HPK-LS/LE/LS4/LE4
Contents
1. VZV Vi OO ZZ Lk A T R gt X D00769 1 ki Fig 7 5 4 1 Mechanical seal M mark on the shaft S face of shaft sleeve 15 KSE HPK LS LE LS4 LE4 Mechanical Part No 412 1 412 2 472 474 475 477 485 520 904 For information only parts not available separately For pump seal components Description O ring O ring Spring loaded ring Thrust ring Seat ring Spring Tappet Sleeve Grub screw part Nos please refer to section 9 7 5 5 Diametral Clearances The clearan Between im ces given refer to the diameter peller and volute casing casing wear ring Discharge nozzle DN HPK LS LS4 HPK LE LE4 lt DN 65 0 40 mm 0 1 0 60 mm 0 1 DN 80 to D N 150 0 50 mm 0 1 0 60 mm 0 1 All HPK LS LS4 pumps are fitted with casing wear rings In plain bearing Bearing bracket Bearing play LPO2 0 03 mm 0 045 LPO3 0 05 mm 0 045 LP04 0 05 mm 0 045 7 6 Spare Parts Stock When ordering spare parts please always quote the following data Type series here HPK L Pump size Works No This data is stated on the pump name plate 7 6 1 Recommended Spare Parts Stock for 2 Years Operation to DIN 24 2962. Materials Part Description Material HPK L No S S4 E E4 102 Volute casing JS 1025 GP240GH 1 7706 N 161 Casing cover C 22 8 C 22 8 C 22 8 210 Shaft 1 4021 QT 1 4021 QT 1 4021 QT 700 700 700 230 Impeller JL 1040 JL 1040 JL 1040 310 01 Plain bearing SSIC SSIC SSIC 310 10 330 Bearing bracket seal JS 1025 JS 1025 JS 1025 housing 476 Seat ring holder 1 4021 QT 1 4021 QT 1 4021 QT 700 700 700 502 01 Casing wear ring JL 1040 5 523 Shaft sleeve 1 4021 QT 1 4021 QT 1 4021 QT 700 700 700 920 95 Impeller nut A4 A4 A4 Pressure class blank PN25 4 _ PN40 KSE D HPK LS LE LS4 LE4 4 3 Design Details Horizontal radially split single stage single flow volute casing pump in back pull out design with radial impeller to EN 22 858 ISO 2858 ISO 5199 Complemented by pumps of nominal size DN 25 4 3 1 Pump Casing Radially split consisting of volute casing on HPK LS LS4 with casing wear ring and casing cover Double volute depending on pump size Pumps of the HPK L series are foot mounted 4 3 2 Impeller Type Closed radial impeller with multiple vanes Axial thrust is balanced by back vanes 4 3 3 Shaft Seal 4 3 3 1 Mechanical Seal for Hot Water Applications Mechanical seal designs and types other than specified herein shall only be used in exceptional cases and only after prior consultation with the KSB factory Due to the complex
3. Part No Description Number of pumps including stand by pumps 2 3 4 5 6 8 10 and more Quantity of spare parts 210 Shaft 1 1 2 2 2 3 30 230 Impeller 1 1 2 2 2 3 30 310 01 Plain bearing product lubricated 2 3 4 5 6 8 100 310 10 320 02 Angular contact ball bearing set 1 1 2 2 3 4 50 330 Bearing bracket 1 2 off 433 Mechanical seal 1 1 2 2 2 3 25 502 01 1 Casing wear ring 2 2 2 3 3 4 50 523 Shaft sleeve 1 1 1 2 2 2 20 Set of sealing elements 4 6 8 8 9 12 150 1 Provided as a standard feature on HPK LS and HPK LS4 only optional feature only on HPK LE and HPK LE4 16 ajqeaBueyosaju ase UWNIOO E ul Jaquinu 9Wes y Guun eej s usuodwo o035W T T Y sap Q R N Z ana St asssissasagsys amp Bo Nea oe OOP nn nn PIPPI 2 NIP PIP ENER o 3 Pea NO DO N oa G1 OOOO NOO O O O O O OO zo Z 901 00 0 olol OC 0 0 0 0 0 CO CO OCH oO oO 5 O oOo o T not interchangeable among different pump 102 Volute casing Ke p 161 Casing cover e o ALA A Alb N 183 Support foot N 210 Shaft not interchangeable among different pump sizes 230 Impeller 310 01 Plain bearing 310 10 Plain bearing 320 02 Angular contact ball bearing N 33
4. KSB designation FAG designation SKF designation B G B TVP UA BGM BUA BG B G 8 BUA 80 BEGP C 86 Standard bearing assembly Bearing Pump end Motor end bracket Plain bearing Angular contact ball bearing LPO2 SSIC 37 2 x 7307 BG LPO3 SSiC 50 2 x 7307 BG LP04 SSiC 50 2 x 7309 BG8 KSB b HPK LS LE LS4 LE4 4 3 5 Permissible Forces and Moments at the Pump Nozzles Discharge nozzel Fyt Fy 1 00 Fx Mz Suction nozzle Fx 0 50 100 120 150 200 250 300 350 400 C 000176 The forces and moments were determined on the basis of API 610 The data on forces and moments apply to static pipelines only If the 6th edition table 2 doubled values limits are exceeded they must be checked and verified If a computerized strength analysis is required please contact KSB The resulting permissible forces have been determined according to The values are only applicable if the pump is installed on a completely grouted baseplate and bolted to a rigid and level foundation Fres D F F2 and Fress Fy F32 For temperatures gt 120 C the values indicated must be reduced in accordance with the above diagram Pump sizes Forces Moments Suction nozzle in N Discharge nozzle in N Suction nozzle in Nm Discharge nozzle in Nm Fx Fy Fz Fres Fx FyTens FyPress F
5. mm P 15 Bend back lockwasher 931 01 unscrew keywayed nut 920 21 right hand thread Remove lockwasher 931 01 fan impeller 831 bearing cover 360 02 spacer sleeve 525 24 and drive end ring 500 32 16 Unscrew grub screws 904 32 take out support disc 550 59 LPO2 and LPO3 only and O ring 412 07 Pull shaft sleeve 523 with mechanical seal 433 02 off shaft 210 towards the pump end For mechanical seal also refer to section 7 5 4 17 Remove seat ring holder 476 with the seat ring of the mechanical seal towards the pump end Take the seat ring out of seat ring holder 476 18 Pull bearing 320 02 off the shaft Take thrower 507 12 spacer sleeve 525 03 and pump end ring 500 32 off shaft 210 r The bearings are packed with grease and must not be heated up for dismantling If heated up they must be re packed with grease The plain bearing 310 01 can only be replaced completely 19 Pull the complete assembly consisting of circlip 932 05 bearing bush 545 21 bearing carrier 382 02 and tolerance ring 500 61 as well as spring type straight pins 562 01 outof the bearing bracket and replace After disassembly the individual components of plain bearings 310 01 must not be re used They must be re placed by a new assembly 310 01 which must only be used as a complete assembly Individual components from different assemblies must not be combined 20 Clean all components and inspect them for signs of wear Re work damaged componen
6. If the flexible coupling elements begin to show Caution A signs of wear they must be replaced in due time 7 2 2 Lubrication and Lubricant Change 7 2 2 1 Lubrication Intervals The pumps are supplied with the rolling element bearings packed with a high quality grease Under normal conditions grease lubricated rolling element bearings will run for 25 000 operating hours Under unfavourable operating conditions e g high room temperature high atmospheric humidity dust laden air aggressive industrial atmosphere etc the bearings shallbe checked earlier and cleaned and re lubricated if required The bearings are designed for a lifetime L10h of at least 25 000 hours This corresponds to a continuous operating period of almost three years After this period the rolling element bearings should be replaced 7 2 2 2 Grease Quality The grease must meet the requirements of DIN 51825 K1 2 P 20 Use a calcium sulphonate complex free of resin and acid not liable to crumble and with good rust preventive characteristics The grease should have a penetration number between 1 and 2 corresponding to a worked penetration between 265 and 340 mm 10 Its drop point must not be below 175 C The bearing cavities must only be half filled with grease Recommended grease quality FINA CERAN HV If required the bearings may be lubricated with greases of other soap bases Since greases of differing soap bases must not be mixed the bearings mu
7. 3 0 58 0 57 0 55 5 68 5 62 5 60 5 75 0 75 5 74 0 71 5 82 0 76 5 73 5 4 0 60 0 58 5 57 0 70 0 64 0 62 0 90 0 76 5 75 0 72 0 82 5 77 0 74 0 5 5 61 5 60 0 58 5 71 5 65 5 63 0 110 0 78 0 76 0 73 0 83 0 775 75 0 7 5 63 0 62 0 60 0 73 0 67 0 64 5 132 0 79 0 77 0 74 0 83 5 78 0 75 5 11 0 65 0 64 0 62 0 75 0 68 5 66 0 160 0 80 0 78 0 75 0 84 5 79 0 76 0 15 0 67 0 65 5 63 5 76 0 70 0 67 5 200 0 81 0 79 0 76 0 85 0 79 5 76 5 18 5 68 0 66 5 64 5 77 0 71 0 68 5 250 0 81 5 79 5 85 5 80 5 22 0 69 0 67 5 65 5 77 5 71 5 69 0 e 30 0 71 0 69 0 670 79 0 73 0 70 5 1 Measured at a distance of 1 m from the pump outline 37 0 72 0 70 5 68 0 79 5 73 5 71 0 KSE HPK LS LE LS4 LE4 4 4 Accessories Coupling flexible coupling with without spacer sleeve Contact guard coupling guard Baseplate cast or fabricated for the complete unit pump and motor in torsion acc to ISO 3661 _ resistant design Special accessories as required If a complete unit is supplied coupling and coupling guard are provided by the supplier 4 5 Dimensions and Weights For dimensions and weights please refer to the pump installation plan 5 Installation at Site 5 1 Safety Regulations Electrical equipment operated in hazardous locations must comply with explosion protection regulations This is indicated on the motor rating plate If the equipment is installed in hazardous locations the applicable loc
8. LE LS4 LE4 6 1 7 Start up Strainer If a start up strainer has been fitted to protect the pumps against dirt and or to retain contamination from the plant the strainer s contamination level must be monitored by measuring the differential pressure so as to ensure adequate inlet pressure for the pump If the start up strainer is included in the scope of supply of the pump please refer to the supplementary operating instructions supplied for installation and monitoring 6 1 8 Start up Before starting the pump ensure that the shut off valve in the suction line is fully open The pump may be started up againsta closed discharge side swing check valve or shut off valve Only after the pump has reached full rotational speed shall the shut off valve in the discharge line be opened further and adjusted to comply with the duty point When starting up against an open discharge side shut off valve take the resulting increase in input power into account 24 hours after the operating temperature has been reached and or in the event of leakage switch off the unit allow to cool down and re tighten the connection bolts between the casing cover and the casing For permissible tightening torques please refer to section 7 5 3 1 Check the coupling alignment at operating ion s p cauno temperature as described in section 5 3 1 and re align if necessary 6 1 9 Venting During Pump Operation If the pumped product is expected to libera
9. i e Safety instructions for the operator user 2 5 4 Designation 4 2 5 Di tala 755 16 Safety regulations 5 1 8 AREAS 2 Shaft seal 4 3 3 6 Dimensions and weights 4 5 8 6 1 2 10 Dismantling 7 4 13 7 5 4 15 Dismantling general 7 4 2 13 Shutdown 6 1 10 11 Drainage disposal 7 3 12 Shutdown storage preservation 6 3 11 Final check 55 9 Spare parts stock 7 6 16 Fundamental instructions or recommen 7 4 1 e Se _ 6 1 8 11 dations for dismantling Start up strainer 6 1 7 11 General 1 4 Storage of new pumps 6 3 1 11 General drawings lists of components 9 19 Supervision of operation 7 2 1 12 General instructions for maintenance 7 1 12 Switching frequency 6 2 2 11 Impeller type 4 3 2 6 Technical specification 4 1 5 Installing the pump unit 5 3 8 Temperature of medium handled ambi 6 2 1 11 Interim storage preservation 3 2 5 Ti we SE TR m Lubrication intervals 7 2 2 1 12 SZYN al Mai Transport 3 1 5 RE ze 12 Transport and interim storage 3 5 aintenance repair 2 12 Trouble shooting 8 18 Marking of instructions in the manual 2 1 4 nauthorized rhodes EN 28 Measures for prolonged shutdown 6 3 2 12 S i Mechanical seal 7 5 4 15 Unauthorized modification and manufac 2 7 Minimum maximum flow 6 2 5 11 ture ot apare patis Venting 6 1 9 11 KSE D HPK LS LE LS4 LE4 1 General This KSB product has been developed in accordance with state of the art technology it is manufactured with utmost care and subject to continuous quality control The
10. conditions in hot water systems the use of mechanical seals not approved by KSB shall not be covered by KSB s scope of warranty The following seal design is used for hot water applications 4 3 3 1 1 Mechanical seal in dead end arrangement 00016871 Fig 4 3 1 Mechanical seal in dead end arrangement The pump is fitted with a single acting balanced standardized mechanical seal The seal chamber is located between the product lubricated pump side plain bearing and the outboard motor side rolling element bearing The seal chamber is cooled by cooling fins and ambient cooling air without special external cooling devices 4 3 4 Bearings 4 3 4 1 Design Specifications At the motor end the shaft runs in grease lubricated angular contact ball bearings which are sealed for life The bearings are fixed bearings limiting the rotor s axial movement to max 0 5 mm The bearings are sealed off by axial joint rings on both sides The pump end bearing is a product lubricated ceramic bearing It is a radial bearing which can only absorb radial loads 4 3 4 2 Designation of Bearing Bracket L P 03 Air cooled bearing bracket with inte grated shaft seal chamber Back pull out design Size code based on dimensions of seal chamber and shaft end For the applicable bearing bracket version please refer to the data sheet 4 3 4 3 Bearings Used Bearing Design
11. manual must be read and understood both by the installing personnel and the responsible trained personnel operators prior to installation and commissioning and it must always be kept close to the location of operation of the machine unit for easy access Not only must the general safety instructions laid down in this chapter on Safety be complied with but also the safety instructions outlined under specific headings 2 1 Marking of Instructions in the Manual The safety instructions contained in this manual whose non observance might cause hazards to persons are specially marked with the general hazard sign namely safety sign to DIN 4844 W9 The electrical danger warning sign is safety sign to DIN 4844 W8 is used to introduce safety instructions whose non observance may lead to damage to the machine and its functions The word Instructions attached directly to the machine e g arrow indicating the direction of rotation markings for fluid connections must always be complied with and be kept in a perfectly legible condition at all times 2 2 Personnel Qualification and Training All personnel involved in the operation maintenance inspection and installation of the unit must be fully qualified to carry out the work involved Personnel responsibilities competence and supervision must be clearly defined by the operator If the personnel in question is not already in possession of the requisite know how appropriat
12. or misalignment Clean all components of plain bearing sleeve 310 10 and make sure that there are no dirt particles between the conical surfaces of the bearing components The components will not 14 be centered correctly otherwise which will result in failure of the plain bearing Prior to re assembly check whether the bearing components and the impeller can be easily fitted on shaft 210 11 Place guard 680 onto the bearing bracket 12 Place O ring 412 82 onto the seat ring holder Push shaft 210 with all assembled components into the bearing bracket Make sure all sealing elements and sealing surfaces are clean Fasten the bearing cover with socket head cap screws 914 02 13 Carefully insert joint ring 411 11 Place bearing bracket 330 into casing cover 161 and firmly tighten with nuts 920 04 14 Slip taper lock ring 515 22 bearing sleeve 529 21 taper lock ring 515 21 and cup spring 950 23 onto the shaft F Mount cup springs 950 23 in such a way that the outside diameter of the cup spring rests against taper lock ring 515 21 15 Insert key 940 01 and pull impeller 230 onto shaft 210 Insert disc 550 87 and tighten hex nut 920 95 with a torque wrench Tighten evenly to prevent damage to the bearings Rotate the shaft by hand several times while tightening It must be easy to rotate the shaft Stop the tightening procedure if the shaft seems to be blocked Loosen the nut and repeat the tightening procedure If
13. system short service lives of the mechanical seals are to be expected during the initial phase of plant operation The water in the circulation line must be analysed at regular intervals The hot water shall comply with the minimum requirements of the VdTUV regulations TCH 1466 AGFW 5 15 edition 2 89 In particular the following limits must not be exceeded Requirements Electrical conductivity us cm lt 250 pH value at 25 C 9 10 5 Silicates SiO2 mg lt 10 Solids mg l lt 5 For hot water with an electrical conductivity exceeding 250 us cm and for hot water with unknown water quality no warranty can be given on the service life of the mechanical seal S When conditioners producing a greasy film on caution j seal faces are used e g Maxigard Antifrogen N Preventol Cl 2 Kebo X Nalfleet 9 11 no warranty can be given on the seal life because of their adverse effect on the seal Insuch cases please contact KSB For high purity water fully demineralized with an electrical conductivity lt 2 us cm the temperature at the seal faces must be at least 20 C below the boiling point 6 10 3 Priming the Pump and Checks to be Carried out Before start up the volute casing bearing bracket and inlet line must be vented and primed with the liquid to be pumped The pump can be primed with clean product from the system via the inlet line Open the discharge side shut off valve to vent the vo
14. toxic hot must be contained so as to avoid any danger to persons or the environment All relevant laws must be heeded Electrical hazards must be eliminated In this respect refer to the relevant safety regulations applicable to different countries and or the local energy supply companies 2 6 Safety Instructions for Maintenance Inspection and Installation Work The operator is responsible for ensuring that all maintenance inspection and installation work be performed by authorized qualified specialist personnel who are thoroughly familiar with the manual The pump must have cooled down to ambient temperature pump pressure must have been released and the pump must have been drained KSE D HPK LS LE LS4 LE4 Work on the machine unit must be carried out only during standstill The shutdown procedure described in the manual for taking the unit out of service must be adhered to without fail Pumps or pump units handling media injurious to health must be decontaminated Immediately following completion of the work all safety relevant and protective devices mustbe re installed and or re activated Please observe all instructions set out in the chapter on Commissioning Start up before returning the unit to service 2 7 Unauthorized Modification and Manufacture of Spare Parts Modifications or alterations of the equipment supplied are only permitted after consultation with the manufacturer Original sp
15. 0 Bearing bracket a 360 Bearing cover W 433 02 Mechanical seal W 476 Seat ring holder z agl zlo sao gz D o wl 502 01 Casing wear ring X 507 01 Thrower W N 523 Shaft sleeve 525 03 Spacer sleeve 525 24 Spacer sleeve 680 Guard 831 Fan impeller 832 Fan hood 920 95 Hex nut LL Q as siusuodwo9 dung jo Ayyjiqeabueyoie u 901 Y31V7STV3T1V STNdH KSB b HPK LS LE LS4 LE4 8 Trouble Shooting Qa Qa 2 o o 3 as Jalle o o 8 2 D o o 5 8 KO Gla Slas 5 E Q g s s e so EI 2 2 8 0 g 2al 8 E Glao a e o 6 0 OE slo E o 5 3 3 2 3 3 v0oj2a ase 2 5 s s elel ejele 5 2 5 a 59 6 5S 6 JEER a l5 4 8 S 2 5 Cause Remedy 1 Pump delivers against an excessively high discharge pressure Re adjust duty point Excessively high back pressure Check plant for impurities Increase the speed turbine LC engine Pump or piping are not completely vented or primed Vent and or prime Supply line or impeller clogged Remove deposits in the pump and or piping Formation of air pockets in the piping Alter piping layout Fit a vent valve Pump is warped or sympathetic vibrations in piping Check pipeline connections and secure fixing of pump if re quired reduce the distances between the pipe clamps Fix the pipelines using anti vibration mat
16. 0 with shaft 210 impeller 230 and casing cover 161 out of volute casing 102 If necessary clean the thread of forcing screws 901 31 and use forcing screws 7 Undo hex nut 920 95 and take disc 550 87 off shaft 210 Pull impeller 230 off shaft 210 and remove key 940 01 8 Pull cup spring 950 23 and taper lock ring 515 21 off the shaft If possible also pull out taper lock ring 515 22 and bearing sleeve 529 21 in the process 9 Undo the socket head cap screw or grub screw in the coupling hub and use an extractor to pull the coupling half off the pump shaft Remove key 940 02 10 Loosen hex head bolts 901 84 and remove fan hood 832 11 Loosen hex head bolt 901 04 with spring washer 930 01 on the bearing bracket remove support foot 12 For work on the rolling element bearings or mechanical seal casing cover 161 need not be disassembled from bearing bracket 330 In all other cases unscrew hex nuts 920 04 and pull bearing bracket 330 out of casing cover 161 13 Unscrew socket head cap screws 914 02 and gently drive shaft 210 together with rolling element bearings 320 02 bearing cover 360 02 fan impeller 831 seat ring holder 476 and mechanical seal 433 out of bearing bracket 330 towards the drive end 14 Taper lock ring 515 22 and bearing sleeve 529 21 are pulled off the shaft in the process unless this has already been done in operation 8 Take taper lock ring 515 22 and bearing sleeve 529 21 out of the bearing bracket
17. Re balance the impeller Increase pressure at the pump suction nozzle The unit is misaligned Check the coupling re align if required Insufficient or excessive quantity of lubricant or unsuitable Top up reduce or change lubricant lubricant Non compliance with specified coupling distance Correct distance according to the installation plan Operating voltage is too low Increase the voltage Rotor is out of balance Clean the impeller Re balance the impeller 1 Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure 2 Contact KSB 18 HPK LS LE LS4 LE4 th List of Components ing wi kse D 9 General Draw Z NU Ll SS D 70d Z INTE NI L07 06 72 07 007606 EZS ZE 06 DEZ 257196 OZIY 657055 LEI EBI R 20728 NI Gel 19 005 t L0 OLE 40106 507ZE6 075Z5 127545 CND Isis 20 0 6 EZ 056 OL OLE Lui 7 591000 LZ SLS 56 026 DND 10 0 6 NI LB OSS Z 00S 107295 20 09 107205 207416 NI LEB 40 06 LEB 107195 EO LLY 2 0 06 4 0SS S8 E06 10 026 Z0 LLY 20026 its 947 7B L0G SB LLY oiz firita L0 206 20 06 20 4E 005 089 Z8 Z1 ZO EEY OEE 70026 191 OL LLY 70 206 19 When ordering spare parts please always specify Type series pump size works No stamped on
18. The same applies to screwed connections 7 5 2 Reassembly General Reassembly is effected in reverse order to dismantling Use the general drawing and the list of components for orientation All screws and bolts must be properly tightened during assembly For required torques see 7 5 3 1 Use only the bearing types and sizes specified in section 4 3 4 Angular contact ball bearings 320 02 must be installed in O arrangement Angular contact ball bearings installed in pairs must always be from the same manufacturer The bearings are packed with grease and must not be heated up for dismantling If heated up they must be re packed with grease The correct axial position of shaft sleeve 523 and mechanical seal 433 02 on shaft 210 is indispensable for the trouble free operation of the mechanical seal If positioned incorrectly hot liquid and steam may spurt out during operation See fig 7 5 4 1 1 Slip thrower 507 12 spacer sleeve 525 03 and ring 500 32 onto shaft 210 2 Press angular contact ball bearing 320 02 onto the shaft as far as it will go 3 Push spacer sleeve 525 24 onto shaft 210 and use a C wrench to tighten keywayed nut 920 21 without lockwasher 931 01 then unscrew the keywayed nut again 4 Slip ring 500 32 bearing cover 360 02 and fan impeller 831 onto the shaft 5 Put a few spots of Molykote on the contact faces of the lockwasher and of the keywayed nut slip on lockwasher 931 01 tighten keywayed nu
19. aces must be freely exposed to the atmosphere 4 It is assumed that the pump internals including seal chamber and auxiliary systems are completely filled with the product to be handled during pump operation so that an explosive atmosphere is prevented If this cannot be ensured suitable monitoring facilities must be provided 5 Explosion protection is subject to the following material requirements For combustible liquids all pressure retaining components must be made of ductile materials For coupling parts made of aluminium the coupling guard must be made of brass The material variants supplied by KSB meet these requirements 6 Ifthere is a risk of explosion during the installation phase the direction of rotation must not be checked by starting up the unfilled pump set even for a short period If it is not possible to fill the pump the direction of rotation must be checked with the pump motor coupling removed 7 The pump must never be operated with the shutoff valves in the suction and or discharge lines closed 10 11 12 13 14 For minimum flow operation with liquids whose physical properties are distinctly different from water itis essential to check if an additional heat build up may occur and if the flow rate must therefore be increased To do so please proceed as described in section 6 2 5 of the operating instructions Contact the manufacturer if necessary and observe the information prov
20. al explosion protection regulations and the regulations of the test certificate supplied with the equipment and issued by the responsible approval authorities must be observed and complied with The test certificate must be kept close to the location of operation for easy access e g foreman s office 5 2 Checks to be Carried out Prior to Installation All structural work required must have been prepared in accordance with the dimensions stated in the dimension table installation plan The concrete foundations shall have sufficient strength min BN 15 to ensure safe and functional installation in accordance with DIN 1045 or equivalent standards Make sure that the concrete foundation has set firmly before placing the unit on it Its surface shall be truly horizontal and even The foundation bolts shall be inserted in the baseplate 5 3 Installing the Pump Unit After placing the pump on the foundation align it with the help of a spirit level placed on the shaft discharge nozzle Permissible deviation 0 2 mm m The correct distance between the coupling halves as specified in the installation plan must be observed Shims shall be fitted between the baseplate and the foundation itself they shall always be inserted to the left and right of the foundation bolts and in close proximity to these bolts For a bolt to bolt clearance gt 800 mm additional shims shall be inserted halfway between the adjoining holes All shims mustlie perfec
21. are parts and accessories authorized by the manufacturer ensure safety The use of other parts can invalidate any liability of the manufacturer for consequential damage 2 8 Unauthorized Modes of Operation The warranty relating to the operating reliability and safety ofthe unit supplied is only valid if the equipment is used in accordance with its designated use as described in the following sections The limits stated in the data sheet must not be exceeded under any circumstances 3 Transport and Interim Storage 3 1 Transport Transport of the unit requires proper preparation and handling Always make sure that the pump or the unit remains in horizontal position during transport and cannot slip out of the transport suspension arrangement Do notuse alifting sling on the free shaft end of the pump or the motor eyebolt If the pump unit slips out of the suspension arrangement it may cause personal injury and damage to property IN 117 D00766 Fig 3 1 1 Transport of HPK L pump D00767 Fig 3 1 2 Transport of complete HPK L unit The HPK L pump is fitted with a ceramic plain bearing which is sensitive to shock and impact During transport make sure that neither the pump the unit nor the bare shaft ends in particular hit any other objects 3 2 Interim Storage Indoors Preservation When the unit is temporarily put into storage only the wetted low alloy componen
22. d to use a motor protection device VDE 0171 2 61 stipulates that explosion proof motors type of protection IP 54 increased sefety Ex EEx temperature class T3 must always be connected via a motor protection switch KSE D HPK LS LE LS4 LE4 6 Commissioning Start up Shutdown Compliance with the following requirements is of Caution 3 paramount importance Damage resulting from non compliance shall not be covered by the scope of warranty 6 1 Commissioning Before starting up the pump make sure that the following requirements have been checked and fulfilled The operating data must have been checked The direction of rotation 6 1 4 must have been checked The pump and the bearing bracket mechanical seal chamber must have been primed 6 1 3 Make sure that the unit has been properly connected to the electric power supply and is equipped with all protection devices Make sure that all auxiliary lines 5 4 1 are connected and functioning Ifthe pump has been out of service for a longer period of time proceed in accordance with section 6 4 6 1 1 Lubricants The rolling element bearings are grease packed for life at the factory and do not require any special measures prior to commissioning See section 7 2 2 on maintenance and re lubrication 6 1 2 Shaft Seal Mechanical seals have been fitted prior to delivery When new plants are commissioned and a large amount of foreign matter is in the
23. e free operation The temperature of the ambient air must not exceed 40 C Take the necessary precautions to avoid burns 5 4 Connecting the Piping Never use the pump itself as an anchorage point for the piping The permissible pipeline forces moments must not be exceeded see 4 3 5 Suction lift lines shall be laid with a rising slope towards the pump and suction head lines with a downward slope towards the pump The pipelines shall be anchored in close proximity to the pump and connected without transmitting any stresses or strains The nominal diameters of the pipelines shall be atleast equal to the nominal diameters of the pump nozzles It is recommended to install check and shut off elements in the system depending on the type of plant and pump It must be ensured however that the pump can still be drained and dismantled without problems Thermal expansions of the pipelines must be compensated by appropriate measures so as not to impose any extra loads on the pump exceeding the permissible pipeline forces and moments An excessive impermissible increase in the pipeline forces may cause leaks on the pump where the medium handled can escape into the atmosphere Danger of life when toxic or hot media are handled The flange covers on the pump suction and discharge nozzles must be removed prior to installation in the piping 5 4 1 Auxiliary Connections The HPK L pump is designed to give trouble free operation witho
24. e training and instruction must be provided If required the operator may commission the manufacturer supplier to take care of such training In addition the operatoris responsible for ensuring that the contents of the operating instructions are fully understood by the responsible personnel 2 3 Non compliance with Safety Instructions Non compliance with safety instructions can jeopardize the safety of personnel the environment and the machine unit itself Non compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages In particular non compliance can for example result in failure of important unit plant functions failure of prescribed maintenance and servicing practices hazard to persons by electrical mechanical and chemical effects hazard to the environment due to leakage of hazardous substances 2 4 Safety Awareness It is imperative to comply with the safety instructions contained in this manual the relevant national health and safety regulations and the operator s own internal work operation and safety regulations 2 5 Safety Instructions for the Operator User Anyhotorcold components that could pose a hazard must be equipped with a guard by the operator Guards which are fitted to prevent accidental contact with moving parts e g coupling must not be removed whilst the unit is operating Leakages of hazardous media handled e g explosive
25. earing bush 545 21 circlip 932 05 spring type straight pin 562 01 with taper lock rings 515 21 22 bearing sleeve 529 21 cup spring 950 23 Comprising all parts marked with O ring 412 07 support disc 550 59 LPO2 and LPO3 only grub screws 904 32 with joint ring 411 01 02 03 04 10 11 20 85 O ring 412 07 82 2 Can only be supplied and replaced as a complete unit 01 12 2000 XBS Subject to technical modifications a as YA UYSUA UVSTAdH Supplementary operating instructions 1070 83 10 G2 Explosion Protection Short operating instructions concerning explosion protection for type series CPK CPKN CPP Eta R HPK HPH KWP and RPH These short operating instructions cover only the aution RAE F main issues concerning explosion protection The operating instructions for the pump or pump set as applicable for the specific works number must also be complied with The following points must be adhered to 1 The explosion protection marking on the pump only refers to the pump part The coupling if any must have an EC manufacturer s declaration The driver must be regarded separately Example of marking on the pump part Ex II2 G T1 T5 2 Any operation of the pump outside its specified operating range and any unauthorized modes ofoperation may result in the specified temperature limits being exceeded 3 In all areas of elevated temperatures bearing bracket in particular the unit surf
26. ee HPK LS LE LS4 LE4 HPK L Hot Water Circulating Pump without external cooling Standard programme Works No Type series These operating instructions contain fundamental information and precautionary notes Please read the manual thoroughly prior to installation of unit electrical connection and commissioning It is imperative to comply with all other operating instructions referring to components of individual units This manual shall be kept either near or directly at the pump set KSB Aktiengesellschaft Industry and Water Engineering Pumps P O Box 1361 D 91253 Pegnitz Bahnhofplatz 1 D 91257 Pegnitz Tel 49 92 41 71 0 Fax 49 92 41 71 17 91 http www ksb industry com KSE HPK LS LE LS4 LE4 Contents Page Page 1 General 4 6 Commissioning Start up Shutdown 10 2 Safety 4 6 1 Commissioning 10 2 1 Marking of Instructions in the Manual 4 6 1 1 Lubricants 10 2 2 Personnel Qualification and Training 4 6 1 2 Shaft Seal 10 23 Non compliance with Safety Instructions 4 6 1 3 Priming the Pump and Checks to be Carried 10 2 4 Safety Awareness 4 6 14 king the Directi Rotati 10 2 5 Safety Instructions for the Operator User 4 615 c SS EH i 2 6 Safety Instructions for Maintenance Inspec 4 zy o9 ing 2 tion and Installation Work 6 1 6 Cleaning the Plant Piping 10 2 7 Unauthorized Modification and Manufacture 5 6 1 7 Start up Strainer 11 of Spare Parts 6 1 8 Start up 11 2 8 Unauthorized Modes of Op
27. eration 5 6 1 9 Venting during Pump Operation 11 3 Transport and Interim Storage 5 6 1 10 Shutdown 11 31 Transport 5 6 2 Operating Limits 11 32 Interim Storage Indoors Preservation 5 6 2 1 Temperature of Medium Handled Ambient 11 N Temperature 4 SE of the Product and Acces 5 6 2 2 Switching Frequency 11 41 Technical Specification 5 6 2 3 Density of Medium Handled 11 42 Designetion 5 6 2 4 Abrasive Media 11 43 Design Details 6 6 2 5 Minimum Maximum Flow 11 43 i gt Pumpeasing 6 6 3 Shutdown Storage Preservation 11 43 2 impeller Type 6 6 3 1 Storage of New Pumps 11 433 Shaft Seal 6 6 3 2 Measures to be Taken for Prolonged Stor 12 RE age Se Bearings 6 6 4 Returning to Service after Storage 12 4 3 5 Permissible Forces and Moments at the 7 Pump Nozzles 7 Maintenance Repair 12 4 3 6 Noise Characteristics 7 7A General Instructions 12 44 Accessories 8 7 2 Maintenance Inspection 12 45 Dimensions and Weights 8 7 2 1 Supervision of Operation 12 5 Installation at Site 8 7 2 2 Lubrication and Lubricant Change 12 5 1 Safety Regulations 8 Ce GE 5 2 Checks to Be Carried out Prior to Installa 8 i leaning i 3 tion 7 4 1 Fundamental Instructions and Recommen 13 5 3 Installing the Pump Unit 8 745 a ling G i 5 3 1 Aligning the Pump Drive 8 4 2 Dismantling General 13 5 3 2 Place of Installation 9 13 Reassembly 13 5 4 Connecting the Piping 9 7 5 1 General Instructions 13 5 4 1 Auxiliary Connections 9 o Heassembly General 18 5 4 2 Coupling G
28. erial Suction head is too high NPSH ayailable positive suction head Check alter liquid level is too low Fully open shut off valve in the suction line Change suction line if the friction losses in the suction line are too high Check any strainers installed suction opening Observe permissible speed of pressure fall Increased axial thrust 2 Correct rotor adjustment Air intake at the shaft seal Fit new shaft seal Reverse rotation Interchange two of the phases of the power supply cable Motor is running on two phases only Replace the defective fuse Check the electric cable connections Speed is too low 2 Increase speed Defective bearings Fit new bearings Insufficient rate of flow Increase the minimum rate of flow Wear of internal pump parts Replace worn components by new ones Pump back pressure is lower than specified in the purchase Adjust duty point accurately order Density or viscosity of the fluid pumped is higher than statedin 2 the purchase order Use of unsuitable materials Change the material combination Speed is too high Reduce speed 2 Tie bolts seals and gaskets Tighten the bolts Fit new seal elements Worn shaft seal Fit new shaft seal Score marks or roughness on shaft protecting sleeve Fit new shaft protecting sleeve Fit new shaft seal Dismantle to find out Correct Vibrations during pump operation Improve suction conditions Re align the pump
29. ided in the data sheet Responsibility for compliance with the specified product temperature lies with the operator If temperature classes T 5 100 C and T6 85 C have to be complied with special measure may have to taken with regard to bearing temperature In such cases and if ambient temperature exceeds 40 C contact the manufacturer Both gland packings and mechanical seals may exceed the specified temperature limits if run dry Dry running may result from incompletely filled seal chamber excessive gas content in medium handled unauthorized mode of operation or if gland packing is tightened too much there must be visible leakage The correct function of the shaft seal must be checked regularly The bearing assembly must be checked regularly for correct function running noises and heat build up The same applies to lubricants In hazardous areas compliance with IEC60079 14 is an additional requirement for electrical connection Belt driven pump sets must always be earthed The condition of the belts must be checked regularly The belts must be made of conductive material KSB b Explosion Protection Kse D KSB Aktiengesellschaft P O Box 1361 91253 Pegnitz Bahnhofplatz 1 91257 Pegnitz Germany Tel 49 92 41 71 0 Fax 49 92 41 71 17 91 www ksb com Subject to technical modifications XBS d 1 15 9 2001
30. ity of the medium must comply with the data specified on the purchase order 6 2 4 Abrasive Media When the pump handles liquids containing abrasive substances increased wear of the hydraulic system shaft seal and plain bearing are to be expected The intervals recommended for servicing and maintenance shall be shortened 6 2 5 Minimum Maximum Flow Unless specified otherwise in the characteristic curves or on the data sheets the following applies Qmin 0 1 X Qopt for short operation Omin 0 3 x Qopt for continuous operation Qmax 1 1 X Qopt for 2 pole operation Qmax 1 25 X Qopt for 4 pole operation Qopt optimum efficiency 6 3 Shutdown Storage Preservation Each KSB pump leaves the factory carefully assembled If commissioning is to take place some time after delivery we recommend that the following measures be taken for pump storage 6 3 1 Storage of New Pumps New pumps are supplied by our factory duly prepared for storage Maximum protection for up to 12 months if the pump is properly stored indoors Store the pump in a dry location Rotate the shaft by hand once a month 11 KSE HPK LS LE LS4 LE4 6 3 2 Measures to be Taken for Prolonged Shutdown 1 The pump remains installed periodic check of operation In order to make sure that the pump is always ready for instant start up and to prevent the formation of deposits within the pump and the pump intake area start up the pump set regular
31. lified specialist personnel who are thoroughly familiar with the manual A regular maintenance schedule will help avoid expensive repairs and contribute to trouble free reliable operation of the pump with a minimum of maintenance expenditure and work Work on the unit must only be carried out with the electrical connections disconnected Make sure that the pump set cannot be switched on accidentally danger of life Pumps handling liquids posing health hazards must be decontaminated When draining the medium see to it that there is no risk to persons or the environment All relevant laws must be adhered to danger of life 7 2 Maintenance Inspection 7 2 1 Supervision of Operation The pump must run quietly and free from vibrations at all times The pump must never be allowed to run dry Prolonged operation against a closed shut off valve is not permitted When operating the pump set against a closed shut off valve in the discharge line for a short period of time make sure not to exceed the permissible pressure and temperature limits The bearing temperature may exceed room temperature by up to 50 C but must never rise above 90 C The shut off valves and the auxiliary feed lines must not be closed during operation 12 Any stand by pumps installed shall be switched on and then immediately off again once a week to keep them operational Attention shall be paid to the correct functioning of the auxiliary connections
32. ller fastening 920 95 and grub screws 904 32 for fastening the shaft sleeve must be tightened with a torque wrench The tightening torques given in the table shall apply These values are determined on the basis of a friction coefficient u 0 12 KSE HPK LS LE LS4 LE4 Tightening torque Nm Pos Screw Material Stamp mark 1902 01 Stud 1 7709 05 GA Monix 3K 7 MM 902 04 DIN 939 1920 01 Hex nut 1 7258 A2D G Monix 3K 7 MM M3k 920 04 ISO 4032 Thread New 15 20 New 15 20 M12 80 68 64 130 111 104 M16 190 162 152 914 02 Socket head cap 8 8 8 8 screw DIN 7984 Thread New 15 20 M8 25 21 20 M10 35 30 28 904 32 Grub screw A4 50 DIN 916 Thread M6 5 9 1920 95 Hex nut A4 7 A4 ISO 8673 Thread New 15 20 M16x1 5 100 85 80 M20x1 5 120 102 96 The New column applies to the initial tightening of brand new LI da 412 2 475 threads After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 see table 15 20 They do not apply if general drawings or other instructions state different values 7 5 4 Mechanical Seal Installation The following rules must be observed when installing the mechanical seal Extreme care and cleanliness during installation are of overriding importance for the trouble free o
33. lute casing If the pump is not pressurized the bearing bracket can also be filled through connection 13D after the vent valve has been removed To vent the bearing bracket open the 10 vent valve installed at auxiliary connection 13D repeatedly fora short period Rotate the shaft by hand several times when priming the pump to ensure complete venting of the bearing bracket Liquid escapes After priming has been completed close the vent valve on connection 13D Depending on the system pressure and temperature of the medium handled hot liquid or steam may escape or spurt out under high pressure when the vent valve is opened Risk of scalding Protect the electrical components against escaping liquid Caution Dry running will result in failure of the plain bearing and the mechanical seal and must be avoided 6 1 4 Checking the Direction of Rotation When the unit has been connected to the electric power supply verify the following local and national regulations have to be taken into account separately For trouble free operation of the pump the correct direction of rotation of the impeller is of paramount importance If running in the wrong direction of rotation the pump cannot reach its duty point vibrations and overheating will be the consequence The unit or the shaft seal might be damaged Correct direction of rotation The direction of rotation must correspond to the direction indicated by the arrow on the pump Verify b
34. ly once a month or once every 3 months fora short time approx 5 minutes during prolonged shutdown periods Prior to an operation check run ensure that there is sufficient liquid available for operating the pump 2 The pump is removed from the pipe and stored Before putting the pump into storage carry out all checks and maintenance work specified in sections 7 1 to 7 4 Then apply appropriate preservatives Spray coat the inside wall of the pump casing and the mechanical seal chamber with a preservative in particular the impeller clearance areas Spray the preservative through the suction and discharge nozzles It is advisable to close the pump nozzles e g with plastic caps or similar Ifthe pump has been out of service for more than 1 year the elastomer components of mechanical seal shaft sleeve and seat ring holder must be replaced 6 4 Returning to Service after Storage Before returning the pump to service carry out all checks and maintenance work specified in sections 7 1 and 7 2 In addition the instructions laid down in the sections on Commissioning 6 1 and Operating Limits 6 2 must be observed Immediately following completion of the work all safety relevant and protective devices must be re installed and or re activated 7 Maintenance Repair 7 1 General Instructions The operator is responsible for ensuring that all maintenance inspection and installation work be performed by authorized qua
35. peration of the mechanical seal The protective wrapping of the contact faces shall only be removed immediately before assembly takes place The seat ring and its secondary seal are mounted in seat ring holder 476 The rotating components of the mechanical seal tappet springs spring loaded ring secondary seal etc must be pushed onto the shaft sleeve as a complete sub assembly until they will not go any further and locked with the grub screws The shaft sleeve must be mounted on the shaft flush with the mark on the shaft and all three grub screws 904 32 must be tightened firmly For tightening torques please refer to section 7 5 3 The shaft sleeve is correctly positioned on the shaft when its pump end face S in fig 7 5 4 1 is aligned with the mark on the shaft M in fig 7 5 4 1 On pumps with bearing bracket size LP04 no mark is supplied on the shaft the shaft sleeve must be aligned with the shaft collar in this case see fig 7 5 4 1 When all components have been mounted on the shaft immediately before the shaft is pushed into the bearing bracket operation 11 make sure that the contact faces are slightly pre loaded by the springs of the mechanical seal The correct axial position of shaft sleeve 523 and mechanical seal 433 02 on shaft 210 is indispensable for the trouble free operation of the mechanical seal If incorrectly positioned hot liquid or steam may spurt out during operation 904 485 472 z
36. re it cannot be switched on accidentally The shut off valves in the suction and discharge lines must be closed The pump must have cooled down to ambient temperature pump pressure must have been released and the pump must have been drained Dismantling and reassembly must always be carried out in accordance with the relevant sectional drawing 7 4 1 Fundamental Instructions and Recommendations Repair and maintenance work to the pump must only be carried out by specially trained personnel using original spare parts see 2 7 Observe the safety regulations laid down in section 7 1 Any work on the motor shall be governed by the specifications and regulations of the respective motor supplier Dismantling and reassembly must always be carried out in accordance with the relevant general drawing The general drawing and other relevant documents are found in the annex The dismantling sequence can be derived from the general drawing For installation and in case of damage you can always contact our service departments 7 4 2 Dismantling General 1 Remove the coupling guard 2 Remove the coupling spacer or if not applicable remove the drive If required refer to the additional sheet concerning the coupling Disconnect and remove all auxiliary pipework Unscrew baseplate fixing bolts on support foot 183 Loop a rope tightly around the neck of bearing bracket 330 Unscrew hex nuts 920 01 and pull complete bearing bracket 33
37. se operating instructions are intended to facilitate familiarization with the unit and its designated use The manual contains important information for reliable proper and efficient operation Compliance with the operating instructions is of vital importance to ensure reliability and along service life of the unit and to avoid any risks These operating instructions do not take into account local regulations the operator mustensure that such regulations are strictly observed by all including the personnel called in for installation This pump unit must not be operated beyond the limit values forthe medium handled capacity speed density pressure temperature and motor rating specified in the technical documentation Make sure that operation is in accordance with the instructions laid down in this manual or in the contract documentation Contact the manufacturer if required The name plate indicates the type series size main operating data and works number please quote this information in all queries repeat orders and particularly when ordering spare parts If you need any additional information or instructions exceeding the scope of this manual or in case of damage please contact KSB s nearest customer service centre Noise characteristics see section 4 3 6 2 Safety These operating instructions contain fundamental information which must be complied with during installation operation and maintenance Therefore this operating
38. st be thoroughly cleaned beforehand The re lubrication intervals required must then be adjusted to the greases used A Please observe the local laws applicable to the disposal of such substances 7 2 2 3 Grease Quantity Bearing Bearing Grease qty per single bear bracket ing LPO2 7307 BG 6 5 to 8 g LPO3 7307 BG 6 5 to 8 g LPO4 7309 BG8 13 to 15 5g The grease quantity indicated must be used for each single bearing of a bearing pair 7 3 Drainage Disposal If the pump was used for handling liquids posing health hazards see to it that there is no risk to persons or the environment when draining the medium All relevant laws must be heeded If required wear safety clothing and a protective mask If the media handled by the pumps leave residues which might lead to corrosion when coming into contact with atmospheric humidity or which might ignite when coming into contact with oxygen then the unit must be flushed through neutralized and then for drying purposes anhydrous gas mustbe blown through the pump To drain the pumped product use connection 6B 1 on the volute casing and 6B 2 on the bearing bracket see installation plan KSE D HPK LS LE LS4 LE4 The flushing liquid used and any liquid residues in the pump must be properly collected and disposed of without posing any risk to persons or the environment 7 4 Dismantling Before dismantling the pump secure it so as to make su
39. stance from each shaft at all points around the circumference In addition the distance between the two coupling halves must remain the same all around the circumference Use a feeler gauge a wedge gauge or a dial micrometer to verify see figs 5 3 2 and 5 3 3 Straight edge Straight edge Fig 5 3 2 Gauge Aligning the coupling with the help of a gauge and a straight edge Straight edge Straight edge Fig 5 3 3 Aligning a spacer type coupling KSE HPK LS LE LS4 LE4 The radial and axial deviation between the two coupling halves must not exceed 0 1 mm If other couplings are used please refer to the enclosed supplementary operating instructions Improper alignment of the unit can cause damage to both the coupling and the unit itself Motor alignment by means of adjusting screws In order to re align the coupling first loosen the 4 hex head bolts on the motor as well as the lock nuts Turn adjusting screw by hand or by means of an open jawed wrench until the coupling alignment is correct Then re tighten the 4 hex head bolts and the lock nuts Hex head bolt Adjusting screw Lock nut Fig 5 3 4 Motor alignment with adjusting screws 5 3 2 Place of Installation The volute casing and casing cover take on roughly the same temperature as the medium handled The casing cover and the bearing bracket must not be insulated An unimpeded supply of cooling air is nf caution zue for troubl
40. t and bend over lockwasher 6 Insert the seat ring and the secondary seal of the mechanical seal into seat ring holder 476 and push onto the shaft from the pump end 7 Mount the mechanical seal on shaft sleeve 523 The mechanical seal must be pushed onto the shaft sleeve as far as it will go and locked with grub screws 8 For LP02 and LPO3 Push the shaft sleeve on the shaft Then guide O ring 412 07 and support disc 550 59 carefully along the shaft and press them into the recess of the shaft sleeve Make sure the sealing elements and sealing surfaces are clean Screw in grub screws 904 32 by several turns to hold the support disc in place For LP04 Place O ring 412 07 into shaft sleeve 523 Carefully guide the shaft sleeve along the shaft 9 Push shaft sleeve 523 onto shaft 210 up to the mark See section 7 5 4 In doing so the springs of the mechanical seal are compressed and the seal faces are pressed against each other Firmly tighten all grub screws 904 32 If plain bearing 310 01 has to be replaced 10 Press plain bearing assembly 310 01 into the bearing bracket Drill a hole into both bearing carrier 382 02 and bearing bracket 330 together and fix with spring type straight pins 562 01 The plain bearing assembly 310 01 bush must be used as complete assembly only Individual components from different assemblies must not be combined After dismantling the individual components must not be re used Risk of breakage
41. te gas Caution SA e g during the commissioning phase of a plant or when the pump is filled with tap water the bearing bracket must be vented at regular intervals For venting we recommend to switch off the pump for a short period and let it run down to a standstill to ensure reliable venting of any gases Depending on the system configuration the shut off valves may have to be closed to do so To ventthe bearing bracket open the valve fitted at connection 13D repeatedly for a short period until no further gases escape Excessive venting shall be avoided as hot product from the piping system will flow through the volute casing into the mechanical seal chamber and result in an inadmissible heat build up in the mechanical seal The vent valve must be closed again as soon as no further gases escape Depending on the system pressure and temperature of the medium handled hot liquid or steam may escape or spurt out under high pressure when the vent plug is opened Risk of scalding The venting intervals required depend on the amount of gas escaping during the venting process 6 1 10 Shutdown Close the shut off valve in the discharge line If the discharge line is equipped with a non return or check valve the shut off valve may remain open If shut off is not possible the pump will run in reverse direction The reverse runaway speed must be lower than the rated speed Switch off the drive making sure that the unit runs down smoothl
42. the nameplate and on the suction nozzle flange motor No serial No year of construction quantity required part No description material medium handled sectional drawing No and mode of dispatch Part No 102 161 183 210 230 310 01 310 10 320 02 330 330 360 02 411 20 411 85 433 02 476 500 32 507 12 523 525 24 525 03 550 87 561 52 680 720 22 831 832 901 84 903 20 903 85 914 02 920 95 99 9 Description Volute casing Casing cover Support foot Shaft Impeller Plain bearing bush 2 Plain bearing sleeve Angular contact ball bearing Bearing bracket Bearing bracket com plete Bearing cover Joint ring Joint ring Mechanical seal Seat ring holder Ring Thrower Shaft sleeve Spacer sleeve Spacer sleeve Disc Grooved pin Guard Nipple joint Fan impeller Fan hood Hex head bolt Screwed plug Screwed plug Socket head cap screw Hex nut Set of sealing elements 1 For HPK LS LS4 only Scope of supply with joint ring 411 01 02 03 04 10 casing wear ring 502 011 parallel pin 561 011 stud 902 01 screwed plug 903 01 02 03 04 hex nut 920 01 with joint ring 411 11 hex head bolt 901 31 stud 902 04 hex nut 920 04 with hex head bolt 901 04 spring washer 930 01 with disc 550 87 keywayed nut 920 21 hex nut 920 95 lockwasher 931 01 key 940 01 02 with bearing carrier 382 02 tolerance ring 500 61 b
43. the shaft is blocked repeatedly dismantle the components again and check for cleanliness and correct dimensions After the rotating pump assembly pump without casing has been assembled check the radial shaft run out at the impeller Maximum permissible run out 0 15 mm 16 Carefully insert joint ring 411 10 into volute casing 102 Guide the rotating pump assembly into volute casing 102 and tighten nut 920 01 Check whether the rotor can easily be turned by hand 17 Bolt support foot 183 to bearing bracket 330 and to the baseplate 18 Mount fan hood 832 together with guard 680 using hex head bolts 901 84 19 Insert key fasten coupling half on the shaft 20 After the rotor bearing bracket assembly has been fitted to the volute casing which has remained in the piping and on the baseplate the pump shall be re commissioned as described in section 6 1 Connect and open auxiliary feed lines prime the pump Verify coupling alignment as described in section 5 3 1 21 Start up the pump for a short period switch off again and re check coupling alignment at operating temperature and system pressure as described in section 5 3 1 7 5 3 Tightening Torques 7 5 3 1 Tightening Torques of Screwed Connections The threaded connections between volute casing and casing cover 902 01 920 01 between casing cover and bearing bracket 902 04 920 04 and between bearing cover and bearing bracket 914 02 as well as the hex nut for impe
44. tly flush Insert the foundation bolts and set them into the foundation using concrete When the concrete has set align the baseplate as described in section 5 3 1 and tighten the foundation bolts evenly and firmly Then grout the baseplate using low shrinkage concrete with a standard particle size and a water concrete ratio of lt 0 5 The flowability must be produced with the help of a solvent Secondary treatment of the concrete to DIN 1045 is an absolute necessity Foundation bolts Fig 5 3 1 Fitting required shims To ensure low noise operation the unit can be mounted on vibration dampers please confirm with KSB first Expansion joints can be fitted between pump and suction discharge line 5 3 1 Aligning the Pump Drive After fastening the baseplate on the foundation and connecting the piping the coupling must be thoroughly checked and the pump set be re aligned at the motor if required The HPK L pump is fitted with a ceramic plain bearing which may be damaged by shock or impact e g from pump alignment by hammer or lead slug Prior to checking the alignment re alignment loosen support foot 183 and re tighten without transmitting any stresses or strains Coupling check and re alignment must be effected even if pump and motor are supplied completely assembled and aligned on a common baseplate The pump set is correctly aligned if a straight edge placed axially on both coupling halves is the same di
45. ts e g JL1040 JS1025 C22 8 GP240GHH N etc must be preserved Commercially available preservatives can be used for this purpose Please observe the manufacturer s instructions for application removal The relevant procedure is described in section 6 3 The unit pump should be stored in a dry room where the atmospheric humidity is as constant as possible If stored outdoors the unit and crates must be covered by waterproof material to avoid any contact with humidity Protect all stored goods against humidity dirt vermin and unauthorized access All openings of the assembled unit components are closed and must only be opened when required during installation All blank parts and surfaces of the pump are oiled or greased silicone free oil and grease to protect them against corrosion 4 Description of the Product and Accessories 4 1 Technical Specification HPK L pumps in standard design are suitable for plants where hot water is to be pumped through piping or tank systems particularly for medium and large scale heating systems forced circulation boilers district heating systems and similar unless inspection in acc with German Pressure Vessel Regulations Technische Regeln f r Druckbeh lter or DIN 4752 is required 4 2 Designation HPK L S 4 80 200 Type series Air cooled Material of wetted components Pressure class Discharge nozzle DN Nom impeller diameter in mm
46. ts or replace by new ones 7 5 Reassembly 7 5 1 General Instructions The pump shall be reassembled in accordance with the rules of sound engineering practice Clean all dismantled components and check them for signs of wear Damaged or worn components are to be replaced by original spare parts Make sure thatthe seal faces are clean and that gaskets are properly fitted Always use new sealing elements O rings gaskets whenever the pumpis reassembled Make sure that new gaskets have the same thickness as the old ones Gaskets made of graphite or other asbestos free materials must always be fitted without using lubricants such as copper grease or graphite paste Avoid the use of mounting aids as far as possible Should a mounting aid be required after all use a commercially available contact adhesive e g Pattex The adhesive shall only be applied at selected points 3 to 4 spots and in thin layers Do notuse cyanoacrylate adhesives quick setting adhesives If in certain cases mounting aids or anti adhesives other than described herein are required please contact the sealing material manufacturer i All graphite gaskets must only be used once 13 KSE D HPK LS LE LS4 LE4 Do not coat O rings with graphite or similar products Use animal fats or silicone base or PTFE base lubricants instead The locating surfaces of the individual components must be coated with graphite or similar before reassembly
47. uard 9 7 5 8 Tightening Torques 14 5 5 Final Check 9 7 5 4 Mechanical Seal Installation 15 56 Connection to Power Supply 9 7 5 5 Diametral Clearances 16 7 6 Spare Parts Stock 16 7 6 1 Recommended Spare Parts Stock for 2 16 Years Operation 7 6 2 Interchangeability of Pump Components 17 8 Trouble shooting 18 9 General Drawings Lists of Components 19 KSE HPK LS LE LS4 LE4 Index Section Page Section Page Abrasive media 6 2 4 11 Noise characteristics 4 3 6 7 Accessories 4 4 8 Non compliance with safety instructions 2 3 4 Assembly installation at site 5 8 Operating limits 6 2 11 Auxiliary connections 5 4 1 9 Permissible forces and moments atthe 4 3 5 7 Bearings 4 3 4 6 pump nozzles Bearings maintenance repair 7 2 12 Personnel qualification and training 2 2 4 Checking the direction of rotation 6 1 4 10 Place of installation 5 3 2 9 Checks to be carried out prior to installa 5 2 8 Plain bearing 4 3 4 6 tion Priming the pump 6 1 3 10 Commissioning 6 1 10 Pump casing 4 3 1 6 Commissioning start up shutdown 6 10 Reassembly 7 5 13 Configuration and function 4 3 6 Recommended spare parts stock for 2 7 6 1 16 Connecting the piping 5 3 4 9 years operation Connection to power supply 5 6 9 Returning to service after storage 6 4 12 Density of medium handled 6 2 3 11 Safety 2 4 Description of the product and acces 4 5 Safety awareness 2 4 4 sories Safety instructions for maintenance in 2 6 4 Design details 4 3 6 spection and installation work
48. ut external cooling facilities The mechanical seal does not require any cooling liquid sealing liquid or flushing liquid In the as supplied condition auxiliary connection 13D for venting the seal chamber is closed with a screwed plug with vent hole Itis recommended to replace it with a globe valve and drain line at the site so that gases and hot liquid can be drained safely during the venting process The pump can be supplied with auxiliary connections e g for pressure or temperature measuring instruments depending on the pump version Auxiliary connections for pump drainage and leakage disposal are also provided The dimensions and locations of all auxiliary connections are indicated on the installation plan or piping layout 5 4 2 Coupling Guard In compliance with the accident prevention regulations the pump must not be operated without a coupling guard If the customer specifically requests not to include a coupling guard in our delivery then the operator must supply one The coupling guard must not obstruct air flow to the fan hood and the bearing bracket 5 5 Final Check Verify the alignment as described in section 5 3 It must be easy to rotate the shaft by hand at the coupling 5 6 Connection to Power Supply Connection to the power supply must be effected by a trained electrician only Check available mains voltage against the data on the motor rating plate and select appropriate start up method We strongly recommen
49. y switching the motor on and then off again immediately Before checking the direction of rotation make sure that there is no foreign matter in the pump casing Never hold your hands or any other objects into the pump Do not run the pump without liquid while checking the direction of rotation If there is no medium handled available the motor s direction of rotation must be checked with the pump decoupled If the pump runs in the wrong direction of rotation interchange two of the three phases in the control cabinet or motor terminal box 6 1 5 Cooling On the HPK L pump the mechanical seal is integrated in the bearing bracket The latter is cooled by the ambient air via the cooling fins An integrated fan impeller generates a continuous cooling air flow An unobstructed supply of cooling air to the fan hood and fan impeller must be ensured at all times In exceptional cases the pump can also be operated without the integrated fan impeller 831 e g if the cooling air intake would be blocked by coarse dust In this case also remove the fan hood 832 remove the guard 680 ensure a cooling air flow with a cooling air velocity of atleast 4 m s in the proximity of the cooling fins e g from the motor cooling device or an external fan 6 1 6 Cleaning the Plant Piping The cleaning operation mode and duration for flushing and pickling service must be matched to the casing and seal materials used ksB D HPK LS
50. y to a standstill In the event of frost and or prolonged shutdowns the pump incl the mechanical seal chamber in the bearing bracket must be drained or otherwise protected against freezing Secure the pump setin such a way thatit cannot be switched on while in reverse rotation 6 2 Operating Limits The pump s unit s application limits regarding pressure temperature and speed are stated on the data sheet and must be strictly adhered to If a data sheet is not available contact KSB 6 2 1 Temperature of the Medium Handled Ambient Temperature Bearing Temperature Do not operate the pump at temperatures exceeding those specified on the data sheet or the name plate unless the written consent of the manufacturer has been obtained Damage resulting from disregarding this warning will not be covered by the KSB warranty Ambient temperature must not exceed 40 C Bearing bracket temperature see 7 2 1 6 2 2 Switching Frequency To prevent high temperature increases in the motor and excessive loads on the pump coupling motor seals and bearings the switching frequency shall not exceed the following number of start ups per hour S Motor rating kW max S start ups h up to 12 25 up to 100 20 more than 100 10 6 2 3 Density of the Medium Handled The power input of the pump will increase in proportion to the density of the medium handled To avoid overloading of the motor pump and coupling the dens
51. z Fres Mx My Mz Mx My Mz 25 160 1050 700 850 1100 500 350 650 450 700 550 450 300 400 300 200 200 32 160 1350 900 1100 1400 700 450 850 550 900 700 550 350 450 350 250 200 250 40 160 1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 550 450 300 200 250 50 160 2150 1400 1700 2200 1100 700 1350 900 1400 1450 1100 750 700 550 350 200 250 65 160 2700 1750 2150 2750 1400 900 1750 1150 1800 2000 1500 1000 1150 850 600 200 250 80 160 3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 750 200 250 100 200 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000 250 125 250 4700 3100 3750 4750 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400 150 250 7350 4700 5700 7400 3750 2350 4700 3100 4850 5300 3850 2650 3450 2650 1750 4 3 6 Noise Characteristics Rated Sound pressure level L pA dB 1 Rated Sound pressure level L pA dB 1 power Pump only Pump with motor power Pump only Pump with motor input PN 2900 1450 960 760 2900 1450 960 760 input PN 2900 1450 960 760 2900 1450 960 760 kW 1 min 1 min 1 min 1 min 1 min 1 min kW 1 min 1 min 1 min 1 min 1 min 1 min 1 5 54 5 53 5 52 5 64 0 59 0 56 5 45 0 73 0 71 5 69 0 80 5 74 5 72 0 2 2 56 5 55 5 54 0 67 0 61 0 59 0 55 0 74 0 72 5 70 0 81 0 75 0 72 5
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