KSB Etachrom L Installation & Operating Manual
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KSB Etachrom L Installation & Operating Manual

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Standardised Pump
Etachrom L
Installation/Operating Manual

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  • Page 1 Standardised Pump Etachrom 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 11/08/2021...

  • Page 3: Table Of Contents

    Contents Contents Glossary .............................. 6 General.............................. 7 Principles ................................ 7 Installation of partly completed machinery.................... 7 Target group.............................. 7 Other applicable documents.......................... 7 Symbols ................................ 7 Key to safety symbols/markings........................ 8 Safety .............................. 9 General................................ 9 Intended use .............................. 9 Personnel qualification and training....................... 9 Consequences and risks caused by non-compliance with this manual ............ 10 Safety awareness ............................ 10 Safety information for the operator/user ..................... 10 Safety information for maintenance, inspection and installation .............. 10...
  • Page 4 Contents 5.6.2 Motors without adjusting screw ....................... 31 Electrical connection ............................ 32 5.7.1 Setting the time relay ........................ 32 5.7.2 Earthing .............................. 32 5.7.3 Connecting the motor ........................ 33 Checking the direction of rotation........................ 33 Commissioning/Start-up/Shutdown.................... 34 Commissioning/Start-up .......................... 34 6.1.1 Prerequisites for commissioning/start-up .................. 34 6.1.2 Filling in lubricants.......................... 34 6.1.3 Priming and venting the pump...................... 34 6.1.4...
  • Page 5 Contents EU Declaration of Conformity ...................... 64 Certificate of Decontamination...................... 65 Index .............................. 66 Etachrom L 5 of 70...

  • Page 6: Glossary

    Glossary Glossary French drinking water regulations (ACS = Attestation de Conformité Sanitaire) Back pull-out design The complete back pull-out unit can be pulled out without having to remove the pump casing from the piping. Back pull-out unit Pump without pump casing; partly completed machinery Certificate of decontamination A certificate of decontamination is enclosed by the...

  • 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

    1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product 1.6 Key to safety symbols/markings Table 3: Definition of safety symbols/markings Symbol Description DANGER DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

  • Page 9: Safety

    2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER In addition to the present general safety information the action-related safety information given in the other sections must be observed. 2.1 General ▪ This operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property.

  • Page 10: Consequences And Risks Caused By Non-Compliance With This Manual

    2 Safety 2.4 Consequences and risks caused by non-compliance with this manual ▪ Non-compliance with these operating instructions will lead to forfeiture of warranty cover and of any and all rights to claims for damages. ▪ Non-compliance can, for example, have the following consequences: –...

  • Page 11: Unauthorised Modes Of Operation

    2 Safety ▪ When taking the pump set out of service always adhere to the procedure described in the manual. (ð Section 6.1.7, Page 36) (ð Section 6.3, Page 39) ▪ Decontaminate pumps which handle fluids posing a health hazard. (ð Section 7.3, Page 46) ▪ As soon as the work has been completed, re-install and re-activate any safety- relevant devices and protective devices.

  • 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

    4. Always complete and enclose a certificate of decontamination when returning the pump. Indicate any safety measures and decontamination measures taken. (ð Section 11, Page 65) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination Etachrom L 14 of 70...

  • Page 15: Disposal

    3 Transport/Storage/Disposal 3.5 Disposal WARNING Fluids handled, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! ▷ Collect and properly dispose of flushing fluid and any fluid residues. ▷ Wear safety clothing and a protective mask if required. ▷...

  • Page 16: Description Of The Pump (Set)

    See name plate and data sheet See data sheet Table 6: Designation key Position Code Description Pump type ETCL Etachrom L 5-16 Size, e.g. Nominal suction nozzle diameter [mm] Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Pump casing material Stainless steel 1.4571...
  • Page 17 Design Materials in contact with food to Regulation (EC) 1935/2005 Bottle rinser variant Approved for drinking water to ACS Approved for drinking water to KSB standard Standard Approved for drinking water to UBA Approved for drinking water to WRAS Non-standard (BT3D, BT3)

  • Page 18: Name Plate

    Mat. No. 01216137 ZN 3823 - 217 Fig. 5: Etachrom L name plate (example) Type series, size and version Material number (optional) KSB order No., order item No. and Flow rate consecutive No. Kinematic viscosity of the fluid Minimum efficiency index handled...
  • Page 19 ▪ Duty type: continuous duty S1 ▪ Enclosure IP55 ▪ Thermal class F ▪ 3 PTC thermistors ▪ KSB surface-cooled IEC frame three-phase current squirrel-cage motor as described above, but West European make to our choice Explosion-proof design: ▪ Surface-cooled IEC three-phase current squirrel-cage motor ▪...

  • Page 20: Configuration And Function

    4 Description of the Pump (Set) 4.6 Configuration and function Fig. 6: Sectional drawing Clearance gap Discharge nozzle Casing cover Shaft Bearing bracket Suction nozzle Impeller Shaft seal Rolling element bearing, pump end Rolling element bearing, drive end Design The pump is designed with an axial fluid inlet and a radial outlet. The hydraulic system runs in its own bearings and is connected to the motor by a shaft coupling.

  • Page 21: Scope Of Supply

    4 Description of the Pump (Set) Rated power input P Pump Pump set [kW] 1450 rpm 2900 rpm 1450 rpm 2900 rpm [dB] [dB] [dB] [dB] 18,5 4.8 Scope of supply Depending on the model, the following items are included in the scope of supply: ▪...

  • Page 22: Installation At Site

    5 Installation at Site 5 Installation at Site 5.1 Checks to be carried out prior to installation Place of installation WARNING Installation on a mounting surface which is unsecured and cannot support the load Personal injury and damage to property! ▷...

  • Page 23: Installation On The Foundation

    5 Installation at Site 5.2.1 Installation on the foundation Fig. 7: Fitting the shims Bolt-to-bolt distance Shim Shim if (L) > 800 mm Foundation bolt ü The foundation has the required strength and characteristics. ü The foundation has been prepared in accordance with the dimensions given in the outline drawing/general arrangement drawing.

  • Page 24: Installation Without Foundation

    5 Installation at Site 5.2.2 Installation without foundation Fig. 8: Adjusting the levelling elements 1, 3 Locknut Adjusting nut Machine mount ü The installation surface has the required strength and characteristics. 1. Position the pump set on the machine mounts (4) and align it with the help of a spirit level (on the shaft/discharge nozzle).
  • Page 25 5 Installation at Site NOTE Installing check and shut-off elements in the system is recommended, depending on the type of plant and pump. However, such elements must not obstruct proper drainage or hinder disassembly of the pump. ü Suction lift lines have been laid with a rising slope, suction head lines with a downward slope towards the pump.

  • Page 26: Permissible Forces And Moments At The Pump Nozzles

    5 Installation at Site CAUTION Aggressive flushing liquid and pickling agent Damage to the pump! ▷ Match the cleaning operation mode and duration of flushing and pickling to the casing materials and seal materials used. 5.3.2 Permissible forces and moments at the pump nozzles Hmax Vmax tmax...

  • Page 27: Vacuum Balance Line

    5 Installation at Site Size Vmax Hmax tmax [kN] [kN] [kNm] 100-080-200 1,45 100-080-250 1,45 5.3.3 Vacuum balance line NOTE Where fluid has to be pumped out of a vessel under vacuum, installing a vacuum balance line is recommended. The following rules apply to vacuum balance lines: ▪...

  • Page 28: Checking The Coupling Alignment

    5 Installation at Site WARNING The volute casing and casing/discharge cover take on the same temperature as the fluid handled Risk of burns! ▷ Insulate the volute casing. ▷ Fit protective equipment. CAUTION Heat build-up in the bearing bracket Damage to the bearing! ▷...
  • Page 29 5 Installation at Site Fig. 13: Spacer-type coupling, checking the coupling alignment Straight edge Gauge Fig. 14: Double Cardan spacer-type coupling, checking the coupling alignment Straight edge Gauge Table 9: Permissible alignment offset of coupling halves Coupling type Radial offset Axial offset [mm] [mm] Non-spacer-type coupling (ð Fig. 12) ≤ 0,1...

  • Page 30: 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 31: Motors Without 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

    5 Installation at Site 5.7 Electrical connection DANGER Electrical connection work by unqualified personnel Risk of fatal injury due to electric shock! ▷ Always have the electrical connections installed by a trained and qualified electrician. ▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079. WARNING Incorrect connection to the mains Damage to the power supply network, short circuit!

  • Page 33: Connecting The Motor

    5 Installation at Site 5.7.3 Connecting the motor NOTE In compliance with IEC 60034-8, three-phase motors are always wired for clockwise rotation (looking at the motor shaft stub). The pump's direction of rotation is indicated by an arrow on the pump. 1.

  • Page 34: Commissioning/Start-Up/Shutdown

    6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/Start-up 6.1.1 Prerequisites for commissioning/start-up Before commissioning/starting up the pump set, make sure that the following conditions are met: ▪ The pump set has been mechanically connected as specified. ▪ The pump set has been properly connected to the power supply and is equipped with all protection devices.

  • Page 35: Final Check

    6 Commissioning/Start-up/Shutdown 6.1.4 Final check 1. Remove the coupling guard and its footboard, if any. 2. Check the coupling alignment; re-align the coupling, if required. (ð Section 5.5, Page 28) 3. Check proper functioning of coupling/shaft. Check that coupling/shaft can be easily rotated by hand. 4.

  • Page 36: Checking The Shaft Seal

    6 Commissioning/Start-up/Shutdown CAUTION Start-up against open discharge line Motor overload! ▷ Make sure the motor has sufficient power reserves. ▷ Use a soft starter. ▷ Use speed control. 1. Fully open the shut-off element in the suction head/suction lift line. 2.

  • Page 37: Operating Limits

    6 Commissioning/Start-up/Shutdown 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. 6.2 Operating limits DANGER Non-compliance with operating limits for pressure, temperature, fluid handled and speed Explosion hazard! Hot or toxic fluid could escape!

  • Page 38: Fluid Handled

    6 Commissioning/Start-up/Shutdown The frequency of starts is usually determined by the maximum temperature increase of the motor. This largely depends on the power reserves of the motor in steady- state operation and on the starting conditions (DOL, star-delta, moments of inertia, etc).

  • Page 39: Shutdown/Storage/Preservation

    6 Commissioning/Start-up/Shutdown The fluid handled may contain abrasive particles up to a maximum content of 5 g/ and a maximum particle size of 0.5 mm. DANGER Abraded casing wall Explosion hazard! ▷ Use a pump with anti-swirl baffle. ▷ Adjust the inspection intervals to the increased abrasion. ▷...
  • Page 40 6 Commissioning/Start-up/Shutdown NOTE If the equipment has been out of service for more than one year, replace all elastomer seals. Etachrom L 40 of 70...

  • Page 41: Servicing/Maintenance

    7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations DANGER Improper cleaning of coated pump surfaces Explosion hazard by electrostatic discharge! ▷ When cleaning coated pump surfaces in atmospheres of Explosion group IIC, use suitable anti-static equipment. DANGER Sparks produced during servicing work Explosion hazard! ▷...

  • Page 42: 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 43 7 Servicing/Maintenance CAUTION Increased wear due to dry running Damage to the pump set! ▷ Never operate the pump set without liquid fill. ▷ Never close the shut-off element in the suction line and/or supply line during pump operation. CAUTION Impermissibly high temperature of fluid handled Damage to the pump! ▷...

  • Page 44: Inspection Work

    7 Servicing/Maintenance 7.2.2 Inspection work DANGER Excessive temperatures caused by friction, impact or frictional sparks Explosion hazard! Fire hazard! Damage to the pump set! ▷ Regularly check the coupling guard, plastic components and other guards of rotating parts for deformation and sufficient distance from rotating parts. DANGER Electrostatic charging due to insufficient potential equalisation Explosion hazard!

  • Page 45: Lubrication And Lubricant Change Of Rolling Element Bearings

    7 Servicing/Maintenance 7.2.2.3 Cleaning filters CAUTION Insufficient inlet pressure due to clogged filter in the suction line Damage to the pump! ▷ Monitor contamination of filter with suitable means (e.g. differential pressure gauge). ▷ Clean filter at appropriate intervals. 7.2.2.4 Checking the bearing seals DANGER Excessive temperatures caused by mechanical contact Risk of explosion!

  • Page 46: Drainage/Cleaning

    7 Servicing/Maintenance 7.2.3.1.3 Grease quantity Table 16: Grease quantity per grease-lubricated DIN 625 radial ball bearing Nominal impeller diameter [mm] Code Grease Code Grease Code Grease Code Grease bearing bearing bearing bearing 6305 2Z C3 6305 2Z C3 6305 2Z C3 6305 2Z C3 ✘...

  • Page 47: Dismantling The Pump Set

    In the event of damage you can always contact our service departments. 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 48: Preparing The Pump Set

    7 Servicing/Maintenance 7.4.2 Preparing the pump set 1. Interrupt the power supply and secure the pump against unintentional start-up. 2. Disconnect and remove all auxiliary pipework. 3. Remove the coupling guard. 4. Remove the coupling spacer, if any. 7.4.3 Removing the motor NOTE On pump sets with spacer-type couplings, the back pull-out unit can be removed while the motor remains bolted to the baseplate.

  • Page 49: Removing The Mechanical Seal

    7 Servicing/Maintenance 7.4.6 Removing the mechanical seal ü The notes and steps stated in (ð Section 7.4.1, Page 47) to (ð Section 7.4.5, Page 48) have been observed/carried out. ü The back pull-out unit has been placed in a clean and level assembly area. 1. Remove the rotating assembly of the mechanical seal (primary ring) from shaft sleeve 523 (shaft unit 35) or shaft 210.

  • Page 50: Installing The Bearing Assembly

    7 Servicing/Maintenance Assembly aids Avoid the use of assembly adhesives if possible. Should an assembly adhesive be required after all, use a commercially available contact adhesive (e.g. Pattex) or sealant (e.g. HYLOMAR or Epple 33). Only apply adhesive at selected points and in thin layers. Never use quick-setting adhesives (cyanoacrylate adhesives).

  • Page 51: Installing The Mechanical Seal

    7 Servicing/Maintenance 7.5.3 Installing the mechanical seal Installing the The following rules must be observed when installing the mechanical seal: mechanical seal ▪ Work cleanly and accurately. ▪ Only remove the protective wrapping of the contact faces immediately before installation takes place. ▪...

  • Page 52: Fitting The Impeller

    7 Servicing/Maintenance 6. Fit the rotating assembly of the mechanical seal (primary ring) on shaft sleeve or shaft 210. 7.5.4 Fitting the impeller ü The notes and steps stated in (ð Section 7.5.1, Page 49) to (ð Section 7.5.3, Page 51) have been observed/carried out. ü The assembled bearing bracket as well as the individual parts have been placed in a clean and level assembly area.

  • Page 53: Tightening Torques

    7 Servicing/Maintenance 7.6 Tightening torques 7.6.1 Tightening torques for the pump UG1543921_D01_102 Fig. 19: Tightening points for impeller diameters 125, 160, 200, except 065-050-200, 080-065-200, 100-080-200 UG1542651_D01_102 Fig. 20: Tightening points for impeller diameter 250 and sizes 065-050-200, 080-065-200, 100-080-200 Table 17: Tightening torques for bolted/screwed connections at the pump Position Thread Tightening torque...
  • Page 54 7 Servicing/Maintenance Position Thread Tightening torque [Nm] M12 × 1,5 M16 × 1,5 M24 × 1,5 M30 × 1,5 Etachrom L 54 of 70...

  • Page 55: Tightening Torques For The Pump Set

    7 Servicing/Maintenance 7.6.2 Tightening torques for the pump set Fig. 21: Position of bolts/screws at the pump set Table 18: Tightening torques for bolted/screwed connections at the pump set Position Thread size Tightening torque Notes [Nm] Pump on baseplate M24 × 1,5 Adjusting screws in baseplate M36 ×...

  • Page 56: Spare Parts Stock

    7 Servicing/Maintenance 7.7 Spare parts stock 7.7.1 Ordering spare parts Always quote the following data when ordering replacement or spare parts: ▪ Order number ▪ Order item number ▪ Consecutive number ▪ Type series ▪ Size ▪ Material variant ▪ Seal code ▪...

  • Page 57: Recommended Spare Parts Stock For 2 Years' Operation To Din 24296

    502.06 Casing wear ring, 50 % impeller Shaft sleeve 50 % Only for Etachrom L 080-065-250, 100-080-200, 100-080-250 Not for Etachrom L 050-025-125.1, 050-025-125, 050-025-160, 050-032-125.1, 050-032-125, 050-032-160, 065-040-125, 065-050-125 Only for Etachrom L 080-065-250, 100-080-250 Etachrom L 57 of 70...

  • Page 58: Interchangeability Of Etachrom L And Etachrom B Pump Components

    7 Servicing/Maintenance 7.7.3 Interchangeability of Etachrom L and Etachrom B pump components Table 20: Pump components Etachrom L Size 050-025-125.1 ✘ 1* ✘ 1* 1* ✘ ✘ ✘ ✘ 050-025-125 ✘ 1* ✘ ✘ ✘ 1* 1* ✘ ✘ 050-025-160 ○ ✘ 5* ✘...

  • Page 59: 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 60 8 Trouble-shooting A B C D E F G H Possible cause Remedy ✘ - Use of unsuitable shaft seal materials Change the material combination. - Speed is too high. Reduce speed. ✘ ✘ ✘ - Tie bolts/sealing element defective Fit new seal between volute casing and discharge cover.

  • Page 61: Related Documents

    Bearing cover 940.01/.02 411.01 Joint ring 412.35 O-ring Mechanical seal Connections 502.01/.02 Casing wear ring Fluid drain Only for versions with mechanical seal type C19 Not for Etachrom L 050-025-125.1, 050-025-125, 050-025-160, 050-032-125.1, 050-032-125, 050-032-160, 065-040-125, 065-050-125 Etachrom L 61 of 70...
  • Page 62 9 Related Documents 9.1.2 Design for shaft unit 25.2 This view applies to the following pump sizes: 050-025-250 050-032-250 065-040-250 065-050-200 080-065-200 065-050-250 [ Supplied in packaging units only 321.01/.02 411.01 502.02 502.01 132.01 360.01/.02 132.01 903.01 902.06 901.31 920.01 920.06 914.02 920.95...
  • Page 63 Safety device 400.75 Gasket 932.01/.02 Circlip 411.01/.77/.78 Joint ring 940.01/.02 412.35 O-ring Mechanical seal 502.01/.02/.06 Casing wear ring Connections Shaft sleeve Fluid drain Only for versions with mechanical seal type C19 Only for Etachrom L 080-065-250, 100-080-250 Etachrom L 63 of 70...
  • Page 64 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: Etabloc, Etabloc SYT, Etaline, Etaline SYT, Etaline Z, Etachrom B, Etachrom L, Etanorm, Etanorm SYT, Etanorm V, Etaprime L, Etaprime B KSB order number: ....................▪ is in conformity with the provisions of the following directives / regulations as amended from time to time: –...
  • Page 65 11 Certificate of Decontamination 11 Certificate of Decontamination Type: ..........................Order number / Order item number ..........................Delivery date: ..........................Application: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ ⃞ Corrosive Oxidising Flammable Explosive Hazardous to health ⃞...
  • Page 66 Index Index Installation Installation on a foundation 23 Applications 9 without foundation 24 Automation 19 Installation at site 22 Intended use 9 Interchangeability of pump components 58 Bearing temperature 43 Bearings 19 Key to safety symbols/markings 8 Certificate of Decontamination 65 Clearances 44 Maintenance 42 Commissioning 34 Mechanical seal 36 Contact guard 21 Monitoring equipment 12 Coupling 21, 44 Coupling alignment 28, 29 Name plate 18 Noise characteristics 20...
  • Page 67 Index Temperature limits 11 Tightening torques 53, 55 Transport 13 Warnings 8 Warranty claims 7 Etachrom L 67 of 70...
  • Page 70 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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