Ecochem Non-Seal HN - KSB SE · 1 General 1.1 Principles This operating manual is supplied as an integral part of the type series and variants indicated on the front cover. The manual

Canned Motor Pump

Ecochem Non-Seal HN

Motor size F

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual Ecochem Non-Seal HN

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited orprocessed for any other purpose, nor otherwise transmitted, published or made available to a third party withoutthe manufacturer's express written consent.

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft, Frankenthal 21.04.2015

Contents

Glossary .................................................................................................5

1 General ..................................................................................................6

1.1 Principles ........................................................................................................... 6

1.2 Installation of partly completed machinery .................................................... 6

1.3 Target group ..................................................................................................... 6

1.4 Other applicable documents ............................................................................ 6

1.5 Symbols ............................................................................................................. 6

2 Safety .....................................................................................................8

2.1 Key to safety symbols/markings ....................................................................... 8

2.2 General .............................................................................................................. 8

2.3 Intended use ..................................................................................................... 9

2.4 Personnel qualification and training ............................................................... 9

2.5 Consequences and risks caused by non-compliance with this manual ......... 9

2.6 Safety awareness .............................................................................................. 9

2.7 Safety information for the user/operator ..................................................... 10

2.8 Safety information for maintenance, inspection and installation work ..... 10

2.9 Unauthorised modes of operation ................................................................ 10

2.10 Explosion protection ...................................................................................... 10

3 Transport/Temporary Storage/Disposal .............................................13

3.1 Checking the condition upon delivery .......................................................... 13

3.2 Transport ......................................................................................................... 13

3.3 Storage/preservation ...................................................................................... 13

3.4 Return to supplier ........................................................................................... 14

3.5 Disposal ........................................................................................................... 14

4 Description ..........................................................................................15

4.1 General description ........................................................................................ 15

4.2 Designation ..................................................................................................... 15

4.3 Name plate ...................................................................................................... 16

4.4 Design details .................................................................................................. 17

4.5 Configuration and function ........................................................................... 18

4.6 Noise characteristics ....................................................................................... 19

4.7 Scope of supply ............................................................................................... 19

4.8 Dimensions and weights ................................................................................ 19

5 Installation at Site ...............................................................................20

5.1 Safety regulations ........................................................................................... 20

5.2 Checks to be carried out prior to installation ............................................... 20

5.3 Installing the pump set .................................................................................. 20

5.4 Piping .............................................................................................................. 22

Contents

Ecochem Non-Seal HN 3 of 98

5.5 Enclosure/insulation ....................................................................................... 28

5.6 Electrical system .............................................................................................. 29

5.7 Checking the direction of rotation ................................................................ 54

6 Commissioning/Start-up/Shutdown ...................................................55

6.1 Commissioning/start-up ................................................................................. 55

6.2 Operating limits .............................................................................................. 58

6.3 Shutdown/storage/preservation .................................................................... 60

6.4 Returning to service ....................................................................................... 60

7 Servicing/Maintenance .......................................................................61

7.1 Safety regulations ........................................................................................... 61

7.2 Servicing/inspection ........................................................................................ 62

7.3 Drainage/disposal ........................................................................................... 67

7.4 Dismantling the pump set .............................................................................. 69

7.5 Reassembling the pump set ........................................................................... 73

7.6 Tightening torques ......................................................................................... 81

7.7 Spare parts stock ............................................................................................. 83

8 Trouble-shooting ................................................................................85

9 Related Documents ............................................................................87

9.1 General assembly drawing with list of components .................................... 87

9.2 Flamepaths ...................................................................................................... 90

9.3 Size/casing cover combinations ..................................................................... 92

9.4 Motor size/bearing size combinations .......................................................... 93

10 EC Declaration of Conformity ............................................................94

11 Certificate of Decontamination .........................................................95

Index ....................................................................................................96

Contents

4 of 98 Ecochem Non-Seal HN

Glossary

Back pull-out design

The complete back pull-out unit can be pulledout without having to remove the pump casingfrom the piping.

Back pull-out unit (canned motor pump)

Drive unit with impeller but without pumpcasing and possibly without baseplate; partlycompleted machinery

Certificate of decontamination

A certificate of decontamination is enclosed bythe customer when returning the product tothe manufacturer to certify that the producthas been properly drained to eliminate anyenvironmental and health hazards arising fromcomponents in contact with the fluid handled.

Control cable

An electrical cable used for electricity supply tothe pump set's sensors and for signaltransmission.

Discharge line

The pipeline which is connected to thedischarge nozzle

Motor unit

Drive component consisting of motor housing,stator, can, terminal box.

Power cable

An electrical cable used to supply the pumpset's motor with electrical power from themains.

Pump

Machine without drive, additional componentsor accessories

Pump set

Complete pump set consisting of pump, drive,additional components and accessories

Spare motor unit

Drive component (consisting of motor housing,stator, can, terminal box) which can bepurchased as a separate spare part.

Suction lift line/suction head line

The pipeline which is connected to the suctionnozzle

Glossary


1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variantsindicated on the front cover. The manual describes the proper and safe use of thisequipment in all phases of operation.

The name plate indicates the type series and size, the main operating data, the ordernumber and the order item number. The order number and order item numberuniquely identify the pump (set) and serve as identification for all further businessprocesses.

In the event of damage, immediately contact your nearest KSB service centre tomaintain the right to claim under warranty.

Noise characteristics see

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB refer to the sub-sections underServicing/Maintenance. ( Section 7.5.12 Page 80)

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialisttechnical personnel. ( Section 2.4 Page 9)

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsData sheet Description of the technical data of the pump (set)General arrangement drawing/outline drawing

Description of mating and installation dimensionsfor the pump (set), weights

Drawing of auxiliary connections Description of auxiliary connectionsHydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power inputGeneral assembly drawing1) Sectional drawing of the pumpSub-supplier product literature1) Operating manuals and other product literature

describing accessories and integrated machinerycomponents

Spare parts lists1) Description of spare partsPiping layout1) Description of auxiliary pipingList of components1) Description of all pump componentsSupplementary operatinginstructions for monitoringsystems

Description of suitable monitoring systems andsuggested wiring concepts

For accessories and/or integrated machinery components, observe the relevantmanufacturer's product literature.

1.5 Symbols

Table 2: Symbols used in this manual

Symbol Description Conditions which need to be fulfilled before proceeding with the

step-by-step instructions⊳ Safety instructions

1) If inclusion in the scope of supply has been agreed.

1 General


Symbol Description Result of an action Cross-references1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General


2 SafetyAll the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.Explosion protectionThis symbol identifies information about avoiding explosions inpotentially explosive atmospheres in accordance with EC Directive94/9/EC (ATEX).General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies information aboutprotection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

Warning: Strong magnetic fieldIn conjunction with one of the signal words this symbol indicates ahazard involving magnetic fields and identifies information aboutprotection against magnetic fields.Warning for persons with pacemakerIn conjunction with one of the signal words this symbol indicates ahazard involving magnetic fields and identifies special informationfor persons with a pacemaker.

2.2 General

This manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent personal injuryand damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the specialist personnel/operators responsible prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pump must always be complied with and bekept in a perfectly legible condition at all times. This applies to, for example:

Arrow indicating the direction of rotation

Markings for connections

Name plate

The operator is responsible for ensuring compliance with all local regulations nottaken into account in this manual.

! DANGER

2 Safety


2.3 Intended use

The pump (set) must only be operated within the operating limits described inthe other applicable documents.

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 productliterature of the pump model or variant.

Never operate the pump without the fluid to be handled.

Observe the minimum flow rates indicated in the data sheet or product literature(to prevent overheating, bearing damage, etc).

Do not throttle the flow rate on the suction side of the pump (to preventcavitation damage).

Consult the manufacturer about any use or mode of operation not described inthe data sheet or product literature.

The ambient temperature for the motor must be within the temperature rangeindicated on the name plate or in the data sheet.

Prevention of foreseeable misuse

Never open the discharge-side shut-off elements further than permitted.

– The maximum flow rates specified in the product literature or data sheetwould be exceeded.

– Risk of cavitation damage

– Risk of bearing damage/motor damage

Never exceed the permissible operating limits specified in the data sheet orproduct literature regarding pressure, temperature, etc.

Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintainand inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved intransport, installation, operation, maintenance and inspection must be clearlydefined by the operator.

Deficits in knowledge must be rectified by means of training and instructionprovided by sufficiently trained specialist personnel. If required, the operator cancommission the manufacturer/supplier to train the personnel.

Training on the pump (set) must always be supervised by technical specialistpersonnel.

2.5 Consequences and risks caused by non-compliance with this manual

Non-compliance with this operating manual will lead to forfeiture of warrantycover and of any and all rights to claims for damages.

Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,the following safety regulations shall be complied with:

2 Safety


Accident prevention, health and safety regulations

Explosion protection regulations

Safety regulations for handling hazardous substances

Applicable standards, directives and laws

2.7 Safety information for the user/operator

The operator shall fit contact guards for hot, cold and moving parts and checkthat the guards function properly.

Do not remove any contact guards during operation.

Provide the personnel with protective equipment and make sure it is used.

Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.explosive, toxic, hot) so as to avoid any danger to persons and the environment.Adhere to all relevant laws.

Eliminate all electrical hazards. (In this respect refer to the applicable nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

If shutting down the pump does not increase potential risk, fit an emergency-stop control device in the immediate vicinity of the pump (set) during pump setinstallation.

2.8 Safety information for maintenance, inspection and installation work

Modifications or alterations of the pump are only permitted with themanufacturer's prior consent.

Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughlyfamiliar with the manual.

Only carry out work on the pump (set) during standstill of the pump.

The pump casing must have cooled down to ambient temperature.

Pump pressure must have been released and the pump must have been drained.

When taking the pump set out of service always adhere to the proceduredescribed in the manual. ( Section 6.3 Page 60) ( Section 6.3.1 Page 60)

Decontaminate pumps which handle fluids posing a health hazard.

As soon as the work has been completed, re-install and/or re-activate any safety-relevant and protective devices. Before returning the product to service, observeall instructions on commissioning. ( Section 6.1 Page 55)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in thismanual.

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.

2.10 Explosion protection

Always observe the information on explosion protection given in this section whenoperating the pump in potentially explosive atmospheres.

! DANGER

2 Safety


Only pumps/pump sets marked as explosion-proof and identified as such in the datasheet may be used in potentially explosive atmospheres.

Special conditions apply to the operation of explosion-proof pump sets to ECDirective 94/9/EC (ATEX). Especially adhere to the sections in this manual marked with the Ex symbol and thefollowing sections ( Section 2.10.1 Page 11) to ( Section 2.10.4 Page 12) . The explosion-proof status of the pump set is only assured if the pump set is used inaccordance with its intended use. Never operate the pump set outside the limits stated in the data sheet and on thename plate.Prevent impermissible modes of operation at all times.

2.10.1 Marking

The temperature class is indicated in the data sheet and on the name plate.

Temperature class: T5, T4, T3II 2G c Ex de IIC T.. Gb

In case of special coatings with a total film thickness exceeding 0.2 mmII 2G c Ex de IIB T..Gb

Customer's marking

To safeguard its explosion-proof status, the pump set must not be damaged by holesdrilled or rivets used, e.g., to attach customer's marking signs. The use of adhesivelabels or sign holders attached with fastening straps is recommended.

2.10.2 Temperature limits

The surface temperature at the pump casing corresponds to the temperature of thefluid handled; responsibility therefore lies with the operator.

The sensors and relevant monitoring devices for surface temperature monitoring inthe motor area must be properly connected and set. The temperature class indicatedin the data sheet and on the name plate for the entire pump set corresponds to thatof the motor. Refer to the data sheet and name plate for the settings to be observedfor surface temperature compliance.

Table 4: Temperature limits

Temperature class to EN 13463-1 Maximum permissible motorhousing surface temperature

T3 200 °CT4 135 °CT5 100 °C

If the sensors and relevant monitoring equipment for temperature monitoring areproperly connected and set, the permissible temperature limits are complied withduring heater operation.

2.10.3 Monitoring equipment

The pump set must only be operated at the duty point/design point indicated in thedata sheet and on the name plate.

To ensure that the temperature limits are complied with, the monitoring concept( Section 4.3 Page 16) indicated on the name plate ( Section 5.6.4.1 Page 44) mustbe strictly adhered to.

Hydraulic system

Motor

Heater operation withanti-condensation heater

2 Safety


Table 5: Monitoring equipment for the pump set

Monitoring equipment For operation in potentially explosive atmospheres

Required Optional2)

Temperature monitoring -Fill level monitoring 3) -Bearing monitoring - Leakage monitoring for the second pressure boundary - Direction-of-rotation monitoring - Pump power monitoring -

2.10.4 Repair

Special regulations apply to repair work on explosion-proof pumps. Modifications oralterations of the pump set can affect explosion protection and are only permittedafter consultation with the manufacturer.

The actual dimensions of the flameproof joints are not necessarily identical withthose stipulated in EN 60079-1 Tables 1 and 2.

2) Refer to the supplementary operating instructions for detailed information3) The customer must ensure that the pump set (and hence the rotor space) is filled with fluid. Only if the rotor space is

completely filled, can a potentially explosive atmosphere be excluded.

2 Safety


3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

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 andnotify KSB or the supplying dealer (as applicable) and the insurer about thedamage in writing immediately.

3.2 Transport

DANGER

The pump (set) could slip out of the suspension arrangementDanger to life from falling parts!

▷ Always transport the pump (set) in the specified position.

▷ Never attach the suspension arrangement to the free shaft end or the motoreyebolt.

▷ Give due attention to the weight data and the centre of gravity.

▷ Observe the applicable local health and safety regulations.

▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.

To transport the pump/pump set suspend it from the lifting tackle as shown.

≤ 90 °

Fig. 1: Transporting the pump set with the baseplate

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for pump (set) storage.

CAUTIONDamage during storage by humidity, dirt, or verminCorrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessorieswith waterproof material.

CAUTIONWet, contaminated or damaged openings and connectionsLeakage or damage to the pump!

▷ Clean and cover pump openings and connections as required prior to puttingthe pump into storage.



Store the pump (set) in a dry, protected room where the atmospheric humidity is asconstant as possible.

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, observe the instructions in( Section 6.3 Page 60) .

3.4 Return to supplier

1. Drain the pump as per operating instructions.

2. Always flush and clean the pump, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.

3. If the pump set has handled fluids whose residues could lead to corrosion in thepresence of atmospheric humidity or could ignite upon contact with oxygen,the pump set must also be neutralised, and anhydrous inert gas must be blownthrough the pump to ensure drying.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set).Always indicate any safety and decontamination measures taken. ( Section 11Page 95)

NOTEIf required, a blank certificate of decontamination can be downloaded from theKSB web site at: www.ksb.com/certificate_of_decontamination

3.5 Disposal

WARNINGFluids, consumables and supplies which are hot and/or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pump (set).

2. Separate and sort the pump materials, e.g. by:- Metals- Plastics- Electronic waste

3. Dispose of materials in accordance with local regulations or in anothercontrolled manner.



http://www.ksb.com/GRAS-Cert

4 Description

4.1 General description

Pump for handling aggressive, flammable, toxic, volatile, explosive or valuable liquidsin the chemical and petrochemical industries, in environmental and industrialengineering.

Standardised chemical pump with canned motor

4.2 DesignationEcochem Non-Seal HN 080-050-3151 F3 CC

Table 6: Designation key

Code DescriptionEcochem Non-Seal Type seriesHN Additional code, e.g. HN = standard080 Nominal suction nozzle diameter [mm]050 Nominal discharge nozzle diameter [mm]315 Nominal impeller diameter [mm]1 Additional code, e.g. 1 = low-flow hydraulic systemF3 Motor sizeC Casing material, e.g. C = stainless steelC Impeller material, e.g. C = stainless steel

4 Description


4.3 Name plate

KSB Aktiengesellschaft67227 Frankenthal

Mat. No. 01573637 ZN 3828 - 87

Q

ºC

Ecochem Non-Seal

cos φ

m3/h n 1/minH m

IN

kWP1 IP

TM

3 ~°C

°CØ mm

p test barp MAWP bar /SP2 kWIAA A

m kgTambTEx

P00100 A/P00100B

2014

HN 050-032-2001 A3 CC

3,1 27,8 290075

160

2416 801 65 C220

Tetrachlorsilane

S/400V/50 Hz 1,30,8 VFD 30-50 Hz2,4 13,1

0,8980-20/ +40PTC + PT100 (125 ºC)

0044

licenced by Nikkiso-KSB GmbH

997285947001001Made in Germany

II 2 G c Ex de II C T3 Gb Ib


Mat. No. 01573637 ZN 3828 - 87

Q

ºC

Ecochem Non-Seal

cos φ

m3/h n 1/minH m

IN

kWP1 IP

TM

3 ~°C

°CØ mm


m kgTambTEx

P00100 A/P00100B

2014

HN 050-032-2001 A3 CC

3,1 27,8 290075

160

2416 801 65 C220

Tetrachlorsilane

S/400V/50 Hz 1,30,8 VFD 30-50 Hz2,4 13,1

0,8980-20/ +40PTC + PT100 (125 ºC)

Ineris 14ATEX 0019X

0044



II 2 c G Ex de II C T3 Gb Ib

Ineris 14ATEX 0019X

6

78

9

10

14

12345

1516171819

22

30

2324

2526

2728

29

2120

11

12

13

Fig. 2: Name plate (example)

1 Type series 2 Designation3 KSB order number 4 Flow rate at duty point5 Fluid handled 6 Max. permissible application pressure/

temperature7 Starting method/rated motor voltage/

frequency8 Rated motor current

9 Sensor type (set limit)4) 10 ATEX marking of pump set11 Head at duty point 12 Motor input power at rated power13 Starting current (static) 14 Monitoring concept to be applied15 Customer-specific information (optional) 16 Rotational speed at duty point17 Fluid temperature at pump inlet 18 Test pressure for casings19 Motor operating mode 20 Motor output power at rated power21 cos phi at rated power 22 Permissible ambient temperature23 Impeller diameter 24 Year of construction

4) Only applicable for monitoring concepts Ia and Ib.

4 Description


25 Terminal box enclosure 26 Thermal class of motor winding27 Three-phase motor 28 Permissible control range of frequency

inverter29 Weight (optional) 30 No. of type test certificate

4.4 Design detailsDesign

Canned motor pump

Back pull-out design

Horizontal installation

Single-stage

Dimensions and ratings to ISO 2858complemented by pumps of nominal diameter DN 25

Pump casing

Radially split volute casing

Single or double volute, depending on the pump size

Volute casing with integrally cast pump feet

Impeller type

Closed radial impeller with multiply curved vanes

Axial thrust balancing by means of sealing clearance and balancing holes

Bearings

Hydrodynamic plain bearings

Product-lubricated

Shaft seal

Seal-less, with canned motor

Drive

Special motors cooled by the fluid handled

Table 7: General motor data

Characteristic ValueStarting method DOL startingRated voltages5) 50 Hz: 400 V, 500 V, 690 V

60 Hz: 480 V, 600 VTolerance Voltage: ± 10 %

Frequency: ± 2 %Operation on a frequencyinverter6)

( Section 5.6.1.1 Page 29)

Motor supply voltage limits:

du/dt < 1000 V/µs

Û < 1000 VMarking to 94/9/EC II 2 G Ex de IIC7) T5, T4 or T3Enclosure to EN 60034 IP658)

Thermal class C 220

General motor data

5) Special voltages on request6) Only possible in combination with (PTC) thermistors and Ex d terminal boxes7) Not applicable for special coatings8) Supplied in IP54

4 Description


Characteristic ValueOperating mode to EN 60034 S1

S2-S99)

Monitoring equipment PTC

4.5 Configuration and function

1 2 3 4 5 6 7

8

9 10 11 1312

Fig. 3: Sectional drawing

1 Impeller 2 Bore3 Plain bearing (pump-end) 4 Support sleeve5 Circular clearance 6 Axial bore7 Terminal box 8 Plain bearing (drive-end)9 Bore 10 Shaft11 Rotor 12 Stator13 Can

The hydraulic system and the motor are firmly connected and form a close-coupledunit.Both impeller (1) and rotor (11) are arranged on a common shaft (10).

The shaft runs in product-lubricated plain bearings (3 and 8). The rotor space issealed off towards the stator space by the can (13). The can, which is made ofcorrosion-resistant material, rests on the stator (12) and the support sleeves (4) tocompensate for the forces resulting from the pressure within the rotor space.

The plain bearings (3, 8) are lubricated by the fluid handled in the rotor space. Whenthe pump is started up, the fluid enters the rotor space via the bores (2, 9) while theair in the rotor space is vented via an axial bore in the shaft. The partial flow tapped

Design

Function

9) Depending on monitoring concept

4 Description


from the fluid flow through the bores (2, 9) surrounds the rotor during pumpoperation and enters an axial bore (6) provided at the rear end of the rotor shaft.The axial bore (6) ends at the front face of the impeller-side shaft end.

The pressure difference between the bores (2, 9) and the outlet of the axial bore (6)through the shaft at the impeller-side shaft end results in a continuous partial flowof fluid handled. As this partial flow passes through the circular clearance (5)between the rotor (11) and the can (13), it dissipates the heat generated in themotor. At the same time, the intensive exchange of fluid between the hydraulicsection and the rotor space ensures sufficient lubrication of the plain bearings (3, 8).

The pump is a seal-less canned motor pump.The rotor space is sealed off towards the stator space by the can (13).

Static sealing is provided by PTFE U-rings or graphite gaskets. The pump set is notfitted with any dynamic sealing elements.

4.6 Noise characteristics

Table 8: Surface sound pressure level LpA10)11)

Motor size Surface sound pressure level L of pumpset[dB]

F2, F3, F4 80

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

Pump set complete with terminal box

Baseplate

Cast or welded baseplate for the complete unit (pump and motor), in torsion-resistant design

Channel section steel or folded steel plate

Special accessories

As required

4.8 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outlinedrawing of the pump/pump set.

Sealing

10) Spatial average; as per ISO 3744 and EN 12639; valid for operating range Q/Qopt = 0.8 - 1.1 and for non-cavitating pumpoperation. If noise levels are to be warranted: add +3 dB for measuring and constructional tolerance.

11) Increase for 60 Hz operation: 3500 rpm +3 dB

4 Description


5 Installation at Site

5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheresExplosion hazard!Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations.

▷ Observe the information in the data sheet and on the name plates of pump andmotor.

5.2 Checks to be carried out prior to installation

WARNINGInstallation on mounting surface which is unsecured and cannot support the loadPersonal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets therequirements of exposure class XC1 to EN 206-1.

▷ The mounting surface must have set and must be completely horizontal andeven.

▷ Observe the weights indicated.

CAUTIONAdditional temperature rise in the motor due to exposure to direct sunlightEvaporation of cooling/lubricating fluid!Plain bearing damage resulting from insufficient lubrication!

▷ Protect pump sets installed outdoors against direct sunlight.

Any resonances at the usual excitation frequencies (1 x and 2 x rotational frequency,vane passing frequency) must be prevented both in the foundation and in theconnected piping, as such frequencies may cause extreme vibrations.

1. Check the structural requirements.All structural work required must have been prepared in accordance with thedimensions stated in the outline drawing/general arrangement drawing.

When the pump set is installed outdoors make sure that the motor is not heated upany further as a result of exposure to intensive direct sunlight, as this condition willnot have been taken into account during pump set selection. This may lead to theevaporation of the cooling/lubricating fluid inside the motor. If required, providesuitable protection for the pump set.

5.3 Installing the pump set

Position the pump set horizontally with the discharge nozzle on top to ensurepriming/venting and drainage.Depending on the motor size and the structural conditions, the pump set can beinstalled on hard and even concrete, on foundation rails or on a baseplate.The foundation bolts or heavy-duty anchor bolts are not included in KSB's scope ofsupply.

5.3.1 Installing the pump set with a baseplate

Installation with extra support under the motor

Pump sets combined with these motors are installed with an extra support under themotor.

Resonances

Outdoor installation



The pump set must always be installed by means of a baseplate which is usuallyalready mounted to the pump set when supplied. Depending on how the baseplate ismounted on the foundation and depending on plant conditions, two installationtypes are available.

Installation on a foundation with grouted baseplate

L1

32

Fig. 4: Fitting the shims

L Bolt-to-bolt distance 1 Shim2 Shim if (L) > 800 mm 3 Foundation bolt

The foundation has the required strength and characteristics.

The foundation has been prepared in accordance with the dimensions given inthe outline drawing/general arrangement drawing.

1. Position the pump set on the foundation and level it with the help of a spiritlevel placed on the discharge nozzle.Permissible deviation 0.2 mm/m.

2. Use shims (1) for height compensation, if necessary. Always fit shims, if any, immediately to the left and right of the foundationbolts (3) between the baseplate/foundation frame and the foundation. For a bolt-to-bolt distance (L) > 800 mm fit additional shims (2) halfwaybetween the bolt holes. All shims must lie perfectly flush.

3. Insert the foundation bolts (3) into the holes provided.

4. Use concrete to set the foundation bolts (3) into the foundation.

5. Wait until the concrete has set firmly, then level the baseplate.

6. Tighten the foundation bolts (3) evenly and firmly.

7. Grout the baseplate using low-shrinkage concrete with a standard particle sizeand a water/cement ratio of ≤ 0.5.Produce flowability with the help of a solvent.Perform secondary treatment of the concrete to DIN 1045.

NOTEExpansion joints can be fitted between the pump and the suction/discharge line.

Fastening



5.4 Piping

5.4.1 Installing the level transmitter in the pipeline

The level transmitter can assume different monitoring tasks, depending on the placeof installation. Whether the level transmitter is installed on the suction or dischargeside depends on the system or process. Observe the following table when selectingthe place of installation.

Table 9: Recommended place of installation

Monitoring scope Suction line Discharge line

h1

< in

stal

lati

on

hei

gh

t <

(h

2 +

h1)

Inst

alla

tio

n h

eig

ht

≥ (h

2 +

h1)

Inst

alla

tio

n h

eig

ht

≥ (h

2 +

h1)

Fill level in Suction line - Hydraulic system of the pump - Rotor space With internal circulation - With external liquid feed12) - - -Protection against dry running of plain bearingassembly

- -

h2

h1

Fig. 5: Dimensions h1 and h2

DANGER

Unfilled, dry pumpDry runningFormation of a potentially explosive atmosphere!

▷ No shut-off elements shall be located between the level transmitter and thepump.

12) The customer must ensure that the pump set is filled with fluid.



DANGER

Fork of level transmitter contacts the flow of fluid handledMalfunctions!

▷ Never allow the fork to protrude into the pipeline.

▷ Observe the manufacturer’s installation instructions.

The level transmitter can be installed in the pipeline as follows:

Using a weld-in socket/tee

Using an intermediate piece (optional accessory)

202

67

G3/

4A

24.5

182.5

47.5

60

G3/

4A

Installing the level transmitter with aweld-in socket in the pipeline

Installing the level transmitter with anintermediate piece in the pipeline

Installing the level transmitter in the suction line:

h1

+ h

2

h2

h1

Fig. 6: Installing the level transmitter in the suction line

NOTEThe installation height must amount to at least h1 (middle of suction nozzle). Toensure that the level transmitter can assume comprehensive monitoring tasks, KSBrecommends that you position the transmitter at the height of the discharge nozzleor higher (>= h1 + h2).

1. Select the proper installation height (observe "Recommended place ofinstallation" table).

2. Screw the level transmitter into the intermediate piece, for example.

Suction-side installation



NOTETo ensure that a change in the fill level can be detected reliably and as early aspossible, the fork of the level transmitter must be correctly positioned with the "O"marking on the WAF32 hexagon pointing upwards.

3. Align the level transmitter such that the "O" marking on the WAF32 hexagon ispointing upwards (see illustration titled "Fitting level transmitter in pipeline").

Installing the level transmitter in the discharge line:

> h

1 +

h2 h

2h

1

Fig. 7: Installing the level transmitter in the discharge line

The installation height must amount to at least h1 + h2 (height of discharge nozzle).

1. Select appropriate installation height (observe installation recommendations).

2. Screw the level transmitter into the intermediate piece, for example.

NOTETo ensure that a change in the fill level can be detected reliably and as early aspossible, the fork of the level transmitter must be correctly positioned with the "O"marking on the WAF32 hexagon pointing upwards.

Fig. 8: Fitting level transmitter in pipeline

3. Align the level transmitter such that the "O" marking on the WAF32 hexagon ispointing upwards (see illustration titled "Fitting level transmitter in pipeline").

Discharge-side installation



5.4.2 Connecting the piping

DANGER

Impermissible loads acting on the pump nozzlesDanger to life from leakage of hot, toxic, corrosive or flammable fluids!

▷ Do not use the pump as an anchorage point for the piping.

▷ Anchor the pipelines in close proximity to the pump and connect them withouttransmitting any stresses or strains.

▷ Observe the permissible forces and moments at the pump nozzles. ( Section5.4.3 Page 26)

▷ Take appropriate measures to compensate for thermal expansion of the piping.

CAUTIONIncorrect earthing during welding work on the pipingDestruction of electronic parts in the terminal box!

▷ Never earth the electric welding equipment on the pump or baseplate.

The suction lift line has been laid with a rising slope, the suction head line witha downward slope towards the pump.

A flow stabilisation section having a length equivalent to at least twice thediameter of the suction flange has been provided upstream of the suctionflange.

The nominal diameters of the pipes are equal to or greater than the nominaldiameters of the pump nozzles.

Adapters to larger nominal diameters are designed with a diffuser angle ofapprox. 8° to avoid excessive pressure losses.

The pipelines have been anchored in close proximity to the pump andconnected without transmitting any stresses or strains.

CAUTIONWelding beads, scale and other impurities in the pipingDamage to the pump!

▷ Free the piping from any impurities.

▷ If necessary, install a filter.

▷ Comply with the instructions set out in ( Section 7.2.2.2 Page 64) .

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections(especially of new installations).

2. Before installing the pump in the piping, remove the flange covers on thesuction and discharge nozzles of the pump.

3. Check that the inside of the pump is free from any foreign objects. Remove anyforeign objects.

4. If required, install a filter in the piping (see drawing: Filter in the piping).



1

2

Fig. 9: Filter in the piping

1 Differential pressure gauge 2 Filter

NOTEUse 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.

5. Connect the pump nozzles to the piping.

CAUTIONAggressive flushing and pickling agentsDamage to the pump!

▷ Match the cleaning operation mode and duration for flushing and picklingservice to the casing and seal materials used.

5.4.3 Permissible forces and moments at the pump nozzles

The data on forces and moments apply to static piping loads only. If the limits areexceeded, they must be checked and verified.If a computerised strength analysis is required, values are available on request only. The values are only applicable if the pump is installed on a completely groutedbaseplate and bolted to a rigid and level foundation.

For installation without foundation the values for forces and moments can besupplied on request.

Table 10: Forces and moments at the pump nozzles for material variant C (1.4408/A743 GR CF8M) at 20° C.

Size Suction nozzle Discharge nozzle

DN Fx

[N]Fy

[N]Fz

[N]∑F[N]

Mx

[Nm]My

[Nm]Mz

[Nm]DN Fx

[N]Fy

[N]Fz

[N]∑F[N]

Mx

[Nm]My

[Nm]Mz

[Nm]040-025-160 40 970 780 650 1404 845 585 683 25 490 455 600 898 370 390 455040-025-200 40 970 780 650 1404 845 585 683 25 460 455 600 898 370 390 455050-032-250.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555050-032-125.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555050-032-160.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555050-032-200.1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555050-032-125 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555050-032-160 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555050-032-200 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555050-032-250 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555065-040-125 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685065-040-160 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685

[+]Fz

Fy

Fx

Fx

Fy

Fz

Fx

Fy

Fz

Mz

My

Mx

Fig. 10: Forces andmoments at the pumpnozzles



Size Suction nozzle Discharge nozzle

DN Fx

[N]Fy

[N]Fz

[N]∑F[N]

Mx

[Nm]My

[Nm]Mz

[Nm]DN Fx

[N]Fy

[N]Fz

[N]∑F[N]

Mx

[Nm]My

[Nm]Mz

[Nm]065-040-160.1 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685065-040-250.1 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685065-040-200 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685065-040-250 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685065-040-315 65 1600 1300 1105 2339 1050 715 780 40 780 650 1000 1425 845 585 685080-050-315.1 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750080-050-125 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750080-050-160 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750080-050-200 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750080-050-250 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750080-050-315 80 2000 1550 1333 2860 1330 748 1010 50 1000 880 1250 1827 910 650 750100-065-125 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790100-065-160 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790100-065-200 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790100-065-250 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790100-065-315 100 2500 1950 1755 3624 1850 900 1400 65 1300 1105 1600 2339 1050 715 790125-080-160 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000125-080-200 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000125-080-250 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000125-080-315 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000125-080-400 125 3400 2700 2200 4867 2550 1250 1950 80 1550 1335 1950 2826 1350 750 1000125-100-160 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400125-100-200 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400125-100-250 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400125-100-315 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400125-100-400 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400150-125-200 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900150-125-250 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900150-125-315 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900150-125-400 150 4300 3450 2850 6206 3200 1600 2450 125 2700 2200 3400 4867 2550 1300 1900200-150-200 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450200-150-250 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450200-150-315 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450200-150-400 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450200-150-500 200 6750 5250 4300 9572 4850 2450 3550 150 3450 2850 4300 6206 3150 1600 2450200-200-250 200 6750 5250 4300 9572 4850 2450 3550 200 5250 4300 6750 9572 4850 2450 3550250-200-315 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550250-200-400 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550250-200-500 250 9200 7350 6150 13285 6900 3350 5250 200 5250 4300 6750 9572 4850 2450 3550300-250-315 300 11000 9200 7350 16114 8400 4150 6350 250 7350 6150 9150 13250 6900 3350 5250

Correction coefficients depending on material and temperature (see diagram below).

C, V

E

D

0,6

0,7

0,8

0,9

1

1,2

0 50 100 150 200 250 300 400°C

350

1,1D

Y

Correction coefficient

Fig. 11: Temperature correction diagram for "E, D, C, V, Y" variants



5.4.4 Auxiliary connections

DANGER

Risk of potentially explosive atmosphere by mixing of incompatible fluids in theauxiliary pipingRisk of burns!Explosion hazard!

▷ Make sure that the barrier fluid and quench liquid are compatible with thefluid pumped.

WARNINGFailure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushingliquid, etc.)Risk of injury from escaping fluid!Risk of burns!Malfunction of the pump!

▷ Refer to the general arrangement drawing, the piping layout and pumpmarkings (if any) for the quantity, dimensions and locations of auxiliaryconnections.

▷ Use the auxiliary connections provided.

Fig. 12: Auxiliary connections

19A.1

19E.1

16B.1

If a barrier fluid has been specified in the data sheet, connection 10E must beconnected to ensure motor cooling and plain bearing lubrication.

5.5 Enclosure/insulation

DANGER

Incorrect insulationExplosion hazard!

▷ The enclosure's surface is considered a new surface as per ATEX. Contact of theenvironment with the motor housing surface must be prevented.



WARNINGThe volute casing and casing/discharge cover take on the same temperature as thefluid handledRisk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

102 161

82-5

Fig. 13: Area where insulation is permitted

102 Volute casing 161 Casing cover (if fitted)82-5 Adapter

Area where insulation is permitted13)

NOTEMonitoring systems can be connected to motor housing cover 812. Ensure duringinsulation that the sensor connections and displays remain accessible. Also observethe sensor manufacturer's specifications regarding the permissible ambienttemperature.

5.6 Electrical system

5.6.1 Information for planning the control system

For the electrical connection of the pump set observe the circuit diagrams. ( Section5.6.1.3.4 Page 33) The pump set is supplied with a terminal box and wired for DOL starting.

NOTEWhen laying a cable between the control system and the pump set's connectionpoint, make sure that the number of cores is sufficient for the sensors. A minimumcross-section of 1.5 mm² is required.

The motors can be connected to electrical low-voltage grids with rated voltages andvoltage tolerances to IEC 38 or to other grids or power supply facilities withmaximum rated voltage tolerances of ± 10 %.

5.6.1.1 Operation on a frequency inverter

The pump set is suitable for operation on a frequency inverter as per IEC 60034-17.

13) Identifies components where insulation is permitted but does not indicate a specific insulation type or design.



NOTEPump sets operated on frequency inverters must only be used in combination withEx d terminal boxes.

DANGER

Operation outside the permitted frequency rangeExplosion hazard!

▷ Never operate an explosion-proof pump set outside the specified range.

DANGER

Incorrect selection and setting of the frequency inverterExplosion hazard!

▷ Observe the following information on selecting and setting a frequencyinverter.

When selecting a frequency inverter, check the following details:

Data provided by the manufacturer

Electrical data of the pump set, particularly the rated current

Observe the following limits during operation on a frequency inverter:

Only utilise up to 95 % of the motor rating P2 indicated on the name plate.

Do not exceed the rated current indicated on the name plate.

Permissible control range of frequency inverter:

– Maximum frequency (see data sheet or name plate)

– Minimum rated frequency14) (see data sheet or name plate)

Operation on a frequency inverter produces interference emissions whose level variesdepending on the inverter used (type, interference suppression, make). To preventthe drive system, consisting of a canned motor and a frequency inverter, fromexceeding any given limits always observe the EMC information provided by theinverter manufacturer. If a shielded power cable is recommended, a shielded powercable must be used.

The canned motor pump generally meets interference immunity requirements. Formonitoring the sensors installed the operator must ensure sufficient interferenceimmunity by appropriately selecting and laying the power cables in the plant.

5.6.1.2 Motor temperature

DANGER

Insufficient coolingExplosion hazard!Winding damage!

▷ Never operate a pump set without operational temperature monitoring.

▷ For explosion-proof pump sets use a thermistor tripping unit with manual resetwhich is ATEX-approved for monitoring the temperature of explosion-proofmotors with "flameproof enclosure" Ex d type of protection.

The motors are equipped with at least three series-connected (PTC) thermistors tomonitor the winding and, if required, the cooling liquid temperature. Connect the(PTC) thermistors in compliance with the selected explosion protection monitoringconcept and the required temperature class (see name plate and/or data sheet). Use athermistor tripping unit with manual reset.

Selection

Operation

Electromagneticcompatibility

Interference immunity

14) For other frequencies please contact KSB.



5.6.1.3 Explosion protection monitoring concepts

The pump set features sensors designed to prevent hazards and damage to the pumpset.

The sensors also monitor compliance with the permissible surface temperaturesdefined for potentially explosive atmospheres.

Measuring transducers are required for analysing the sensor signals supplied. Suitabledevices for 230 V AC can be supplied by KSB.

Temperature sensors are fitted inside the pump set and connected via the terminalbox. Depending on the explosion protection monitoring concept, it is necessary toconnect an external Pt100 resistance thermometer. For information on wiring and core identification please refer to the "Circuitdiagrams" section. ( Section 5.6.1.3.4 Page 33) The individual sensors and the limit values to be set are described in the followingsections.

Compliance with the motor surface temperature limits in potentially explosiveatmospheres requires the application of either of the specified monitoring concepts:Ia, Ib or II (see name plate ( Section 4.3 Page 16) ( Section 4.3 Page 16) ).

Table 11: Monitoring equipment/devices to be connected depending on the explosion protection monitoringconcept

Monitoring equipment/devices Monitoring concept

Ia( Section5.6.1.3.1Page 31)

Ib( Section5.6.1.3.2Page 32)

II( Section5.6.1.3.3Page 32)

Fluid temperature in the rotor space Pt100 resistance thermometer15) - PTC - - Motor surface temperature Overcurrent relay - - PTC -

Table 12: Applications for explosion protection monitoring concepts

Monitoring equipment/devices Monitoring concept

Ia Ib IICan be used up to temperature class T3 T4 T5 -Mode of operation S1 Other than S1 - Operation on a frequency inverter - Anti-condensation heater -

5.6.1.3.1 Explosion protection monitoring concept Ia

The temperature developed around the pump set largely depends on the heatdeveloped in the motor and the fluid temperature. The sensors installed monitorthese heat sources separately. The motor is tripped before the surface temperaturedefined by the temperature class is reached.

The overcurrent relay measures the current absorbed by the motor. The motor inputcurrent level is an indicator for the motor surface temperature. The value set at theovercurrent relay limits the motor input current and trips the pump set.

Overcurrent relay

15) It may be possible to use other temperature measurement equipment following consultation with KSB.



The Pt100 resistance thermometer measures the fluid temperature at the hottestanticipated location in the rotor space. The value set at the limit switch prevents afurther temperature rise and trips the pump set.

The configuration must be such that the pump set is tripped automatically as soon asthe set limit value of the Pt100 resistance thermometer or the set limit value at theovercurrent relay are exceeded. Automatic re-starting after the motor has cooleddown is not permitted.

5.6.1.3.2 Explosion protection monitoring concept Ib


The (PTC) thermistors fitted in the motor directly measure the temperature at therelevant locations inside the motor. The pump set is automatically tripped via athermistor relay (PTC thermistor tripping unit) fitted in the control cabinet when thecut-out temperature is reached. Automatic re-starting after the motor has cooleddown is not permitted.

The Pt100 resistance thermometer measures the fluid temperature at the hottestanticipated location in the rotor space. The value set at the limit switch prevents afurther temperature rise and trips the pump set automatically.

The configuration must be such that the pump set is tripped automatically as soon asthe set limit value of the Pt100 resistance thermometer is exceeded or the rated cut-out temperature of the (PTC) thermistors has been reached. Automatic re-startingafter the motor has cooled down is not permitted.

The optional overcurrent relay is not relevant for monitoring concept Ib. Theovercurrent relay measures the current absorbed by the motor.

5.6.1.3.3 Explosion protection monitoring concept II


The thermistors (PTCs) fitted in the motor directly measure the temperature at therelevant locations inside the motor. The pump set is tripped via a thermistor relay(PTC thermistor tripping unit) fitted in the control cabinet when the cut-outtemperature is reached.

The configuration must be such that the pump set is tripped automatically as soon asthe rated cut-out temperature of the thermistors (PTCs) has been reached. Automaticre-starting after the motor has cooled down is not permitted.

The optional overcurrent relay is not relevant for monitoring concept II. Theovercurrent relay measures the current absorbed by the motor.

Pt100 resistancethermometer

(PTC) thermistors

Pt100 resistancethermometer

Overcurrent relay(optional)

(PTC) thermistors

Overcurrent relay(optional)



5.6.1.3.4 Circuit diagrams

5.6.1.3.4.1 Circuit diagram for monitoring concept Ia

DANGER

Incorrect installation of the Pt 100 resistance thermometerDeviating/corrupted readings!Explosion hazard!

▷ Properly install the resistance thermometer. ( Section 5.6.4.1.1.3 Page 46)

▷ Other devices must be installed as per manufacturer's technical productliterature.

▷ When other devices are used, check that they function properly and the valuesmeasured are plausible.

NOTEThe monitoring equipment/devices selected are examples. If other monitoringequipment/devices are fitted than those stipulated, the operator must ensure thatthe devices used comply with the 94/9/EC directive.

D00

796/

5

8 56

1 4

5

3

3

6

weiß / white

2

rot / redrot / red

1--2+

1 5 6 4 4

2 7 8 7 1

Fig. 14: Example: circuit diagram for monitoring concept Ia

Table 13: Examples of monitoring equipment/devices

Symbols Type designation Description0A1 (optional) FTL325N Isolating amplifier0A2 CF1M Limit switch0A3 Z 954 Barrier0S1 (optional) Liquiphant M Level transmitter



Symbols Type designation Description0S2 TR 55 three-wire system Pt 100 resistance thermometerF2 (must be supplied by the

customer)Overcurrent relay

5.6.1.3.4.2 Circuit diagram for monitoring concept Ib

Fig. 15: Example: circuit diagram for monitoring concept Ib with temperature class T3



Fig. 16: Example: circuit diagram for monitoring concept Ib with temperatureclasses16) T4/T5


Symbols Type designation Description0A1 MK 9163N.12/110 PTC tripping unit for

potentially explosiveatmospheres

0A2 (optional) FTL325N Isolating amplifier0A3 CF1M Limit switch0A4 Z 954 Barrier0S1 (optional) Liquiphant M Level transmitter0S2 TR 55 three-wire system Pt100 resistance

thermometerF2 (optional) (must be supplied by the

customer)Overcurrent relay

Also see

Installing the Pt100 resistance thermometer in the pump [ 46]

16) The temperature class to be complied with is specified by the manufacturer (see data sheet/name plate).



5.6.1.3.4.3 Circuit diagram for monitoring concept II

Fig. 17: Example: circuit diagram for monitoring concept II with temperature class T3



Fig. 18: Example: circuit diagram for monitoring concept II with temperature class T4


Symbols Type designation Description0A1 MK 9163N.12/110 PTC tripping unit for

potentially explosiveatmospheres

0A2 (optional) FTL325N Isolating amplifier0A3 CF1M Limit switch0A4 Z 954 Barrier0S1 (optional) Liquiphant M Level transmitter

5.6.1.4 Motor connection cables

The type of connection cable you choose depends on various factors such as, forexample, the type of connection, the ambient conditions and the type of system.

Connection cables must be used in accordance with their intended use, and themanufacturer's specifications regarding rated voltages, current ratings, operatingtemperatures and thermal effects must be observed.

Connection cables must not be routed across or near hot surfaces (unless they havebeen designed for this kind of application).

The cables used for connections to fixed devices should be as short as possible andproperly connected to these devices.



Operation on a frequency inverter: Shielded cables should be used as powercables.

Mains operation: Unshielded cables can be used as power cables.

The power cable must be suitable for the local conditions; observe the following forappropriate cable selection:

The cable type must be suitable for the terminal box temperature as a minimum.

The cable's cross-section must be calculated in accordance with the rated current(see name plate), ambient temperature and the manner the cables are laid.

Length of power cable for operation on a frequency inverter

The cable between frequency inverter and motor should not exceed 10 m. If longerconnection cables are required, we recommend installing a suitable output filterbetween the frequency inverter and the motor to be controlled. These filters reducethe voltage ramp-up time of the frequency inverter output voltages and limit theirpeaks.

Shielded cables must be used as control cables.

5.6.1.5 Terminal box

The electrical power supply is ensured via a terminal box. Depending on the scope ofsupply, the following terminal boxes are available:

Ex e terminal box

Ex d terminal box

Ex e terminal box with E-Monitor

Ex d terminal box with E-Monitor

Refer to the name plate for the terminal box version ( Section 4.3 Page 16) used.

The terminal box is composed of a terminal box base and a cover with gasket.The gaskets prevent entry of moisture and ensure ignition protection.

The joint between the motor connection flange and the terminal box base isdesigned as a flamepath. ( Section 9.2 Page 90) The joint is required to maintainexplosion protection and must not be changed.

A gasket is fitted at the contact face between the terminal box base and theterminal board to establish an IP enclosure as per name plate.

The cables enter the terminal box base via several tapped holes.

– For transportation, the tapped hole for power cable connection is sealedwith a dust-proof cap. This cap must be replaced with a cable gland forelectrical connection.

– The cable glands used must comply with the same type of protection as theterminal box.

– Tapped holes which are not used must be sealed. If required, use plugs whichhave the same type of protection as the terminal box.

– In addition to cable glands or plugs, sealing elements must always be used.These sealing elements must comply with the IP enclosure indicated on thename plate.

Ex d terminal boxes must only be opened/closed by electricians specially trainedfor explosion protection equipment, as this involves handling Ex d enclosures("flameproof enclosure").

The surfaces of the flamepaths must never be damaged. ( Section 9.2 Page 90)

Protect the surfaces of flamepaths against corrosion. 17) ( Section 9.2 Page 90)

Power cable

Control cable

Special features of Ex dterminal box

17) The grease used for corrosion protection must be compliant with EN 60079-1: The grease used must not contain anyvolatile solvents, it must not become hard and it must not cause corrosion.



5.6.1.5.1 Terminal box configuration

UG1542740

1

Fig. 19: Cross-section of terminal box for motor size F

1 without function400.80 Cover gasket 81-36.01 Terminal box base400.81 Housing gasket 835.01 Terminal board412.81 O-ring 901.77 Hexagon head bolt (PE)554.07 Washer 901.83 Hexagon head bolt81-11.02 Earthing Connect 914.82 Hexagon socket head cap

screw81-22.01 Cover 932.88 Spring washer

5.6.1.5.2 Cable entry

The cable entry direction is supplied as indicated in the purchase order. If required,the cable entry direction can be adjusted to the site requirements. The terminal boxcan be rotated by +/- 90 ° from the as-supplied condition.

90 ° -90 °

a) b) c)

Fig. 20: Cable entry direction

a Cable entry rotated by 90 °b Cable entry in standard conditionc Cable entry rotated by -90 °

Motor size F



5.6.1.5.3 Cable gland

Table 16: Technical data – Tapped holes for connection cables

Motor size

FDesignation 1 = power cable

2a, 2b = control cableIllustration of tapped holes forcable glands

E-Monitor (without function)

Terminal boxPower cable (1) Thread M63×1.5 Tightening torque [Nm]18) 10Control cable (2a, 2b) Thread M20×1.5 Tightening torque [Nm]18) 4

5.6.1.5.4 Earth conductor

A brass earthing screw is provided on the inside of the terminal box.

Table 17: Technical data – Earthing connection

Characteristic Motor size

FThread M12Connection cross-section Up to 10 mm²Tightening torque 12 Nm

5.6.1.6 Potential equalisation

The pump sets are provided with an external potential equalisation connection.Potential equalisation shall be provided for in compliance with IEC 60204.

Table 18: Technical data – Potential equalisation connection

Characteristic ValueConnection cross-section 1.5 to 25 mm²Tightening torque 4 Nm

18) Values for Orientation for cables glands made of PA



5.6.2 Changing the cable exit direction

NOTEOnly electricians specially trained for explosion protection equipment are allowedto dismantle the terminal box base and/or change the cable exit direction, as thisinvolves handling Ex d enclosures ("flameproof enclosure").If Ex d terminal boxes are fitted, check that all joints relevant to explosionprotection (flamepaths) are undamaged before re-mounting the terminal box. Anycomponents with damaged flamepaths must be replaced. Observe the flamepathpositions specified in the Annex. ( Section 9.2 Page 90)

Terminal box cover 81-22 has been removed.

1. Remove screws 914.82 together with detent-edged washers 550.78.

2. Carefully lift terminal box base 81-36 until the terminal box can be turned inthe required direction. Observe the maximum angle of rotation. ( Section5.6.1.5.2 Page 39)

3. Before re-mounting the terminal box check that gasket 400.81 is properly fitted,and correct if necessary.

4. Insert screws 914.82 together with detent-edged washers 550.78 and tighten.Observe the tightening torques.

5.6.3 Electrical connection

DANGER

Damage to sealing of terminal studsExplosion hazard!

▷ Carry out the electrical connection thoroughly and carefully.

▷ Observe the permissible tightening torques for the electrical connection.

▷ Never start up pump sets with damaged sealing (damaged terminal board).

DANGER

Operating an incompletely connected pump setExplosion hazard!Damage to the pump set!

▷ Never start up a pump set with incompletely connected power connectioncables or non-operational monitoring devices.

DANGER

Electrical connection work by unqualified personnelDanger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualifiedelectrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

DANGER

Connection of damaged power cablesDanger of death from electric shock!

▷ Check the power cables for damage before connecting them.

▷ Never connect damaged power cables.

▷ Replace damaged power cables.



WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

CAUTIONMotor overloadDamage to the motor!

▷ Protect the motor by a thermal time-lag overload protection device inaccordance with IEC 947 and local regulations.

NOTEEx d terminal boxes must only be opened/closed by electricians specially trained forexplosion protection equipment, as this involves handling Ex d enclosures("flameproof enclosure").

For the electrical connection observe the circuit diagrams ( Section 5.6.1.3.4 Page33) and the information for planning the control system ( Section 5.6.1 Page 29) .

The connection is established via the terminal box. Observe the following for theelectrical connection:

Always use insulated closed cable terminals (ring-type cable terminals) for theelectrical connection and the sensor connection.

No more than two cores (ring-type cable terminals) may be connected perterminal stud.

Table 19: Technical data – Terminal board

Motor size F

Codes C1, C2, S1, S2 = terminal studs for the control cables (thermistors)PE = earth conductorU, V, W = terminal studs for the power cables

Terminal board diagramU

V

W

S1

PE

C1

S2

C2

Control cables (C1, C2, S1, S2) Thread M6 Tightening torque

[Nm]5

Control cables (U, V, W) Thread M16 Tightening torque

[Nm]25



Motor size F

Earth conductor (PE) Thread M12 Tightening torque

[Nm]12

1

234

6

5

Fig. 21: Stud-type feed-through terminal

1 Ring-type cable terminal 2 Terminal stud3 Nut 4 Spring lock washer5 Washer 6 Sealant

The tapped holes in the terminal box required for electrical connection areopen.

The power cable cores are provided with insulated ring-type cable terminals.

The PE conductor is provided with a ring-type cable terminal.

1. Open terminal box 81-22, noting position of gasket 400.80.

2. Thread the power cable through the respective tapped hole (1) and seal with asuitable cable gland19) as per the wiring diagram (see table: Technical data –Tapped holes for connection cables).

3. Fasten the PE conductor (green, yellow) using a brass earthing screw.

4. Assign the cores to the terminal board studs as follows: - L1 to U- L2 to V - L3 to W

5. If prescribed in the monitoring concept, connect thermistors according to themonitoring concept ( Section 5.6.4.1.1 Page 45) . Refer to the name plate forthe monitoring concepts to be applied. ( Section 4.3 Page 16) .

6. For connecting the control cables use tapped holes 2a and/or 2b and a suitablecable gland.

7. Only for terminal box in Ex e design: Wet the surfaces of the flamepath with ananti-corrosive. Properly position terminal box cover 81-22 and gasket 400.80 onthe terminal box and tighten crosswise using bolts 901.83 and discs 550.79.Observe the tightening torques.Only for terminal box in Ex d design: Check the surfaces of the flamepath( Section 9.2 Page 90) for any damage. Wet the surfaces of the flamepath( Section 9.2 Page 90) with an anti-corrosive. ( Section 5.6.1.5 Page 38)Properly position terminal box cover 81-22 and gasket 400.80 on the terminalbox and tighten crosswise using bolts 901.83 and discs 550.79. Observe thetightening torques.

19) For terminal box design Ex e a suitable cable gland is provided. For terminal box design Ex d a cable gland for this type ofprotection must be provided by the customer.



5.6.3.1 Connecting the potential equalisation conductor

DANGER

Electrostatic chargingExplosion hazard!Damage to the pump set!

▷ Connect the PE conductor to the earthing terminal provided.

▷ Provide for potential equalisation between the pump set and foundation.

81-51

Fig. 22: Connection of potential equalisation conductor to motor housing cover

The conductor must be connected in a suitable manner in accordance withEN 60999-1

1. Connect the potential equalisation conductor to terminal 81-51 provided on theoutside of motor housing cover 812.

2. Secure with hexagon head bolts and spring lock washers.

5.6.4 Connecting the monitoring equipment

5.6.4.1 Temperature monitoring

DANGER

Operating an incompletely connected pump setExplosion hazard!Damage to the pump set!

▷ Never start up a pump set with incompletely connected power connectioncables or non-operational monitoring devices.

CAUTIONIncorrect wiringDamage to the sensors!

▷ Observe the limits stated in the following sections of this manual whenconnecting the sensors.

Temperature sensors are fitted inside the pump set and connected via the terminalbox. Depending on the explosion protection monitoring concept, it is necessary toconnect an external Pt100 resistance thermometer. For information on wiring and core identification please refer to the "Circuitdiagrams" section. ( Section 5.6.1.3.4 Page 33) The individual sensors and the limit values to be set are described in the followingsections.

Compliance with the motor surface temperature limits in potentially explosiveatmospheres requires the application of either of the specified monitoring concepts:Ia, Ib or II (see name plate ( Section 4.3 Page 16) ( Section 4.3 Page 16) ).



5.6.4.1.1 Installing and connecting the sensors

NOTEThe monitoring equipment/devices selected are examples. If other monitoringequipment/devices are fitted than those stipulated, the operator must ensure thatthe devices used comply with the 94/9/EC directive.

DANGER

Incorrect installation of the Pt 100 resistance thermometerDeviating/corrupted readings!Explosion hazard!

▷ Properly install the resistance thermometer. ( Section 5.6.4.1.1.3 Page 46)

▷ Other devices must be installed as per manufacturer's technical productliterature.

▷ When other devices are used, check that they function properly and the valuesmeasured are plausible.

The following monitoring equipment/devices must be installed, connected andset:

– Overcurrent relay ( Section 5.6.4.1.1.1 Page 45)

– Pt100 resistance thermometer20)

( Section 5.6.4.1.1.3 Page 46) ( Section 5.6.4.1.1.4 Page 47)

Circuit diagram ( Section 5.6.1.3.4.1 Page 33)

The following monitoring equipment/devices must be installed, connected andset:

– (PTC) thermistors

– Pt100 resistance thermometer20)

( Section 5.6.4.1.1.3 Page 46) ( Section 5.6.4.1.1.4 Page 47)

Circuit diagram

Connection principle

The following monitoring equipment/devices must be connected:

– (PTC) thermistors

Circuit diagram

Connection principle

5.6.4.1.1.1 Installing the overcurrent relay

The overcurrent relay must be installed in the control cabinet in accordance with themanufacturer's instructions at a location outside the area with a potentially explosiveatmosphere.

1. Protect the pump set against overloading by a thermal time-lag overcurrentrelay in accordance with IEC 947 and local regulations.

2. Set the overcurrent relay to the rated current specified on the name plate/datasheet.

5.6.4.1.1.2 (PTC) thermistor connection principle

Electrical connection

Monitoring concept Ia

Monitoring concept Ib

Monitoring concept II

20) It may be possible to use other temperature measurement equipment following consultation with KSB.



5.6.4.1.1.2.1 (PTC) thermistor connection principle, monitoring concept Ib

S1

C1

S2

C2

Fig. 23: Terminal studs for the control cables (thermistors)

S1 S2PTCT3:

C1 S1T4, T5: PTC

Fig. 24: (PTC) thermistor connection principle, monitoring concept Ib

5.6.4.1.1.2.2 (PTC) thermistor connection principle, monitoring concept II

S1

C1

S2

C2

Fig. 25: Terminal studs for the control cables (thermistors)

C2 S2PTCT3:

C1 C2PTCT4:

Fig. 26: (PTC) thermistor connection principle, monitoring concept II

5.6.4.1.1.3 Installing the Pt100 resistance thermometer in the pump

DANGER

Leaks and/or corrosion damage on monitoring systemsNo fault indications!Leakage of fluid handled!

▷ Never install damaged or corroded monitoring systems in the pump.

▷ Check monitoring systems for damage and correct function prior to installation.



1 2a 1 2b

3

54

3

54

Fig. 27: Installing the Pt100 resistance thermometer (TR 55)

1 Compression fitting 2a Head JS (without head transmitter)2b Head BSZ (with head transmitter

T 32)3 Motors housing cover 812

4 Measuring point 5 Screw plug 903.91

1. Remove the (plastic) plug from the connection hole in screw plug 903.91.

2. Screw the compression fitting up to the stop.

3. Insert the Pt100 resistance thermometer into the compression fitting until thetip of the Pt100 thermometer contacts the bottom of screw plug 903.91.

4. Press the spring-loaded sensor tip in until it does not go any further byovercoming the spring's resistance, and hold.

5. Turn the connection head of the Pt100 resistance thermometer to the requiredposition, and hold. Make sure that the sensor tip's spring resistance ismaintained.

6. Pull the Pt100 resistance thermometer back by approximately 1 to 2 mm.

7. To prevent the Pt100 resistance thermometer from loosening and rotating,tighten the compression fitting using the locknut.

5.6.4.1.1.4 Electrical connection of the Pt100 resistance thermometer

DANGER

Incorrect electrical installationExplosion hazard!

▷ For electrical installation, also observe the requirements of IEC 60079-11.

▷ Implement a suitable measuring chain.

DANGER






Red

ϑ ϑ

RedRed

White

White (White)

Fig. 28: Terminal assignment for TR 55 (head JS)

Fig. 29: Terminal assignment for TR 55 (head BSZ with head transmitter T 32)

1. Open the connection head.

2. Connect the Pt100 resistance thermometer. (Observe terminal assignment. Seeillustrations.)

5.6.4.1.1.5 Measuring chain design

The design of the measuring chain is influenced by the following factors:

Potentially explosive or non-potentially explosive atmosphere

Output signal (Ω or mA)

The measuring chain must be designed and configured in accordance with thesefactors. Observe the following illustration for selection.

Terminal assignment TR 55(head JS)

Terminal assignment TR 55(head BSZ with head

transmitter T 32)



(ATEX) barrier

Limit switch

Output signal

in Ω

Pt100 resistance thermometer with ceramic terminal block

4...20 m A

(ATEX) transmitter supply unit

Limit switch

Output signal

Pt100 resistance thermometer head transmitter

Measuring chain 1 Measuring chain 2

Potentially explosive atmosphere

Fig. 30: Measuring chain design

Description, measuring chain 1 (potentially explosive atmosphere)

Measuring chain 1 comprises the following elements:

Table 20: Description, measuring chain 1 (potentially explosive atmosphere)

Element KSB devicerecommendation

For details, refer to...

Pt100 resistance thermometerwithout head transmitter

TR 55orKsb-4,13,xx,2

(ATEX) barrier Z 954 Limit switch CS4M

Description, measuring chain 2 (potentially explosive atmosphere)

Measuring chain 2 comprises the following elements:

Table 21: Description, measuring chain 2

Element KSB devicerecommendation

For details, refer to...

Pt100 resistance thermometerwith head transmitter

Ksb-4,13,xx,1

(ATEX) transmitter supply unit KFD2-STC4-EX1 Limit switch DGW 1.00 or DWG 4.00

Measuring chain design



5.6.4.1.1.6 Analysis of output signals

Determining the limit value

DANGER

Excessive surface temperaturesExplosion hazard!

▷ Make sure that the limit value for stopping the pump (TEX)as specified on thename plate is never exceeded.

1. Refer to the name plate for the limit value TEX to be set. ( Section 4.3 Page 16)

2. Set the limit switch to TEX.

NOTEIf required due to system conditions (e.g. max. fluid temperature, polymerisation ofthe fluid handled, etc.), the TEX limit value set on the limit switch may be lower thanthe value specified for TEX on the name plate.

5.6.4.1.1.6.1 Sensor Accessories

5.6.4.1.1.6.1.1 Additional components in potentially explosive atmosphere

DANGER

Excessively high surface temperatures and production of sparksExplosion hazard!

▷ Observe IEC 60079-11.

▷ Insert additional safety component in measuring chain.

Analog sensor*)

*) Simple apparatus

Energy supplyLimit switchComponent restricting energy supply

Digital sensor*) Energy supplyComponent restricting energy supply

Intrinsically safe

cable

Intrinsically safe

cable

Fig. 32: Schematic representation of measuring chain

When a failure occurs (e.g. as a result of a short circuit), electrical energy is released,which can cause ignition in the presence of hot surfaces or sparks. The energysupplied to the intrinsically safe area must therefore be restricted such that ignition isnot possible. To this end, an additional component is used that restricts, or limits, thetransmission of electrical energy from a non-potentially explosive atmosphere to thepotentially explosive atmosphere (intrinsically safe wiring).


Mat. No. 01573637 ZN 3828 - 87

Q

ºC

Ecochem Non-Seal

cos φ

m3/h n 1/minH m

IN

kWP1 IP

TM

3 ~°C

°CØ mm


m kgTambTEx

P00100 A/P00100B

2014

HN 050-032-2001 A3 CC

3,1 27,8 290075

160

2416 801 65 C220

Tetrachlorsilane

S/400V/50 Hz 1,30,8 VFD 30-50 Hz2,4 13,1

0,8980-20/ +40PTC + PT100 (125 ºC)

0044



II 2 G c Ex de II C T3 Gb Ib

Ineris 14ATEX 0019X

Fig. 31: Limit value TEX



Components are therefore used that must be coordinated with the monitoringsensor employed and its output signal. A matching zener barrier or signal isolatormust be selected with respect to the sensor and output signal. The zener barrier orsignal isolator must always be installed in a non-potentially explosive atmosphere(see "Schematic representation of measuring chain" illustration). Also observe thecircuit diagrams.

The following signal isolators can be ordered from KSB (observe assignment to sensorand output signal):

Table 22: Signal isolator

Sensor Analog output signal Digitaloutputsignal

KSB devicerecommendation

For product literature,see

in mA in ohms Description TypePt100 - - Transmitter

supply unitKFD2-STC4-EX1

Manufacturer/type leaflet

Level transmitter - - Isolatingamplifier

FTL235N Manufacturer/type leaflet

Contact pressuregauge

- - Switchingamplifier

KFA6-SR2-EX1.W

Manufacturer/type leaflet

The following zener barriers can be ordered from KSB (observe assignment to sensorand output signal):

Table 23: Zener barrier

Sensor Analog output signal Digitaloutputsignal

KSB devicerecommendation

For product literature,see

in mA in ohms Description TypePt100 - - Barrier Z954 Manufacturer/type leaflet

5.6.4.1.1.6.1.2 Additional information, limit switch CS4M

5.6.4.1.1.6.1.2.1 Technical data, limit switch CS4M

D00784/1

60

136.5

97

Fig. 33: Dimensions

Table 24: Technical data, limit switch CS4M

Characteristic ValueType CS4MPower supply 95 ... 240 V AC, 50/60 HzPower consumption Approx. 5 VAOutput Relay contact, 250 V A, 3 A (ohmic)/1 A

(ind.)Ambient temperature 0 ... 50 °C



Characteristic ValueInstallation In the control cabinet, can be snapped

onto 35 mm standard rail toDIN EN 60715 by means of the mountingadapter supplied

Enclosure IP 20

5.6.4.1.1.6.1.2.2 Installing the CS4M limit switch

The limit switch must be installed in the control cabinet in the non-potentiallyexplosive atmosphere.

The limit switch is inserted into the rectangular cutout of the mounting anglesupplied with the display pointing forwards and secured from the rear by means ofthe locking clip. The mounting angle can then be snapped onto the top hat rail.

5.6.4.1.1.6.1.2.3 Setting the sensor type

Setting the resistance thermometer sensor type

The CS4M limit switch is preprogrammed at the factory for use with the Pt100resistance thermometer. After the power supply is applied, the limit switch is in basicmode. The sensor type set briefly appears on the display of the limit switch (for Pt100

with the icon).

If the sensor type must be reset, proceed as follows:

1. Simultaneously press the UP, DOWN and MODE keys for approx. 3 seconds.

The following display appears for selecting a sensor:

2. Set the Pt100 sensor type using the UP or DOWN arrow keys (icon: ).

3. Press the MODE key to confirm your entry.

The sensor type is set. The limit switch is back in basic mode.

5.6.4.1.1.6.1.2.4 Setting the limit value for the cut-out temperature

After the selected sensor type has been displayed momentarily, the actualtemperature value is displayed (red point LED below "PV" is lit). Proceed as follows to change the cut-out temperature:

1. Press the MODE key.

2. Use the UP or DOWN arrow keys to enter the respective limit value.

3. Press the MODE key to confirm your entry.

The set value is accepted. The limit switch is back in basic mode. The actual valueset is now displayed.

The limit switch is now ready to be used.

5.6.4.2 Fill level monitoring

In a potentially explosive atmosphere, precautions must be taken to ensure that noexplosive atmosphere forms inside the pump set. To avoid an explosive atmospheredeveloping inside the pump, the pump's interior in contact with the fluid handledmust always be filled with fluid.

It must be ensured that the pump's interior in contact with the fluid handledincluding rotor space and auxiliary systems is filled with fluid. If it cannot be ensuredon site that the pump's interior is filled with fluid, it is necessary to use a fill levelmonitoring device. The following monitoring options are available:

Indirect monitoring using monitoring equipment already available in the plant

Direct monitoring using equipment on the pump set

A level transmitter (e.g. Liquiphant) can be used for fill level monitoring.

Function



For the connection of monitoring equipment, refer to the connection principleexamples for the respective explosion protection monitoring concepts. ( Section5.6.1.3.4 Page 33)

The rotor is supported by product-lubricated plain bearings. If lubrication becomesinsufficient or dry running occurs, the plain bearings can be damaged and the pumpmay fail.

5.6.4.2.1 Electrical connection of level transmitter (Liquiphant)

DANGER

Incorrect electrical installationExplosion hazard!

▷ For electrical installation, also observe the requirements of IEC 60079-11.

▷ Implement a suitable measuring chain.

DANGER




Fig. 34: Electrical connection of level transmitter

1 Isolating amplifier to IEC 60947-5-6 (NAMUR)

1. Electrically connect level transmitter (Liquiphant) (observe "Electricalconnection of level transmitter" illustration.)

2. Note/observe the setting for the switches and correct if necessary.



Table 25: Switch setting of level transmitter (Liquiphant) – Fill level monitoring

Switch PositionMAX / MIN - MIN> 0,7 / > 0,5 > 0,7 -

5.7 Checking the direction of rotation

DANGER

Temperature increases resulting from contact between rotating and stationarycomponentsExplosion hazard!Damage to the pump set!

▷ Never check the direction of rotation by starting up the unfilled pump.

WARNINGHands inside the pump casingRisk of injuries, damage to the pump!

▷ Always disconnect the pump set from the power supply and secure it againstunintentional start-up before inserting your hands or other objects into thepump.

CAUTIONDrive and pump running in the wrong direction of rotationDamage to the pump!

▷ Refer to the arrow indicating the direction of rotation on the pump.

▷ Check the direction of rotation. If required, check the electrical connection andcorrect the direction of rotation.

The correct direction of rotation of the motor and pump is clockwise (seen from thedrive end).

1. Start the motor and stop it again immediately to determine the motor'sdirection of rotation.

2. Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the directionof rotation on the pump.

3. If the motor is running in the wrong direction of rotation, check the electricalconnection of the motor and the control system, if applicable.

No rotating parts of the pump are visible from the outside. The following methodsfor determining the direction of rotation are available:

Prior to establishing the electrical connection

Check using a direction of rotation indicator (phase sequence indicator)

Following electrical connection, during commissioning/start-up

Checking via the discharge-side pressure gaugeWith this method the canned motor is briefly operated in both directions ofrotation, measuring the pressure in the process. If the direction of rotation iscorrect, a higher pressure can be observed when the discharge-side shut-off valveis closed.

If the motor is rotating in the wrong direction, the discharge pressure deliveredagainst the closed shut-off element is approx. 60 to 70 % of the shut-off headwhich is specified in the data sheet or test log.

Optional: On pumps equipped with an E-Monitor, the correct direction ofrotation can be determined via the E-Monitor's LED display ("REV").

Methods to determine thedirection of rotation



6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

The pump set has been properly connected to the electric power supply and isequipped with all protection devices.

The pump has been primed with the fluid to be handled. The pump has beenvented.

The direction of rotation has been checked.

All auxiliary connections required are connected and operational.

After prolonged shutdown of the pump (set), the activities required for returningthe pump (set) to service have been carried out.

6.1.2 Priming and venting the pump

DANGER

Risk of potentially explosive atmosphere by mixing of incompatible fluids in theauxiliary pipingRisk of burns!Explosion hazard!

▷ Make sure that the barrier fluid and quench liquid are compatible with thefluid pumped.

DANGER

Formation of a potentially explosive atmosphere inside the pumpExplosion hazard!

▷ The pump's interior in contact with the fluid handled must be continuouslyfilled with the fluid.

▷ Provide sufficient inlet pressure.

▷ Provide an appropriate monitoring system.

1. Vent the pump and suction line and prime both with the fluid to be handled.

2. Fully open the shut-off element in the suction line.

3. Completely open all auxiliary connections (e.g. barrier fluid)

6.1.3 Heating

CAUTIONHeating continued during pump standstillPump heats up intensely!Excessive pressure in the pump casing!

▷ Observe the pump's pressure and temperature limits.

6.1.3.1 Heatable pump casing

The pump casing can be heated if required.

Hot water

Steam

Permissible heating media:



CAUTIONLack of heating mediumDamage to the pump!

▷ Provide sufficient quantities of a suitable heating medium.

CAUTIONTime for warming up the pump too shortDamage to the pump!

▷ Check that the pump is sufficiently warmed up throughout.

CAUTIONImpermissibly high temperature of the heating mediumFluid or heating medium could escape!

▷ Observe the application limits of the heating media.

DANGER

Excessive surface temperatureExplosion hazard!Risk of burns!

▷ Observe the permissible temperature classes.

Table 26: Temperature limits, supply temperature, heating medium

Temperature class of pump as per nameplate

Tmax

[°C]T5 90T4 125T3 190

Pmax: 10 bar

6.1.3.2 Motor standstill heater (optional)

DANGER

Excessive surface temperatureExplosion hazard!Risk of burns!

▷ Observe the permissible temperature classes.

The motor standstill heater is factory-set. In continuous operation, the rotor spacemay be heated up to 80 - 100 °C. Temperature class T4 is observed in this case.

The motor standstill heater is set to the rotor space temperature required (T<100 °C)by means of a control unit combined with a measuring resistor fitted to the can ofthe rotor space.

The motor standstill heater and control unit must be installed in the control cabinet.

Observe the supplementary operating instructions for the motor standstill heater.



6.1.4 Keeping pump set warm/heating up pump set

CAUTIONPump blockageDamage to the pump!

▷ Prior to pump start-up, heat up the pump as described in the manual.

Take the melting point of the fluid handled into account if the pump is used forhandling solidifying fluids.Do not start up the pump set until the pump temperature is higher than the meltingpoint of the fluid handled.

Observe the following when heating up the pump (set) and keeping it warm:

Make sure that the temperature is increased continuously.

Heating speed: max. 5 °C/min (5 K/min)

When the pump is used for handling fluids at temperatures above 150 °C make surethat the pump has been heated throughout before starting it up.

The temperature difference between the pump's surface and the fluid handled mustnot exceed 100 °C (100 K) when the pump is started up.

6.1.5 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits if the pump isoperated with the suction and discharge lines closed.Explosion hazard!Leakage of hot or toxic fluids!

▷ Never operate the pump with the shut-off elements in the suction line and/ordischarge line closed.

▷ Only start up the pump set against a slightly open discharge-side shut-offelement.

DANGER

Excessive temperatures due to dry running or excessive gas content in the fluidhandledExplosion hazard!Damage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Prime the pump as per operating instructions.

▷ Always operate the pump within the permissible operating range.

CAUTIONAbnormal noises, vibrations, temperatures or leakageDamage to the pump!

▷ Switch off the pump (set) immediately.

▷ Eliminate the causes before returning the pump set to service.

The system piping has been cleaned.

Pump, suction line and inlet tank, if fitted, have been vented and primed withthe fluid to be pumped.

The priming lines and venting lines have been closed.

Any auxiliary lines have been opened.

1. Fully open the shut-off element in the suction head/suction lift line.

2. Slightly open the shut-off element in the discharge line.

Solidifying fluids

Fluid temperatures above150 °C

Temperature difference



3. Briefly start up the pump set and stop it again after 2-3 seconds. Then wait for10 seconds. Repeat this procedure three times.

4. Start up the pump set.

5. When there is a pressure reading on the pressure gauge, open the gate valve inthe discharge line until the correct duty point is reached.

6.1.6 Shutdown

The shut-off element in the suction line is and remains open.

1. Close the shut-off element in the discharge line.

2. Switch off the motor and make sure the pump set runs down smoothly to astandstill.

NOTEIf the discharge line is equipped with a check valve, the shut-off element in thedischarge line may remain open, provided the site's requirements and regulationsare taken into account and observed.

For prolonged shutdown periods:

1. Close the shut-off element in the suction line.

2. Drain all fluids which tend to polymerise, crystallise, solidify, etc. from the pumpand the motor/rotor space.

3. Flush the pump set with a suitable liquid, if necessary.If the pump was used for handling fluids posing a health hazard, observe theinformation for draining the pump set.

4. Close any auxiliary lines.Only turn off the cooling liquid supply after the pump has cooled down.

CAUTIONRisk of freezing during prolonged pump shutdown periodsDamage to the pump!

▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protectthem against freezing.

6.2 Operating limits

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled andspeedExplosion hazard!Hot or toxic fluid could escape!

▷ Comply with the operating data indicated in the data sheet.

▷ Never use the pump for handling fluids it is not designed for.

▷ Avoid prolonged operation against a closed shut-off element.

▷ Never operate the pump at temperatures, pressures or rotational speedsexceeding those specified in the data sheet or on the name plate unless thewritten consent of the manufacturer has been obtained.

6.2.1 Ambient temperature

CAUTIONOperation outside the permissible ambient temperatureDamage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.



Observe the following parameters and values during operation:

Table 27: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °C21)

Minimum -20 °C22)

6.2.2 Frequency of starts

DANGER

Excessive surface temperature of the motorExplosion hazard!Damage to the motor!

▷ Monitor motors which are not used in continuous operating mode. Formonitoring, use thermistors (PTC thermistors) embedded in the windings andan approved thermistor relay (PTC thermistor tripping unit).

To prevent high temperature increases in the motor, do not exceed the followingnumber of start-ups per hour.

Table 28: Frequency of starts

Motor size Maximum number of start-ups

[Starts/hour]F 3

CAUTIONRe-starting while motor is still running downDamage to the pump (set)!

▷ Do not re-start the pump set before the pump rotor has come to a standstill.

6.2.3 Fluid handled

6.2.3.1 Density of the fluid handled

The pump input power changes in proportion to the density of the fluid handled.

CAUTIONImpermissibly high density of the fluid handledMotor overload!

▷ Observe the information on fluid density in the data sheet.

▷ Make sure the motor has sufficient power reserves.

6.2.3.2 Abrasive fluids

When the pump handles fluids containing abrasive substances, increased wear of thehydraulic system and the rotor space are to be expected. In this case, reduce thecommonly recommended inspection intervals.

21) 60 °C possible (optional), see data sheet/name plate22) -50 °C possible (optional), see data sheet/name plate



CAUTIONAbrasive and/or magnetic particles in the fluid handledDamage to the can!

▷ Take appropriate measures (e.g. filter/magnetic filter) to prevent abrasiveand/or magnetic particles from entering the rotor space.

▷ To ensure sufficient throughflow in the rotor space, monitor the filter/magneticfilter by measuring the differential pressure.

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains installed

Sufficient fluid is supplied for the operation check run of the pump.

The fluid handled does not change during pump shutdown (e.g. freeze orpolymerise).

1. For prolonged shutdown periods, start up the pump (set) regularly betweenonce a month and once every three months for approximately five minutes. This will prevent the formation of deposits within the pump and the pumpintake area.

The pump (set) is removed from the pipe and stored

The pump has been properly drained and the safety instructions for dismantlingthe pump have been observed.

1. Spray-coat the inside wall of the pump casing, and in particular the impellerclearance areas, with a preservative.

2. Spray the preservative through the suction and discharge nozzles.It is advisable to close the pump nozzles (e.g. with plastic caps or similar).

3. Oil or grease all exposed machined parts and surfaces of the pump (withsilicone-free oil and grease, food-approved if required) to protect them againstcorrosion.Observe the additional instructions .

If the pump set is to be stored temporarily, only preserve the wetted componentsmade of low-alloy materials. Commercially available preservatives can be used forthis purpose. Observe the manufacturer's instructions for application/removal.

Observe any additional instructions and information provided. ( Section 3 Page 13)

6.4 Returning to service

For returning the pump to service observe the sections on commissioning/start-upand the operating limits.

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service.

WARNINGFailure to re-install or re-activate protective devicesRisk of personal injury from moving parts or escaping fluid!

▷ As soon as the work is complete, re-install and/or re-activate any safety-relevantand protective devices.



7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Sparks produced during servicing workExplosion hazard!

▷ Observe the safety regulations in force at the place of installation!

▷ Always perform maintenance work at an explosion-proof pump (set) outside ofpotentially explosive atmospheres.

DANGER

Improperly serviced pump setExplosion hazard!Damage to the pump set!

▷ Service the pump set regularly.

The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughly familiarwith the manual.

WARNINGUnintentional starting of pump setRisk of injury by moving parts!

▷ Ensure that the pump set cannot be started up unintentionally.

▷ Always make sure the electrical connections are disconnected before carryingout work on the pump set.

WARNINGFluids, consumables and supplies which are hot and/or pose a health hazardRisk of injury!

▷ Observe all relevant laws.

▷ When draining the fluid take appropriate measures to protect persons and theenvironment.

▷ Decontaminate pumps which handle fluids posing a health hazard.

WARNINGInsufficient stabilityRisk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to preventtipping or falling over.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the pump, pump set and pump parts with aminimum of servicing/maintenance expenditure and work.

NOTEAll maintenance, service and installation work can be carried out by KSB Service orauthorised workshops. Find your contact in the attached "Addresses" booklet or onthe Internet at "www.ksb.com/contact".

Never use force when dismantling and reassembling the pump set.



https://shop.ksb.com/esales/contactfinder/contact.jsp?language=en&country=_C

7.2 Servicing/inspection

7.2.1 Supervision of operation

CAUTIONIncreased wear due to dry runningDamage 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 duringpump operation.

CAUTIONImpermissibly high temperature of fluid handledDamage to the pump!

▷ 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 onoperating limits.

While the pump is in operation, observe and check the following:

Check the flanged connections for integrity.

The pump must run quietly and free from vibrations at all times.

Check the bearings for running noises.Vibrations, noise and an increase in current input occurring during unchangedoperating conditions indicate wear.

Monitor the correct functioning of any auxiliary connections.

Monitor the stand-by pump.To make sure that stand-by pumps remain ready for instant start-up, start upstand-by pumps regularly between once a month and once every three monthsfor approximately five minutes.

7.2.2 Inspection work

DANGER

Excessive temperatures caused by friction, impact or frictional sparksExplosion hazard!Fire hazard!Damage to the pump set!

▷ Regularly check the cover plates, plastic components and other guards ofrotating parts for deformation and sufficient distance from rotating parts.



7.2.2.1 Checking the clearances

S1

S2

S3

S4

l1

l2l2

Fig. 35: Clearances

The back pull-out unit must be removed to check the clearances. If the clearance is larger than permitted (see the following table), fit a new casingwear ring 502.01 and/or 502.02.The clearances given refer to the diameter.

Table 29: Clearances between impeller and casing

Casing material Clearances S1 and S2 [mm]

New Maximum permissibleenlargement

D, E, Y 0,3 0,9C, V 0,5 1,5

To check the clearances, remove the back pull-out unit. If the plain bearing clearance is larger than permitted (see the following table), checkwhether the bearing bushes show visible signs of wear. If required, replace bearingcarrier 382 and/or bearing ring carrier 391 (further parts subjected to wear can be:bearing sleeves 529.06/.21, thrust bearings 314.01/.02).The clearances given refer to the diameter.

NOTEThe clearances and plain bearings depend on the the bearing bush materials.

Table 30: Plain bearing clearances: SSiC/SSiC (bearing bush / bearing sleeve) [mm]

S3 S4 l1 l2

0,05...0,1 0,05...0,1 40-0,05 5,15



Table 31: Plain bearing clearances: SiC30/SSiC (bearing bush / bearing sleeve) [mm]

S3 S4 l1 l2

0,05...0,3 0,05...0,3 40-0,05 5,15

7.2.2.2 Cleaning filters

CAUTIONInsufficient inlet pressure due to clogged filter in the suction lineDamage to the pump!

▷ Monitor contamination of filter with suitable means (e.g. differential pressuregauge).

▷ Clean filter at appropriate intervals.

7.2.2.3 Lubrication of plain bearings

The hydrodynamic plain bearings are lubricated by the fluid handled or the barrierfluid during pump operation. Bearings shall be checked for wear in the followingcases:

When the pump has been operated under dry-running or cavitation conditions,the bearings should be checked immediately, if possible.

Vibrations, noise and an increase in current input occurring during unchangedoperating conditions indicate wear at the bearings (insufficient lubrication).In this case, checking the bearings is also required.

7.2.2.4 Checking the power cables

The pump set has been removed from the plant and cleaned.

1. Measure the resistance between earth conductor and earth.The resistance must be lower than 1 Ω.

2. Replace any damaged components by original spare parts.

DANGER

Defective earth conductorElectric shock!

▷ Never switch on a pump set with a defective earth conductor.

7.2.2.5 Measuring the insulation resistance at the motor terminals

Measure the insulation resistance of the motor winding during annual maintenancework.

The pump set has been disconnected from the power supply in the terminalbox.

Use an insulation resistance measuring device.

The recommended measuring voltage is 1000 V DC.

1. Measure the winding to earth.To do so, connect all winding ends together.

2. Measure the winding temperature sensors to earth.To do so, connect all core ends of the winding temperature sensors togetherand connect all winding ends to earth.

3. Measure the connection points of the winding temperature sensor to the statorwinding (1000 V DC).To do so, connect the two core ends of the winding temperature sensorstogether and connect all stator winding ends together.

Earth conductor test



If resistance to earth ≧ 5 MΩ: motor winding in working order. The pump can bere-installed.

If resistance to earth < 5 MΩ: find cause, consult KSB Service if required.

The insulation resistance of the core ends to earth must not be lower than 1 MΩ.

NOTEIf the motor's insulation resistance values are lower than 1 MΩ, the windinginsulation is defective. The pump set must not be returned to service in this case.Check whether the motor can be repaired by KSB Service.

7.2.2.6 Checking the sensors

CAUTIONExcessive test voltageDamage to the sensors!

▷ Use a commercially available ohmmeter to measure the resistance.

The tests described below measure the resistance at the core ends of the controlcable. The actual sensor function is not tested.

NOTEEx d terminal boxes must only be opened/closed by electricians specially trained forexplosion protection equipment, as this involves handling Ex d enclosures("flameproof enclosure").

Table 32: Resistance measurement

Measurement between terminals ... ResistanceDepending on explosion protectionmonitoring concept ( Section 5.6.4 Page44)

< 1 Ω

a, b, c and d 200 Ω to 750 ΩIf the specified tolerances are exceeded, open the motor by removing the terminalboard.

Re-check the sensor cables located directly on the underside of the terminal board. Iftolerances are also exceeded here, contact KSB Service. The temperature sensors arefitted in the stator winding and cannot be replaced. If they are defective, a repair isnot possible.

The rotor space temperature sensor (if present) is fitted on the outside. Terminalassignment of KSB's standard Pt100

Table 33: Resistance measurement, Pt100 rotor space temperature sensor

Measurement between terminals ... Resistance 100 Ω - 120 Ω

7.2.2.7 Checking the monitoring equipment

During system/pump maintenance, the ATEX monitoring equipment must be checkedfor proper functioning at regular intervals (at least once a year).

7.2.2.8 Checking the terminal box condition (for models with terminal box Ex donly)

The condition of the flamepaths in the area of the terminal box cover ( Section9.2.2 Page 92) must be checked periodically (when the pump is being serviced). Therequirements to be met by the flamepaths are as follows:

Free from mechanical damage

Free from corrosion

Temperature sensors inthe motor winding

Rotor space temperaturesensor



The flamepaths' surfaces may be protected against corrosion using an appropriategrease. The requirements to be met by the grease are as follows:

The grease must not become hard during ageing.

The grease must not contain volatile solvents.

The grease must protect against corrosion.

It must be possible to use the grease for the temperature in the terminal box.

7.2.3 Action in the event of damage

7.2.3.1 Event of damage

Damaged cans can only be replaced/repaired by the manufacturer. It is thereforenecessary to adhere to a particular procedure if stator can damage is suspected (e.g.motor failure, rotor blocking due to solids).

Inspect the stator space for contamination/damage.

Before returning the motor unit to the manufacturer, contact the repair serviceto find out whether the unit can be repaired.

Always enclose a completed certificate of decontamination when returning theunit.

7.2.3.2 Inspecting the stator space for contamination/damage

WARNINGPossible fluid residuesHazard to persons and the environment!

▷ Wear safety clothing and a protective mask.

▷ Collect and dispose of any fluid residues.

WARNINGSolids in the fluid handled, corrosion, or contact between the stator and rotor cansif permissible bearing clearances are exceeded.Damage to the cansFluid handled is in the winding space or rotor

▷ Wear protective clothing.

1. Inspect the rotor and stator can surfaces for visible damage (grinding marks,scratches, scoring).When evaluating the damage, consider that the wall thickness of the cans isapprox. 0.45 mm.

2. Always remove terminal board 835 of terminal box 833, drain the windingspace and decontaminate it if required.

3. Dispose of defective motor unit or return to KSB for repair.

7.2.3.3 Removing the terminal board






NOTEDismantling the terminal board is only required in the event of damage, i.e. if thestator space needs cleaning to remove fluid which has penetrated the stator.Terminal boards must only be removed and/or installed by electricians speciallytrained for explosion protection equipment, as this involves handling Ex denclosures ("flameproof enclosure").

The notes and steps stated in ( Section 7.4.1 Page 69) to ( Section 7.4.2 Page69) have been observed/carried out.

1. Undo bolts 901.83 and remove terminal box cover 81-22.01.

2. Undo screws 914.82 and lift off terminal box base 81-36.01, gasket 400.81,detent-edged washers 550.78 and terminal board 835.01.

3. If required, remove any fluid handled from the stator space.

4. Fit terminal board 835.01 again.

5. Carefully place gasket 400.81 on terminal board 835 and position terminal boxbase 81-36.01.

6. Secure with screws 914.82.

7. Position the terminal box cover 81-22.01 and secure it with bolts 901.83.

7.3 Drainage/disposal

DANGER

Insufficient preparation of work on the pump (set)Risk of injury!

▷ Properly shut down the pump set.

▷ Close the shut-off elements in the suction line and discharge line.

▷ Release pump pressure.

▷ Shut off any auxiliary feed lines.

▷ Allow the pump set to cool down to ambient temperature.

WARNINGFluids posing a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of the flushing liquid and any liquid residues.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations and internal safety information on the disposal offluids posing a health hazard.

If the fluids handled by the pump set leave residues which might lead to corrosiondamage when coming into contact with atmospheric humidity, or which might ignitewhen coming into contact with oxygen, the pump set must be flushed through,neutralised, and anhydrous inert gas must be blown through the pump for dryingpurposes.



Fig. 36: Connections for pump set design with Pt100 resistance thermometer

Fig. 37: Connections for pump set design without Pt100 resistance thermometer

Table 34: Connections

Connection Description1M.1/ 1M.2 Connection for pressure gauge,

PumpMeter, etc.6B Fluid drain7B Cooling liquid drain10 E Barrier fluid11E Flushing liquid

Depending on the installation type, choose one of the following connections fordraining:

Table 35: Connections for draining

Installation type ConnectionHorizontal 6BVertical (motor on top) 6BVertical (motor below) 6B.4/11E

1. Open connection 6B.4 or connection 11E, depending on the type of installation.

2. Connect the flushing device (e.g. pipe union G 3/8 with nozzle).

3. Open connection 6B or the flushing valve in the suction line, depending on thetype of installation.

4. Flush the pump set towards the suction side.The duration of flushing depends on the nature and quantity of the fluidhandled inside the pump.For information on the quantity refer to the table below.

5. Do not stop flushing until the fluid residue inside the pump has beensufficiently diluted (concentration, colour, smell).This process will usually take 10 minutes.

Draining

Flushing



Table 36: Quantity of fluid handled in the rotor space

Motor size Fluid handled in the rotor space[dm³]

F 3,2

Utmost care must be taken when highly toxic fluids have been handled. In this case,the complete pump set must be thoroughly flushed through. Always watch out for possible liquid residues even when the pump has been flushedand drained!

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

WARNINGUnqualified personnel performing work on the pump (set)Risk of injury!

▷ Always have repair and maintenance work performed by specially trained,qualified personnel.

WARNINGHot surfaceRisk of personal injury!

▷ Allow the pump set to cool down to approx. 35 °C.

WARNINGImproper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to moveheavy assemblies or components.

Observe the general safety instructions and information.

For any work on the motor, observe the instructions in this manual.

For dismantling and reassembly observe the exploded views and the generalassembly drawing. ( Section 9.1 Page 87)

In the event of damage you can always contact our service staff.

DANGER

Insufficient preparation of work on the pump (set)Risk of personal injury!

▷ Properly shut down the pump set.

▷ Close the shut-off elements in the suction and discharge line.

▷ Drain the pump and release the pump pressure.

▷ Close any auxiliary connections.

▷ Disconnect the pump at the terminal box or in the control cabinet.

▷ Allow the pump set to cool down to approx. 35 °C.

7.4.2 Disconnecting the electrical connections

Observe the information in ( Section 7.4.1 Page 69) .

Undo bolts 901.83.

1. Remove terminal box cover 81-22.

2. Disconnect the cables (power and/or control cables) at the terminal studs.

If handling highly toxicfluids



3. Disconnect the PE conductor (green, yellow).

4. Unscrew the cable glands at the terminal box and pull out the cables.

5. Fit gasket 400.80.

6. Fit terminal box cover 81-22. Secure it with bolts 901.83 and detent-edgedwasher 550.79.

7. Only for designs with Pt100 resistance thermometer: Disconnect the electricalconnection of the Pt100 resistance thermometer. Remove it from screw plug903.91. Screw plug 903.91 must not be loosened in this process.

7.4.3 Removing the pump from the system and dismantling the pump casing


1. Drain and flush the pump.

2. Close connections 6B and 11E.

3. Undo the flanged connections.

4. If fitted, undo the bolted connection between the pump foot and baseplate/foundation.

5. Remove the pump from the piping and place it on a clean and level surface.

WARNINGPump tipping over or overturningRisk of injury/crushing!

▷ Protect the pump against tipping over; use suitable lifting tackle or otherequipment.

6. Position the pump as follows:Place the pump set in a horizontal position so that it sits on the motor withoutthe pump casing (and support foot, if applicable) resting on the supportsurface. Secure the pump set against tipping over sideways. When handling larger hydraulic systems or motors, it may be advisable to placethe motor vertically onto a suitable holder (impeller pointing upwards) and todismantle the pump in this position.




7. Undo nuts 920.01.

8. If necessary, use forcing screws to remove the pump casing.

9. Remove joint ring 411.10. Clean the sealing surface. If graphite gaskets areused, take particular care to clean the sealing surface thoroughly and carefully.

7.4.4 Removing the support foot

If further components need to be dismantled other than the impeller, removing thesupport foot23) first is recommended.


23) If any



WARNINGPump tipping over or overturningRisk of injury/crushing!

▷ Protect the pump against tipping over; use suitable lifting tackle or otherequipment.

1. Undo and remove bolts 901.04.

2. Remove support foot 183.

7.4.5 Removing the impeller


1. To undo impeller nut 920.95 hold the impeller with a belt wrench at theimpeller eye or, if required, at the outer impeller diameter.

2. Remove disc 550.87.

3. Pull off the impeller with a suitable impeller removal device.

7.4.6 Removing the casing cover/bearing ring carrier/adapter

CAUTIONUncontrolled loosening of the clamped plain bearing assemblyDamage to the bearing sleeves!

▷ Check during the individual dismantling steps whether the parts of the clampedplain bearing assembly (thrust bearing 314.01, bearing sleeve 529.21) come offindividually; in this case, remove them individually.

Table 37: Design features of casing cover fastening

Bolted casing cover Clamped casing cover


1. Model with bolted casing cover: undo nuts 920.15 and remove casing cover 161from adapter 82-5. Model with clamped casing cover: undo screws 902.15 and remove casing cover161 from adapter 82-5.

2. Remove U-ring 411.12. If a graphite gasket has been used instead of a U-ring,remove it completely.

3. Pull bush 543.23 and disc springs 950.23 off the pump shaft.

4. To pull thrust bearing 314.01 off the pump shaft, insert suitable screws into thetapped holes of the thrust bearing's front face (if necessary) and pull out thethrust bearing.

5. Remove hexagon socket head cap screws 914.07.



6. Slightly lift rotor 818 to take the weight off the bearing's location and useforcing screws to remove bearing ring carrier 391 from its seat and pull it outcarefully. Carefully place rotor 818 down again.

7. Undo nuts 920.04 and pull off adapter 82-5. Ensure that this part does not comeinto contact with bearing sleeve 529.21 and/or the shaft of rotor 818. Ifnecessary, use suitable lifting equipment to support weight.

8. Remove U-ring 411.11. If a graphite gasket has been used instead of a U-ring,remove it completely and with care.

9. Pull pump-end bearing sleeve 529.21 off the shaft (unless this has already beendone).

10. Pull thrust bearing 314.02 off the pump shaft.

7.4.7 Removing the motor housing cover

The notes and steps stated in ( Section 7.4.1 Page 69) tohave been observed/carried out.

1. Undo nuts 920.03 and remove motor housing cover 812.

2. Remove U-ring 411.15. If a graphite gasket has been used instead of a U-ring,remove it completely and with care.

7.4.8

Also see

General information/Safety regulations [ 69]

Removing the motor housing cover [ 72]

7.4.9 Dismantling the rotor


CAUTIONIncorrect dismantlingDamage to rotor and can!

▷ Keep the rotor straight to prevent any rubbing contact with the can whenpulling the rotor out.

1. Carefully pull rotor 818 out of the rotor space at the pump end.Slide a thin Teflon strip (approx. 150 to 200 mm wide, length corresponding tomotor housing, thickness depending on motor size, i.e. 0.3 - 0.4 mm for motorsize A and 0.5 - 0.8 mm for motor sizes B, C, D) under the rotor and pull therotor out of the rotor space on the Teflon strip.

2. Place rotor 818 down in a suitable holder to prevent it from being damagedand rolling sideways.

7.4.10 Dismantling the (motor-end) bearing assembly

Dismantling the rotating components of the bearing assembly

Further dismantling steps are normally only required if spare parts need to be fitted(e.g. bearing sleeve) or if components need to be completely cleaned (e.g. change offluid handled).


1. Undo shaft nut 920.50 (left-hand thread!).

2. Pull taper lock rings 515.24, bearing sleeve 529.06 and taper lock ring 515.23 offthe shaft end.

3. Pull disc springs 950.24 and backing ring 50-3.24 off the shaft end.



Dismantling the non-rotating components of the bearing assembly

Further dismantling steps are normally only required if spare parts need to be fitted.


1. Undo screws 914.09. Separate bearing carrier 382 from bearing disc 32-5.

7.4.11 Dismantling the motor unit

NOTESpecial regulations apply to repair work on explosion-proof pump sets.Modifications or alteration of the pump set may affect explosion protection and areonly permitted after consultation with the manufacturer.

NOTEThe motors of explosion-proof pump sets are supplied in "flameproof enclosure"type of protection. Any work on the motor which may affect explosion protectionmust be performed by the motor manufacturer. No modifications must be made tothe internal configuration of the motor space. Repair work at the flameproof jointsmust only be performed in accordance with the manufacturer's instructions. Repairsin accordance with the values specified in tables 1 and 2 of EN 60079-1 are notpermitted.

Dismantling the terminal board is only permitted in the event of damage, i.e. if thestator space needs cleaning to remove fluid which has penetrated the stator.

Apart from removing the terminal board, the motor unit cannot be furtherdismantled. ( Section 7.2.3 Page 66) Contact the manufacturer for any repair to be carried out on the winding and/or can.

7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

DANGER

Leaks and/or corrosion damage on monitoring systemsNo fault indications!Leakage of fluid handled!

▷ Never install damaged or corroded monitoring systems in the pump.

▷ Check monitoring systems for damage and correct function prior to installation.

WARNINGImproper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to moveheavy assemblies or components.

WARNINGComponents with sharp edgesRisk of cutting or shearing injuries!

▷ Always use appropriate caution for installation and dismantling work.

▷ Wear work gloves.



CAUTIONImproper reassemblyDamage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of soundengineering practice.

▷ Use original spare parts only.

NOTEBefore reassembling the motor section, check that all joints relevant to explosionprotection (flamepaths) are undamaged. Any components with damagedflamepaths must be replaced. Refer to the "Flamepaths" annex for the position ofthe flamepaths.

Always reassemble the pump set in accordance with the corresponding generalassembly drawing and/or list of components.

Check U-rings for any damage and replace by new U-rings if required.

Always use new graphite profile rings as specified in the list of components, makingsure that they have the same thickness as the old ones.

Always fit gaskets of asbestos-free materials or graphite without using lubricants(e.g. copper grease, graphite paste).

Always replace the gaskets during maintenance/servicing.

For reassembly, tighten all screws and bolts as specified in this manual. .

Avoid the use of assembly adhesives, if possible.

Should an assembly adhesive be required after all, use a commercially availablecontact 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).

Coat the locating surfaces of the individual components and screwed connectionswith assembly paste, e.g. Altemp, graphite or assembly aids similar to graphite,before reassembly.

7.5.2 Cleaning and checking the components

The notes and steps stated in ( Section 7.5.1 Page 73) have been observed andcarried out.

1. Clean all dismantled components and inspect them for signs of damage.

2. Carefully clean all sealing areas and check for damage (e.g. scratches).

3. Replace any damaged components by original spare parts. Always replacegraphite gaskets with new ones.

4. If the can is damaged:- Replace the complete motor unit.- If required open the stator space for disposal. Completely remove the terminalboard from the terminal box and drain the fluid which has penetrated thestator space during the failure.

5. Inspect the bores located in the following components for cleanliness and freepassage. Clean them, if necessary.- Impeller 230- Thrust bearings 314.01/.02- Bearing carrier 382- Rotor 818 (radial bores; axial bore)- Bearing ring carrier 391- Adapter 82-5- Vent plug (grub screw with bore) 913.06

Sequence

Sealing elements

Tightening torques

Assembly adhesives



7.5.3 Installing the motor unit

NOTEBefore reassembling the motor section, check that all joints relevant to explosionprotection (flamepaths) are undamaged. Any components with damagedflamepaths must be replaced. Only use original spare parts made by KSB forexplosion-proof pumps. Observe the flamepath positions specified in the Annex.( Section 9.2 Page 90)

DANGER

Wrong screws/boltsExplosion hazard!

▷ Always use the original screws/bolts for assembling an explosion-proof pumpset.

▷ Never use screws/bolts of different dimensions or of a lower property class.

NOTEMotor units supplied as spare parts (spare motor unit) come with the terminal boxalready fitted.


The individual parts have been placed in a clean and level assembly area.

All dismantled parts have been cleaned and checked for wear.

Any damaged or worn parts have been replaced by original spare parts.

The sealing surfaces have been cleaned.

1. Insert gasket 400.81.

2. If dismantled, fit terminal box 81-36.

3. Tighten screws 914.82 with detent-edged washers 550.78.Observe the tightening torque.

7.5.4 Fitting the bearing assembly

7.5.4.1 Fitting the (motor-end) bearing assembly

If the motor-end bearing assembly has not been dismantled, the next assembly stepscan be ignored.

We recommend fastening the rotor via the rotor core pack to the support surface sothat the torque required to clamp the bearing assembly can be applied.

1 23

4

Fig. 38: Assembly fixture

1 Rotor 2 Felt or rubber base3 Support 4 Strap

Assembly fixture




1. Slide backing ring 543.24 onto the free (drive-end) shaft end until it abuts theshaft shoulder.

2. Fit disc springs 950.24 (pointing in the same direction). The disc springs arecorrectly fitted if the outside diameter rests against backing ring 543.24 and thehighest point of the disc spring pack points towards the shaft end.

3. Fit locking ring 515.23, bearing sleeve 529.06, locking ring 515.24.

4. Apply a thin coat of assembly paste to the thread of shaft nut 920.50, fasten(left-hand thread!) and slightly tighten the nut by hand.

5. Slightly turn plain bearing sleeve 529.06 in the conical seat to avoid jamming ofthe bearing sleeve.

6. Tighten shaft nut 920.50 using a suitable tool (left-hand thread!).Observe the tightening torque.

7.5.4.2 Fastening the pump-end bearing to the rotor


CAUTIONDry bearing surfaces during assemblyDry running of the bearings at pump start-up!

▷ Before installing the bearings, wet the running surfaces of the bearings with asuitable fluid (e.g. water or oil).

1. Wet the running surfaces of the thrust bearings with liquid.

2. Push pump-end thrust bearing 314.02 onto the pump-end shaft end until it willnot go any further.

7.5.5 Fitting the rotor

The notes and steps stated in ( Section 7.5.1 Page 73) to ( Section 7.5.4 Page75) have been observed and carried out.

CAUTIONIncorrect assemblyDamage to rotor and can!

▷ Keep the rotor straight to prevent any rubbing contact with the can wheninserting it.

1. Carefully fit rotor 818 into the rotor space from the pump end.Insert a thin Teflon strip (approx. 150 to 200 mm wide, length corresponding tomotor housing, thickness depending on motor size, i.e. 0.3 - 0.4 mm for motorsize A or 0.5 - 0.8 mm for motor sizes B, C, D) into the rotor space and slide therotor into the rotor space on the Teflon strip until the motor-side shaft endprotrudes from the other side of the motor housing.



Fig. 39: Position of shaft end with regard to the motor housing

X End position of rotor with regard to the motor housing (initial rotor positionfor mounting the bearing carrier)

7.5.6 Fitting the bearing carrier

The notes and steps stated in ( Section 7.5.1 Page 73) to have been observed/carried out.

1. Carefully slide bearing disc 32-5 with bolted bearing carrier 382 with thebearing bush over bearing sleeve 529.06 and into its seat; take the weight offthe bearing's location by slightly lifting rotor 818.Check that bearing carrier 382 is positioned correctly. The marking on thebearing carrier must point upwards. Verify the correct position of bearing disc 32-5. The M6 jacking threads must behorizontal, the vent/drain holes must be vertical or the vent bore on top like theposition marking of bearing carrier 382.

2. If required, apply assembly paste to screws 914.10, screw them in and slightlytighten crosswise by hand. Observe the tightening torque!

7.5.7 Fitting the motor housing cover


1. Fit U-ring 411.15 in motor housing cover 812. Motor size A (PN25 and PN40 only), B, C and D: A graphite gasket can be fittedinstead of a U-ring. If a graphite gasket is used, insert the gasket gently into thegroove for the sealing element. Make sure that the contact face of motorhousing cover/motor housing is free from any dirt particles, remove them ifrequired.

2. Position motor housing cover 812 on studs 902.03 and press into its seat.Check that motor housing cover 812 is positioned correctly. The marking (notch)on motor housing cover 812 must point upwards.

3. If required, apply assembly paste to studs 902.03 and slightly tighten nuts920.03 crosswise by hand. Observe the tightening torque.

Fig. 40: Marking onbearing carrier



7.5.8 Fitting the adapter and bearing ring carrier


The rotor has been installed.

Thrust bearing 314.02 has been positioned on the pump shaft.

The Teflon strip used for mounting the rotor has been removed from the rotorspace.

1. Insert U-ring 411.11 into the groove for the sealing element in the adapter. If agraphite gasket is used instead of a U-ring, carefully fit it in the groove for thesealing element. Make sure that the contact face of adapter/motor housing isfree from any dirt particles, remove them if required.

2. Fit adapter 82-5 on studs 902.04 at the motor housing and slide to its mountingposition. Ensure that this part does not come into contact with the shaft ofrotor 818. If necessary, use suitable lifting equipment to support weight.Check that the adapter is positioned correctly. The marking (notch) on theadapter must point upwards so that the two inclined bores for venting anddraining lead to the highest and lowest point, respectively.

3. If required, apply assembly paste to studs 902.04 and evenly tighten nuts 920.04crosswise.

CAUTIONDry bearing surfaces during assemblyDry running of the bearings at pump start-up!

▷ Before installing the bearings, wet the running surfaces of the bearings with asuitable fluid (e.g. water or oil).

4. Wet the bearing bush with liquid.

5. Install bearing ring carrier 391 with the bearing bush.Check that bearing ring carrier 391 is positioned correctly. The marking (notch)on bearing ring carrier 391 must point upwards.

6. If required, apply assembly paste to screws 914.07 and evenly tighten crosswise.Observe the tightening torques.

7. Pull the free shaft end of the rotor towards the pump end by hand until thrustbearing 314.02 rests against the face of the bearing bush.

8. Wet the contact surface of bearing sleeve 529.21 with liquid and slide bearingsleeve 529.21 over the shaft end and into its position in the bearing bush. Takethe weight off the bearing's location by slightly lifting rotor 818.

9. Check whether the rotor can be easily rotated by hand.

10. Wet the contact surface of thrust bearing 314.01 with liquid and slide on theshaft end as far as possible.

11. Fit disc springs 950.23 (pointing in the same direction). The disc springs arecorrectly fitted if the outside diameter rests against thrust bearing 314.01 andthe highest point of the disc spring pack points towards the impeller.

12. Fit U-ring 411.12 in the corresponding groove in the adapter.

13. Push ring 543.23 onto the free shaft collar until the ring rests against the discspring pack.

Fig. 41: Marking (notch)on adapter

Fig. 42: Marking onbearing ring carrier



7.5.9 Fitting the casing cover

Table 38: Design features of casing cover fastening

Bolted casing cover Clamped casing cover

The notes and steps stated in ( Section 7.5.1 Page 73) to have been observedand carried out.

1. Insert U-ring 411.12 into the groove for the sealing element in adapter 82-5. If agraphite gasket is used instead of a U-ring, carefully fit it in the groove for thesealing element in the adapter. Make sure that the contact face of adapter/casing cover is free from any dirt particles, remove them if required.

2. For models with bolted casing cover: position casing cover 161 on adapter 82-5and slightly tighten nuts 920.15 crosswise. Observe the tightening torques. For models with clamped casing cover: position casing cover 161 on adapter82-5 and tighten studs 902.15. Observe the tightening torques.

7.5.10 Fitting the impeller


1. Insert key 940.01 into the shaft keyway.

2. Slide impeller 230 onto the pump shaft.

3. Slide disc 550.87 onto the threaded stub.

4. Apply a thin coat of suitable assembly paste to the thread.

5. Fit and tighten impeller nut 920.95 hand tight.

6. To tighten impeller nut 920.95 hold the outside impeller diameter with a beltwrench. To avoid stress or distortion in the plain bearing when tighteningimpeller nut 920.95, move the impeller slightly to and fro with the belt wrench.Observe the tightening torque! During tightening, some resistance must be felt due to the pre-loaded discsprings before complete contact of all parts is established.

7. If no resistance can be felt during tightening:- Verify that the disc springs have been fitted correctly. The disc springs are correctly fitted if the outside diameter rests against thethrust bearing and the highest point of the disc spring pack points towards theimpeller.

8. Rotate and axially move the rotor by hand.Check that the rotor is able to move freely and easily (axial movementapproximately 0.5 mm).If there are any rubbing noises or stresses and strains: find the cause and takeremedial action.

7.5.11 Fitting the support foot

If the support foot has been removed, we recommend fitting it prior to inserting theback pull-out unit into the pump casing.




1. Position support foot 183.

2. Insert and tighten bolts 901.04. Observe the tightening torque.

7.5.12 Installing the back pull-out unit in the pump casing


Studs 902.01 have been fitted in the pump casing and assembly paste appliedwhere necessary.

1. Insert joint ring 411.10 into the centring recess of pump casing 102.

2. Insert the pre-assembled studs in pump casing 102 into the holes on casingcover 161 (on adapter 82-5 for motor size A only).

3. Fit nuts 920.01.

4. Check that the rotor can be rotated easily.

5. Tighten nuts 920.01.Observe the tightening torque.

6. Fit screw plug 903.91 with new joint ring 411.91 on motor housing cover 812,and tighten.Observe the tightening torque.

7. If required, fit screw plug 903.01 with new gasket 411.01 on the pump casing.

7.5.13 Checking reassembly

Checking the rotor for smooth rotation


The pump rotor can be rotated freely and easily.

1. Rotate the impeller by hand in clockwise direction.Use a socket wrench on impeller nut 920.95, if required.

2. If rotating the impeller proves difficult or rubbing noises can be heard, openthe pump and eliminate the causes.

Checking the pump for leakage


The pump rotor can be rotated freely and easily.

1. Close the flanges and screw plugs of the pump.

2. Subject the pump to a leak test.- Medium: dry compressed air or nitrogen- Pressure: 2 bar- Duration: 30 minutes

3. Apply a leak detection spray to all sealed parts (e.g. casing seals, screw plugs).

4. If the pressure drops, locate the cause (with the leak detection spray) andensure tight sealing.

5. If the pressure does not drop, the pump can be returned to operation. For installing the pump in the system observe the information in ( Section 5Page 20) .For storage observe the instructions in ( Section 6.3 Page 60) .



7.6 Tightening torques

Fig. 43: Model with clamped casing cover

Fig. 44: Ausführung mit geklemmtem Gehäusedeckel



Fig. 45: Ausführung mit geschraubtem Gehäusedeckel

Table 39: Tightening torques for screwed connections

Part No. Description Thread Material Tightening torque [Nm]

PN16 (C,V)24)

PN25 (E,D)24)

PN40(Y)24)

901.04 Hexagon head bolt M8 10.9 30901.83 Hexagon head bolt M8 8.8 24902.15 Stud M6 A4-70 5914.07 Hexagon socket head cap screw M10 A4-70

1.4462

20

914.09 M6 1.4462 4,5914.10 M6 A4-70

1.4462

4,5

914.82 M8 8.8 24920.0125) Nut M12 A4-70 /

A193Gr.B8MCl.2 / G4303Gr.A4-70(austenitic)

50 57,5 82,5M16 135 155 210

920.0126) M12 50 65 130M16 125 165 320

920.03 M16 135 155 210920.04 M16 135 155 210

24) Casing material: C, V = stainless steel; E = unalloyed steel; D = duplex stainless steel; Y = high-temperature resistant caststeel 1.7706

25) Clamped casing cover26) Bolted casing cover



Part No. Description Thread Material Tightening torque [Nm]

PN16 (C,V)24)

PN25 (E,D)24)

PN40(Y)24)

920.15 M12 1.7225/ A193Gr. B7 / G4107 Cl.2SNB7

Monix 1.6772

50 57,5 82,5

920.95 Nut M16 × 1,5 A4-70 901.4462 72

M20 × 1,5 A4-70 901.4462 180

920.50 Shaft nut M30 × 1,5-LH A4-70 1201.4462 140

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

Type series

Size

Material variant

Year of construction

Refer to the name plate for all data.

Also specify the following data:

Part No. and description ( Section 9.1 Page 87)

Quantity of spare parts

Shipping address

Mode of dispatch (freight, mail, express freight, air freight)

7.7.2 Recommended spare parts stock for 2 years' operation

Table 40: Quantity of spare parts for recommended spare parts stock as per API 685 , 2nd edition, 10.2.3 Table 14

Part No. Description Number of pump sets (including stand-by pumps)

1 to 3 4 to 7 8 to 10- Set of sealing elements 1 2 3502.01/.02 Casing wear ring (if fitted) 1 2 3503.01/.02 Impeller wear ring (if fitted) 1 2 3314.01/.02, 391,529.21

Plain bearing, pump-end 1 2 3

382, 515.23 (2x),529.06

Plain bearing, drive-end 1 2 3

230, 550.87, 920.95,940.01

Impeller27) 1 1 2

- Rotor28) 1 1 1

24) Casing material: C, V = stainless steel; E = unalloyed steel; D = duplex stainless steel; Y = high-temperature resistant caststeel 1.7706

27) Impellers are generally ordered with full diameters as this allows head adjustments within the permissible range orinterchangeability with other pumps using the same impeller size.

28) Rotor comprising shaft with rotor core pack (without bearing components or impeller).




1 to 3 4 to 7 8 to 10- Back pull-out unit29)30) 1 1 1- Spare motor unit29)30) 1 1

Table 41: Quantity of spare parts for recommended spare parts stock to DIN 24296


1 to 3 4 to 7 8 to 10- Set of sealing elements 1 2 3502.01/.02 Casing wear ring (if fitted) 1 2 3503.01/.02 Impeller wear ring (if fitted) 1 2 3314.01/.02, 391,529.21

Plain bearing, pump-end 1 1 1

382, 515.23 (2x),529.06

Plain bearing, drive-end 1 1 1

230, 550.87, 920.95,940.01

Impeller 1 1 1

- Rotor28) - 1 1- Back pull-out unit - - -- Spare motor unit - - 1

29) Vital-service pumps (API 685, 2nd edition): "Vital-service pumps are generally unspared. When a vital machine is down,production loss or violation of environmental permits results. At least one noted item should be available for eachdesignated vital-service pump. Some users may choose to have an uninstalled spare pump as opposed to, or in addition toparts shown."

30) Essential-service pumps (API 685, 2nd edition): "Essential-service pumps are required for operation and have an installedspare. A production loss occurs only if main and spare fail simultaneously. At least one noted item should be available foreach designated set of essential-service pumps to minimize the period without an available spare."



8 Trouble-shooting

WARNINGImproper work to remedy faultsRisk of injury!

▷ For any work to remedy faults observe the relevant information in this manualor in the relevant accessory manufacturer's product literature.

If problems occur that are not described in the following table, consultation withKSB’s customer service is required.

Pump is running but does not deliver

Pump delivers insufficient flow rate

Motor is overloaded

Excessive current consumption

Excessive power consumption

Leakage at the pump

Vibrations during pump operation

Impermissible temperature increase in the pump set

Rubbing noises

Table 42: Trouble-shooting

A B C D E F G H I Possible cause Remedy31)

- - - - - - - - Pump delivers against an excessively highpressure.

Re-adjust to duty point by opening theshut-off valves accordingly.

Check system for impurities. Fit largerimpeller.32)

- - - - - - Pump or piping are not completelyvented or primed.

Vent and/or prime.

- - - - - - Pump suction line or impeller clogged Remove deposits in the pump and/orpiping.

- - - - - - - - Formation of air pockets in the piping Alter piping layout.

Fit a vent valve.- - - - - - NPSHavailable (positive suction head) is too

low.Raise fluid level in the inlet tank. Fullyopen shut-off element in the suction/inletline.

Change suction/inlet line, if the frictionlosses in the suction/inlet line are toohigh.

Check any strainers installed/suctionopening; clean if required

Observe permissible speed of pressure fall.- - - - - - - - Wrong direction of rotation Check the electrical connection at the

control system and correct if necessary.- - - - - - - - Speed is too low31)32)

– if operated on a frequency inverter.Increase voltage/frequency at thefrequency inverter in the permissiblerange.

- - - - - - - - Speed is too low31)32)

– if not operated on a frequency inverter.Check voltage.

- - - Wear of internal components Replace worn components by new ones.- - - - - - Pump back pressure is lower than

specified in the purchase order.Re-adjust to duty point (e.g. reduce flowrate).

In the case of persistent overloading, turndown impeller.32)

A

B

C

D

E

F

G

H

I

31) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.32) Contact KSB.

8 Trouble-shooting


A B C D E F G H I Possible cause Remedy31)

- - - - - Density or viscosity of the fluid handled ishigher than stated in the purchase order.

32)

- - - - - - - Operating voltage is too low. Increase voltage; check voltage drop inthe power cable.

- - - - - Motor is running on 2 phases only. Replace the defective fuse.

Protect the motor with an all-pole circuitbreaker.

Check electrical connections.- - - - - - - - Stud connections 902.01/920.01,

902.04/920.04, 902.15/920.15 or902.03/920.03 have loosened.

Tighten nuts (see tightening torques)

Replace sealing elements if required.

- - - - - - - - Rotor out of balance Balance the rotor.

Re-balance the impeller.- - - - - Defective bearing(s) Repair necessary (find cause for bearing

damage and take remedial action).- - - - - - - - Flow rate is too low. Observe the minimum flow rate (data

sheet). - - - - - - - - Motor is not running because of lack of

voltage.Check electrical connections.

- - - - - - - - Rotor blocked due to corrosion oroxidation (risk of dry running)

32)

- - - - - - - Motor winding or electric cable aredefective.

32)

- - - - - - - - Excessive temperatureFluid temperature is too high.

Adjust the fluid temperature to the valuegiven in the data sheet.

- - - - - - - Incorrect operating data Reduce the flow rate.- - - - - - - Viscosity too high32) Reduce the flow rate.

32)

- - - - - - - - Impeller or rotor rub on the pump casing. Clean impeller or rotor.

Check bearings for wear.

Pump maintenance- - - - - - - Bores for cooling/lubricating flow are

clogged.Clean.

- - - - - - - - Filter (e.g. main flow ~, internal ~ orfilter in suction/inlet line) is clogged.

Clean.

- - - - - - Pump is tripped via thermistor relay(PTC).

Find cause for excessive temperature risein motor and take remedial action.

- - - - - - Pump is tripped via limit switch (Pt 100). Find cause for excessive temperature risein motor and take remedial action.

Compare set temperature against dataindicated on name plate; correct setting ifnecessary.

- - - - - - - - Ascertained during dismantling (e.g.pinched seal)

Repair necessary.

31) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

8 Trouble-shooting


9 Related Documents

9.1 General assembly drawing with list of components

9.1.1 General assembly drawing, motor size F

Fig. 46: General assembly drawing of pump set, motor size F, with bolted casing cover

9 Related Documents


Fig. 47: General assembly drawing of pump set, motor size F, with clamped casing cover

9 Related Documents


9.1.2 List of components

Table 43: List of components

Part No. Comprising Description102 102 Volute casing

411.01/.0233)/0333)/.0433)/.1034) Joint ring502.0133) Casing wear ring902.01 Stud903.01/.0233)/.0333)/.0433) Screw plug920.01 Hexagon nut

16135) 161 Casing cover502.0233) Casing wear ring901.22 36)/.31 Hexagon head bolt902.02 Stud920.02 Hexagon nut

183 183 Support foot230 230 Impeller

503.01/.0233) Impeller wear ring314.01 314.01 Thrust bearing ring314.02 314.02 Thrust bearing ring382 382 Bearing carrier

914.10 Hexagon socket head cap screw391 391 Bearing ring carrier

914.07 Hexagon socket head cap screw932.0737) Circlip

411.11/12/.15 411.11/.12/.15 Joint ring411.91 411.91 Joint ring502.0133) 502.0133) Casing wear ring502.0233) 502.0233) Casing wear ring503.0133) 503.0133) Impeller wear ring503.0233) 503.0233) Impeller wear ring515.23/. 24 515.23/ .24 Locking ring529.06/ .21 529.06/ .21 Bearing sleeve543.24 543.24 Backing ring550.20/.87 550.20/.87 Disc745.04 745.04 Sheet metal filter81-36 81-36 Terminal box base

400.80/.81 Gasket550.78/.79 Detent-edged washer81-22 Terminal box cover835 Terminal board901.83 Hexagon head bolt914.82 Hexagon socket head cap screw

81-59 81-59 Spare motor unit- Motor housing- Stator- Stator can81-36 Terminal box base920.03/04 Nut902.03/.04 Stud

82-5 82-5 Adapter502.0234) Casing wear ring

812 812 Motor housing cover411.91 Joint ring903.91 Screw plug

33) Not on all versions34) Joint ring 411.10 depending on application temperature. To be ordered separately in spare parts order35) Not for motor size A36) On models with clamped casing cover only

9 Related Documents


Part No. Comprising Description818 818 Rotor

- Shaft- Rotor core pack- Can913.06 Vent plug (grub screw with bore)

89033) 89033) Baseplate99-9 99-9 Set of sealing elements

411.01/.02/.03/.04/.10/.11/.15/.91 Joint ring400.80 Gasket

901.04/.83 901.04/.83 Hexagon head bolt902.01/.03/.04/.15 902.01/.03/.04/.15 Stud903.46/.91 903.46/.91 Screw plug914.07/.09/.10 914.07/.09/.10 Hexagon socket head cap screw913.06 913.06 Vent plug (grub screw with bore)920.01/.03/.04/.15 920.01/.03/.04/.15 Nut920.50 920.50 Shaft nut920.95 920.95 Impeller nut932.0633) 932.0633) Circlip932.0737) 932.0737) Circlip940.01 940.01 Key950.23/.24 950.23/.24 Disc springs

The relevant version is indicated in the product literature supplied.

9.2 Flamepaths

NOTEThe width of the flameproof joints is wider than specified in the tables of EN60079-1. The gap of the flameproof joints is smaller than specified in the tables of EN60079-1.

37) For motor size A only

9 Related Documents


9.2.1 Flamepaths for pump sets with Ex e terminal box

1

23

Ex d

Ex e

Fig. 48: Flamepaths for pump sets with Ex e terminal box

1, 2, 3 Flamepaths

9 Related Documents


9.2.2 Flamepaths for pump sets with Ex d terminal box

1

23

Ex d

Ex d

6

5

4

Fig. 49: Flamepaths for pump sets with Ex d terminal box

1, 2, 3 ,4, 5, 6 Flamepaths

9.3 Size/casing cover combinations

Table 44: Size/casing cover combinations

Pump size Motor size

⃝ = Clamped casing cover = Bolted casing cover

A B C D F040-025-160 ⃝ - - -040-025-200 - -050-032-125.1 ⃝ - - -050-032-125 ⃝ - - -050-032-160.1 ⃝ ⃝ - -050-032-160 ⃝ ⃝ - -050-032-200.1 - -050-032-200 - -050-032-250.1 - -

9 Related Documents


Pump size Motor size

⃝ = Clamped casing cover = Bolted casing cover

A B C D F050-032-250 - -065-040-125 ⃝ ⃝ - -065-040-160.1 ⃝ ⃝ - -065-040-160 ⃝ ⃝ - -065-040-200 ⃝ -065-040-250.1 - -065-040-250 - -065-040-315 - - 080-050-125 ⃝ ⃝ - -080-050-160 ⃝ ⃝ - -080-050-200 - ⃝ -080-050-250 - - 080-050-315.1 - - 080-050-315 - - 100-065-125 ⃝ ⃝ - -100-065-160 - ⃝ -100-065-200 - ⃝ -100-065-250 - - 100-065-315 - - - 125-080-160 - ⃝ -125-080-200 - - ⃝ ⃝125-080-250 - - 125-080-315 - - - 125-100-160 - - ⃝ ⃝125-100-200 - - ⃝ ⃝125-100-250 - - - 125-100-315 - - - 150-125-200 - - - ⃝ ⃝

9.4 Motor size/bearing size combinations

Main bearing (pump-end) Radial bearing (drive-end)

Table 45: Motor size/bearing size combinations

Motor size Main bearing Radial bearingA P02CF P02CRB P03CFC P03CRD P05CFF

9 Related Documents


10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump (set):

Ecochem Non-Seal HN (motor sizes A, B, C, D, F)

KSB order number: ...................................................................................................

is in conformity with the provisions of the following Directives as amended from time to time:

– Pump (set): Machinery Directive 2006/42/EC

– Pump: ATEX Equipment Directive 94/9/EC

The manufacturer also declares that

the following harmonised international standards have been applied:

– ISO 12100,

– EN 809,

– EN 60034-1, EN 60034-5/A1,

– EN 60079-0:2012, EN 60079-1:2007, EN 60079-7:2007,

– EN 13463-1, EN 13463-5, EN 1127-1

In compliance with Directive 94/9/EC the pump set is marked as follows:II 2 G c Ex de IIC or IIB T5, T4 or T3 Gb

An EC type test certificate is available for the pump set, motor sizes A, B, C, D, F.

The manufacturer's quality assurance system is monitored by 0044 TÜV Nord CERT GmbH, Germany.

Person authorised to compile the technical file: Name

Function Address (company)Address (Street, No.)Address (post or ZIP code, city) (country)

The EC Declaration of Conformity was issued in/on:

Place, date

..............................38).............................

Name

FunctionCompanyAddress

38) A signed, legally binding declaration of conformity is supplied with the product.

10 EC Declaration of Conformity


11 Certificate of Decontamination

Type: ................................................................................................................................Order number/Order item number39): ................................................................................................................................

Delivery date: ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled39): ................................................................................................................................

Please tick where applicable39):

⃞ ⃞ ⃞ ⃞Radioactive Explosive Corrosive Toxic

⃞ ⃞ ⃞ ⃞Harmful Bio-hazardous Highly flammable Safe

Reason for return39): ................................................................................................................................

Comments: ................................................................................................................................ ................................................................................................................................

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal.

We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.

For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has beenremoved from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern,leakage barrier and bearing bracket or intermediate piece have also been cleaned.

For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage atthe stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it hasbeen removed.

⃞ No special safety precautions are required for further handling.⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

...............................................................................................................................................................

...............................................................................................................................................................

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with therelevant legal provisions.

.................................................................... ....................................................... .......................................................Place, date and signature Address Company stamp

39) Required fields

11 Certificate of Decontamination


Index

AAbrasive fluids 59Anti-condensation heater 11Applications 9Auxiliary connections 28

BBack pull-out unit 80

CCasing cover

Design features 71, 79Certificate of decontamination 95Clearances 63Connection cables

Control cable 38Power cable 38

DDescription 15Direction of rotation 54Dismantling 69Disposal 14

EEarth conductor 40Earthing 40Electrical connection 42Electromagnetic compatibility 30Event of damage

Ordering spare parts 83Explosion protection 11, 20, 30, 41, 44, 47, 53, 54, 55,56, 57, 58, 59, 61, 62, 75

FFaults

Causes and remedies 85Filter 25, 64Fluid handled

Density 59Frequency of starts 59

HHeating 55, 56Heating medium 56Heating speed 57Heating up 57

IInstallation

Installation on a foundation 21Insulation 29Intended use 9Interference immunity 30

KKeeping warm 57

MMisuse 9

NName plate 16Noise characteristics 19

OOperating limits 58Operation on a frequency inverter 30Order number 6Other applicable documents 6Overload protection 45

PPartly completed machinery 6Permissible forces and moments at the pump nozzles26Piping 25Power cable

Length 38Preservation 14, 60Priming and venting 55Product description 15

RReassembly 69, 74Resonances 20Return to supplier 14Returning to service 60

SSafety 8Safety awareness 9Scope of supply 19Sensors 31, 44Servicing/maintenance 61Setting of level transmitter

Level measurement 54Shutdown 58, 60Spare part

Ordering spare parts 83Spare parts stock 83, 84Special accessories 19Start-up 57Storage 14, 60

TTapped hole for connection cables 40Technical data

Limit switch 51

Index


Temperature difference 57Temperature limits 11Terminal box 38Thermistor connection principle

Monitoring concept Ib 46Monitoring concept II 46

Tightening torques 82Transport 13

VVibrations 20

Index


2940

.85/

01-E

N (

0165

3577

)

KSB Aktiengesellschaft67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)Tel. +49 6233 86-0 • Fax +49 6233 86-3401www.ksb.com