Instructions Manual

MIF-0500/10-I [12-2012] IN
Centrifugal Pumps

Original manual

This manual contains important instructions and warnings.

You must read them before mounting, making the electrical
connections and starting up. You must also comply with the
instructions for the components related to this pump.

Please remember that this Manual must be kept close to the

motor pump group.
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Contents
7 MAINTENANCE/CONSERVATION.......................... 12
1 GENERAL ITEMS ...................................................... 3
7.1 GENERAL INSTRUCTIONS ......................................... 12
2 SAFETY...................................................................... 3 7.2 MAINTENANCE/INSPECTION...................................... 12
7.2.1 Checking instructions .................................. 12
2.1 MARKING OF WARNINGS IN THIS MANUAL ..................... 3 7.2.2 Lubrication .................................................. 13
2.2 PERSONNEL QUALIFICATIONS AND INSTRUCTION .......... 3 7.3 EMPTYING/DRAINAGE ............................................. 13
2.3 RISKS OF FAILING TO COMPLY WITH THE SAFETY 7.4 DISMOUNTING ........................................................ 13
INSTRUCTIONS ................................................................. 3 7.4.1 Fundamental instructions/observations....... 13
2.4 CONSCIENTIOUS SAFETY AT WORK ............................. 3 7.4.2 Tubular coupling guards.............................. 13
2.5 SAFETY INSTRUCTIONS FOR USERS AND SERVICE 7.4.3 Coupling...................................................... 13
PERSONNEL..................................................................... 3 7.4.4 Mechanical seal .......................................... 14
2.6 SAFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION 7.4.5 Packing ....................................................... 14
AND ASSEMBLY WORK ....................................................... 3 7.4.6 Pump........................................................... 14
2.7 MODIFICATIONS AND ARBITRARY MANUFACTURE OF 7.5 ASSEMBLY ............................................................. 14
SPARE PARTS .................................................................. 4 7.5.1 Tubular coupling guards.............................. 14
2.8 UNAUTHORISED OPERATION MODES ........................... 4 7.5.2 Coupling...................................................... 15
7.5.3 Mechanical seal .......................................... 15
2.9 WARNINGS FOR EQUIPMENT WITH MARKING ...... 5 7.5.4 Packing ....................................................... 15
3 TRANSPORT AND STORAGE .................................. 5 7.5.5 Pump........................................................... 16
7.5.6 Tightening torque of the screws/nuts1) ........ 16
3.1 TRANSPORT AND HANDLING....................................... 5 7.5.7 Tightening torque of the impeller nuts ......... 16
3.2 PROVISIONAL STORAGE/CONSERVATION .................... 5 7.6 RECOMMENDED SPARE PARTS ................................. 17
3.3 DISPOSAL................................................................ 5 7.7 PREVENTATIVE MAINTENANCE .................................. 17
4 GROUP DESCRIPTION ............................................. 5 8 TROUBLE-SHOOTING ............................................ 18
4.1 GENERAL DESCRIPTION ............................................ 5
4.2 DECLARATION FOR EU – DIRECTIVE NO. 547/2012 (FOR 9 ANNEXES................................................................. 19
WATERPUMPS) BASED ON ERP – DIRECTIVE 2009/125/EG) 5
9.1 SECTIONAL PLANS .................................................. 19
4.3 DENOMINATION ........................................................ 6 9.2 TROLLEY-MOUNTED PUMPS ..................................... 21
4.4 FORM OF CONSTRUCTION.......................................... 6 9.2.1 Warnings ..................................................... 21
4.5 NOISE. PERMITTED LEVELS ....................................... 6 9.2.2 Start-up ....................................................... 21
4.6 NAME PLATE ............................................................ 6 9.2.3 Maintenance ............................................... 21
4.7 FORCES AND MOMENTS PERMITTED IN THE NOZZLES .... 7 9.2.4 Safety.......................................................... 21
5 INSTALLATION ......................................................... 8 EC DECLARATION OF CONFORMITY………………….24
5.1 CHECK BEFORE ASSEMBLY ........................................ 8
5.2 GROUP POSITIONING ................................................ 8
5.2.1 Groups with horizontal base frame ............... 8
5.3 PIPE JOINT .............................................................. 9
5.3.1 Auxiliary connections .................................... 9
5.4 ELECTRICAL CONNECTION: ........................................ 9
5.4.1 Motor connection ........................................ 10
5.4.2 Time relay adjustment ................................ 10
5.4.3 Rotation direction. Check............................ 10
5.5 NON ELECTRIC MOTORS .......................................... 10
6 START-UP................................................................ 10
6.1 FIRST START-UP..................................................... 10
6.1.1 Lubricant ..................................................... 10
6.1.2 Filling (priming) of the pump ....................... 11
6.1.3 Final control ................................................ 11
6.1.4 Start-up....................................................... 11
6.1.5 Shutdown.................................................... 12
6.2 SERVICE LIMITS...................................................... 12
6.2.1 Switching frequency.................................... 12
6.2.2 Temperature of the liquid to be pumped ..... 12
6.2.3 Density of the liquid to be pumped.............. 12
6.2.4 Viscosity of the liquid to be pumped ........... 12
6.2.5 Maximum pump speed ............................... 12
6.3 STARTING UP AFTER STORAGE................................. 12

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1 General items - Rotation direction arrow
This KSB ITUR equipment has been - Fluid connections identifications
Note
developed in line with state-of-the-art These must be complied with, and conserved in a manner
technology, manufactured with great care and put through which ensures they are legible.
continuous Quality Control. The present Instructions Manual
will provide you with knowledge of the equipment and the 2.2 Personnel qualifications and instruction
ways it can be applied. All Service, Maintenance, Inspection and Assembly personnel
must be duly qualified. The terms regarding responsibility,
It contains important instructions to operate the equipment
competence and supervision of personnel must be regulated
appropriately and profitably. It is important to comply with the
by the user in an exact manner.
manual in order to guarantee reliability and a long useful life
for the pump, whilst avoiding any possible risks. Any personnel lacking appropriate know-how must be duly
instructed. This preparation can be obtained upon request by
This manual does not include any local regulations or any
the machine user to the manufacturer or supplier of the
instructions with regards to assembly personnel, which the
machine.
user shall be responsible for.
Finally, the user must ensure that all personnel have fully
This group cannot be used in conditions in excess of
understood the content of the instructions manual.
those established in the technical documentation with
regards to the liquid to be pumped, flow, speed (rpm), 2.3 Risks of failing to comply with the safety
density, pressure and temperature, and with regards to the instructions
motor power or anything else set out in the instructions
Failure to comply with the safety instructions may lead to risks
manual and contractual documentation. Check with the
both for people, the environment and the machine, and may
manufacturer as appropriate.
lead to the loss of any entitlement to claims.
The factory plate shows the model/size, the main service data
In particular, failure to comply may cause the following
and the manufacture number of the equipment. Please include
hazards:
these data in any queries, subsequent orders or requests for
spare parts. - Failure of important machine/facility functions.
If you require any additional information or have problems with - Failure of the prescribed maintenance and conservation
regards to failures, please contact the nearest KSB ITUR methods.
service. - Personal hazard resulting from electrical, mechanical or
2 Safety chemical effects.

This instructions manual contains fundamental indications - Danger to the environment due to escaping noxious
which must be complied with in assembly, service and products.
maintenance. It must be read by assembly personnel, 2.4 Conscientious safety at work
competent technical personnel and users before installing and
The safety instructions contained in this Manual must be
starting up, and it must be available at all times at the place of
observed, as must international prescriptions on Health and
location of the machine.
Safety at Work and any possible Safety Regulations at the
Proceed not only in line with this main safety chapter, but also workplace of the user.
observing the instructions described in other similarly
important safety points. 2.5 Safety instructions for users and service
personnel
In order to prevent and avoid any possible risks which
may affect the safety of people, facilities and the The operator is responsible for keeping the
environment, pay special attention to the information temperature of the fluid within the pump classification
contained in the manuals for the pumps which make up this temperature limits.
equipment.
- The installer must ensure that the parts of the machine
All regulations in the country of use must be borne in which may create danger due to heat or cold are
mind and complied with. protected against accidental contact. The operator shall
Unauthorised changes are forbidden. Always check check as well that the coupling guard is in place and
with KSB ITUR before modifying the equipment. firmly secured.

2.1 Marking of warnings in this manual - The contact protections of moving parts (e.g. couplings)
must not be removed whilst the machine is in service.
All instructions in this manual which may involve personal
hazard if not complied with are indicated with a general hazard - Provide the personnel with protective equipment and
sign. make sure it is used.

Safety instructions which may involve a hazard to - Any possible leaks (e.g. through the shaft sealing) of
people and facilities if not complied with in accordance hazardous products must be channelled in such a
manner as they do not present any risk to people or the
with ISO 7000-0434. environment, in line with corresponding legislation.
Safety instructions to prevent electrical hazards in - Follow safety instructions due to use of power. In this
accordance with IEC 417-5036. respect refer to the applicable national safety regulations
Safety instructions which may affect the and/or regulations issued by the energy supply company.
Note
equipment and its operation if not complied
2.6 Safety instructions for maintenance,
with.
inspection and assembly work
The details shown directly on the machine, such as:

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The user must ensure that all maintenance, inspection and - Do not wear loose or baggy clothing or wear long hair
assembly tasks are carried out by authorised, qualified, loose near rotation areas to avoid clothes or hair getting
specialised personnel who have been sufficiently informed caught and causing serious accidents.
through careful study of the instructions manual.
- Do not force jammed rotating parts manually when the
It is a fundamental principle that any work on the machine pump is in operation.
must be carried out whilst it is shutdown. It is essential to
respect the pump shutdown procedure described in the When the pump is joined to considerably long piping,
instructions manual. waterhammer may occur when it is stopped. Should this arise,
appropriate anti-waterhammer elements must be put in place.
When the pump is stopped it is liable to remain under
pressure. The pump frame must have returned to All the safety regulations indicated by the pump drive
environmental temperature. Before dismantling it, is must be manufacturer must be observed and complied with.
depressurised by making drain openings (or air vents) leading Inappropriate installation may lead to the unit breaking and
to a safe area. consequent risks to persons and/or the environment. It is
All pumps or motor pumps which pump hazardous materials therefore necessary to:
must be decontaminated. - Vent the pumps appropriately before operation, checking
Connect an earth conductor to the metal casing of the pump that the pump is full of liquid.
or baseplate if the fluid handled is electrostatically charged. - Check that the pump discharge and suction valves are
Never connect the earth of the electric welding equipment to fully open and that there is no dirt or foreign bodies in the
pump or baseplate. piping.

As soon as the work is complete, all safety and protection Regarding overload conditions:
devices must be installed and put into operation. - Do not exceed the maximum permitted values
Before starting up again, all that described in the First Start-Up (temperature, suction pressure, discharge pressure,
section must be fulfilled. rpm.) indicated in this instructions manual, offer and
technical catalogue.
Due to the fact that the unit contains small parts such as
- Do not exceed the maximum loads permitted on the
nuts, screws, etc., whose accidental contact may lead to suction and discharge connections.
small cuts on the hands, operators are recommended to
use gloves when handling. - The pumps must only be used in the conditions and with
the liquid indicated in the offer and/or order.
The following additional risk-prevention instructions
An unforeseen failure in the drive power may lead to danger
shall be fulfilled:
due to spontaneous start-up of the unit; it is up to the
The pumped liquid may cause injuries, burns, poisoning, etc. It customer to take the necessary steps to avoid this.
is therefore necessary:
When the CONTROL SYSTEM is not supplied by KSB ITUR,
- To check the temperature and amount of leaks occurring the customer is responsible for the entire machine complying
at the mechanical seal or packing area. Conduct such with the machine safety directive, including these controls
leaks to a safe area through a controlled drainage
system, specially indicated for the case of break of 2.7 Modifications and arbitrary manufacture of
mechanical seal. spare parts
- To take appropriate measures to avoid direct contact with The machine must not be modified or changed without prior
the pumped liquid when it is necessary to prime or fill the agreement from the manufacturer. Only original spare parts
pump or unit. and accessories approved by the manufacturer can guarantee
safety. The use of other parts invalidates any liability of KSB
- Before dismantling the pump, if the liquid is toxic or ITUR for consequential damage.
dangerous, it must be decontaminated. For this purpose
the unit must be cleaned inside by introducing a cleaning 2.8 Unauthorised operation modes
liquid into the pump and emptying it subsequently The safe service of the supplied pump can only be guaranteed
through the drainage connection. The cleaning liquid through correct use, in line with section 4 of the Instructions
must not create hazardous situations and must be Manual. The operation limits established in the Datasheet
compatible with the pump components (CONSULT) must not be exceeded under any circumstance.
- To take appropriate measures to avoid contact with the
pump if liquids are pumped at temperatures over 40ºC.
- In the event of a liquid with high steam pressure being
used, beware of the danger of explosion due to pressure
confinement with the pump stopped. This confinement
must be avoided by opening inlet or discharge valves, or
by providing a properly conducted air-vent connection in
the pump discharge for liquid evacuation.

For rotating parts:

- The pump should never work without its coupling guard
in place and firmly secured.

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The shiny (mechanised) parts and surfaces of the pump must
2.9 Warnings for equipment with marking be protected from corrosion using silicone-free grease or oil.
KSB ITUR pumps marked with the ATEX plate are All equipment supplied on a transport bench (forklift
valid for group II category 2 and 3, zones 1, 21, 2 and truck, carriage, etc) should be secured using the
22 temperature class as shown on the plate and Conformity envisaged attachment device or brake. Ask KSB
Certificate. ITUR for the specific instructions manual for your transport
bench if you do not have one already. (see annex 9.2)
Reliability may be lost through incorrect use, poor
The electric motor must be disconnected, the
connections or any modifications, however small.
connection cables removed and the terminal box
If the liquid is fuel, the pump frame pieces are closed with its cover on.
constructed from ductile material and the impact test
The switchboards must be in vertical position and
described in EN 13463-1 has been passed.
disconnected.
It is necessary to take into account the rules on the
connection and use of electrical devices in hazardous
3.3 Disposal
areas, in particular national regulations on installation. Only Fluids and supplies posing a health hazard and/or
qualified personnel who are familiar with these rules should hot fluids and supplies. Hazard to persons and
handle this type of machine. environment!
Any repair made by the end user, unless explicitly - Collect and properly dispose of flushing medium and
approved by KSB ITUR, shall release the any residues of the fluid handled.
manufacturer from any liability relating to Directive 94/9/EC.
- Wear safety clothing and a protective mask, if required.
Individual pieces supplied as spare parts must be originals,
supplied and checked by KSB ITUR - Observe all the legal regulations on the disposal of
fluids posing a health hazard.
3 Transport and storage 1. Dismantle the pump (set). Collect greases and other
lubricants during dismantling.
3.1 Transport and handling
2. Separate and sort the pump materials, e.g. by:
The transport and handling of the equipment must be
carried out using suitable means in line with the • Metals
weight to be supported. The weight is generally • Plastics
shown on the delivery note or on the factory plate; if it is not, • Electronic waste
and the equipment cannot be handled safely, please contact
KSB ITUR. • Greases and other lubricants
3. Dispose of materials in accordance with local regulations
Remember that the equipment must never be lifted using the
or in another controlled manner.
ring bolts of the different items (e.g. motor and pump ring bolt),
which are exclusively for independent transport.
4 Group description
Note It is also important not to use the pump and
pipe flanges or joining elements, e.g. 4.1 General description
couplings Horizontal centrifugal pump, for the pumping of clean liquids
If the equipment is to be lifted using straps, or liquids with little load.
Note
these must always be run underneath the 4.2 Product information according to Regulation
motor and pump support.
547/2012 (for waterpumps with a maximum shaft
When the pumps are dismounted from their transport power of 150 kW) based on Directive 2009/125/EC
pallet, suitable means must be used to ensure the “Ecodesign Directive”
stability of the equipment, until it is finally secured at
its definitive location. • Minimum efficiency index: see the name plate

3.2 Provisional storage/Conservation • The benchmark for most efficient water pumps is MEI ≥
0,70
During provisional storage, it is necessary to protect the parts
with preservation products from contact with the low alloy • Construction year: see name plate
liquid (e.g. grey casting, nodular casting, etc). Preservation
• Manufacturer name or plant mark, commercial registry
products available on the sector market can be used, in line
number and manufacturing place: see datasheet and
with the manufacturer's instructions on application and
order documentation
disposal.
• Type and product size indications: see name plate
The pump, or motor pump, shall be placed in a dry site where
the relative humidity is as constant as possible. • Hydraulic efficiency (%) with a trimmed impeller: see
When stored outside, it is necessary to keep the pump/motor datasheet
pump in an impermeable box, ensuring it does not come into • Pump performance curves, efficiency curves included:
contact with external humidity. see the performance curve from the documentation
Note Protect the stored product from humidity, dirt, • The efficiency of a pump with a trimmed impeller is
parasites and unauthorised access. All usually lower than that of a pump with the full impeller
openings must remain closed, and must not be opened until diameter. The trimming of the impeller will adapt the
necessary during assembly. pump to a fixed duty point, leading to reduced energy

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consumption. The minimum efficiency index (MEI) is 4.5 Noise. Permitted levels
based on the full impeller diameter.
The acoustic pressure level of these pumps is less than 95 dB
• The operation of this water pump with variable duty (A) at 1 m in any operation point within the operation range
points may be more efficient and economic when without cavitation. The acoustic power is less than 105 dB (A).
controlled, for example, by the use of a variable speed
drive that matches the pump duty to the system 4.6 Name plate
• Information on dismantling, recycling and disposal, see
chapter 3.3
• Information on benchmark efficiency and benchmark
efficiency graph for MEI = 0,7 (0,4) for the pump based
on the model shown in the figure is available on:
http://www.europump.org/efficiencycharts

4.3 Denomination
IN - 100 / 250 B

Series

DN discharge nozzle [mm] a Year of construction f

3
Flow rate in m /h
b Pump model g Head in meters
DN impeller [mm] c Pump No i Motor voltage in Volts
d Customer item MEI Minimum Efficiency index
Impeller Hydraulics e Speed in rpm η Efficiency

4.4 Form of construction

Spiral pump casing with axial suction and radial impulsion.
Single-stage impeller closed.
Bearings: Depending on the size of the pump, bearings
lubricated with lifelong grease or lubricated with exterior
grease.
Shaft sealing: Mechanical seal or packing.

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4.7 Forces and moments permitted in the nozzles

CAST IRON OR BRONZE CASING

SUCTION IMPULSION
FORCES MOMENTS FORCES MOMENTS
[N] [N.m] [N] [N.m]
SIZE Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
PUMP
32/--- 420 380 340 350 250 290 230 220 270 280 190 220
40/--- 530 470 430 380 280 300 280 250 320 330 230 270
50/--- 530 470 430 380 280 300 380 340 420 350 250 290
65/--- 630 570 520 400 290 330 470 430 530 380 280 300
80/--- 840 750 680 440 320 370 570 520 630 400 290 330
100/--- 990 890 800 530 380 480 750 680 840 440 320 370
125/--- 1250 1130 1020 630 440 520 890 800 990 530 380 480
150/--- 1680 1500 1350 820 580 670 1130 1020 1250 630 440 520
200/240
1680 1500 1350 820 580 670 1500 1350 1680 820 580 670
200/250
200/330
200/400 2090 1870 1690 1120 790 920 1500 1350 1680 820 580 670
200/500
250/300 2090 1870 1690 1120 790 920 1870 1690 2090 1120 790 920
250/400
2500 2240 2020 1520 1080 1240 1870 1690 2090 1120 790 920
250/500
300/300 2500 2240 2020 1520 1080 1240 2240 2020 2500 1520 1080 1240
300/350
2920 2620 2350 1940 1380 1590 2240 2020 2500 1520 1080 1240
300/400

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5 Installation Cementing

The design of the pipe systems, anchorings Pour an initial layer of mortar cement into the orifices of the
Note
and other installation areas corresponds to bolts, contacting throughout the periphery with the base of the
other parties. KSB ITUR only offers details and comments as base frame. Once the mortar cement has set, tighten the
a help, but does not assume any responsibility with regards to anchor pins in a balanced manner.
the design, assembly and operation of any installation. We Connect the suction and impulsion nozzles to the installation
recommend that customers should check with a specialist in and proceed with an initial alignment of the equipment.
the design of castings, pipes, wells, etc, to supplement and
interpret the information provided by KSB ITUR and to ensure Proceed to fill the lower part, or the cavities between the base
proper operation. If wearing plastic bushings between pin frame profiles, with concrete.
clamp screw and motor foot, the removal of these plastic
When using folded steel base frames, make a small mould in
bushings is required before alignment of the group and
the front and rear part.
subsequent start-up.
5.1 Check before assembly
Before positioning, check that the assembly base is in line with
the dimensional plan of the equipment.
The slab upon which the equipment is to be positioned must
have completely set.
The concrete used must be of sufficient resistance (minimum
X0) to allow functional assembly in line with DIN-1045.
The upper surface of the base must be horizontal and flat. The concrete must be of minimum contraction, normal
granulometry, with a water/cement ratio (W/C Ratio) of ≤0.5. It
If the anchor pins are to be placed in existing holes, place the is necessary to use additives which improve fluidity for correct
anchor pins in their orifices suspended from the pump. filling.
Do not connect the suction and impulsion nozzles until the We recommend treating the concrete in line with DIN-1045.
equipment is completely installed on its base and the cement
has completely set. In order to carry out the final alignment, wait until the
installation is ready and at operation temperature.
5.2 Group positioning
5.2.1 Groups with horizontal base frame
Levelling

Pump-motor alignment
In order to prevent misalignment between the axes, it is
necessary to correctly install, check and maintain the coupling.
See the instructions manual for the coupling.
The coupling may produce a source of ignition or high
Place wedges on both sides of the anchor pins if the base temperature in the event of incorrect operation. The
frame does not include levelling screws. coupling must be classified as non-electric equipment with at
least the same type of area and temperature as the pump. It is
When the distance between anchor pins is over 800 mm, use
necessary to follow the instructions in the coupling manual
levelling wedges in the middle, both on the sides and at the
which is included with the pump (only if special coupling is
front.
mounted)
Use a spirit level to level the equipment. Use wedges to alter
When the supply includes the complete group (pump – motor),
the height at different points. The maximum deviation
the equipment has been aligned at factory, although, due to
permitted is 0.2 mm/m.
transport and to the anchoring to the casting, the equipment
The separation between the two coupling halves must be should be realigned before proceeding with start-up. (Could be
maintained. necessary to remove the engine alignment plug)
All equipment supplied on a transport bench (forklift The correct alignment of the standard KSB ITUR coupling
truck, carriage, etc) should be secured using the involves correcting any possible errors of parallelism and
envisaged attachment device or brake. Ask KSB concentricity using metal wedges in the motor.
ITUR for the specific instructions manual for your transport
Use appropriate instruments to carry out the following
bench if you do not have one already. (See annex 9.2)
measurements in 4 positions offset 90º between the faces of
the coupling:

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a1 a1 Before starting up a new installation, it is necessary to
thoroughly clean the tanks, pipes and accessories by brushing
Ø Ø
and blowing. Welding material, scales and other impurities are
D D often cast off some time after. We recommend using an
oversized sieve filter in suction in order to prevent dirt larger
a2 a2 than that permitted by the pump from coming in.
High suction pressure may overload the bearings and lead to
their overheating. This circumstance must be avoided, to
b b
Ø Ø
which end the suction pressure must not exceed that shown in
D D
the data sheet, either through manual control by the operators
or through devices which shutdown the equipment in the event
S1 S2 of excessive pressure.
The pump must not work without liquid under any
|a1-a2| and b maximums [mm]
DØ S1 S2 circumstance. If this condition may come about, the
[mm] 0-1500 1500-3000 3000-4000 [mm] [mm] installation must be fitted with safety devices which prevent
[rpm] [rpm] [rpm] the operation of the pump without liquid inside, or have
automatic devices to discharge the minimum flow of the pump.
58-140 0.20 0.15 0.10 4 5 See the section on minimum flow.
160-225 0.30 0.20 0.15 6 5.3.1 Auxiliary connections
250-280 0.35 0.30 --- 8 The equipment is normally delivered mounted and ready for
immediate operation, with only the hydraulic and exterior
Note: For other types of coupling, see their instructions
electrical connections being necessary.
manual.
When using clean fluids, the cooling of the mechanical seal is
Note The equipment must always be aligned after
by way of the recirculation of the pumping fluid (it is not
mounting and preparing for start up, check
necessary to inject exterior fluid).
that the assembly can rotate freely when operated by hand
Note Auxiliary pipes are designed exclusively to
5.3 Pipe joint support internal stresses due to the pressure
In no case can the pump be used as a fixed point for the of the circulating fluid, to which end it is forbidden to subject
pipes. them to additional exterior stresses (e.g. for support, etc.)
If the pumping liquid is fuel and the leak can lead to
The pipe system must at no time exercise force in ignition, this contingency should be avoided through
excess of the values shown in the chart in point 4.7 constant control of the seal tightness of the auxiliary pipe
(due to connection, thermal variation, etc) in the joints by the plant operator.
pump. 5.4 Electrical connection:
The short pipes must be of at least the diameter of the pump
The electrical connection must be carried out by a
connections. The diameter of long pipes is, in some cases,
specialist electrician. Applicable regulations must be
determined by economic criteria.
complied with.
Transition pieces at larger diameters must have an extension
Check the mains voltage available and the factory plate, and
angle of around 8°, in order to prevent pressure drops.
choose the appropriate connection.
Note The convenience of installing foot valves
The technical connection conditions and the conditions of the
when the pump is working in suction or
local energy supply company must be observed when carrying
retention when loaded, along with seal valves, will depend on
out the connections.
the type of installation.
We strongly recommend the use of a safety circuit breaker for
The thermal expansions of the pipes must be compensated
the motor and a thermistor associated to a trigger device.
with suitable measures, in order not to exceed the maximum
stresses permitted on the pump. These instructions apply to asynchronous three-phase
standard electric motors with a squirrel cage both in horizontal
The diameters of the pipes, valves and accessories must be
and vertical execution, in IP-23, IP-54 and IP-55 protection
calculated in line with the load losses envisaged in the
grades, with frame sizes of between 56L and 355S, both
installation, meaning the fluid speeds will be:
inclusive, with voltages of 200 to 500 V between phases.
- Speed in the discharge pipe: from 2 to 3 m/s
The electric motor as well as whole electric installation shall
- Speed in the suction pipe: from 1 to 2 m/s accomplish with all safety norms that may be applied to it.
Exceeding the admitted stresses of the pipes may Earthing
lead to leaks in the pump and to the fluid escaping. Before starting up the pump, the earth of the pump, the
Hazard of death with hot liquids! baseplate or the motor must be connected to an effective
earthed point of the installation.
When designing the suction piping check that the available
NPSH is higher than required NPSH of the pump in order to If the baseplate is not within the scope of supply of KSB ITUR,
avoid cavitation in whole admissible operation range. do not paint either the support surfaces of the pump feet or of
the motor in order to ensure a good conductivity between the
The suction and impulsion nozzle covers of the pump must be
pump and the earth of the electric motor
removed before connecting the pipes.

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5.4.1 Motor connection 5.4.3 Rotation direction. Check
Whilst connecting the cables, ensure it is not possible Note Check the motor rotation direction by starting
for voltage to appear. up and immediately shutting down. The
rotation direction must correspond with that shown by the
Check that the earth connection is in line with local pump arrow located on the pump casing or support. If the
regulations. rotation direction is not correct, any two phases L1, L2 or L3 of
the power cable must be inverted in the motor terminal box.
The motor may produce a source of ignition or high The incorrect rotation of the pump may lead to the incorrect
temperature in the event of incorrect operation. For operation of the seal and the heating of its faces. For this
this reason, the motor must be classified with at least the reason, correct rotation direction must be ensured using the
same type of zone and temperature as the pump. It is arrow shown on the pump, with the pump completely filled
necessary to follow the instructions in the motor manual which with liquid and properly vented.
is included with the pump.
5.5 Non electric motors
Connection in single speed motors
Shall fulfil all that may be applicable to non electric material
Direct start-up: and follow the instructions stated in their specific instructions
manual.
In direct start-up the motor can be used in two different
connections: Likewise in the case of internal combustion engine refer to the
instructions of the engine manual for recommendations for
The voltage and the connection, e.g. 400 VY, 240 VD is safe gas exhaust and air supply required in the installation
stamped on the motor plate. This means that the motor can
connect at 400 volts in star connection (Y) or at 240 volts in 6 Start-up
delta connection (D).
Before starting up, both the pump and the mechanical seal
process pipes, where appropriate, must be completely filled
with liquid.
It is necessary to prevent the formation of explosive
atmosphere within the frame and the seal housing. Although
there are interior evacuation conducts which remove the
possibility of the air becoming blocked, it is necessary to fully
vent the pump and its process pipes, when fitted, before
starting up.

Start-up shall be carried out when all the necessary

mechanical, hydraulic, electrical and pneumatic connections
Star connection Delta connection are complete. The coupling guard must as well be in place
and firmly secured.
Star-delta start-up:
In star-delta start-up, the line voltage must coincide with the Motor checks.
voltage shown on the motor for delta start up (D). The six When making the electrical connection, ensure the
terminals indicated in the following diagram will be connected: type of current and nominal voltage shown on the
Connection to the star-delta contactor motor's factory plate concur with the type of current
and the mains voltage in the place of installation.
Follow the indications described in the motor manual.

6.1 First start-up

The pump cannot operate with a closed impulsion valve, as
this may lead to overheating of the pumped liquid. If it is
necessary to work with the discharge valve closed, a minimum
flow relief device is required at the output. This device does
not form part of the pump and will be separate from the
pump's discharge flange.

5.4.2 Time relay adjustment Other recommended devices include the constant output
orifice plates, constant bypass valves and automatic
In the star-delta start-up of three-phase motors, it is necessary recirculation valves. If you require further details, please check
to ensure that the switching from star to delta takes place with KSB ITUR.
quickly. Prolonged time will cause damage to the pump.
The pump cannot work in closed suction valve conditions. If
Time relay adjustment in the star-delta connection: this condition may come about, the plant operator must use a
device which detects this condition and forces the pump to
shutdown when it occurs.
Motor power Time adjustment -Y
6.1.1 Lubricant
≤ 30 kW < 3 sec.
> 30 kW < 5 sec. BEARINGS:

10
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Lubricated with grease. PUMP WITHOUT GREASE 6.1.3 Final control
NIPPLES: The pump bearings are closed on both sides and Make the final check of the group alignment in accordance
have lifetime lubrication. Lubricant is not required. with 5.2.1. The coupling/shaft must allow easy manual
Lubricated with grease. PUMP WITH GREASE NIPPLES: rotation.
The pump leaves the factory with the bearings greased for Check all the auxiliary connections are correct and
approximately 1000 hours of operation. See lubricant in functioning.
section 7.2.2.
According to the rules on the prevention of
See section 7.2.2 to know the type of lubrication of each accidents at work, equipment cannot be started up
pump. without protection for the coupling. If the buyer has
The bearings must be lubricated with oil/grease in a good expressly requested that this guard be excluded from supply,
state, to which end it is essential to follow the lubrication it must be provided by the user.
instructions indicated in 7.2.2. Before and during the operation of the pump, the coupling
guard must be in place and firmly secured. Regularly check
If the bearings support suffers impediments which prevent
this state in order to prevent problems resulting from incorrect
correct air-cooling, the resulting excess temperature may be
positioning or deficient attachment. The coupling guard must
excessive for the classification temperature class. For this
be free of any foreign elements.
reason, the support must be kept free of obstacles, thus
facilitating natural air cooling. 6.1.4 Start-up
6.1.2 Filling (priming) of the pump Before starting up the group, check all the sections with
regards to chapter 6.
The pump must be primed before starting up for the first time
or following a long period of inactivity. To do this: The start-up must be carried out with the suction valve
completely open and the impulsion valve partially closed.
EQUIPMENT IN LOAD:
Once the pump has reached its service speed and the suction
4. Disconnect the voltage from the motor or batteries. air has been eliminated, regulate the operation point using the
impulsion valve.
5. Close the suction valve and the discharge valve.
During the priming stage, check that all the suction pipe air is
6. Remove the venting plug located in the casing or open a perfectly discharged.
discharge pipe vent (before the check valve).
If the electric motor guard is triggered when starting up, close
7. Partially open the suction valve until the liquid overflows the impulsion valve more until the equipment starts up
through the vent. normally.
8. Close the vent. The pump must NEVER work with zero flow or flow
9. Fully open the suction valve. which is less than the operating minimum, as internal
recirculation will cause the fluid to heat up quickly,
10. Check the rotation direction of the pump. leading to hazards (including explosion) as a result of the high
11. Fully open the discharge valve. pressures reached within the frame. Check the minimum flow
in the operation curves.
EQUIPMENT IN SUCTION:
Minimum flow necessary for the pump
1. Disconnect the voltage from the motor or batteries.
The pumps cannot work below the minimum flow specified in
2. Close the discharge valve. the datasheets.
3. Remove the venting plug located in the casing or If this condition may come about, the installation must be fitted
open a discharge pipe vent (before the check valve). with safety devices which prevent the operation of the pump
4. Pour the liquid to be pumped through the vent until it without liquid inside, or have automatic devices to discharge
overflows. the minimum necessary flow of the pump.
5. Close the vent. For liquids other than water, the minimum flow is determined
by the following formula:
6. Check the rotation direction of the pump.
3.600.000 x Pa
7. Fully open the discharge valve. Qmin = Pe x Ce
The priming should be checked in subsequent start-ups.
In which:
Shaft sealing
Qmin: Minimum flow in m3/h
Packing: The gland nuts must be gently tightened (by hand). Pa: Power absorbed by the pump in kW at closed valve.
The gland must form a right angle to the shaft. There should
be a larger leak after filling the pump and before starting up. Ce: Specific heat of the fluid in J/kg*ºC.
3
Pe: Specific weight of the fluid in kg/m
Mechanical seal: The mechanical seal does not require
maintenance. Check that there are no leaks. Maximum flow permitted by the pump
Unless indicated in another datasheet, the maximum flow
permitted is 1.1x optimum flow of the pump with the supplied
impeller diameter.

11
 IN
6.1.5 Shutdown If eventually it would be wished to perform the pump at higher
Close the discharge pipe valve. speed, it is necessary to consult with KSB

If there is anti-return in impulsion with counterpressure, leave 6.3 Starting up after storage
the impulsion valve open. If the storage and/or shutting down of the pump has been for
- Shutdown the motor. Check that shutdown is normal. a prolonged period of time (over 6 months), it is necessary to:
- Check the state of the joints.
- In prolonged periods of non-operation, close the suction
pipe valve and the auxiliary connection valves. - Check the levelling.
- In suction pumps using a low vacuum tank, the supply of - Check all the auxiliary connections.
liquid must also be maintained at the shaft seal whilst the - Renew the lubrication of the bearings (where fitted).
pump remains shutdown.
- Change the packing (when fitted).
- The pump must be protected from freezing whenever this
risk exists, and must be emptied in prolonged periods of - After a short storage period, simply turn the pump shaft
non-operation. manually to unlock the rotor equipment.
If, whilst the pump is shutdown, it must remain on standby for - Follow the specific post-storage instructions in the motor
service, start up at regular intervals for around 5 minutes (see manuals and other items.
also 7.2) - Observe all the steps shown in the "Start-up" section.
- Fire pumps: 1x/month, at minimum.
Note If the equipment is to be halted for a certain
- Drink-safe water pumps: 1x/48 hours, at minimum. period of time and there is the possibility of
- Reserve pumps: 1x/week, at minimum. freezing temperatures, it is necessary to completely drain the
pump in order to prevent any deterioration from the freezing of
(It is best to change the operating pump every day). the contained fluid.
The seal tightness and function of the auxiliary connections
must be examined during these start-ups. 7 Maintenance/Conservation
6.2 Service limits 7.1 General instructions
6.2.1 Switching frequency Before dismounting, ensure that:
In order to prevent abnormally high temperatures and The motor must not be started up involuntarily, and
overloading of the motor, pump, coupling, seals, etc, the so must be disconnected from the grid (e.g.
switching- frequencies indicated below must not be exceeded: removing cut-outs, unplugging, disconnecting the
MOTOR POWER MAX. SWITCHING/HOUR automatic circuit breaker, etc.) or the start-up batteries
(disconnect operating energy).
Up to 3 kW 20
From 4 to 11 kW 15 The pump is free of pumped fluid, cleaning it
From 11 to 45 kW 10 internally with appropriate liquid whenever it is a
hazardous fluid (hot, contaminant, inflammable…).
From 45 kW 5
7.2 Maintenance/inspection
6.2.2 Temperature of the liquid to be pumped
7.2.1 Checking instructions
The permitted operation temperature is indicated in
the order and in the ATEX conformity declaration. If During the first minutes of operation:
the pump is to work at a higher temperature or you do not
have the data sheet, please ask KSB ITUR. In cases of mechanical seal

6.2.3 Density of the liquid to be pumped - There may be a brief large leak during start up. Should
this leak persist, shutdown the group and determine the
The power absorbed by the pump increases in direct cause. The causes may be, amongst others, dirt in the
proportion to the density of the impelled liquid. In order pumped area or dry operation due to incomplete
to prevent overloading in the motor, pump and coupling, this discharge of the pump air.
density must not exceed that shown in the order and in the
ATEX declaration of conformity. In cases of packing:

6.2.4 Viscosity of the liquid to be pumped - There is no leak; immediately loosen the gland to obtain
small dripping.
The power absorbed by the pump increases with the
viscosity of the impelled liquid. In order to prevent - Excessive fluid leak; leave to settle for 10 minutes; tighten
overloading in the motor, pump and coupling, this viscosity the gland by turning 1/6th and leave for 5 minutes.
must not exceed that shown in the order and in the ATEX Repeat the process until between 20 and 60 drops per
declaration of conformity. minute are achieved.

6.2.5 Maximum pump speed After a few hours operation:

In order to protect the pump from over speed, the maximum Note Check the bearing temperature at the point in
rotation speed shall be that shown on the name plate the bearing location area. Normal
engraved in the pump- If the speed shall not be indicated in temperature can reach up to 40°C above environmental
the name plate it is necessary to consult with KSB ITUR. temperature, but must never exceed 90°C.
Observe the anomalies indicated in point 8 of this manual.

12
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The reserve pumps should be started up and shutdown once Pump Amount of
a week, in order to ensure they are always in service Periodicity [h]
size grease [g]
conditions.
200/330
27
The failure of one or both sides of the seal may lead to 250/300
excess heating. This can be corrected by following the 150/500
instructions of the seal manufacturer, both with regards to its
200/400
assembly and the maintenance of the auxiliary seal devices, 4000
where appropriate. Alternatively, the pump may be fitted with a 200/500
monitoring device if the purchaser has so specified. 250/400
42
250/500
7.2.2 Lubrication
300/300
The type of lubrication of the bearings of the pump depends 300/350
on its size and construction: 300/400
SIZE Lubricant change
LUBRICATION
PUMP
150/500 In order to completely change the grease, first dismount the
bearings and carefully clean their positions in the support in
200/330
order to remove old grease.
200/400
200/500 Exterior Type of grease:
Grease
250/300 We recommend using lytic-based lubrication grease with
(bearing support
250/400 with lubrication antioxidant additives, of consistency 2, in line with DIN-51502
250/500 nipples) K2K.
300/300 7.3 Emptying/Drainage
300/350
300/400 The emptying and drainage of pumps used to expel
Lifelong grease liquids which are a health hazard must be carried out
(bearing support in such a way as there is no risk to people or to the
Rest of sizes
without lubrication environment, in line with legislation. If necessary, use
nipples) protective clothing and mask.

Before lubricating the pump, ensure that: 7.4 Dismounting

The pump is shutdown and cannot be started up 7.4.1 Fundamental instructions/observations

accidentally. Note Before dismounting, ensure the pump cannot
The bearing support temperature is less than 40ºC, be started up.
in order to prevent burns to the hands. To do this, The suction and impulsion valves must be closed.
measure the temperature with a thermocouple.
The pump frame must have returned to environmental
The absence of oil/grease in the bearing support may lead to temperature.
a lack of lubrication of the lip seals, which will come into dry
contact with the shaft. This contact may lead to a high shaft The pump frame must be depressurised and emptied.
temperature which might cause ignition. To prevent this, Comply with all safety measures in accordance with 7.1.
regularly check the oil/grease level in the bearings support. When working on the motor, also take into account the rules
BEARINGS: and instructions of the manufacturer.

Lubricated with grease. PUMP WITHOUT GREASE 7.4.2 Tubular coupling guards
NIPPLES: When dismounting, follow the chapters on assembly but in
The pump has special bearings, with dual closure and grease reverse order.
in the interior, capable of working without outer grease 7.4.3 Coupling
maintenance. The pump does not, therefore, have grease
nipples in the support. 1.- Remove the coupling guard

Note Special attention must be paid to the type of 2.- Uncouple the pump from the motor, as indicated:
bearing when this is replaced, which must be
2.1.- COUPLING WITHOUT DISTANCER. Release the
of the same type (2RS).
motor attachment bolts and remove the motor along with
Lubricated with grease PUMP WITH GREASE NIPPLES: the male coupling.
The pump leaves the factory with the bearings greased for
approximately 1000 hours of operation.
For lubrication, a chart is attached with the amount of grease
to be applied in each greaser, along with the regularity.

13
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7.4.5 Packing
- Release the gland.
- Extract the seal. If the lantern ring is also extracted, note
down the order.
7.4.6 Pump
It is necessary to dismount practically the entire pump in order
to extract the bearings, shaft, etc.
To do this, observe the attached sectional plan.
As a general guide to dismount the equipment, follow these
steps:
- Remove the coupling guard and then the coupling as
described in point 7.4.2.
- Extract the support - cover, including the moving parts.
The wear rings are accessible at this moment.
- Release the impeller nut and extract it.
- Extract the mechanical seal or the packing as
2.2.- COUPLING WITH DISTANCER. Release the appropriate. (see point 7.4.4 and 7.4.5)
coupling attachment screws and remove the distancer
pipe. Separate the male coupling. - Release and extract the pump cover.
- Remove the shaft deflector and release the support
covers.
- Extract the shaft with the bearings, by hitting the pump
end with a plastic hammer.
Failure of the bearings may cause ignition through increased
heat on the surface of the bearings. This can be avoided by
using officially approved quality bearings, which are supplied
as original spare parts.
Regularly check the correct state of the protector
deflector, and replace in the event of deterioration.
7.5 Assembly
7.5.1 Tubular coupling guards
1. Install the distancer cylinder and seal using the
clamps (1)
1

3.- If the pump needs to be repaired, release the casing/cover

attachment screws, along with those of the rear support foot.
4.- If you need to release the coupling, use an extractor. Never
bang in order to extract, as this may cause serious damage to
the bearings.
2. Position the side cover (2) leaving the rims (3) in the
7.4.4 Mechanical seal upper section
- Dismount in reverse order to assembly, point 7.5.3. 3. Join the side cover (2) with the fastening screws (4)
to the lifting plate (5). The screws should not be fully
- The PTFE seal should be removed from the casing. A tightened at this moment. If there is no lifting plate,
new tape must be used every time it is remounted. mount the assembly plate and place the screws
Note For the correct operation of the seal it is through the threaded orifices.
necessary to: 3
- Take great care when cleaning the different parts of the 5
mechanical seal, especially the contact faces. Never use
lubricant on the contact faces, use only clean water with
a cloth specifically for cleaning optical devices. 4 2

- Not damage the O-rings during assembly.

- Not turn the mechanical seal while dry.

14
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4. Without tightening the screws (4) completely, turn the
equipment around the shaft.
5. Adjust the length of the covers so the shaft and the
attachment are fully covered.
6. Secure the lifting plate (5) to its support (6) using the
corresponding screws (7). If there is no lifting plate,
the locking screws (4) are longer and also fulfil this
function.

- Mount the impeller until it comes into contact with the

casing.
- Firmly tighten the impeller nut until the casing comes into
4 contact with the shaft.
6 5 - Remove the excess PTFE.
7
- Finish mounting the pump.
7. Finish tightening the locking screws (4). 7.5.4 Packing
7.5.2 Coupling - Cut the new packing, forming as many rings as required.
1.- Mount the pump (when it has been dismounted) and The cuts, seen from above, may be straight or inclined at
tighten the casing - cover attachment nuts. 45º.

2.- Couple the pump to the motor, as indicated:

2.1.- COUPLING WITHOUT DISTANCER. Position the
motor in place, introducing the male coupling. Position the
pins, but DO NOT tighten them until alignment is complete.
2.2.- COUPLING WITH DISTANCER. Mount the male
coupling, introducing the teeth in the rubber plugs located
in the female coupling. Mount the intermediate pipe and
secure it using the screws, both to the plate and to the
male coupling.
3.- Align the coupling (see point 5.2 of this manual)
4.- Mount the coupling guard.
7.5.3 Mechanical seal
- Mount the fixed part of the mechanical seal.

- We recommend leaving a small clearance of 0.5 mm in

the packing cut.
- Position the rings one by one, pushing on them but
without excessive force. The rings shall be introduced
with the cut ends alternated 90°.
- Mount the rotating part of the seal on the casing, taking - Take care to introduce the lantern ring in the same order
care not to damage the o-ring. as before.
- If locking bushing is included, take the exact measures - Once the packing has been introduced, check that the
for location in accordance with the manufacturer's shaft rotates freely without any stiff points.
catalogue or plan.
- The gland must not penetrate the entire free length. If
- If separation bushing is included, attach it to the casing necessary, introduce more rings.
using the bushing, or introduce it in the shaft up to the
stopper. - Gently tighten the gland nuts.

- Form a PTFE coil in the area of the shaft where the - In order to determine the appropriate torque of the
casing is to be supported. The height of the coil must be packing, proceed as indicated in point 7.2.1 of this
equal to or greater than the casing. Introduce the casing. manual.

15
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7.5.5 Pump 7.5.7 Tightening torque of the impeller nuts
Mount the pump in reverse order to when dismounting (see Metric Tightening Torque in [N·m]
point 7.4.6) thread (for non-lubricated thread)
Additional observations: M14x1.5 38
M20x1.5 100
- All the joints intervening in the dismounting of the pump M27x1.5 250
must be renewed. M33x1.5 460
- Use the bearings (320) indicated. M52x1.5 2000
- Do not forget to correctly position the deflector (507)
through the window of the cover (161).

Note -Check the correct location of pieces,

especially the seals and impellers, and
tighten the impeller nuts as shown in the chart in point
7.5.7.
- Do not forget to position all the safety and
protection elements, such as coupling guards,
before starting up the equipment.
The pump materials have been selected in accordance with
the process fluid indicated in the datasheets. If this fluid is
modified, check with KSB ITUR that the new fluid is suitable
for the pump.
7.5.6 Tightening torque of the screws/nuts1)
Steel Stainless steel
ISO Metric Tightening Torque in [N·m]
thread (for non-lubricated thread)
M4 3.1 2.15
M5 6.1 4.25
M6 10.4 7.3
M8 25.2 17.7
M10 49.5 34.8
M12 85.2 59.9
M16 211 148
M20 412 290
M24 710 276
M27 1050 409
M30 1420 554

1) For 00 material variant (volute casing and casing

cover in GG-25/JL1040 and screw/nuts class 8.8)
apply following tightening torque in screws/nuts
between volute casing and casing cover in “X”
sequence:

ISO Metric Tightening Torque in [N·m]

thread (for non-lubricated thread)
M8 20
M10 33
M12 57
M16 136

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7.6 Recommended spare parts
Recommended spare parts (1)
Piece denomination Reference No.
Start-up 2 years 5 years
Joints (set) --- 1 2 5
Mechanical seal 433 1 2 3
Packing 461 1 2 5
Bearing (set) 320 1 2
Felt ring 422 1 2
Lantern ring 458 1 2
Wear ring (set) 502 1 2
Deflector protection 507 1 2
Shaft wearing sleeve 523 1 2
Coupling flexible (set) --- 1 2
Impeller nut 922 1 2
Key (set) 940 1 2
Pump shaft(s) (set) 210 1
Impeller 230 1
Coupling --- 1
(1) Amounts recommended for a continuous service pump.

7.7 Preventative maintenance

Nº DESCRIPTION OF THE OPERATION TO BE PROCEDURE REGULARITY CONSEQUENCE

CARRIED OUT
1 Check for mechanical seal leaks Visual inspection Weekly 16
2 Check for packing leaks Visual inspection Weekly 17, 19
Check for leaks between the casing and the
3 Visual inspection Monthly 15
cover
4 Check for leaks between flanges Visual inspection Monthly 15
5 Check for grease nipple leaks Visual inspection Monthly 13, 18
5, 14 Dismount the
6 Check for heating of the bearings With thermocouple Quarterly
support
Check tightness of connecting bolts for
motor/base frame, pump/base frame,
7 Manually Twice a year 8
cover/casing, support/support supplement,
flanges/casing
Twice a year and
See point 5.2.1 of the
8 Checking and aligning the coupling every time they are
manual
dismounted
Checking and
dismounting the 1,2,3,4,6,7,10,11,
9 COMPLETE PUMP CHECK Yearly
pump. See point 7 of 13,14,18
the manual
Dismount casing,
10 Check for wear of the impeller and rings Yearly
visual inspection
Dismount support,
11 Check for wear of the shaft and bearings Yearly
visual inspection
See point 7.4.3 and
12 Change the coupling flexible Twice a year
7.5.2 of the manual
See point 7.2.2 of the
13 Change the grease of the bearings Twice a year
manual
In accordance with Check the
14 Check functional characteristics loss Instrument reading
use installation, 9
Every time they are
15 Change the joints Manually
removed
See point 7.4.4 and When leaks are
16 Change the mechanical seal
7.5.3 of the manual detected
When the leaks are
17 Tighten the gland Manually
excessive
See point 7.2.2 of the Every 4000 hours of
18 Refill the support grease
manual operation
See point 7.4.5 and Every 4000 hours of
19 Change the packing
7.5.4 of the manual operation

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8 Trouble-shooting
The pump does not move the fluid
| Insufficient pressure or flow
| | Excessive absorbed power
| | | Excessive vibrations and noise
| | | | Excessive bearing support temperature
| | | | | Mechanical seal leakage
| | | | | | Wear rings deteriorate quickly
| | | | | | | Cause Solution
Open the suction valve or search for work point
x x Suction or impulsion valves closed or poorly regulated
with the impulsion valve
x Incorrect rotation direction Change the motor connections
x Air comes in through the suction pipe, Check the seal tightness of the pipe
Correctly prime the pipe by positioning vent
x Pump or suction pipe poorly primed connections in the highest points. Prime the
pump
Increase the rotation speed. If this is not
Maximum height generated by the pump lower than that required
x possible, a larger impeller or larger pump needs
by the installation
to be assembled. Please ask.
Measure the speed, check the motor drive
x Rotation speed incorrect
power supply voltage
Refill the pump and pipes and carefully
x Poorly primed
discharge the air.
x Air comes in through the sealing system Dismount the seal system and check it
x Pipe obstruction Clean the pipes
Dismount the impeller, and inspect, balance or
x x x Impeller obstructed, deteriorated or imbalanced
change it.
Dismount the rings and change them or reinstall
x x Wear rings deteriorated or incorrectly assembled
them.
Increase the rotation speed. If this is not
x Counter pressure too high possible, a larger impeller or larger pump needs
to be assembled. Please ask.
x Liquid viscosity or density greater than normal. Reduce the design point or change the motor
x x x x Poor alignment between the pump and motor Align the coupling
x Obstruction inside the pump, impeller or nozzles Dismount the pump and clean
Real height to be generated by the pump is lower than that of the
x Partially close the impulsion valve
design point, meaning the flow and power are greater
Ball bearings deteriorated, poorly assembled, poorly lubricated Change them, check assembly, lubricate them
x x x
or excessively lubricated. or adjust them in their support
Dismount the pump and check its elements are
x Excessive contact in rotating parts
correctly assembled
x x Misaligned or deformed shaft Dismount it and replace it
x Loose impeller support nuts Dismount the pump and tighten them
x x x Pipe tensions on the pump Reinforce the pipes and level the equipment
x Lack of rigidity in the foundations or anchor bolts loose Make new foundations or tighten the bolts
x x Pump cavitation Improve the suction. Please ask.
x Insufficient pipe diameters Larger diameter pipes, whenever possible
Poorly assembled coupling, without suitable separation between
x Check the coupling
its two parts
x High suction pressure Please ask
Very deteriorated mechanical seal, seal spring broken or without
Dismount and replace the seal, or dismount,
x elasticity, poorly assembled seal, or joints broken, deformed or
review damage and change as appropriate.
without elasticity.
x Re-changeable sleeve scratched or deteriorated Dismount and change the sleeve

18
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9 Annexes
9.1 Sectional plans

Ref. Denomination Ref. Denomination Ref. Denomination

102 Volute casing 412 O-ring 554 Flat washer
161 Casing cover 422 Felt ring 636 Grease nipple
183 Support foot 433 Mechanical seal 901 Hexagonal head screw
210 Shaft 452 Glands 902 Bolt
230 Impeller 458 Lantern ring 903 Plug
320 Bearing 461 Packing 914 Allen screw
350 Bearing support 502 Wear ring 920 Nut
360 Support cover 504 Distancer ring 922 Impeller nut
400 Gasket 507 Guard deflector 940 Key
411 Circular gasket 523 Shaft casing

Sectional C-1263 (bearing support without grease nipples)

920.1 902.1 412 360 350 320.1 400.2 360

102

903.1

411.1

230

161

433

523

940.1

922

504

502.1 940.2

502.2
914
411.2

903.2

400.1 920.2 902.2 507 914 400.2 320.2 210 183 920.3 554 901

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Sectional C-1262 (bearing support with grease nipples)

920.1 902.1 412 636 360 350 320.1 400.2 636 360

102

903.1

411.1

230

161

433

523

940.1

922

504

502.1 940.2

502.2 422
914
411.2

903.2

400.1 920.2 902.2 507 914 422 400.2 320.2 210 183 920.3 554 901

458 461 452 920.3 902.3

Details of variant with packing

20
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9.2 Trolley-mounted pumps

9.2.1 Warnings 9.2.4 Safety

The instructions in this annex must be used along with the All the instructions in the pump instructions manual
corresponding pump instructions. on safe operation and handling of the equipment
must be followed.
All the instructions in this manual should be followed,
especially those regarding operation safety and handling of In particular, in order to prevent the equipment from moving
the equipment. and creating a hazard, it should ALWAYS be positioned on a
flat, non-sloping surface, with locking wedges preventing any
We reserve the right to make technological innovation movement.
modifications.
9.2.2 Start-up
Before starting up the equipment, check that it is completely
stable and that the wheels are locked in place using locking
wedges. These locking wedges are not supplied by KSB ITUR
and should therefore be provided by the customer.
The surface upon which the wheels are placed must be flat,
non-sloping and clean in order to prevent any displacement.
If operation is by way of an electric motor with a pluggable
connection, check that the circuit breaker or operation selector
is in shutdown position before connecting to the grid.
The start-up instructions in the pump and motor manuals must
be followed.
9.2.3 Maintenance
Apart from the particular instructions on maintenance of the
pump and motor, it is only necessary to regularly check the
lubrication and the state and correct attachment of the wheels
to the shaft.

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23
 WARRANTY
KSB ITUR undertakes:

To repair or replace at any of its ASSOCIATED TECHNICAL SERVICE CENTRES or at its factory in Zarautz, free of charge and for a period of
12 months as of the date of dispatch from our warehouses, any product which shows manufacture defects. This warranty will be reduced to 6
months for continuous or permanent operation pumps. This warranty does not include any pieces which are liable to experience deterioration
through the envisaged use of the product. The instructions set out in the maintenance and operation manual for the equipment must be fulfilled
in order to prevent excessive wear and tear.

Whenever the equipment or pumps supplied by KSB ITUR are to be used prior to installation, in such a manner as they require handling,
assembly and adjustment either before or after installation by parties other than KSB ITUR, KSB ITUR shall not be liable for any defects in the
equipment following installation unless the purchaser is able to legally prove that these defects existed prior to installation and assembly.

KSB ITUR shall in no case be liable for any direct or indirect damage which the Product may suffer as a result of defective installation, incorrect
storage, lack of maintenance, negligent handling, handling by unauthorised personnel, overloading or deficient functions, or for any damages
resulting from external influences such as chemical, electrochemical and electrical agents. The responsibility of KSB ITUR is limited in all cases
to the replacement, as speedily as possible, of the defective part, without it being in any way liable for other responsibilities or compensation.

EC DECLARATION OF CONFORMITY
(Directive 2006/42/EC ANNEX IIA)

KSB ITUR Spain, S.A., with address in footer

PUMP SERIES: IN
S/N: 7432024-9200000

KSB ITUR hereby declares, under its responsibility, that its aforementioned
machine, to which this Declaration refers, is in conformity with the
applicable provisions of the following Directives:

Machinery: 2006/42/EC
Ecodesign: 2009/125/EC, Regulation 547/2012 (In case it applies)

Applied harmonised standards: EN 14121-1, EN 809/A1

The collection of relevant technical documentation will be made in the

address in the footer

Zarautz, 29.12.2009
Post Head of Engineering
Name Ángel Fernández
MIF-0500/10-I [12-2012]

KSB ITUR Spain, S.A.

P.O. Box 41 / Camino de Urteta, s/n
20800 ZARAUTZ (Gipuzkoa) Spain
Tel.: +34 943 899 899 – Fax +34 943 130 710
E-mail: [email protected] – www.ksb-itur.es