KSB Etachrom NC Installation & Operating Manual
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KSB Etachrom NC Installation & Operating Manual

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Etachrom NC
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Summary of Contents for KSB Etachrom NC

  • Page 1 Standardised Pump Etachrom NC Installation/Operating Manual...
  • Page 2 Legal information/Copyright Installation/Operating Manual Etachrom NC Original operating manual KSB Aktiengesellschaft 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 KSB's express written consent.

  • Page 3: Table Of Contents

    Configuration and function ................18 Noise characteristics ..................18 Scope of supply ....................19 Dimensions and weights ................19 Installation at Site ................20 Safety regulations ................... 20 Checks to be carried out prior to installation ..........20 Etachrom NC 3 of 62...
  • Page 4 Tightening torques ..................48 Spare parts stock ..................... 50 Trouble-shooting ................53 Related Documents ................5 5 Exploded view / List of components .............. 55 EC Declaration of Conformity ............58 Certificate of Decontamination ............59 Index ....................60 4 of 62 Etachrom NC...

  • Page 5: Glossary

    Suction lift line/suction head line Discharge line The line which is connected to the suction The line which is connected to the discharge nozzle nozzle Etachrom NC 5 of 62...

  • Page 6: General

    (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 (⇨ Section 4.7 Page 18) 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 Etachrom NC 7 of 62...

  • Page 8: Safety

    ▪ Only operate pumps/pump sets which are in perfect technical condition. ▪ Do not operate the pump (set) in partially assembled condition. ▪ Only use the pump to handle the fluids described in the data sheet or product literature of the pump model. 8 of 62 Etachrom NC...

  • Page 9: Personnel Qualification And Training

    In addition to the safety information contained in this manual and the intended use, the following safety regulations shall be complied with: ▪ Accident prevention, health and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards and laws Etachrom NC 9 of 62...

  • Page 10: Safety Information For The Operator/User

    Section 2.10.1 Page 11) to(⇨ Section 2.10.4 Page 12) (⇨ Section 2.10.3 Page 11). The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. 10 of 62 Etachrom NC...
  • Page 11 If the pump is to be operated at a higher temperature, if there is no data sheet or if the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature. 2.10.3 Monitoring equipment The pump (set) must only be operated within the limits specified in the data sheet and on the name plate.
  • Page 12 2 Safety Contact KSB for further information on monitoring equipment. 2.10.4 Operating limits The minimum flows indicated in (⇨ Section 6.2.3.1 Page 35) refer to water and water- like fluids. Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures at the pump surface.

  • Page 13: Transport/Temporary Storage/Disposal

    On transfer of goods, check each packaging unit for damage. 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 14: Storage/Preservation

    3.4 Return to supplier Drain the pump as per operating instructions.(⇨ Section 7.3 Page 42) Always flush and clean the pump, particularly if it has been used for handling noxious, explosive, hot or other hazardous fluids. 14 of 62 Etachrom NC...

  • Page 15: Disposal

    Always indicate any safety and decontamination measures taken.(⇨ Section 11 Page 59) NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids, consumables and supplies which are hot or pose a health hazard Hazard to persons and the environment! ▷...

  • Page 16: Description Of The Pump (Set)

    ▪ Information on benchmark efficiency or benchmark efficiency graph for MEI = 0.7 (0.4) for the pump based on the model shown in the Figure are available at: http://www.europump.org/efficiencycharts 4.3 Designation Example: Etachrom NC 50-160 C10 Table 5: Key to the designation Code Description Etachrom...

  • Page 17: Name Plate

    /s | n 2900 min | 2013 η --,-% MEI ≥ 0,60 Mat.-No. 01216137 ZN 3823-217 Fig. 5: Name plate (example) Etachrom NC Type series, size and version (⇨ Material number (optional) Section 4.3 Page 16) KSB order number, order item...

  • Page 18: Configuration And Function

    Spatial average; as per ISO 3744 and EN 12639; valid for operating range Q/Qopt = 0.80 - 1.1 and non-cavitating pump operation. If noise levels are to be warranted: Add +3 dB for measuring and constructional tolerance. Increase for 60 Hz operation: 3500 rpm +3 dB; 1750 rpm +1 dB 18 of 62 Etachrom NC...

  • Page 19: Scope Of Supply

    ▪ Channel section steel or folded steel plate Baseplate optional: ▪ Cast baseplate (to ISO 3661) ▪ As required Special accessories 4.9 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump/pump set. Etachrom NC 19 of 62...

  • Page 20: Installation At Site

    ▷ Install the pump in horizontal position to ensure self-venting of the pump. 5.3.1 Installation on the foundation Fig. 7: Fitting the shims Bolt-to-bolt distance Shim Shim if (L) > 800 mm Foundation bolt ✓ The foundation has the required strength and characteristics. 20 of 62 Etachrom NC...
  • Page 21 For baseplates made of grey cast iron it is recommended to grout the baseplate with low-shrinkage concrete. NOTE For low-noise operation contact KSB to check whether the pump set can be installed on anti-vibration mounts. 5.3.2 Installation without foundation Fig. 8: Adjusting the levelling elements...

  • Page 22: Piping

    Before installing the pump in the piping, remove the flange covers on the suction and discharge nozzles of the pump. Check that the inside of the pump is free from any foreign objects. Remove any foreign objects. 22 of 62 Etachrom NC...
  • Page 23 Neither the load direction nor the load distribution among the nozzles are taken into account in these sums. Table 7: Forces and moments at the pump nozzles Pump size Vmax Hmax tmax [kN] [kN] [kNm] 25-125.1 0.55 25-125 0.55 Etachrom NC 23 of 62...
  • Page 24 Where fluid has to be pumped out of a vessel under vacuum, it is recommended to install a vacuum balance line. The following rules apply to vacuum balance lines: ▪ Minimum nominal line diameter 25 mm. ▪ The line extends above the highest permissible fluid level in the vessel. 24 of 62 Etachrom NC...

  • Page 25: Enclosure/Insulation

    Risk of burns! ▷ Insulate the volute casing. ▷ Fit protective equipment. CAUTION Heat build-up in the bearing bracket Damage to the bearing! ▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover. Etachrom NC 25 of 62...

  • Page 26: Checking The Coupling Alignment

    The radial and axial deviation between the two coupling halves must not exceed 0.1 mm, during standstill as well as at operating temperature and under inlet pressure. If alignment is correct, re-install the coupling guard and its footboard, if any. 26 of 62 Etachrom NC...

  • Page 27: Aligning The Pump And Motor

    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 28: 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 29 (looking at the motor shaft stub). The pump's direction of rotation is indicated by an arrow on the pump. Match the motor's direction of rotation to that of the pump. Observe the manufacturer's product literature supplied with the motor. Etachrom NC 29 of 62...

  • Page 30: Checking The Direction Of Rotation

    The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. If the motor is running in the wrong direction of rotation, check the electrical connection of the motor and switchgear, if any. 30 of 62 Etachrom NC...

  • Page 31: Commissioning/Start-Up/Shutdown

    6.1.4 Final check Remove the coupling guard and the footboard for the coupling guard, if any. Check the coupling alignment; re-align the coupling if required.(⇨ Section 5.6 Page 26) Etachrom NC 31 of 62...
  • Page 32 Close or slightly open the shut-off element in the discharge line. Start up the motor. Immediately after the pump has reached full rotational speed, slowly open the shut-off element in the discharge line and adjust it to comply with the duty point. 32 of 62 Etachrom NC...
  • Page 33 Close the shut-off valve in the suction line. Close the auxiliary connections. CAUTION Risk of freezing during prolonged pump shutdown periods Damage to the pump! ▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect them against freezing. Etachrom NC 33 of 62...

  • Page 34: Operating Limits

    (h) with the discharge-side gate valve slightly open. CAUTION Re-starting while motor is still running down Damage to the pump (set)! ▷ Do not re-start the pump set before the pump rotor has come to a standstill. 34 of 62 Etachrom NC...
  • Page 35 Abraded casing wall Risk of explosion! ▷ Use a pump with anti-swirl baffle. ▷ Adjust the inspection intervals to the increased abrasion. ▷ For combustible fluids: The fluids must not contain any abrasive particles. Best efficiency point Etachrom NC 35 of 62...

  • Page 36: Shutdown/Storage/Preservation

    Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant and protective devices. NOTE If the pump has been out of service for more than one year, replace all elastomer seals. 36 of 62 Etachrom NC...

  • Page 37: 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 38: Maintenance/Inspection

    ▷ Prolonged operation against a closed shut-off element is not permitted (heating up of the fluid). ▷ Observe the temperature limits in the data sheet and in the section on operating limits.(⇨ Section 6.2 Page 34) 38 of 62 Etachrom NC...
  • Page 39 (see the following table), fit new casing wear ring 502.1 and/or 502.2. (⇨ Section 7.4.5 Page 44) The clearances given refer to the diameter. Table 12: Clearances between impeller and casing [mm] Size Suction side Discharge side Nominal impeller diameter ✘ ✘ 0,45 Etachrom NC 39 of 62...
  • Page 40 Under normal conditions the grease-lubricated bearings will run for 15,000 operating hours or 2 years. Under unfavourable operating conditions (e.g. high room temperature, high atmospheric humidity, dust-laden air, aggressive industrial atmosphere etc.), check the bearings earlier and clean and relubricate them, if required. 40 of 62 Etachrom NC...
  • Page 41 ▷ Thoroughly clean the bearings. ▷ Adjust the re-lubrication intervals to the grease used. ✓ The pump has been dismantled for changing the grease.(⇨ Section 7.4 Page 42) Only half-fill the bearing cavities with grease. Etachrom NC 41 of 62...

  • Page 42: Drainage/Cleaning

    For dismantling and reassembly observe the exploded views and the general assembly drawing.(⇨ Section 9.1 Page 55) 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 43 ▷ Suspend or support the bearing bracket at the pump end. If required, suspend or support bearing bracket 330 to prevent it from tipping over. Unbolt support foot 183 from the baseplate. Undo hexagon nut 920.1 and hexagon head bolt 901.1 at the pump casing. Etachrom NC 43 of 62...

  • Page 44: Reassembling The Pump Set

    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. 44 of 62 Etachrom NC...
  • Page 45 Make sure the bearing end with cover plate rests against the shaft shoulder (see illustration: Installing the radial ball bearing). Push the pre-assembled shaft into bearing bracket 330. Fit circlips 932. Fit bearing cover 360. Fit axial sealing rings 411. Etachrom NC 45 of 62...
  • Page 46 Fit the double PTFE encapsulated O-ring with the joint of the outer sheath pointing outwards. Fitting direction 1773:16/4 Fig. 16: PTFE encapsulated O-ring Joint of the outer PTFE sheath Fit discharge cover 163 into the locating fit of bearing bracket 330 or intermediate piece 132. 46 of 62 Etachrom NC...
  • Page 47 Shift the motor to connect it to the pump via the coupling. Fasten the motor to the baseplate. Align pump and motor.(⇨ Section 5.7 Page 27) Connect the motor to the power supply (refer to manufacturer's product literature). Etachrom NC 47 of 62...

  • Page 48: Tightening Torques

    Fig. 18: Tightening points for impeller diameters 250, 50-200, 65-200, 80-200 Table 14: Tightening torques for screwed connections at the pump Position Thread size Rated torque [Nm] M12 x 1.5 M16 x 1.5 M24 x 1.5 M30 x 1.5 48 of 62 Etachrom NC...
  • Page 49 [Nm] Pump on baseplate M24 x 1.5 Levelling screws in baseplate M36 x 1.5 Motor on baseplate or motor on levelling screws or shims Coupling (only for spacer-type coupling made by Flender) Coupling guard Etachrom NC 49 of 62...

  • Page 50: Spare Parts Stock

    Always quote the following data when ordering replacement or spare parts: ▪ Type series ▪ Material variant ▪ Size ▪ Seal code ▪ KSB order number ▪ Order item number ▪ Consecutive number ▪ Year of construction Refer to the name plate for all data. (⇨ Section 4.4 Page 17) Also specify the following data: ▪...
  • Page 51 Casing wear ring, suction side 50 % Casing wear ring, discharge 50 % 502.2 side Shaft sleeve 50 % Not applicable for Etachrom NC 25-125.1, 25-125, 25-160, 32-125.1, 32-125, 32-160, 40-125, 50-125 Etachrom NC 65-250, 80-200, 80-250 only Etachrom NC 51 of 62...
  • Page 52 7 Servicing/Maintenance 7.7.3 Interchangeability of Etachrom NC and BC pump components Components featuring the same number in a column are interchangeable. Table 17: Interchangeability of pump components Size Part description Part No. ✘ ✘ ✘ ✘ 25-125.1 ✘ ✘ ✘...

  • Page 53: Trouble-Shooting

    If problems occur that are not described in the following table, consultation with KSB’s customer service is required. Pump delivers insufficient flow rate Motor is overloaded...
  • Page 54 Defective bearing(s) Fit new bearing(s). ✘ ✘ ✘ Flow rate is too low Increase the minimum flow rate. Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. 54 of 62 Etachrom NC...

  • Page 55: Exploded View / List Of Components

    Support foot O-ring Safety device Shaft Mechanical seal 932.1/.2 Circlip Impeller 502.1/.2 Casing wear ring 940.1/.2 321.1/.2 Radial ball bearing 580.2 Fluid drain Not applicable for Etachrom NC 25-125.1, 25-125, 25-160, 32-125.1, 32-125, 32-160, 40-125, 50-125 Etachrom NC 55 of 62...
  • Page 56 9.1.2 Design for shaft unit 25.2 This view applies to the following sizes: 25-250 32-250 40-250 50-200 65-200 50-250 [ Supplied in packaging units only 1212:17/4 Fig. 21: Etachrom NC Part No. Description Part No. Description Part No. Description Pump casing Bearing bracket 902.2...
  • Page 57 9 Related Documents 9.1.3 Design for shaft unit 35 This view applies to the following sizes: 65-250 80-200 80-250 [ Supplied in packaging units only 1212:339/ 2 Fig. 22: Etachrom NC Part No. Description Part No. Description Part No. Description Pump casing 360.1/.2...

  • Page 58: Ec Declaration Of Conformity

    67227 Frankenthal (Germany) The manufacturer herewith declares that the product: Etabloc, Etabloc SYT, Etaline, Etaline SYT, Etaline Z, Etachrom NC, Etachrom BC, Etanorm, Etanorm SYT, Etanorm GPV/CPV, Etaprime L, Etaprime B/BN, Vitachrom KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: –...

  • Page 59: 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 Etachrom NC 59 of 62...

  • Page 60: Index

    Storage 14, 36 Installation Installation on a foundation 20 Temperature limits 11 Installation without foundation 21 Tightening torques 48, 49 Installation at site 20 Transport 13 Intended use 8 Trouble-shooting 53 Interchangeability of pump components 52 60 of 62 Etachrom NC...
  • Page 62 KSB Aktiengesellschaft 67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com...

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