60) 1)
38 (57) 1)
m1
36 (54) 1)
Foot dimensions
m2
n1
n2
n3
200-320
17 5
17,5
430
315
315
280
200-420
70
480
200-520
400
385
385
22
350
200-670
100
400
400
400
250-370
480
400
100
22
400
400
350
250-480
600
520
250-600
300-300
480
400
400
400
350
300-435
100
22
600
520
300-560
525
525
475
300-700
350-360
400
400
350
350-430
100
22
600
520
525
525
475
350-510
1) for casing material GGG--NiCrNb 202, JS 1030, 1.4517
2) z = clearance above casing cover for dismantling of the rotor
62
G 1/2
G 1/2
G 1/2
G 3/4
a1
a2
d3
450
500
600
650
500
550
650
550
650
700
750
650
750
700
450
500
24 5
24,5
550
500
550
500
550
590
500
240
655
560
600
300
350
600
300
730
630
630
670
710
750
670
350
300
350
350
400
350
810
750
400
655
12,5
24 5
24,5
650
730
655
730
810
550
650
Pump dimensions
f
h1
h2 2)
h3
24,5
n4
s
Shaft
d1
l1
280
20
55
125
350
26
65
140
350
26
65
140
75
160
65
75
140
160
85
180
75
160
85
180
350
475
350
475
26
26
285
310
370
430
320
355
415
360
365
430
480
410
465
420
Weights [kg]
Pump
Water
fill
450
520
840
990
665
830
1215
630
905
1425
1690
865
1285
1395
80
95
115
140
125
145
180
100
190
225
275
160
240
290
l2
l3
399
989
464
1119
464
1119
515
1245
464
515
1119
1245
585
1395
515
1245
585
1395
z 2)
570
620
740
860
640
710
830
720
730
860
960
820
930
840
Omega
Standard flange connections 1):
Pump
Size
JL 1040 / GGG--NiCrNb 202
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
JS 1030 / 1.4517
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
200-320
200-420
PN 16
Table 16/11
200-670
PN 25
Table 25/11
250-370
PN 10
Table 10/11
250-480
PN 16
Table 16/11
250-600
PN 25
Table 25/11
PN 10
Table 10/11
300-560
PN 16
Table 16/11
300-700
PN 25
Table 25/11
Class 250
PN 10
Table 10/11
Class 125
Class 250
200-520
300-300
300-435
PN 25
Table 25/11
Class 250
Class 125
Class 250
PN 25
Table 25/11
Class 250
d2
number of
holes n
Class 125
PN 25
Table 25/11
Class 250
PN 25
Table 25/11
Class 250
350-360
350-430
350-510
1)
k
Other flange connections on request
Flange dimensions -- Hole pattern
Standard
DN 200
d2
k
n
DN 250
d2
k
n
DN 300
d2
k
n
DN 350
d2
k
n
DN 400
d2
k
n
All dimensions in mm
DN 450
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
BS 4504
ANSI B 16.1
Table 16/11
Table 25/11
Class 125
23
28
23
295
310
299
12
12
8
28
31
28
355
370
362
12
12
12
28
31
28
410
430
432
12
16
12
28
34
28
470
490
476
16
16
12
31
37
28
525
550
540
16
16
16
31
37
31
585
600
578
20
20
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
N.B.:
Installation type 3E
If the pump’s direction of rotation is
ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).
Direction of rotation: CLOCKWISE
a2
Z
s2
a1
l2
s1
5D
q
f
5
5D
8B
8B
L
50
h8
h4
6B
h6
1M
1M
DN1
h5
DN2
h7
5D
Grouting
(øN)
200
G1
b2
G2
100
l4
100
l5
100
l5
100
l3
Connections:
- 1M
Pressure gauge
- 5D
Vent
- 6B
Drainage
- 8B
Leakage liq. drain
L
50
h8
VN
b2
G 1/2 100
G 1/2
G 1/2
G 3/4
100
200
l4
100
l3
The motor--dependt dimensions refer to KSB standard motors
Ground baseplate / base frame with low--shrinkage concrete
Dimensions and weights
Pump
Size
80-210
80-270
80-370
100-250
100-310
100-375
1) z
Flange dimensions
Motor-DN1
dependet
-up to 280 M
up 315 S 125
-up to 280 M
up 315 S
up to 280 M 150
up 315 S
--
DN2
80
s1
s2
36
100
29
37
32
a1
a2
300
300
330
330
330
330
370
370
f
415
415
h4
295
320
295
305
330
305
330
305
h5
max.
660
760
h6
i
435
70
460
435
475
500
475
500
475
85
70
70
85
70
85
70
l2
300
300
z 1)
Pump
340
185
Water
fill
10
380
195
15
450
205
20
390
210
20
450
225
25
520
245
30
= clearance above casing cover for rotor removal
Baseplate / base frame and foundation dimensions
BaseplateSize
No.
Drawing no.
1
0W 384 167-00
2
0W 384 169-00
3 2)
0W 384 170-00
2) Base frame
64
All dimensions in mm
Masse [kg]
Pump dimensions
Baseplate-and foundation dimensions
All dimensions in mm
Ancor bolts
Foundation bolts
b2
G1
G2
l3
l4
l5
h8
Weight
[kg]
530
475
590
1190
495
495
120
74
640
580
700
1400
600
600
120
97
670
610
720
1630
715
715
145
105
Size
VN
L
Size
øN
L
M 16x250
100
250
M 12/25
18
110
Omega
Standard flange connections 1):
Pump
Size
JL 1040 / GGG--NiCrNb 202
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
JS 1030 / 1.4517
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
80-210
80-270
80-370
PN 16
100-250
Table 16/11
Class 250
PN 25
Table 25/11
Class 250
100-310
100-375
1)
Other flange connections on request
All dimensions in mm
Flange dimensions -- Hole pattern
Standard
DN
Pump sizes 80-210 up to 80-370
ISO 7005/2
PN 16
DIN 2501
BS 4504
Table 16/11
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
Class 250
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
Class 250
DN
Discharge flange
d2
k
Mating flange
All flanges designed as plate flanges
n
80
19 (M16) 210
8
28 (M24) 220
8
100
23 (M20) 240
19 (M16) 180
k
8
28 (M24) 250
Table 25/11
number of
holes n
23 (M20) 168
150
Table 16/11
d2
19 (M16) 160
23 (M20) 235
Pump sizes 100-250 up to
100-375
PN 16
n
125
Table 25/11
ISO 7005/2
DIN 2501
BS 4504
Suction flange
d2
k
23 (M20) 270
8
23 (M20) 190
23 (M20) 200
12
Baseplate / motor combinations
Pump
Size
Motor Size
100L
112M
132S
132M
No of
poles
4
4
4
80-210
1
1
80-270
80-370
100-250
1
1
100-310
100-375
N.B.:
1
1
160M
160L
180M
4
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
4
180L
4
200L
2
4
225S
4
225M
250M
2
2
4
4
280S
280M
315S
315M
315L
315
2
2
2
2
2
2
3
3
1
1
2
2
1
1
2
2
2
2
3
2
2
2
2
3
3
2
2
2
2
3
3
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
- 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
N.B.:
Installation type 3E
If the pump’s direction of rotation is
ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).
Direction of rotation: CLOCKWISE
a2
Z
s2
a1
l2
s1
5D
q
f
5
5D
8B
8B
L
50
h8
h4
6B
h6
1M
1M
DN1
h5
DN2
h7
5D
Grouting
(øN)
200
G1
b2
G2
100
l4
100
l5
100
l5
100
l3
Connections:
- 1M
Pressure gauge
- 5D
Vent
- 6B
Drainage
- 8B
Leakage liq. drain
L
50
h8
VN
b2
G 1/2
100
G 1/2
G 1/2
G 3/4
100
200
l4
100
l3
The motor--dependt dimensions refer to KSB standard motors
Ground baseplate / base frame with low--shrinkage concrete
Dimensions and weights
Pump size
125 230
125-230
125-290
125-365
125-500
150-290
150-360
1) z
Motordependet
up to 280 M
up 315 S
up to 280 M
up 315 S
-up to 280 M
up 315 S
---
Flange dimensions
DN1 DN2
s1
s2
200
125
200
150
41
35
41
a1
a2
f
370
370
450
450
400
400
515
37
Pump dimensions
h4
h5
h6
max.
320
520
345
545
320
520
345 825 545
320
520
320
520
345
545
320
1050
i
120
z 1)
l2
366
520
420
250
35
460
275
40
520
300
45
610
335
55
490
530
347
359
50
60
= clearance above casing cover for rotor removal
Baseplate-- / base frame and foundation dimensions
Baseplate
Size
No.
Drawing no.
4
0W 384 171-00
5
0W 384 172-00
6 2)
0W 384 173-00
2) Base frame
66
All dimensions in mm
Weight [kg]
Pump
Water
fill
Baseplate and foundation dimensions
All dimensions in mm
Ancor bolts
Foundation bolts
b2
G1
G2
l3
l4
l5
h8
Weight
[kg]
695
635
750
1330
565
565
120
92
695
635
750
1540
670
670
120
106
560
500
610
1820
810
810
145
110
Size
VN
L
Size
øN
L
M 16x250
100
250
M 12/25
18
110
Omega
Standard flange connections 1):
Pump
Size
JL 1040 / GGG-NiCrNb 202
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
125-230
125-290
125-365
PN 16
Table 16/11
125-500
150-290
150-360
1) Other flange connections on request
JS 1030 / 1.4517
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
Class 250
PN 25
Table 25/11
Class 250
All dimensions in mm
Flange dimensions -- Hole pattern
Standard
Suction flange
d2
k
DN
Pump sizes 125-230 up to
125-500
ISO 7005/2
DIN 2501
BS 4504
PN 16
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
Class 250
28 (M24) 310
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
Class 250
12
28 (M24) 220
number of
holes n
8
150
23 (M20) 295
28 (M24) 310
Table 25/11
d2
23 (M20) 235
200
Table 16/11
Mating flange
All flanges designed as plate flanges
n
19 (M16) 210
28 (M24) 330
Pump sizes 150-290 up to
150-360
Discharge flange
d2
k
125
23 (M20) 295
Table 25/11
PN 16
DN
200
Table 16/11
ISO 7005/2
DIN 2501
BS 4504
n
23
240
28
250
23
270
k
8
12
28 (M24) 330
12
Baseplate / motor combinations
Pump
Size
Motor Size
132S
132M
160M
160L
180M
180L
No of poles
4
4
4
4
4
4
125-230
125-290
125-365
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
125-500
150-290
150-360
N.B.:
200L
2
225S
4
4
4
4
4
4
5
5
4
4
4
4
4
5
5
5
4
225M
250M
280S
280M
315S
315M
315L
2
2
2
2
2
2
2
4
5
5
4
5
5
4
5
5
4
5
5
4
6
6
5
5
5
5
5
5
5
5
5
5
5
5
5
4
6
6
6
6
4
315
2
6
6
- 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
N.B.:
Installation type 3E
If the pump’s direction of rotation is
ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
reversed (mirror image).
Direction of rotation: CLOCKWISE
a2
Z
s2
a1
l2
s1
5D
q
f
5
5D
DN1
1M
1M
8B
8B
L
50
h8
h4
6B
h6
DN2
h5
h7
5D
Grouting
(øN)
200
G1
b2
G2
100
100
l4
l5
100
l5
100
l3
Connections:
- 1M
Pressure gauge
- 5D
Vent
- 6B
Drainage
- 8B
Leakage liq. drain
L
50
h8
VN
b2
G 1/2
G 1/2
G 1/2
G 3/4
100
100
200
100
l4
l3
The motor--dependt dimensions refer to KSB standard motors
Ground baseplate / base frame with low--shrinkage concrete
Dimensions and weights
Pump
Size
150-460
150-605
200-320
200-420
200-520
200-670
250-370
300-300
Motordependet
up to 250 M
280 S up to 315
L
-up to 250 M
280 S, M
up to 250 M
280 S up to 315
L
250 M
up 280 S
-250 M
up 280 S
up to 250 M
up 280 S
All dimensions in mm
Flange dimensions
DN1 DN2
s1
s2
a2
450
450
600
500
f
320
200
150
41
37
450
250
200
48
41
(51)1)
300
250
33
350
300
36 (54)1)
1) for casing material GGG--NiCrNb 202, JS 1030, 1.4517
2) z = clearance above casing cover for dismantling of the
68
a1
Pump dimensions
h4
h5
h6
max.
500
450
600
500
650
550
(48)1)
500
500
33 (51)1)
550
500
32
rotor
380
440
380
655
380
440
430
420
480
450
510
580
680
620
680
620
590
440
l2
z 2)
Weight [kg]
Pump
Waterfill
520
1050
500
i
1240
1275
1430
399
215
610
436
75
740
646
90
570
450
80
620
517
95
740
840
115
860
990
140
640
665
125
720
630
100
399
680
740
780
720
780
750
810
150
464
Omega
Baseplate-- / base frame and foundation dimensions
Baseplate
Size
No.
1)
Baseplate
Size
Drawing no.
7
8 1)
9 1)
10 1)
14 1)
15 1)
All dimensions in mm
Baseplate and foundation dimensions
0W 384 174-00
0W 384 175-00
0W 384 176-00
0W 384 478-00
0W 384 479-00
0W 384 480-00
b2
G1
G2
l3
l4
l5
h8
880
820
960
1660
1870
730
835
730
835
120
700
620
750
1970
885
885
2170
2320
985
1060
985
1060
180
Foundation bolts
Weight
[kg]
157
185
204
208
210
215
Size
VN
L
M 20x320
100
320
Base frame
Standard flange connections 2):
Pump
Size
150-460
150-605
200-320
200-420
200-520
200-670
250-370
300-300
2)
JL 1040 / GGG-NiCrNb 202
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
PN 16
Table 16/11
PN 25
Table 25/11
Class 250
PN 16
Table 16/11
PN 25
Table 25/11
PN 10
Table 10/11
JS 1030 / 1.4517
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
PN 25
Table 25/11
Class 250
Class 125
Other flange connections on request
Flange dimensions -- Hole pattern
Standard
Pump sizes 150-460 and 150-605
ISO 7005/2, DIN 2501 PN 16
BS 4504
Table 16/11
ISO 7005/2, DIN 2501 PN 25
BS 4504
Table 25/11
ANSI B 16.1
Class 250
Pump sizes 200-320 up to 200-670
ISO 7005/2, DIN 2501 PN 16
BS 4504
Table 16/11
ISO 7005/2, DIN 2501 PN 25
BS 4504
Table 25/11
ANSI B 16.1
Class 250
Pump sizes 250-370
ISO 7005/2, DIN 2501 PN 10
BS 4504
Table 10/11
ISO 7005/2, DIN 2501 PN 16
BS 4504
Table 16/11
ISO 7005/2, DIN 2501 PN 25
BS 4504
Table 25/11
ANSI B 16.1
Class 125
ANSI B 16.1
Class 250
Pump sizes 300-300
ISO 7005/2, DIN 2501 PN 10
BS 4504
Table 10/11
ISO 7005/2, DIN 2501 PN 16
BS 4504
Table 16/11
ISO 7005/2, DIN 2501 PN 25
BS 4504
Table 25/11
ANSI B 16.1
Class 125
ANSI B 16.1
Class 250
DN
200
Suction flange
d2
k
n
All dimensions in mm
Discharge flange
DN
d2
k
n
150
23 (M20) 295
28 (M24) 310
23 (M20) 240
12
28 (M24) 250
28 (M24) 330
23 (M20) 270
250
Mating flange
All flanges designed as plate flanges
8
d2
12
200
28 (M24) 355
31 (M27) 370
23 (M20) 295
12
28 (M24) 310
28 (M24) 387
number of
holes n
12
28 (M24) 330
300
250
23 (M20) 400
28 (M24) 410
23 (M20) 350
12
28 (M24) 355
31 (M27) 430
16
31 (M27) 370
28 (M24) 432
31 (M27) 451
12
16
28 (M24) 362
28 (M24) 387
350
k
12
16
300
23 (M20) 460
28 (M24) 470
23 (M20) 400
16
34 (M30) 490
28 (M24) 476
31 (M27) 514
12
20
28 (M24) 410
12
31 (M27) 430
16
28 (M24) 432
31 (M27) 451
12
16
Baseplate / motor combinations
Motor Size
Pump
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
N.B.:
Installation type 3E
If the pump’s direction of rotation is
ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
l2 reversed
f (mirror image). q
5
5D
5D
Direction of rotation: CLOCKWISE
a2
Z
s2
a1
s1
8B
8B
L
50
h8
h4
6B
h6
1M
1M
DN1
h5
DN2
h7
5D
Grouting
VN
(øN)
Connections:
- 1M
Pressure gauge
- 5D
Vent
- 6B
Drainage
- 8B
Leakage liq. drain
200
G1
b2
G2
100
l5
l4
100
G 1/2
G 1/2
G 1/2
G 3/4
l5
l4
100
All dimensions in mm
Flange dimensions
DN1
DN2
s1
Pump dimensions
s2
a1
a2
f
h4
h5
h6)
Weight [kg]
i
l2
z 2)
Pump
max.
250-480
250-600
300-435
350-360
1)
2)
300
400
250
51
300
38 (57) 1)
350
48
33 (51) 1)
550
650
500
550
730
480
520
36 (54) 1
1275
1430
1415
Baseplate-- / base frame and foundation dimensions
11 3)
0W 384 177-00
12 3)
0W 384 178-00
16 3)
0W 384 481-00
3) Base frame
70
b2
700
G1
800
710
830
145
830
830
1215
180
730
905
190
820
865
160
210
515
870
620
All dimensions in mm
Baseplate and foundation dimensions
G2
l3
l4
l5
l6
h8
760
1950
875
--
2100
950
--
2450
750
750
Weight
[kg]
Foundation bolts
VN
Size
L
215
200
228
240
Waterfill
for casing material GGG--NiCrNb 202, JS 1030, 1.4517
z = clearance above casing cover for dismantling of the rotor
Baseplate Size
No.
Drawing no.
100
The motor--dependt dimensions refer to KSB standard motors
Dimensions and weights
Size
l6
l3
Ground baseplate / base frame with low--shrinkage concrete
Pump
100
l3
M 20x320
100
320
Omega
Standard flange connections 1):
Pump
Size
250-480
PN 16
Table 16/11
250-600
PN 25
Table 25/11
PN 10
Table 10/11
300-435
350-360
1)
JL 1040 / GGG-NiCrNb 202
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
JS 1030 / 1.4517
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
Class 250
PN 25
Table 25/11
Class 250
Class 125
Other flange connections on request
Flange dimensions -- Hole pattern
All dimensions in mm
Standard
DN
Pump sizes 250-480 and 250-600
ISO 7005/2
DIN 2501
BS 4504
PN 10
ISO 7005/2
DIN 2501
BS 4504
PN 16
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
Class 125
ANSI B 16.1
Class 250
Suction flange
d2
k
n
DN
300
n
250
23 (M20)
Table 10/11
Discharge flange
d2
k
400
23 (M20)
Mating flange
All flanges designed as plate flanges
350
d2
12
Table 16/11
Table 25/11
Pump size 300-435
ISO 7005/2
PN 10
DIN 2501
BS 4504
Table 10/11
28 (M24)
410
28 (M24)
355
31 (M27)
430
16
31 (M27)
370
28 (M24)
432
12
28 (M24)
362
31 (M27)
451
16
28 (M24)
387
400
number of
holes n
12
16
300
k
28 (M24)
515
23 (M20)
400
31 (M27)
525
28 (M24)
410
37 (M33)
550
31 (M27)
430
16
28 (M24)
432
12
31 (M27)
451
16
12
ISO 7005/2
DIN 2501
BS 4504
PN 16
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
Class 125
28 (M24)
540
ANSI B 16.1
Class 250
34
572
Table 16/11
Table 25/11
Pump size 350-360
ISO 7005/2
PN 10
DIN 2501
BS 4504
Table 10/11
16
20
400
350
28 (M24)
515
16
23 (M20)
460
31 (M27)
525
16
28 (M24)
470
37 (M33)
550
16
34 (M30)
490
ISO 7005/2
DIN 2501
BS 4504
PN 16
ISO 7005/2
DIN 2501
BS 4504
PN 25
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
Table 16/11
Table 25/11
16
Baseplate / motor combinations
Pump
Size
Motor Size
250M
280S
280M
315S
315M
315L
315
355
400
No of poles
4
4
4
4
4
4
4
4
4
250-480
250-600
11
11
11
11
11
11
12
12
12
12
16
16
16
11
11
11
11
11
11
11
12
12
12
12
300-435
350-360
N.B.:
11
- 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
N.B.:
Installation type 3E
If the pump’s direction of rotation is
ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is
l2 reversed
f (mirror image). q
5
5D
5D
Direction of rotation: CLOCKWISE
a2
Z
s2
a1
s1
8B
8B
L
50
h8
h4
6B
h6
1M
1M
DN1
h5
DN2
h7
5D
Grouting
VN
(øN)
Connections:
- 1M
Pressure gauge
- 5D
Vent
- 6B
Drainage
- 8B
Leakage liq. drain
200
G1
b2
G2
100
100
l5
l4
l5
l4
100
G 1/2
G 1/2
G 1/2
G 3/4
l6
The motor--dependt dimensions refer to KSB standard motors
Dimensions and weights
Size
All dimensions in mm
Flange dimensions
DN1
DN2
s1
Pump dimensions
s2
a1
a2
f
h4
h5
h6
Weight [kg]
i
l2
z 2)
Pump
max.
300-560
300-700
400
350-430
450
350-510
400
300
57
700
51
41 (60) 1)
350
38 (57) 1)
750
36 (54) 1)
1) for casing material GGG--NiCrNb 202, JS 1030, 1.4517
2) z = clearance above casing cover for dismantling of the
560
650
810
550
700
1430
1415
13 3)
0W 384 179-00
17 3)
0W 384 482-00
18 3)
0W 384 483-00
3) Base frame
72
b2
950
G1
870
G2
1010
l3
910
950
210
585
860
1425
225
960
1690
275
930
1285
240
840
1395
290
All dimensions in mm
Baseplate and foundation dimensions
l4
l5
2195
665
2540
780
2390
730
l6
h8
Foundation bolts
Weight
[kg]
Size
VN
L
M 20x320
100
320
290
200
322
309
Waterfill
rotor
Baseplate-- / base frame and foundation dimensions
Baseplate
Size
No.
Drawing no.
100
l3
Ground baseplate / base frame with low--shrinkage concrete
Pump
100
l3
Omega
Standard flange connections 1):
Pump
Size
300-560
PN 16
Table 16/11
300-700
PN 25
Table 25/11
PN 10
Table 10/11
350-430
350-510
1)
JL 1040 / GGG-NiCrNb 202
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
JS 1030 / 1.4517
Nominal pressure acc. to:
DIN 2501
BS 4504
ANSI B 16.1
ISO 7005/2
Class 250
PN 25
Table 25/11
Class 250
Class 125
Other flange connections on request
Flange dimensions -- Hole pattern
All dimensions in mm
Standard
Suction flange
DN
Pump sizes 300-560 and 300-700
ISO 7005/2
PN 10
DIN 2501
BS 4504
Table 10/11
ISO 7005/2
DIN 2501
BS 4504
PN 16
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
ANSI B 16.1
d2
k
Discharge flange
n
400
515
525
37 (M33)
550
Class 125
28 (M24)
540
Class 250
34
572
Table 25/11
Pump size 350-430
16
20
450
ISO 7005/2
DIN 2501
BS 4504
PN 16
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
ANSI B 16.1
k
23 (M20)
400
n
Mating flange
All flanges designed as plate flanges
d2
12
31 (M27)
PN 10
d2
300
28 (M24)
Table 16/11
ISO 7005/2
DIN 2501
BS 4504
DN
565
31 (M27)
585
37 (M33)
600
Class 125
31 (M27)
578
Class 250
34
629
Table 16/11
Table 25/11
Pump size 350-510
ISO 7005/2
PN 10
DIN 2501
BS 4504
Table 10/11
430
16
28 (M24)
432
12
31 (M27
451
16
k
460
28 (M24)
470
34 (M30)
490
16
28 (M24)
476
12
24
31 (M27)
514
20
23 (M20)
460
28 (M24)
470
34 (M30)
490
28 (M24)
476
31 (M27)
514
20
16
350
28 (M24)
515
31 (M27)
525
37 (M33)
550
ISO 7005/2
DIN 2501
BS 4504
PN 16
ISO 7005/2
DIN 2501
BS 4504
PN 25
ANSI B 16.1
Class 125
28 (M24)
540
ANSI B 16.1
Class 250
34
572
Table 25/11
31 (M27)
23 (M20)
400
Table 16/11
410
350
28 (M24)
Table 10/11
number of
holes n
28 (M24)
16
20
16
12
20
Baseplate / motor combinations
Pump
Size
Motor Size
315M
315L
315
355
400
No of poles
4
4
4
4
4
300-560
300-700
350-430
13
13
13
17
18
18
17
17
13
13
13
13
13
13
18
17
350-510
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
5D
Venting
G 1/2
Venting of barrier liquid
G 1/2
6B
Casing drain
G 1/2
8B
Leakage drain
G 3/4
Enter order--specific data !
Pressure gauge connection, suction
side
G 1/2
Enter order--specific data !
Pressure gauge connection,
discharge side
G 1/2
Enter order--specific data !
9D
1 M.1
(if applicable)
(if applicable)
1 M.2
Connections
Value required
4 M.1
(if applicable)
Temperature measuring point, bearing
Drive end
G 3/8
See section 7.2
4 M.2
(if applicable)
Temperature measuring point,
non--drive end
G 3/8
See section 7.2
26 M.1 (if applicable)
Thread for SPM measurement,
drive end
M8
Enter order--specific data !
26 M.2
Thread for SPM measurement,
non--drive end
M8
Enter order--specific data !
74
. . . and should something have to be replaced,
KSB’s competent Spare Parts Service is at your disposal for the products
D
D
D
D
Amarex/KRT
Sewatec
Amacan
Omega
To:
KSB Aktiengesellschaft
Turmstr. 92
D-06110 Halle/Saale
Ersatzteilabteilung
Fax:
(+49) 345/48 26 4691
D
D
D
D
Amamix/Amaprop
Amajet
Getec
Amaline
Postfach 200743
D-06008 Halle/Saale
Tel:
Date:
(+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
9970428626 000100 2
KRT-F 100-250/7 4 UG-249
2--M01--753328
in addition:
Pump type
e.g. KRT-F 100-250/7 4 UG-249
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
Sample
1384.8/4-10
21.07.2005
Subject to modification without notice
Omega
KSB Aktiengesellschaft
P.O. Box 200743 · 06008 Halle (Saale) · Turmstraße 92 · 06110 Halle (Germany)
Tel. +49 (345) 48 26 0 · Fax +49 (345) 48 26 46 99 · www.ksb.com