KSB Etanorm-R Installation & Operating Manual
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KSB Etanorm-R Installation & Operating Manual

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Etanorm-R
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Summary of Contents for KSB Etanorm-R

  • Page 1 Standardised Pump Etanorm-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 23/08/2021...

  • Page 3: Table Of Contents

    Installation on the foundation...................... 22 5.3.2 Installation without foundation ....................... 23 Piping ................................ 23 5.4.1 Connecting the piping........................ 23 5.4.2 Permissible forces and moments at the pump nozzles.............. 25 5.4.3 Vacuum balance line.......................... 25 5.4.4 Auxiliary connections......................... 26 Enclosure/insulation ............................ 27 Checking the coupling alignment ......................... 27 Etanorm-R 3 of 78...
  • Page 4 Spare parts stock............................. 66 7.7.1 Ordering spare parts.......................... 66 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 .......... 66 7.7.3 Interchangeability of pump components.................. 67 Trouble-shooting.......................... 68 Related Documents .......................... 70 General assembly drawing with list of components .................. 70 Etanorm-R 4 of 78...
  • Page 5 Contents EU Declaration of Conformity ...................... 73 Certificate of Decontamination...................... 74 Index .............................. 75 Etanorm-R 5 of 78...

  • 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 Etanorm-R 6 of 78...

  • 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. Etanorm-R 8 of 78...

  • 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. Etanorm-R 9 of 78...

  • 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. Etanorm-R 10 of 78...

  • Page 11: Unauthorised Modes Of Operation

    They include only a general safety margin for the mechanical seal. For single mechanical seals, the safety margin required for specific operating conditions and mechanical seal designs may be substantially higher. If operating conditions differ Etanorm-R 11 of 78...

  • 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 74) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination Etanorm-R 14 of 78...

  • Page 15: 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. Etanorm-R 15 of 78...

  • Page 16: Description Of The Pump (Set)

    ▪ Information on benchmark efficiency or benchmark efficiency graph for MEI = 0.70 (0.40) for the pump based on the model shown in the Figure are available at: http://www.europump.org/efficiencycharts 4.3 Designation Example: Etanorm-R X G C1 300-400 Table 5: Designation key Code Description Etanorm-R X...

  • Page 17: Name Plate

    40 m n 1488 1/min η --,-% MEI ≥ 0,10 Mat.-No. 01 109 223 ZN 3804 - D 52 x 74 Fig. 5: Name plate (example) Etanorm-R Type series, size and version Customer reference KSB order number Flow rate (ten digits) Speed...
  • Page 18 ▪ Grease-packed deep groove ball bearing ▪ Oil-lubricated deep groove ball bearing Direction of rotation ▪ Clockwise, viewed from the drive end. Automation Automation options: ▪ PumpDrive (wall-mounted model) ▪ PumpDrive (motor-mounted model) For fluid temperatures ≤ 140°C only Etanorm-R 18 of 78...

  • Page 19: Design And Function

    (9 and 10), which are supported by a bearing bracket (5) linked with the pump casing and/or casing cover. Sealing The pump is sealed by a shaft seal (KSB cartridge seal or gland packing). Etanorm-R 19 of 78...

  • 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. For measuring and constructional tolerance, add 1 dB for n ≤ 1750 rpm and 3 dB for n > 1750 rpm. Etanorm-R 20 of 78...

  • Page 21: 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. Etanorm-R 21 of 78...

  • Page 22: Installation On The Foundation

    - Baseplates made of grey cast iron 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. Etanorm-R 22 of 78...

  • Page 23: 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. Etanorm-R 23 of 78...
  • Page 24 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. Etanorm-R 24 of 78...

  • Page 25: Permissible Forces And Moments At The Pump Nozzles

    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: ▪ Minimum nominal line diameter 25 mm. ▪ The line extends above the highest permissible fluid level in the vessel. Etanorm-R 25 of 78...

  • Page 26: 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. Etanorm-R 26 of 78...

  • Page 27: Enclosure/Insulation

    Damage to pump, motor and coupling! ▷ Always check the coupling after the pump has been installed and connected to the piping. ▷ Also check the coupling of pump sets supplied with pump and motor mounted on the same baseplate. Etanorm-R 27 of 78...
  • Page 28 5 Installation at Site Fig. 12: Non-spacer-type coupling, checking the coupling alignment Straight edge Gauge 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 Etanorm-R 28 of 78...

  • Page 29: Aligning The Pump And Motor

    2. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at the baseplate. 3. Turn the adjusting screws (2) by hand or by means of an open-end wrench until the coupling alignment is correct and all motor feet rest squarely on the baseplate. Etanorm-R 29 of 78...

  • Page 30: 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 31: 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 32: Earthing

    CAUTION Incorrect direction of rotation with non-reversible mechanical seal Damage to the mechanical seal and leakage! ▷ Separate the pump from the motor to check the direction of rotation. Etanorm-R 32 of 78...
  • Page 33 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. Etanorm-R 33 of 78...

  • Page 34: Commissioning/Start-Up/Shutdown

    CAUTION Insufficient quantity of lubricating oil in the reservoir of the constant level oiler Damage to the bearings! ▷ Regularly check the oil level. ▷ Always fill the oil reservoir completely. Etanorm-R 34 of 78...

  • Page 35: Priming And Venting The Pump

    ▷ The pump internals in contact with the fluid to be handled, including the seal chamber and auxiliary systems, must be filled with the fluid to be handled at all times. ▷ Provide sufficient inlet pressure. ▷ Provide an appropriate monitoring system. Etanorm-R 35 of 78...

  • Page 36: Final Check

    Check that coupling/shaft can be easily rotated by hand. 4. Fit the coupling guard and its footboard, if any. 5. Check the distance between coupling and coupling guard. The coupling guard must not touch the coupling. Etanorm-R 36 of 78...

  • Page 37: Start-Up

    ▷ Use a soft starter. ▷ Use speed control. 1. Fully open the shut-off element in the suction head/suction lift line. 2. Close or slightly open the shut-off element in the discharge line. 3. Start up the motor. Etanorm-R 37 of 78...

  • Page 38: Checking The Shaft Seal

    2. Use a feeler gauge to verify that the gland follower is mounted centred and at a right angle to the shaft. ð The gland must leak after the pump has been primed. After five minutes of operation Etanorm-R 38 of 78...

  • Page 39: Shutdown

    For prolonged shutdown periods: 1. Close the shut-off element in the suction line. 2. Close any auxiliary lines. If the fluid to be handled is fed in under vacuum, also supply the shaft seal with barrier fluid during standstill. Etanorm-R 39 of 78...

  • Page 40: Operating Limits

    The frequency of starts is determined by the maximum temperature increase of the motor. The frequency of starts depends on the power reserves of the motor in steady-state operation and on the starting conditions (DOL starting, star-delta Etanorm-R 40 of 78...

  • Page 41: Fluid Handled

    Temperature at the casing surface °C Pump efficiency at duty point Temperature difference 6.2.3.2 Density of the fluid handled The power input of the pump set will change in proportion to the density of the fluid handled. Best efficiency point Etanorm-R 41 of 78...

  • Page 42: Shutdown/Storage/Preservation

    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, properly re-install and re-activate any safety- relevant devices and protective devices. Etanorm-R 42 of 78...
  • Page 43 6 Commissioning/Start-up/Shutdown NOTE If the equipment has been out of service for more than one year, replace all elastomer seals. Etanorm-R 43 of 78...

  • 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. Etanorm-R 44 of 78...

  • 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 The bearing temperature must not exceed 90 °C (measured on the outside of the bearing bracket). CAUTION Operation outside the permissible bearing temperature Damage to the pump! ▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured on the outside of the bearing bracket). Etanorm-R 46 of 78...

  • Page 47: Inspection Work

    Table 15: Clearances between impeller neck and casing wear ring Clearance gap 0.4 mm Maximum permissible expansion 0.6 mm Table 16: Clearance gaps between gland follower and shaft protecting sleeve Clearance gap Normal 0.2 mm Maximum permissible expansion 0.6 mm Etanorm-R 47 of 78...

  • Page 48: Lubrication And Lubricant Change Of Rolling Element Bearings

    Lubricating oil Kinematic viscosity at 40 °C 46 ± 4 mm²/s □ C 46 Flash point (to Cleveland) +175 °C CL 46 Solidification point (pour point) -15 °C CLP 46 At least once a year To DIN 51517 Etanorm-R 48 of 78...
  • Page 49 The bearings are supplied packed with high-quality lithium-soap grease. For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB. For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.
  • Page 50 ü The pump has been dismantled for changing the grease. 1. Only half-fill the bearing cavities with grease. 2. Fill the cavities in the bearing cover until they are about 1/3 full. Shaft unit see data sheet. With Nilos ring 6413 AV Etanorm-R 50 of 78...

  • Page 51: Drainage/Cleaning

    ▷ Use suitable transport devices, lifting equipment and lifting tackle to move heavy assemblies or components. Always observe the safety instructions and information. (ð Section 7.1, Page 44) For any work on the motor, observe the instructions of the relevant motor manufacturer. Etanorm-R 51 of 78...

  • Page 52: Preparing 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 53: Removing The Impeller

    3. Place impeller 230 on a clean and level surface. 4. Remove keys 940.01 from shaft 210. 5. If equipped with KSB cartridge seal (4ES): Remove intermediate ring 509.95. Sizes 200-500, 250-300, 300-340 and KSB cartridge seal (4EB): Remove intermediate ring 509.

  • Page 54: Removing The Shaft Seal

    471.01 again. 2. Undo grub screws 904.97 in ring 500.97. 3. Undo nuts 920.05. 4. Remove the KSB cartridge seal from casing cover 161. Removing the KSB cartridge seal (4EB) ü The notes and steps stated in (ð Section 7.4.1, Page 51) to (ð Section 7.4.5, Page 53) have been observed/carried out.

  • Page 55: Dismantling The Bearings

    ü The notes and steps stated in (ð Section 7.4.1, Page 51) to (ð Section 7.4.6, Page 54) have been observed/carried out. 1. Unscrew the hexagon socket head cap screw in the coupling hub. 2. Pull the coupling hub off pump shaft 210 with a puller. 3. Remove key 940.02. Etanorm-R 55 of 78...

  • Page 56: Reassembling The Pump Set

    Coat the locating surfaces of the individual components with graphite or similar before reassembly. Prior to reassembly, screw back any forcing screws and adjusting screws. Tightening torques For reassembly, tighten all screws and bolts as specified in this manual. (ð Section 7.6, Page 64) Etanorm-R 56 of 78...

  • Page 57: Installing The Bearings

    ü The sealing surfaces have been cleaned. 1. Slide (Nilos) rings 500.18/.21 along the shaft until they abut the shaft shoulder. 2. Press radial ball bearings 321.01/.02 onto shaft 210. 3. Insert the pre-assembled shaft into bearing bracket 330. Etanorm-R 57 of 78...

  • Page 58: Fitting The Shaft Seal

    ü The sealing surfaces have been cleaned. 1. Slide thrower 507 (if any) onto shaft 210 from the pump end. 2. Slide the KSB cartridge seal onto casing cover 161 until joint ring 411.15 rests against the casing cover. 3. Bolt seal cover 471.01 to the casing cover. Tighten nuts 920.5 evenly.
  • Page 59 ü A suitable lubricant has been applied to the mechanical seal's O-rings (B) to reduce the friction when sliding on the cartridge seal. ü The KSB cartridge seal is kept in a clean and level assembly area. ü All dismantled parts have been cleaned and checked for wear.
  • Page 60 ü The sealing surfaces have been cleaned. 1. Slide thrower 507 (if any) onto shaft 210 from the pump end. 2. Clean the stationary ring location of the mechanical seal in casing cover 161 and seal cover 471.01. Etanorm-R 60 of 78...
  • Page 61 Ø d Ø d □ 12 x 302 4 packing rings, 1 lantern ring 6 packing rings For operation with positive suction head and suction pressure > 0.5 bar, the lantern ring is replaced by 2 additional packing rings. Etanorm-R 61 of 78...
  • Page 62 5. Use a feeler gauge to verify that gland follower 452.01 is fitted centred and at a right angle to the shaft. 6. Tighten gland follower 452.01 lightly and evenly. The rotor must be easy to rotate. Etanorm-R 62 of 78...

  • Page 63: Fitting The Impeller

    ü Any damaged or worn parts have been replaced by original spare parts. ü The sealing surfaces have been cleaned. 1. If equipped with KSB cartridge seal (4ES): Insert intermediate ring 509.95. Sizes 200-250, 250-300, 300-340 and KSB cartridge seal (4EB): Insert intermediate ring 509.

  • Page 64: Mounting The Motor

    Fig. 29: Tightening points at the pump Table 24: Tightening torques Part No. Description Thread Tightening torques [Nm] 901.01/.02 Hexagon head bolt 901.04 Hexagon head bolt 920.01 Hexagon nut 920.02 Hexagon nut Hexagon nut M20 × 1,5 M24 × 1,5 For unlubricated threads Seal cover only Etanorm-R 64 of 78...

  • Page 65: Tightening Torques For The Pump Set

    Table 25: Tightening torques for bolted/screwed connections at the pump set Position Thread Tightening torques Comments [Nm] Pump on baseplate M 30 M24 × 1,5 Motor on baseplate Coupling Coupling guard 17,5 For unlubricated threads For spacer-type couplings only Etanorm-R 65 of 78...

  • Page 66: Spare Parts Stock

    Mechanical seal 25 % 500.03 Ring 25 % Shaft sleeve 50 % For variants with gland packing: 456.01 Neck bush 30 % Gland packing (set) 100 % Shaft protecting sleeve 50 % For Etanorm-R 125-500/2 only Etanorm-R 66 of 78...

  • Page 67: Interchangeability Of Pump Components

    7 Servicing/Maintenance 7.7.3 Interchangeability of pump components Components featuring the same number in a column are interchangeable. Table 27: Interchangeability of pump components Etanorm-R Description Part No. 125-500/2 150-500.1 200-250 200-260 200-330 200-400 200-500 250-300 250-330 250-400 250-500 300-340 300-360 300-400...

  • Page 68: 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 69 In the case of persistent overloading, turn down impeller. ✘ - Density or viscosity of fluid handled Contact KSB. higher than stated in purchase order - Use of unsuitable shaft seal materials Change the material combination. ✘...

  • Page 70: Related Documents

    901.04 550.41 411.77 731.04 901.31 903.01 411.01 903.08 902.01 903.03 411.08 920.01 411.03 902.04 412.47 920.04 902.01 502.02 920.01 502.04 903.04 411.04 502.03 502.01 525.01 940.01 400.04 230.01 903.62 411.62 901.30 903.01 411.01 731.04 230.02 400.19 Etanorm-R 70 of 78...
  • Page 71 9 Related Documents Fig. 31: a) Etanorm-R (single-entry) b) Etanorm-R (two-stage) c) Clamped casing cover Table 29: List of components Part No. Part No. Description Volute casing 411.01/.03/.04/.08 Joint ring 502.01 Casing wear ring 902.01 Stud 903.01/.03/.04/.08 Screw plug 920.01 Casing cover 400.19...
  • Page 72 731.04 731.04 Pipe union 81-92 81-92 Cover plate 550.74 Disc 901.14 Hexagon head bolt 901.01/.02/.04/.14/.30/.31 901.01/.02/.04/.14/.30/.31 Hexagon head bolt 902.01/.04 902.01/.04 Stud 903.01/.03/.04/.08/.62 903.01/.03/.04/.08/.62 Screw plug 920.01/.04 920.01/.04 Hexagon nut Impeller nut 940.01/.02 940.01/.02 Not shown Etanorm-R 72 of 78...
  • Page 73 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: Etanorm-R KSB order number: ....................▪ is in conformity with the provisions of the following directives / regulations as amended from time to time: –...
  • Page 74 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 Etanorm-R 74 of 78...
  • Page 75 Fluid handled Preservation 14, 42 Density 41 Priming and venting 36 Frequency of starts 41 Product description 16 Function 19 Pure graphite packing 38 General assembly drawing 71 Reassembly 52, 56 Gland packing 38 Return to supplier 14 Grease lubrication Grease quality 50 Returning to service 42 Intervals 50 Running noises 45 Etanorm-R 75 of 78...
  • Page 76 Index Safety 9 Safety awareness 10 Scope of supply 20 Shaft seal 18 Shutdown 42 Spare part Ordering spare parts 66 Spare parts stock 66 Start-up 37 Storage 14, 42 Temperature limits 11 Tightening torques 64, 65 Transport 13 Warnings 8 Warranty claims 7 Etanorm-R 76 of 78...
  • Page 78 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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