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Summary of Contents for KSB Etaline-R
- Page 1 In-line Pump Etaline-R Installation/Operating Manual...
- Page 2 All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent. Subject to technical modification without prior notice. © KSB SE & Co. KGaA, Frankenthal 30/01/2018...
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Page 3: Table Of Contents
Electrical connection ............................ 24 5.6.1 Setting the time relay ........................ 24 5.6.2 Connecting the motor ........................ 25 Checking the direction of rotation........................ 25 Commissioning/Start-up/Shutdown.................... 26 Commissioning/Start-up .......................... 26 6.1.1 Prerequisites for commissioning/start-up .................. 26 6.1.2 Filling in lubricants.......................... 26 6.1.3 Checking the shaft seal........................ 26 Etaline-R 3 of 52... - Page 4 Recommended spare parts stock for 2 years' operation to DIN 24296 .......... 43 7.7.3 Interchangeability of pump components.................. 43 Trouble-shooting.......................... 45 Related Documents .......................... 47 General assembly drawing with list of components .................. 47 EU Declaration of Conformity ...................... 49 Certificate of Decontamination...................... 50 Index .............................. 51 Etaline-R 4 of 52...
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Page 5: Glossary
Pump Machine without drive, additional components or accessories Pump set Complete pump set consisting of pump, drive, additional components and accessories Suction lift line/suction head line The line which is connected to the suction nozzle Etaline-R 5 of 52... -
Page 6: General
The order number and order item number uniquely identify the pump (set) and serve as identification for all further business processes. In the event of damage, immediately contact your nearest KSB service centre to maintain the right to claim under warranty. Noise characteristics see (ð Section 4.7, Page 17) 1.2 Installation of partly completed machinery... - Page 7 1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product Etaline-R 7 of 52...
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Page 8: Safety
▪ Only use the pump to handle the fluids described in the data sheet or product literature of the pump model. ▪ Never operate the pump without the fluid handled. ▪ Observe the minimum flow rates indicated in the data sheet or product literature (to prevent overheating, bearing damage, etc). Etaline-R 8 of 52... -
Page 9: Personnel Qualification And Training
▪ The operator shall fit contact guards for hot, cold and moving parts and check that the guards function properly. ▪ Do not remove any contact guards during operation. ▪ Provide the personnel with protective equipment and make sure it is used. Etaline-R 9 of 52... -
Page 10: Safety Information For Maintenance, Inspection And Installation Work
Never operate the pump (set) outside the limits stated in the data sheet and in this manual. The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use. (ð Section 2.3, Page 8) Etaline-R 10 of 52... -
Page 11: Transport/Temporary Storage/Disposal
1. On transfer of goods, check each packaging unit for damage. 2. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) and the insurer about the damage in writing immediately. -
Page 12: Storage/Preservation
4. Always complete and enclose a certificate of decontamination when returning the pump (set). Always indicate any safety and decontamination measures taken. (ð Section 11, Page 50) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination Etaline-R 12 of 52... -
Page 13: Disposal
Collect greases and other lubricants during dismantling. 2. Separate and sort the pump materials, e.g. by: - Metals - Plastics - Electronic waste - Greases and other lubricants 3. Dispose of materials in accordance with local regulations or in another controlled manner. Etaline-R 13 of 52... -
Page 14: Description Of The Pump (Set)
4.3 Designation Example: Etaline-RG 200 - 400 Table 4: Key to the designation Code Description Etaline-R Type series Casing material, e.g. G = grey cast iron Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Etaline-R 14 of 52... -
Page 15: Name Plate
4 Description of the Pump (Set) 4.4 Name plate KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal Deutschland ETALINE-RG 200-400 2013 0520-5-P-10000-31 P-No. 9971234567 000100 01 600 m 40 m n 1488 1/min η --,-% MEI ≥ 0,70 Mat.-No. -
Page 16: Configuration And Function
(8). The shaft is supported by an oil-lubricated rolling element bearing (7). The motor (5) is connected to the casing via a bearing bracket (1). Sealing The pump is sealed by a shaft seal (8). Etaline-R 16 of 52... -
Page 17: Noise Characteristics
Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.80 - 1.1 range and for non- cavitating operation. If noise levels are to be warranted, add an allowance of +3 dB for measuring and manufacturing tolerances. Increase for 60 Hz operation: 3500 rpm, +3dB; 1750 rpm + 1dB Etaline-R 17 of 52... -
Page 18: Installation At Site
5.3 Installing the pump set CAUTION Dry running / Ingress of leakage into the motor Damage to the motor! ▷ Always install the pump set in vertical position. Etaline-R 18 of 52... - Page 19 Always fit shims, if any, immediately to the left and right of the chemical anchors (3) between the pump and the foundation. For an anchor-to-anchor distance (L) > 800 mm fit additional shims (2) halfway between the anchor holes. All shims must lie perfectly flush. Etaline-R 19 of 52...
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Page 20: Piping
Incorrect earthing during welding work at the piping Destruction of rolling element bearings (pitting effect)! ▷ Never earth the electric welding equipment on the pump or baseplate. ▷ Prevent current flowing through the rolling element bearings. Etaline-R 20 of 52... - Page 21 Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter) made of corrosion-resistant material. Use a filter with a filter area three times the cross-section of the piping. Conical filters have proved suitable. 4. Connect the pump nozzles to the piping. Etaline-R 21 of 52...
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Page 22: Permissible Forces And Moments At The Pump Nozzles
The data on forces and moments apply to static piping loads only. If the limits are exceeded, they must be checked and verified. If a computerised strength analysis is required, please contact KSB. The values are only applicable if the pump is bolted to a rigid and level foundation. -
Page 23: Auxiliary Connections
Risk of burns! Malfunction of the pump! ▷ Refer to the general arrangement drawing, the piping layout and pump markings (if any) for the quantity, dimensions and locations of auxiliary connections. ▷ Use the auxiliary connections provided. Etaline-R 23 of 52... -
Page 24: Enclosure/Insulation
▷ Keep switch-over intervals between star and delta as short as possible. Table 9: Time relay settings for star-delta starting: Motor rating Y time to be set ≤ 30 kW < 3 s > 30 kW < 5 s Etaline-R 24 of 52... -
Page 25: Connecting The Motor
The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. 3. If the motor runs in the wrong direction of rotation, check the electrical connection of the motor and the control system, if applicable. Etaline-R 25 of 52... -
Page 26: Commissioning/Start-Up/Shutdown
For design-inherent reasons some unfilled volume in the hydraulic system cannot be excluded after the pump has been primed for commissioning/start-up. However, once the motor is started up the pumping effect will immediately fill this volume with the fluid handled. Etaline-R 26 of 52... -
Page 27: Start-Up
DANGER Seal leakage at operating temperature Hot or toxic fluid could escape! ▷ Once the operating temperature has been reached, re-tighten the hexagon nuts between casing and casing cover. Etaline-R 27 of 52... -
Page 28: Shutdown
6.2.1 Ambient temperature CAUTION Operation outside the permissible ambient temperature Damage to the pump (set)! ▷ Observe the specified limits for permissible ambient temperatures. Observe the following parameters and values during operation: Etaline-R 28 of 52... -
Page 29: Frequency Of Starts
Temperature at the casing surface °C Pump efficiency at duty point Temperature difference 6.2.3.2 Density of the fluid handled The pump input power changes in proportion to the density of the fluid handled. Duty point at maximum efficiency Etaline-R 29 of 52... -
Page 30: Shutdown/Storage/Preservation
(set) to service. (ð Section 7, Page 32) WARNING Failure to re-install or re-activate protective devices Risk of injury from moving parts or escaping fluid! ▷ As soon as the work is completed, re-install and re-activate any safety-relevant devices and protective devices. Etaline-R 30 of 52... - Page 31 6 Commissioning/Start-up/Shutdown NOTE If the pump has been out of service for more than one year, replace all elastomer seals. Etaline-R 31 of 52...
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Page 32: Servicing/Maintenance
(set) with a minimum of maintenance expenditure and work. NOTE All maintenance, service and installation work can be carried out by KSB Service or authorised workshops. Find your contact in the attached "Addresses" booklet or on the Internet at "www.ksb.com/contact". - Page 33 After commissioning, increased temperatures may occur at grease-lubricated rolling element bearings due to the running-in process. The final bearing temperature is only reached after a certain period of operation (up to 48 hours depending on the conditions). Etaline-R 33 of 52...
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Page 34: Inspection Work
If the clearance gap is larger than permitted (see the following table), fit new casing wear ring 502.1 and, if applicable, 502.2. The clearance gaps given refer to the diameter. Table 13: Clearance gaps between impeller and casing / between impeller and casing cover Etaline-R 0.4 mm Maximum permissible enlargement 0.6 mm 7.2.2.2 Cleaning filters... -
Page 35: Drainage/Cleaning
2. Always flush the pump if it has been used for handling noxious, explosive, hot or other hazardous fluids. Always flush and clean the pump before transporting it to the workshop. Provide a cleaning record for the pump. Shaft unit see data sheet. With Nilos ring 6413 AV Etaline-R 35 of 52... -
Page 36: Dismantling The Pump Set
For dismantling and reassembly observe the exploded views and the general assembly drawing. NOTE All maintenance, service and installation work can be carried out by KSB Service or authorised workshops. Find your contact in the attached "Addresses" booklet or on the Internet at "www.ksb.com/contact". -
Page 37: Preparing The Pump Set
2. Undo hexagon nut 920.1 at the volute casing. 3. Use forcing screws 901.31 to press the back pull-out unit out of volute casing. 4. Remove and dispose of gasket 400.19. 5. Place the back pull-out unit on a clean and level surface. Etaline-R 37 of 52... -
Page 38: Removing The Impeller
7.5 Reassembling the pump set 7.5.1 General information/Safety regulations WARNING Improper lifting/moving of heavy assemblies or components Personal injury and damage to property! ▷ Use suitable transport devices, lifting equipment and lifting tackle to move heavy assemblies or components. Etaline-R 38 of 52... -
Page 39: Installing The Bearings
7. Screw casing cover 161 to bearing bracket 330 using hexagon socket head cap screws 914.03. 7.5.3 Installing the mechanical seal The following rules must be observed when installing the mechanical seal: ▪ Work cleanly and accurately. ▪ Prevent any damage to the sealing surfaces or O-rings. Etaline-R 39 of 52... - Page 40 7 Servicing/Maintenance 400.04 Fig. 11: Installing the KSB cartridge seal 400.04 Gasket Circumferential groove Intermediate ring O-rings Mechanical seal ü The notes and steps stated in (ð Section 7.5.1, Page 38) have been observed/ carried out. ü The bearing assembly as well as the individual parts are kept in a clean and level assembly area.
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Page 41: Fitting The Impeller
1. Fit contact guard 680 over the outer bearing seat of bearing bracket 330. 2. Fit the motor shaft stub into shaft 210. 3. Screw the motor to the bearing bracket with bolt 901.18, disc 550.18/.11 and nut 920.11. Etaline-R 41 of 52... -
Page 42: Tightening Torques
▪ Type series ▪ Size ▪ KSB order number These values are determined on the basis of a friction coefficient of μ = 0.12. After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %. -
Page 43: Recommended Spare Parts Stock For 2 Years' Operation To Din 24296
○ 1▲ 250-250 ○ ￭ ￭ ￭ ￭ ○ 250-260 ○ ￭ ￭ ￭ ￭ ○ 200-330 3● 3● ○ ￭ ￭ ○ 200-400 ○ ￭ ○ 4∆ 200-500 1▲ ○ ￭ ￭ ￭ ￭ ○ Etaline-R 43 of 52... - Page 44 Motor Power .../754, .../406, .../556 .../1104, .../1504, .../756, .../1106 .../1854, .../2204, .../1506 .../3004, .../1856, .../2206 .../3704, .../4504, .../3006 .../5504, …/3706 …/7504, …9004, …/4506, …/5506 …/11004, …/13204, …/16004, …/20004, …/25004, …/31504, …/7506, …/9006, …/11006, …/13206, …/16006, …/20006 Etaline-R 44 of 52...
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Page 45: Trouble-Shooting
If problems occur that are not described in the following table, consultation with KSB’s customer service is required. A Pump delivers insufficient flow rate B Motor is overloaded... - Page 46 Increase the minimum flow rate. ✘ ✘ Incorrect setting of motor protection Check setting. switch Fit new motor protection switch. ✘ ✘ Transport lock has not been removed Remove. from the shaft groove. Please contact KSB. Etaline-R 46 of 52...
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Page 47: Related Documents
9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components Fig. 13: General assembly drawing Etaline-R 47 of 52... - Page 48 Gasket 903.01/.02/.03/.04/.16 Screw plug 411.01/.02/.03/.04/.16/. Joint ring 914.03 Hexagon socket head cap screw Mechanical seal 920.01/.11 500.18/.21 Ring Impeller nut 502.01/.02 Casing wear ring 932.02/.20 Circlip Thrower 940.01 Intermediate ring For sizes 250-250, 250-300, 250-340 only Etaline-R 48 of 52...
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Page 49: Eu Declaration Of Conformity
10 EU Declaration of Conformity 10 EU Declaration of Conformity KSB SE & Co. KGaA Manufacturer: Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: Etaline-R KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: –... -
Page 50: Certificate Of Decontamination
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the relevant legal provisions....................................Place, date and signature Address Company stamp Required fields Etaline-R 50 of 52... -
Page 51: Index
Shaft seal 15 Grease quality 34 Shutdown 30 Intervals 34 Spare parts stock 43 Start-up 27 Impeller type 15 Storage 12, 30 Installation Installation on a foundation 19 Installation at site 18 Transport 11 Intended use 8 Trouble-shooting 45 Interchangeability of pump components 43 List of components 48 Mechanical seal 26 Misuse 9 Etaline-R 51 of 52... - Page 52 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
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