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Summary of Contents for KSB HPK-L
- Page 1 Thermal Oil / Hot Water Pump HPK-L 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 06/10/2021...
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Page 3: Table Of Contents
5.3.2 Permissible forces and moments at the pump nozzles.............. 26 5.3.3 Auxiliary connections......................... 27 Enclosure/insulation ............................ 28 Checking the coupling alignment ......................... 28 Aligning the pump and motor ........................ 30 5.6.1 Motors with adjusting screw...................... 31 5.6.2 Motors without adjusting screw ....................... 31 HPK-L 3 of 74... - Page 4 Fitting the back pull-out unit...................... 59 7.5.9 Mounting the motor ......................... 59 Tightening torques............................ 59 7.6.1 Tightening torques for volute casing/bearing bracket.............. 59 Spare parts stock............................. 60 7.7.1 Ordering spare parts.......................... 60 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 .......... 60 HPK-L 4 of 74...
- Page 5 Contents 7.7.3 Interchangeability of pump components.................. 61 Trouble-shooting.......................... 63 Related Documents .......................... 65 General assembly drawing with list of components .................. 65 EU Declaration of Conformity ...................... 68 Certificate of Decontamination...................... 69 Index .............................. 70 HPK-L 5 of 74...
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Page 6: 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 pipeline which is connected to the suction nozzle HPK-L 6 of 74... -
Page 7: General
In the event of damage, immediately contact your nearest KSB service facility to maintain the right to claim under warranty. 1.2 Installation of partly completed machinery To install partly completed machinery supplied by KSB refer to the sub-sections under Servicing/Maintenance. -
Page 8: Key To Safety Symbols/Markings
In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage. Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions. HPK-L 8 of 74... -
Page 9: Safety
Deficits in knowledge must be rectified by means of training and instruction provided by sufficiently trained specialist personnel. If required, the operator can commission the manufacturer/supplier to train the personnel. Training on the pump (set) must always be supervised by technical specialist personnel. HPK-L 9 of 74... -
Page 10: Consequences And Risks Caused By Non-Compliance With This Manual
▪ Only perform work on the pump set when it has been disconnected from the power supply (de-energised). ▪ The pump (set) must have cooled down to ambient temperature. ▪ Pump pressure must have been released and the pump must have been drained. HPK-L 10 of 74... -
Page 11: Unauthorised Modes Of Operation
The motors used by KSB on pumps with ATEX certification meet this condition. Misuse, malfunctions or non-compliance with the instructions may result in substantially higher temperatures. -
Page 12: Monitoring Equipment
If the pump is to be operated at a higher temperature, the data sheet is missing or if the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature. 2.9.3 Monitoring equipment The pump (set) must only be operated within the limits specified in the data sheet and on the name plate. -
Page 13: Transport/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 and the insurer about the damage in writing immediately. -
Page 14: Storage/Preservation
If properly stored indoors, the pump set is protected for a maximum of 12 months. New pumps/pump sets are supplied by our factory duly prepared for storage. For storing a pump (set) which has already been operated, the shutdown measures must be adhered to. (ð Section 6.3.1, Page 42) HPK-L 14 of 74... -
Page 15: Return To Supplier
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. HPK-L 15 of 74... -
Page 16: Description Of The Pump (Set)
2978 1/min Mat. No. 01220221 ZN 3804 - E 37 X 52 Fig. 5: Name plate (example) Type series, size, material Customer-specific information (optional) KSB order number and order item Flow rate number Speed Year of construction Head HPK-L 16 of 74... -
Page 17: Design Details
1. Never use mechanical seals which have not been approved by KSB. 2. Due to the complex conditions which need to be fulfilled for heat transfer fluid pumps, the use of mechanical seals not approved by KSB shall not be covered by KSB's scope of warranty. - Page 18 Air-cooled bearing bracket with integrated shaft seal chamber Process design Size code (based on the dimensions of seal chamber and shaft end) Refer to the data sheet to find your bearing design. Bearings used Table 7: Bearing design KSB designation FAG designation SKF designation B-TVP-UA BECBP B.G 8...
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Page 19: Configuration And Function
(10). The bearings are supported by a bearing bracket (5) linked with the pump casing and/or casing cover. Sealing The pump is sealed by a KSB mechanical seal as standard. A standardised mechanical seal with shaft sleeve is available as an option. -
Page 20: Noise Characteristics
Surface sound pressure level as per ISO 3744 and DIN EN ISO 20361 ; valid for a pump operating range of Q/ QBEP = 0.8 - 1.1 and non-cavitating operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance. Increase for 60 Hz operation: 3500 rpm +3 dB; 1750 rpm +1 dB; 1160 rpm ±0 dB HPK-L 20 of 74... -
Page 21: Dimensions And Weights
4 Description of the Pump (Set) 4.9 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump/pump set. HPK-L 21 of 74... -
Page 22: Installation At Site
▷ Install the pump in a horizontal position to ensure self-venting of the pump. DANGER Electrostatic charging due to insufficient potential equalisation Explosion hazard! ▷ Make sure that the connection between pump and baseplate is electrically conductive. HPK-L 22 of 74... -
Page 23: Installation On The Foundation
Perform secondary treatment of the concrete to EN 206. NOTE For low-noise operation contact the manufacturer to check whether the pump set can be installed on anti-vibration mounts. NOTE Expansion joints can be fitted between the pump and the suction line or discharge line. HPK-L 23 of 74... -
Page 24: Installation Without Foundation
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. HPK-L 24 of 74... - Page 25 Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of corrosion-resistant material. Use a filter with a filter area three times the cross-section of the piping. Conical filters have proved suitable. 5. Connect the pump nozzles to the piping. HPK-L 25 of 74...
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Page 26: Permissible Forces And Moments At The Pump Nozzles
2200 2750 2100 1400 1450 1100 80-200 3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 80-250 3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 HPK-L 26 of 74... -
Page 27: Auxiliary Connections
▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid handled. The pump is fully functional without any external cooling system. Standard pump sets with one mechanical seal do not require any cooling liquid, barrier fluid or flushing liquid. HPK-L 27 of 74... -
Page 28: Enclosure/Insulation
5.5 Checking the coupling alignment DANGER Inadmissible temperatures at the coupling or bearings due to misalignment of the coupling Explosion hazard! Risk of burns! ▷ Make sure that the coupling is correctly aligned at all times. HPK-L 28 of 74... - Page 29 ▷ Also check the coupling of pump sets supplied with pump and motor mounted on the same baseplate. Fig. 14: Non-spacer-type coupling, checking the coupling alignment Straight edge Gauge Fig. 15: Spacer-type coupling, checking the coupling alignment Straight edge Gauge HPK-L 29 of 74...
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Page 30: Aligning The Pump And Motor
5.6 Aligning the pump and motor After having installed the pump set and connected the piping, check the coupling alignment and, if required, re-align the pump set (at the motor). HPK-L 30 of 74... -
Page 31: Motors With Adjusting Screw
Risk of injury by rotating shafts! ▷ Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one! ▷ Observe all relevant regulations for selecting a coupling guard. -
Page 32: Electrical Connection
Risk of injury by rotating shafts! ▷ Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one! ▷ Observe all relevant regulations for selecting a coupling guard. -
Page 33: Setting The Time Relay
(looking at the motor shaft stub). The pump's direction of rotation is indicated by an arrow on the pump. 1. Match the motor's direction of rotation to that of the pump. 2. Observe the manufacturer's product literature supplied with the motor. HPK-L 33 of 74... -
Page 34: Checking The Direction Of Rotation
The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. 3. If the motor is running in the wrong direction of rotation, check the electrical connection of the motor and switchgear, if any. HPK-L 34 of 74... -
Page 35: Commissioning/Start-Up/Shutdown
Maxigard, Antifrogen N, Preventol Cl-2, KeboX, Nalfleet 9-11, no warranty can be given on the seal life because of their adverse effect on the seal. In such cases please contact KSB. 6.1.2 Filling in lubricants Grease-lubricated bearings have been packed with grease at the factory. -
Page 36: Quench Liquid Supply
Only modify the specified sealing concepts and seal types after consultation with KSB. Due to the complex conditions in hot water systems, the use of mechanical seals not approved by KSB shall not be covered by KSB's scope of warranty. -
Page 37: Final Check
Cooling air flow with a cooling air velocity of at least 4 m/s must be provided in the proximity of the cooling fins. The cooling air flow is generated by the motor cooling device or an external fan. HPK-L 37 of 74... -
Page 38: Heating Up/Keeping Warm The Pump (Set)
ü The system piping has been cleaned. ü The pump, suction line and, if applicable, inlet tank have been vented and primed with the fluid to be handled. ü The lines for priming and venting have been closed. HPK-L 38 of 74... -
Page 39: Checking The Shaft Seal
2. Close the auxiliary connections. If the fluid to be pumped is fed in under vacuum, also supply the shaft seal with barrier fluid during standstill. Only turn off the cooling liquid supply after the pump has cooled down. HPK-L 39 of 74... -
Page 40: Operating Limits
Table 14: Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 °C Minimum See data sheet. 6.2.2 Minimum permissible speed CAUTION Plain bearing is overloaded Damage to the bearings! ▷ Never use a speed of less than 800 rpm. HPK-L 40 of 74... -
Page 41: Frequency Of Starts
If necessary, the minimum flow must be increased. × × × Minimum flow rate Flow rate at best efficiency point Maximum flow rate HPK-L 41 of 74... -
Page 42: Shutdown/Storage/Preservation
Observe the additional instructions on preservation. (ð Section 3.3, Page 14) If the pump set is to be stored temporarily, only preserve the wetted components made of low-alloy materials. Commercially available preservatives can be used for this purpose. Observe the manufacturer's instructions for application/removal. HPK-L 42 of 74... -
Page 43: Returning To Service
▷ As soon as the work is completed, properly re-install and re-activate any safety- relevant devices and protective devices. NOTE If the equipment has been out of service for more than one year, replace all elastomer seals. HPK-L 43 of 74... -
Page 44: Servicing/Maintenance
Fluids handled, consumables and supplies which are hot and/or pose a health hazard Risk of injury! ▷ Observe all relevant laws. ▷ When draining the fluid take appropriate measures to protect persons and the environment. ▷ Decontaminate pumps which handle fluids posing a health hazard. HPK-L 44 of 74... -
Page 45: Servicing/Inspection
NOTE All maintenance work, service work and installation work can be carried out by KSB Service or authorised workshops. For contact details please refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet. - Page 46 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). HPK-L 46 of 74...
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Page 47: Inspection Work
0.05 mm + 0.05 NOTE If the clearances given are exceeded by more than 1 mm (referring to the diameter) replace the affected components or restore the original clearance by means of a casing wear ring. Contact KSB. HPK-L 47 of 74... -
Page 48: Lubrication And Lubricant Change Of Rolling Element Bearings
▪ Under unfavourable operating conditions (e.g. high room temperature, high atmospheric humidity, dust-laden air, aggressive industrial atmosphere) check the bearings earlier and clean and re-lubricate them, if required. ▪ Replace the rolling element bearings after 25,000 operating hours or 3 years of continuous operation. HPK-L 48 of 74... -
Page 49: Drainage/Cleaning
▷ Allow the pump set to cool down to ambient temperature. 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. HPK-L 49 of 74... -
Page 50: Preparing The Pump Set
3. Shift the motor to separate it from the pump. 7.4.4 Removing the back pull-out unit ü On pump sets without spacer-type coupling, the motor has been removed. ü The notes and steps stated in (ð Section 7.4.1, Page 49) to (ð Section 7.4.3, Page 50) have been observed/carried out. HPK-L 50 of 74... -
Page 51: Removing The Impeller
1. Pull cup spring 950.23 and locking ring 515.21 off the shaft. If possible, also pull out locking ring 515.22 and bearing sleeve 529.21 in the process. 7.4.7 Removing the mechanical seals Pump set with KSB mechanical seal 4HL ü The notes and steps stated in (ð Section 7.4.1, Page 49) to (ð Section 7.4.6, Page 51) have been observed/carried out. -
Page 52: Dismantling The Bearings
5. For versions with one mechanical seal and shaft seal ring only: Remove O-ring 412.03 and spacer sleeve 525.03. 6. For versions with one mechanical seal and two angular contact ball bearings only: Remove spacer sleeve 525.03 and thrower 507.12 from shaft 210. HPK-L 52 of 74... -
Page 53: Removing The Plain Bearing Bush
– Never use quick-setting adhesives (cyanoacrylate adhesives). – Coat the locating surfaces of the individual components and screwed connections with graphite or similar before reassembly. – Prior to reassembly, screw back any forcing screws and adjusting screws. HPK-L 53 of 74... -
Page 54: Installing The Bearings
4. Slide spacer sleeve 525.24 onto shaft 210 and use a C-spanner to tighten slotted round nut 920.21 without lock washer 931.01. Then unscrew the slotted round nut again. 5. Slide ring 500.32, bearing cover 360.02 and fan impeller 831 onto the shaft. HPK-L 54 of 74... -
Page 55: Installing The Mechanical Seal
Face of shaft sleeve Bearing brackets LP02, LP03 Bearing brackets LP04, LP05, LP06 Pump set with KSB mechanical seal 4HL ü The notes and steps stated in (ð Section 7.5.1, Page 53) to (ð Section 7.5.2, Page 54) have been observed/carried out. ü The individual parts have been placed in a clean and level assembly area. - Page 56 The mechanical seal is generally positioned correctly when the bolt head is located in the centre of the slotted hole (marking) (see Fig. "Correct position of KSB mechanical seal" ) Fig. 21: Correct position of the KSB mechanical seal Markings on the mechanical seal Bolt head 4.
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Page 57: Fitting The Plain Bearing Bush
The bearing bush is inserted correctly when its groove is on top (12 o’clock position). 3. Insert ring 932.05 into the groove of the bearing bracket to secure the bearing bush axially. HPK-L 57 of 74... -
Page 58: Fitting The Bearing Bracket
Check that they are clean and correctly dimensioned. 3. After the rotating pump assembly (pump without casing) has been assembled, check the radial shaft run-out at the impeller. Maximum permissible run-out: 0.15 mm. HPK-L 58 of 74... -
Page 59: Fitting The Back Pull-Out Unit
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 %. HPK-L 59 of 74... -
Page 60: Spare Parts Stock
10 and more Quantity of spare parts Shaft 30 % Impeller 30 % 310.10 Plain bearing (product- 100 % lubricated) 320.02 Angular contact ball bearing 55 % (set) Bearing bracket 2 pcs. Mechanical seal 25 % HPK-L 60 of 74... -
Page 61: Interchangeability Of Pump Components
LP02 32-125 25-160 32-160 40-160 50-160 25-200 32-200 40-200 50-200 LP03 65-160 80-160 65-200 80-200 100-200 32-250 40-250 50-250 Provided as a standard feature on HPK-LS and HPK-LS4 only, optional feature only on HPK-LE and HPK-LE4 HPK-L 61 of 74... - Page 62 50-315 LP04 100-250 125-250 150-250 65-315 80-315 100-315 125-315 80-400 100-400 125-400 LP05 200-250 150-315 200-315 250-315 150-400 10 12 200-400 10 13 150-500 11 14 200-500 11 17 LP06 250-400 12 17 250-500 13 15 HPK-L 62 of 74...
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Page 63: Trouble-Shooting
If problems occur that are not described in the following table, consultation with the KSB service is required. A Pump delivers insufficient flow rate B Motor is overloaded... - Page 64 In the case of persistent overloading, turn down impeller. ✘ - Density or viscosity of fluid handled Contact KSB. higher than stated in purchase order - Speed is too high. Reduce speed. ✘ ✘ ✘...
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Page 65: Related Documents
Fig. 22: General assembly drawing of HPK-LS/LE/LS4/LE4 Version with two mechanical seals and one deep groove ball Version with one mechanical seal with lip seal and bearing or one four-point bearing one deep groove ball bearing or one four-point bearing HPK-L 65 of 74... - Page 66 Joint ring 411.85 Joint ring 433.02 Mechanical seal Mating ring carrier 500.32 Ring 500.61 Tolerance ring 507.12 Thrower Shaft sleeve 525.03 Spacer sleeve 525.24 Spacer sleeve 545.21 Bearing bush 550.87 Disc 561.52 Grooved pin For HPK-LS/LS4 only HPK-L 66 of 74...
- Page 67 914.02 Hexagon socket head cap screw 920.95 Hexagon nut 932.05 Circlip Shaft sleeve 412.07 O-ring 550.59 Support disc (LP02 and LP03 only) 904.32 Grub screws 99-9 99-9 Set of sealing elements Joint ring 411.01/.02/.03/.04/.10/.11/.20/.85 412.07/.82 O-ring HPK-L 67 of 74...
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Page 68: Eu Declaration Of Conformity
10 EU Declaration of Conformity 10 EU Declaration of Conformity Manufacturer: KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: HPK-L KSB order number: ....................▪ is in conformity with the provisions of the following directives / regulations as amended from time to time: –... -
Page 69: 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 field HPK-L 69 of 74... -
Page 70: Index
Shutdown 39, 42 Heating speed 38 Spare part Heating up 38 Ordering spare parts 60 Spare parts stock 60 Special accessories 20 Impeller type 17 Start-up 38 Installation Storage 14, 42 Installation on a foundation 23 without foundation 24 Installation at site 22 Intended use 9 Interchangeability of pump components 61 HPK-L 70 of 74... - Page 71 Index Temperature difference 38 Temperature limits 12 Transport 13 Trouble-shooting Causes of faults and remedies 63 Warnings 8 Warranty claims 7 HPK-L 71 of 74...
- Page 74 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
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