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Thermal Oil / Hot Water Pump

HPK-L
without external cooling
Standard programme




Installation/Operating
Manual



Installation/Operating Manual HPK-L
Original operating manual

KSB Aktiengesellschaft

All rights reserved. Contents provided herein must neither be distributed, copied, reproduced,
processed for any other purpose, nor otherwise transmitted to a third party without KSBs express
written consent.

Subject to technical modification without prior notice.

KSB Aktiengesellschaft Frankenthal 25.01.2010
Contents

Glossary ................................................................................................ 5
1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Installation of partly completed machinery .................................................. 6
1.3 Target group ................................................................................................... 6
1.4 Other applicable documents .......................................................................... 6
1.5 Symbols ............................................................................................................ 6
2 Safety ................................................................................................... 8
2.1 Key to safety symbols/markings ..................................................................... 8
2.2 General ............................................................................................................ 8
2.3 Intended use .................................................................................................... 8
2.4 Personnel qualification and training ............................................................. 9
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 9
2.6 Safety awareness ............................................................................................. 9
2.7 Safety information for the operator/user .................................................... 10
2.8 Safety information for maintenance, inspection and installation work ... 10
2.9 Unauthorised modes of operation ............................................................... 10
2.10 Explosion protection ..................................................................................... 10
3 Transport/Temporary Storage/Disposal ........................................... 13
3.1 Transport ....................................................................................................... 13
3.2 Storage and preservation ............................................................................. 13
3.3 Return to supplier ......................................................................................... 14
3.4 Disposal .......................................................................................................... 14
4 Description of the Pump (Set) .......................................................... 16
4.1 General description ....................................................................................... 16
4.2 Designation ................................................................................................... 16
4.3 Name plate .................................................................................................... 17
4.4 Design details ................................................................................................ 17
4.5 Configuration and function ......................................................................... 19
4.6 Noise characteristics ..................................................................................... 20
4.7 Scope of supply ............................................................................................. 20
4.8 Dimensions and weights ............................................................................... 20
5 Installation at Site ............................................................................. 21
5.1 Safety regulations ......................................................................................... 21
5.2 Checking the site before installation ........................................................... 21
5.3 Installing the pump set ................................................................................. 21
5.4 Piping ............................................................................................................. 23



Contents
HPK-L 3 of 62
5.5 Protective equipment ................................................................................... 26
5.6 Checking the coupling alignment ................................................................ 26
5.7 Aligning the pump and motor ..................................................................... 27
5.8 Electrical connection ..................................................................................... 29
5.9 Checking the direction of rotation .............................................................. 30
6 Commissioning/Start-up/Shutdown ................................................. 32
6.1 Commissioning/start-up ................................................................................ 32
6.2 Operating limits ............................................................................................ 36
6.3 Shutdown/storage/preservation ................................................................... 38
6.4 Returning to service after storage ............................................................... 39
7 Servicing/Maintenance ...................................................................... 40
7.1 Safety regulations ......................................................................................... 40
7.2 Servicing/inspection ...................................................................................... 40
7.3 Drainage/disposal .......................................................................................... 43
7.4 Dismantling the pump set ............................................................................ 43
7.5 Reassembling the pump set .......................................................................... 47
7.6 Tightening torques ....................................................................................... 51
7.7 Spare parts stock ........................................................................................... 51
8 Trouble-shooting ............................................................................... 55
9 Related Documents ........................................................................... 57
9.1 General assembly drawing with list of components ................................... 57
10 EC Declaration of Conformity .......................................................... 59
11 Certificate of Decontamination ....................................................... 60

Index .................................................................................................. 61

Contents
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Glossary
Back pull-out design
The complete back pull-out unit can be pulled
out without having to remove the pump casing
from the piping.
Back pull-out unit
Pump without pump casing; partly completed
machinery
Certificate of decontamination
A certificate of decontamination certifies that
the pump (set) has been properly drained to
eliminate any environmental and health
hazards arising from components in contact
with the fluid handled.
Discharge line
The line which is connected to the discharge
nozzle
Hydraulic system
The part of the pump in which the kinetic
energy is converted into pressure energy
Pool of pumps
Pumps which are purchased and stored
independently of their later use
Pump
Machine without drive, additional components
or accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Suction lift line/suction head line
The line which is connected to the suction
nozzle


Glossary
HPK-L 5 of 62
1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. It describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics ( Section 4.6 Page 20)
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB, please refer to the sub-
sections under Servicing/Maintenance. ( Section 7.5.5 Page 49)
1.3 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel. ( Section 2.4 Page 9)
1.4 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump
(set)
General arrangement drawing/
Outline drawing
Description of mating and installation dimensions
for the pump (set)
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing
1)
Sectional drawing of the pump
Sub-supplier documentation
1)
Operating manuals and other documentation of
accessories and integrated machinery components
Spare parts lists
1)
Description of spare parts
Piping layout
1)
Description of auxiliary piping
List of components
1)
Description of all pump components
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
Safety instructions
Result of an action
Cross-references











1)
If agreed to be included in the scope of supply

1 General
6 of 62 HPK-L
Symbol Description
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product

1 General
HPK-L 7 of 62
2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
! DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
! WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EC Directive
94/9/EC (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information
about protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
Arrow indicating the direction of rotation
Markings for connections
Name plate
The operator is responsible for ensuring compliance with all local regulations which
are not taken into account in this manual.
2.3 Intended use
The pump (set) may only be operated in the operating conditions which are
described in the other applicable documentation.
Only operate pumps/pump sets which are in perfect technical condition.
Do not operate partially assembled pumps/pump sets.

! DANGER







2 Safety
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Only use the pump to handle the fluids specified in the data sheet or product
literature of the respective design variant.
Never operate the pump without the fluid to be handled.
Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Preventi on of foreseeabl e mi suse
Never open discharge-side shut-off elements further than permitted.
The maximum flow rate specified in the data sheet or product literature
would be exceeded.
Risk of cavitation damage
Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
installation, operation, maintenance and inspection must be clearly defined by the
operator.
Deficits in knowledge must be rectified by sufficiently trained specialist personnel
training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with these operating
instructions
Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
Non-compliance can, for example, have the following consequences:
Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
Failure of important product functions
Failure of prescribed maintenance and servicing practices
Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
Accident prevention, health and safety regulations
Explosion protection regulations









2 Safety
HPK-L 9 of 62
Safety regulations for handling hazardous substances
Applicable standards and laws
2.7 Safety information for the operator/user
The operator shall fit contact guards for hot, cold or moving parts and check that
the guards function properly.
Do not remove the contact guard while the pump is running.
Connect an earth conductor to the metal jacket if the fluid handled is
electrostatically charged.
Provide the personnel with protective equipment and make sure it is used.
Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.8 Safety information for maintenance, inspection and installation work
Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for consequential
damage.
The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
Carry out work on the pump (set) during standstill only.
The pump casing must have cooled down to ambient temperature.
Pump pressure must have been released and the pump must have been drained.
When taking the pump set out of service always adhere to the procedure
described in the manual.
Decontaminate pumps which handle fluids posing a health hazard. ( Section 7.3
Page 43)
As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning. ( Section 6.1 Page 32)
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use. (
Section 2.3 Page 8)
2.10 Explosion protection
Always observe the instructions on explosion protection given in this section when
operating the pump in potentially explosive atmospheres.







! DANGER

2 Safety
10 of 62 HPK-L
Only pumps/pump sets marked as explosion-proof and identified as such in the data
sheet may be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof pump sets to EC
Directive 94/9/EC (ATEX).
Especially adhere to the sections in this manual marked with the Ex symbol and the
following sections ( Section 2.10.1 Page 11) to ( Section 2.10.4 Page 12).
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
Never operate the pump (set) outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.
2.10.1 Marking
The marking on the pump refers to the pump only.
Example of such marking: II 2 G c TX
Refer to the Temperature limits table for the temperatures permitted for the
individual pump variants. ( Section 2.10.2 Page 11)
An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
The motor has its own marking. The marking is maintained on the condition that the
temperatures the pump causes to develop at the motor flange and motor shaft are
permitted by the motor manufacturer.
The motors fitted by KSB on pumps with ATEX certification meet this condition.
2.10.2 Temperature limits
In normal pump operation, the highest temperatures are to be expected on the
surface of the pump casing, at the shaft seal and in the bearing areas.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated in addition, the operator of the system is
responsible for observing the specified temperature classes and fluid temperature
(operating temperature).
The table below lists the temperature classes and the resulting theoretical
temperature limits of the fluid handled (a possible temperature rise in the shaft seal
area has already been taken into account).
The temperature class specifies the maximum permissible temperature at the surface
of the pump set during operation. For the permissible operating temperature of the
pump in question refer to the data sheet.
Table 4: Temperature limits
Temperature class as per EN 13463-1 Maximum permissible fluid
temperature
T1 Maximum 400 C
2)
T2 280 C
T3 185 C
T4 120 C
T5 85 C
T6 Only after consultation
with the manufacturer
In the area of the rolling element bearings, based on an ambient temperature of
40 C and assuming proper service and operation, compliance with the requirements
of temperature class T4 is warranted. If the ambient temperature exceeds 40 C,
contact the manufacturer.
A special design is required to comply with the requirements of temperature class T6
in the bearing area.

Pump
Shaft coupling
Motor


Temperature class T4
Temperature class T6
2)
Depending on the material variant.

2 Safety
HPK-L 11 of 62
Misuse, malfunctions or non-compliance with the instructions may result in
substantially higher temperatures.
If the pump is to be operated at a higher temperature, the data sheet is missing or if
the pump is part of a pool of pumps, contact KSB for the maximum permissible
operating temperature.
2.10.3 Monitoring equipment
The pump (set) must only be operated within the limits specified in the data sheet
and on the name plate.
If the system operator cannot warrant compliance with these operating limits,
appropriate monitoring devices must be used.
Check whether monitoring equipment is required to ensure that the pump set
functions properly.
Contact KSB for further information on monitoring equipment.
2.10.4 Operating limits
The minimum flows indicated in section ( Section 6.2.3 Page 37) refer to water
and water-like fluids. Longer operating periods with these fluids and at the flow
rates indicated will not cause an additional increase in the temperatures on the
pump surface. However, if the physical properties of the fluids handled are different
from water, it is essential to check if an additional heat build-up may occur and if the
minimum flow rate must therefore be increased. The calculation formula in (
Section 6.2.3 Page 37) can be used to check if an additional heat build-up may lead
to a hazardous temperature increase at the pump surface.





2 Safety
12 of 62 HPK-L
3 Transport/Temporary Storage/Disposal
3.1 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
Always transport the pump (set) in horizontal position.
Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
Refer to the weights given in the general arrangement drawing.
Observe the local accident prevention regulations.
Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.
To transport the pump/pump set suspend it from the lifting tackles as follows.
Fig. 1: Transporting the pump
Fig. 2: Transporting the complete pump set
Fig. 3: Transporting the pump on baseplate
CAUTION
Pump (set) or bare shaft end must not hit any objects.???
Damage to the ceramic plain bearing!
Secure them to provide protection.
3.2 Storage and preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.








3 Transport/Temporary Storage/Disposal
HPK-L 13 of 62
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
For outdoor storage cover the pump (set) or the packaged pump (set) and
accessories with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
Only remove caps/covers from the openings of the pump set at the time of
installation.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, observe the relevant
instructions. ( Section 6.3.1 Page 38)
3.3 Return to supplier
1. Drain the pump as per operating instructions. ( Section 7.3 Page 43)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the fluids handled by the pump leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might
ignite when coming into contact with oxygen, the pump set must also be
neutralised, and anhydrous gas must be blown through the pump for drying
purposes.
4. Always complete and enclose a certificate of decontamination when returning
the pump set. ( Section 11 Page 60)
It is imperative to indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the KSB web
site at: www.ksb.com/certificate_of_decontamination
3.4 Disposal
WARNING
Fluids posing a health hazard
Hazardous to persons and the environment!
Collect and properly dispose of flushing liquid and any fluid residues.
Wear safety clothing and a protective mask, if required.
Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set).
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants










3 Transport/Temporary Storage/Disposal
14 of 62 HPK-L
3. Dispose of materials in acc. with local regulations or in another controlled
manner.

3 Transport/Temporary Storage/Disposal
HPK-L 15 of 62
4 Description of the Pump (Set)
4.1 General description
Heat transfer liquid pump with shaft seal
Pump for handling hot water or organic heat transfer fluids in piping or tank
systems.
Standard design for plants (large heating systems, forced circulation boilers, district
heating systems, etc).
4.2 Designation
Exampl e: HPK- L S 4 80- 200
Table 5: Key to the designation
Code Description
HPK Type series
L Air-cooled
S Material of wetted components
4 Pressure class
80 Nominal discharge nozzle diameter [mm]
200 Nominal impeller diameter [mm]
4.2.1 Materials
Table 6: Materials
Part
No.
Designation HPK-L materials
S, S4 E E4
102 Volute casing JS1025 GP240GH+N 1.7706
161 Casing cover P250GH P250GH P250GH
210 Shaft 1.4021+
QT700
1.4021+
QT700
1.4021+
QT700
230 Impeller JL1040 JL1040 JL1040
310.10 Plain bearing SSiC SSiC SSiC
330 Bearing bracket
(=seal housing)
JS1025 JS1025 JS1025
476 Seat ring holder 1.4021+
QT700
1.4021+
QT700
1.4021+
QT700
502.01 Casing wear ring JL1040 - -
523 Shaft sleeve 1.4021+
QT700
1.4021+
QT700
1.4021+
QT700
545.21 Bearing bush (product-
lubricated)
SSiC SSiC SSiC
920.95 Impeller nut A4 A4 A4
Pressure class:
(blank) = PN25
4 = PN40









4 Description of the Pump (Set)
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4.3 Name plate



2009

m/h m
1/min
6
1
2
3
4
5
HPK-LE4 100-250
9971572908 000 10001
287
2978
85
Fig. 4: HPK-LE4 name plate
1 Type series 2 KSB order number
3 Flow rate 4 Speed
5 Year of construction 6 Head
4.4 Design details
Desi gn
Volute casing pump
Horizontal installation
Back pull-out design
Single-stage
Meets technical requirements to ISO 5199
Dimensions and ratings in accordance with EN 22 858/ISO 2858
complemented by pumps with nominal diameters DN 25, DN 200, DN 250 and
nominal impeller diameter 500 mm.
Pump casi ng
Single or double volute, depending on the pump size
Radially split volute casing
Volute casing with pump feet below
Fig. 5: Pump feet below
Volute casing (partly with casing wear ring) and casing cover
DANGER
Combustible fluids
Explosion hazard!
The pump casing must be made of ductile material containing no more than 7.5
% magnesium (see EN 13463-1).
I mpel l er type
Closed radial impeller with multiply curved vanes
Back vanes reduce axial thrust











4 Description of the Pump (Set)
HPK-L 17 of 62
Shaft seal
NOTE
Seal designs and types other than specified herein shall only be used in exceptional
cases and only after prior consultation with the manufacturer.
Single-acting, balanced standardised mechanical seal
The seal chamber is located between the product-lubricated pump-end plain
bearing and the outboard, motor-end rolling element bearing.

Mechani cal seal i n "dead end" arrangement
1. Never use mechanical seals which have not been approved by KSB.
2. Due to the complex conditions which need to be fulfilled for heat transfer liquid
pumps, the use of mechanical seals not approved by KSB shall not be covered by
KSB's scope of warranty.
Fig. 6: Mechanical seal in "dead end" arrangement
The seal chamber is cooled by cooling fins and ambient cooling air.
There is no external cooling system!
Motor-end bearing:
Fixed bearing
Grease-packed angular contact ball bearings sealed for life
Axial joint rings on both sides
Axial movement of the rotor limited to maximum 0.5 mm
Pump-end bearing:
Radial bearing
Absorbs radial loads only
Product-lubricated ceramic bearings
Example: P03
Table 7: Bearing bracket designation
Designation Description
L Air-cooled bearing bracket with integrated shaft seal chamber
P Process design
03 Size code (based on the dimensions of seal chamber and shaft end)
Refer to the data sheet to find your bearing design.
Table 8: Bearing design
KSB designation FAG designation SKF designation
B.G B-TVP-UA BECBP
B.G.8 B-TVP-UA 80 BEC86P





Design specifications
Bearing bracket
designation
Bearings used

4 Description of the Pump (Set)
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Table 9: Standard bearing assembly
Bearing
bracket
Pump end Motor end
Plain bearing (diameter in mm) Angular contact ball bearing
LP02 SSiC, 37 mm 2 x 7307 B.G
LP03 SSiC, 50 mm 2 x 7307 B.G
LP04 SSiC, 50 mm 2 x 7309 B.G.8
LP05 SSiC, 62 mm 2 x 7313 B.G
LP06 SSiC, 72 mm 2 x 7315 B.G
4.5 Configuration and function
1
3
2
6
10
9
4
8
7
5
Fig. 7: Sectional drawing
1 Clearance gap 2 Discharge nozzle
3 Casing cover 4 Drive shaft
5 Bearing bracket 6 Shaft seal
7 Suction nozzle 8 Impeller
9 Plain bearing, pump end 10 Rolling element bearing, motor
end
The pump is designed with an axial fluid inlet and a radial or tangential outlet. The
hydraulic system runs in its own bearings and is connected to the motor by a shaft
coupling.
The fluid enters the pump axially via a suction nozzle (7) and is accelerated outward
in a cylindrical flow by the rotating impeller (8). The flow profile of the pump casing
converts the kinetic energy of the fluid into pressure energy. The fluid is pumped to
the discharge nozzle (2), where it leaves the pump. The clearance gap (1) prevents
any fluid from flowing back from the casing into the inlet. The hydraulic system is
closed with a casing cover (3) at the rear side of the impeller; the shaft (4) enters the
casing via the casing cover (3). The shaft passage through the cover is sealed towards
the atmosphere with a shaft seal (6). The shaft runs in a pump-end plain bearing (9)
and a motor-end rolling element bearing (10). The bearings are supported by a
bearing bracket (5) linked with the pump casing and/or casing cover.


Design
Function

4 Description of the Pump (Set)
HPK-L 19 of 62
The pump is sealed by a standardised mechanical seal.
4.6 Noise characteristics
Table 10: Surface sound pressure level L
pA
3) 4)
Rated
power
input
P
N
[kW]
Pump Pump set
2900 rpm
[dB]
1450 rpm
[dB]
960 rpm
760 rpm
[dB]
2900 rpm
[dB]
1450 rpm
[dB]
960 rpm
760 rpm
[dB]
1 54 53 52 63 58 56
2 56 55 53 66 60 58
3 57 56 55 68 62 60
4 59 58 56 69 63 61
6 61 59 58 71 65 62
8 62 61 59 72 66 64
11 64 63 61 74 68 65
15 66 65 63 75 69 67
19 67 66 64 76 70 68
22 68 67 65 77 71 68
30 70 68 66 78 72 70
37 71 70 67 79 73 70
45 72 71 68 80 74 71
55 73 72 69 80 74 72
75 75 73 71 81 76 73
90 76 74 71 82 76 73
110 77 75 72 82 77 74
132 78 76 73 83 77 75
160 79 77 74 84 78 75
200 80 78 75 84 79 76
250 81 79 - 85 80 -
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
Pump
Surface-cooled IEC three-phase current squirrel-cage motor
Flexible coupling with or without spacer
Coupling guard to EN 294
Baseplate (to ISO 3661), cast or welded, for pump and motor, in torsion-resistant
design
Channel section steel or folded steel plate
As required
4.8 Dimensions and weights
For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump (set).
Sealing




Drive
Shaft coupling
Contact guard
Baseplate
Special accessories


3)
Spatial average; as per ISO 3744 and EN 12639; valid for operating range Q/Qopt = 0.8 - 1.1 and non-cavitating pump
operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance.
4)
Increase for 60 Hz operation: 3500 rpm+3 dB; 1750 rpm +1 dB; 1160 rpm:0 dB

4 Description of the Pump (Set)
20 of 62 HPK-L
5 Installation at Site
5.1 Safety regulations
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
Damage to the pump set!
Comply with the applicable local explosion protection regulations.
Observe the information in the data sheet and on the name plates of pump and
motor.
5.2 Checking the site before installation
Pl ace of i nstal l ati on
WARNING
Installation on foundations which are unsecured and cannot support the load
Personal injury and damage to property!
Make sure the foundation concrete is of sufficient strength (min. X0 to
DIN 1045).
Only place the pump set on a foundation whose concrete has set firmly.
Only place the pump set on a horizontal and level surface.
Refer to the weights given in the general arrangement drawing.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.3 Installing the pump set
Always install the pump set in horizontal position.
DANGER
Excessive temperatures due to improper installation
Explosion hazard!
Install the pump in horizontal position to ensure self-venting of the pump.
5.3.1 Installation on the foundation
1
2
4 3
Fig. 8: Fitting the shims
1 Bolt-to-bolt clearance 2 Shim
3 Shim for bolt-to-bolt clearance >
800 mm
4 Foundation bolt
The foundation has the required strength and characteristics.













5 Installation at Site
HPK-L 21 of 62
The foundation has been prepared in accordance with the dimensions given in
the outline drawing/general arrangement drawing.
1. Position the pump set on the foundation and align it with the help of a spirit
level placed on the shaft and discharge nozzle.
Permissible deviation: 0.2 mm/m.
2. Use shims (2) for height compensation, if necessary.
Always fit shims between the baseplate/foundation frame and the foundation
itself; always insert them to the left and right of the foundation bolts (4) and in
close proximity to these bolts.
For a bolt-to-bolt clearance > 800 mm, fit additional shims (3) halfway between
the adjoining holes.
All shims must lie perfectly flush.
3. Insert the foundation bolts (4) into the holes provided.
4. Use concrete to set the foundation bolts (4) into the foundation.
5. Wait until the concrete has set firmly, then align the baseplate.
6. Tighten the foundation bolts (4) evenly and firmly.
7. Grout the baseplate using low-shrinkage concrete with a standard particle size
and a water/cement ratio of 0.5.
Produce flowability with the help of a solvent.
Perform secondary treatment of the concrete to DIN 1045.
NOTE
For low-noise operation contact KSB to check whether the pump set can be installed on
anti-vibration mounts.
NOTE
Expansion joints can be fitted between pump and suction/discharge line.
5.3.2 Installation without foundation
4
1
2
3
Fig. 9: Adjusting elements
1, 3 Lock nut 2 Adjusting nut
4 Adjusting element
The installation surface has the required strength and characteristics.
1. Position the pump set on the adjusting elements (4) and align it with the help of
a spirit level (on the shaft/discharge nozzle).
2. To adjust any differences in height, loosen the bolts and lock nuts (1, 3) of the
adjusting elements (4).
3. Turn the adjusting nut (2) until any differences in height have been
compensated.





5 Installation at Site
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4. Re-tighten the lock nuts (1, 3) at the adjusting elements (4).
5.4 Piping
5.4.1 Connecting the piping
DANGER
Excessive loads acting on the pump nozzles
Danger to life from leakage of hot, toxic, corrosive or flammable fluids!
Do not use the pump as an anchorage point for the piping.
Anchor the pipelines in close proximity to the pump and connect them without
transmitting any stresses or strains.
Observe the permissible forces and moments at the pump nozzles.
Take appropriate measures to compensate thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
Never earth the electric welding equipment on the pump or baseplate.
Prevent current flowing through the rolling element bearings.
NOTE
It is recommended to install check and shut-off elements in the system, depending on the
type of plant and pump. However, such elements must not obstruct proper drainage or
hinder disassembly of the pump.
The suction lift line/suction head line has been laid with a rising/downward slope
towards the pump.
The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
To prevent excessive pressure losses, adapters to larger diameters have a diffuser
angle of approximately 8.
The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the suction
and discharge nozzles of the pump.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
Free the piping from any impurities.
If necessary, install a filter.
Observe the instructions in ( Section 7.2.2.3 Page 42).
3. If required, install a filter in the piping (see drawing: Filter in the piping).









5 Installation at Site
HPK-L 23 of 62
1
2
Fig. 10: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of
corrosion-resistant material.
Use a filter three times the diameter of the piping.
Conical filters have proved suitable.
4. Connect the pump nozzles with the piping.
CAUTION
Aggressive flushing and pickling agents
Damage to the pump!
Match the cleaning operation mode and duration for flushing and pickling
service to the casing and seal materials used.
5.4.2 Permissible forces and moments at the pump nozzles
[+]
F
y
F
z
F
x
F
x
F
z
F
y
F
x
F
z
F
y
M
y
M
z
M
x
Forces and moments at the pump nozzles
The resulting permissible forces have
been determined according to the
following formulas:

The data on forces and moments apply to static pipelines only. If the limits are
exceeded, they must be checked and verified.
If a computerised strength analysis is required, please contact KSB!
The values are only applicable if the pump is installed on a completely grouted
baseplate and bolted to a rigid and level foundation.
The forces and moments were determined on the basis of API 610 (6th edition), table
2, values doubled.






5 Installation at Site
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Table 11: Forces and moments at the pump nozzles
Pump
sizes
Suction nozzle
[N]
Discharge nozzle
[N]
Suction nozzle
[Nm]
Discharge nozzle
[Nm]
F
x
F
y
F
z
F
res
F
x
F
yTens
+
F
yPress
- F
z
F
res
M
x
M
y
M
z
M
x
M
y
M
z
25-160
25-200
1050 700 850 1100 500 350 650 450 700 550 450 300 400 300 200
32-125
32-160
32-200
32-250
1350 900 1100 1400 700 450 850 550 900 700 550 350 450 350 250
40-160
40-200
40-250
40-315
1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 550 450 300
50-160
50-200
50-250
50-315
2150 1400 1700 2200 1100 700 1350 900 1400 1450 1100 750 700 550 350
65-160
65-200
65-250
65-315
2700 1750 2150 2750 1400 900 1750 1150 1800 2000 1500 1000 1150 850 600
80-160
80-200
80-250
80-315
80-400
3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 750
100-200
100-250
100-315
100-400
3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
125-250
125-315
125-400
4700 3100 3750 4750 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400
150-250
150-315
150-400
150-500
7350 4700 5700 7400 3750 2350 4700 3100 4850 5300 3850 2650 3450 2650 1750
200-250 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
200-315
200-400
200-500
10000 6700 8000 10450 5700 3550 7350 4700 7400 7500 5700 3650 5300 3850 2650
250-315
250-400
250-500
12000 8000 10000 12800 8000 5000 10000 6700 10450 9150 6900 4500 7500 5700 3650
Correction coefficients depending on material and temperature (see diagram below).

5 Installation at Site
HPK-L 25 of 62
1.00
0.75
0.80
0.85
0.90
0.95
0.50
0.55
0.60
0.65
0.70
400 350 300 250 200 150 120
JL1040
GP240GH+N
JS1025
1.4408
C
Correction coefficient
Fig. 11: Temperature correction coefficients
No reduction is necessary for material 1.7706.
5.4.3 Auxiliary connections
The pump works without any external cooling system.
The mechanical seal does not require any cooling liquid, sealing liquid or flushing
liquid.
5.5 Protective equipment
DANGER
An explosive atmosphere forms due to insufficient venting
Explosion hazard!
Never close or cover the perforation of the bearing bracket guards (e.g. by
insulation).
WARNING
The volute casing and casing/discharge cover take on the same temperature as the fluid
handled
Risk of burning!
Insulate the volute casing.
Fit protective equipment.
CAUTION
Heat build-up in the bearing bracket
Damage to the bearing!
Never insulate the bearing bracket, bearing bracket lantern and casing cover.
5.6 Checking the coupling alignment
DANGER
Inadmissible temperatures at the coupling or bearings due to misalignment of the
coupling
Explosion hazard!
Make sure that the coupling is correctly aligned at all times.









5 Installation at Site
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CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
Always check the coupling after the pump has been installed and connected to
the piping.
Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
B
A
A
B
a) b)
B
B
A
A
1
1 2
2 1
1
Fig. 12: a) Checking the coupling alignment and b) Aligning a spacer-type coupling
1 Straight-edge 2 Wedge gauge
The coupling guard and step guard, if any, have been removed.
1. Loosen the support foot and re-tighten it without transmitting any stresses and
strains.
2. Place the straight-edge axially on both coupling halves.
3. Leave the straight-edge in this position and turn the coupling by hand.
The coupling is correctly aligned if the distances A) and B) to the respective shafts
are the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed 0.1 mm
during standstill as well as at operating temperature and under inlet pressure.
4. Check the distance between the two coupling halves around the circumference.
The coupling is correctly aligned if the distance between the two coupling halves
is the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed 0.1 mm
during standstill as well as at operating temperature and under inlet pressure.
5.7 Aligning the pump and motor
After having installed the pump set and connected the piping, check the coupling
alignment and, if required, re-align the pump set (at the motor).





5 Installation at Site
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5.7.1 Motors with levelling screw
1
3
2
Fig. 13: Motor with levelling screw
1 Hexagon head bolt 2 Levelling screw
3 Lock nut
The coupling guard and step guard, if any, have been removed.
1. Check the coupling alignment.
2. Unscrew the hexagon head bolts (1) at the motor and the lock nuts (3) at the
baseplate.
3. Turn the levelling screws (2) by hand or by means of an open-jawed wrench until
the coupling alignment is correct.
4. Re-tighten the hexagon head bolts (1) at the motor and the lock nuts (3) at the
baseplate.
5. Check that the coupling and shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
Observe all relevant regulations for selecting a coupling guard.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!
Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
6. Re-install the coupling guard and step guard, if any.
7. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
5.7.2 Motors without levelling screw
Any differences in the centre heights of the pump and motor shafts are compensated
by means of shims.








5 Installation at Site
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1
Fig. 14: Pump set with shim
1 Shim
The coupling guard and step guard, if any, have been removed.
1. Check the coupling alignment.
2. Unscrew the hexagon head bolts at the motor.
3. Insert shims underneath the motor feet until the difference in shaft centre height
has been compensated.
4. Re-tighten the hexagon head bolts.
5. Check that the coupling and shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
Observe all relevant regulations for selecting a coupling guard.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!
Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
6. Re-install the coupling guard and step guard, if any.
7. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
5.8 Electrical connection
DANGER
Incorrect electrical installation
Explosion hazard!
For electrical installation, also observe the requirements of IEC 60079-14.
Always connect explosion-proof motors via a motor protection switch.
DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
Always have the electrical connections installed by a trained electrician.
Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pump
sets, IEC 60079 (DIN VDE 0165).







5 Installation at Site
HPK-L 29 of 62
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method.
NOTE
It is recommended to fit a motor protection device.
5.8.1 Setting the time relay
CAUTION
Switchover between star and delta on three-phase motors with star-delta starting takes
too long
Damage to the pump (set)!
Keep switch-over intervals between star and delta as short as possible (see table:
Time relay settings for star-delta starting).
Table 12: Time relay settings for star-delta starting:
Motor rating Y time to be set
30 kW < 3 s
> 30 kW < 5 s
5.8.2 Connecting the motor
NOTE
In compliance with DIN VDE 0530 - Part 8, three-phase motors are always wired for
clockwise rotation (looking at the motor shaft stub).
The pump's direction of rotation is indicated by an arrow on the pump.
1. Change the motor's direction of rotation to match that of the pump.
2. Observe the manufacturer's product literature supplied with the motor.
5.9 Checking the direction of rotation
DANGER
Temperature increase resulting from contact between rotating and stationary
components
Explosion hazard!
Damage to the pump set!
Never check the direction of rotation by starting up the unfilled pump set.
Separate the pump from the motor to check the direction of rotation.
WARNING
Hands or objects inside the pump casing
Risk of injuries, damage to the pump!
Never insert your hands or any other objects into the pump.
Check that the inside of the pump is free from any foreign objects.













5 Installation at Site
30 of 62 HPK-L
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
Separate the pump from the motor to check the direction of rotation.
CAUTION
Motor and pump running in the wrong direction of rotation
Damage to the pump!
Refer to the arrow indicating the direction of rotation on the pump.
Check the direction of rotation. If required, interchange any two phases to
correct the direction of rotation.
The correct direction of rotation of motor and pump is clockwise (seen from the
motor end).
1. Start the pump set and stop it again immediately to determine the motor's
direction of rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction
of rotation on the pump.
3. If the motor is running in the wrong direction of rotation, check the electrical
connection of the motor and the control system, if necessary.




5 Installation at Site
HPK-L 31 of 62
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/start-up
6.1.1 Prerequisites for commissioning/start-up
Before starting up the pump set make sure that the following requirements are met:
The pump set has been properly connected to the electric power supply and is
equipped with all protection devices.
The pump, including the bearing bracket (mechanical seal chamber), has been
primed with the fluid to be handled.
The direction of rotation has been checked. ( Section 5.9 Page 30)
The lubricants have been checked.
After prolonged shutdown of the pump (set), the activities described in (
Section 6.4 Page 39) have been carried out.
NOTE
The hot water shall comply with the minimum requirements of the VdTV regulations
TCH 1466/AGFW 5-15 (edition 2.89).
Do not exceed the following limits:
Table 13: Limits for hot water
Limits
Electrical conductivity < 250 s/cm
pH value at 25C 9-10.5
Silicates (SiO
2
) < 10 mg/l
Solids < 5 mg/l
NOTE
No warranty can be given on the service life of the mechanical seal for hot water with an
electrical conductivity exceeding 250 s/cm and for hot water with unknown water quality
For ultra-pure water (fully desalinated, demineralised water) with an electrical
conductivity < 2 s/cm, the temperature at the seal faces must be at least 20 % below
the boiling point.
NOTE
When conditioners producing a greasy film on the seal faces are used, e.g. Maxigard,
Antifrogen N, Preventol Cl-2, KeboX, Nalfleet 9-11, no warranty can be given on the seal
life because of their adverse effect on the seal. In such cases please contact KSB.
6.1.2 Filling in lubricants
Grease-lubricated bearings have been packed with grease at the factory.
6.1.3 Shaft seal
Shaft seals are fitted prior to delivery.
Observe the instructions on dismantling ( Section 7.4.8 Page 46) or reassembly (
Section 7.5.3 Page 48) .
NOTE
When new plants are commissioned and a large amount of foreign matter is in the
system, expect short service lives of the mechanical seal during the initial phase of plant
operation.















6 Commissioning/Start-up/Shutdown
32 of 62 HPK-L
NOTE
Only modify the specified sealing concepts and seal types after consultation with KSB.
Due to the complex conditions in hot water systems, the use of mechanical seals not
approved by KSB shall not be covered by KSB's scope of warranty.
6.1.4 Filling and venting the pump
DANGER
An explosive atmosphere forms inside the pump
Explosion hazard!
The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
Provide sufficient inlet pressure.
Provide an appropriate monitoring system.
DANGER
Shaft seal failure caused by dry running
Hot or toxic fluid could escape!
Damage to the pump!
Before starting up the pump set, vent the pump and suction line and fill both
with the fluid to be handled.
1. Vent the pump and suction line and fill them with the fluid to be handled.
2. Fully open the shut-off element in the suction line.
In the as-supplied condition, auxiliary connection 13 D for venting the seal chamber is
closed with a screwed plug with vent hole 903.85.
High-temperature pumps must be vented before they are commissioned.
As soon as gas stops escaping, close screwed plug 903.85 to prevent any hot fluid
from flowing into the mechanical seal chamber.
13 D
Fig. 15: Auxiliary connection 13 D
13D Screwed plug 903.85
NOTE
On request, the screwed plug can be replaced by a valve in the discharge pipe for
commissioning to safely drain gases and hot fluids during venting.
For temperatures exceeding 200 and pressures exceeding 25 bar, use a vent valve and
vent line.
1. Switch off the pump and let it run down to a standstill.
2. Let gases drain reliably.???
3. Close the shut-off elements as required by the system configuration.
4. To vent the bearing bracket undo screwed plug 903.85 by approx. 1/2 turn at a
time until no more gas escapes.
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






Venting the seal chamber

Venting during pump
operation

Excessive venting

6 Commissioning/Start-up/Shutdown
HPK-L 33 of 62
inadmissible heat build-up in the mechanical seal. The vent valve must be closed
again as soon as no further gases escape.
6.1.5 Final check
1. Remove the coupling guard and step guard, if any.
2. Check the coupling alignment; re-align the coupling, if required. ( Section 5.6
Page 26)
3. Check that the coupling and shaft can easily be rotated by hand.
4. Re-install the coupling guard and step guard, if any.
5. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
6.1.6 Cooling of the mechanical seal chamber
The mechanical seal chamber is integrated in the bearing bracket and cooled by the
ambient temperature via cooling fins.
An integrated fan impeller ensures a continuous cooling air flow.
An unobstructed supply of cooling air to the fan hood and fan impeller must be
ensured at all times!
1. In exceptional cases, the pump can be operated without the integrated fan
impeller.
If the coarse dust blocks the cooling air intake, the following parts also have to
be removed:
Fan hood 832
Guard 680
Cooling air flow with a cooling air velocity of at least 4 m/s in the proximity of the
cooling fins.
The cooling air flow is generated by the motor cooling device or an external fan.
6.1.7 Heating up/keeping warm the pump (set)
CAUTION
Pump blockage
Damage to the pump!
Prior to pump start-up, heat up the pump as described in the manual.
Observe the following when heating up the pump (set) and keeping it warm:
Make sure the temperature is increased continuously.
Max. heating speed: 10 C/min (10 K/min)
If the pump is used for handling fluids with fluid temperatures exceeding 150 C,
make sure that the pump has been sufficiently heated throughout before starting it
up.
The temperature difference between the pump's surface and the fluid handled must
not exceed 100 C (100 K) when the pump is started up.







Fluid temperatures above
150 C
Temperature difference

6 Commissioning/Start-up/Shutdown
34 of 62 HPK-L
6.1.8 Start-up
DANGER
The permissible pressure and temperature limits will be exceeded if the pump is
operated with the suction and discharge lines closed.
Explosion hazard!
Leakage of hot or toxic fluids!
Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
Only start up the pump set with the discharge side gate valve slightly or fully
open.
DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid handled
Explosion hazard!
Damage to the pump set!
Never operate the pump set without liquid fill.
Prime the pump as specified.
Always operate the pump within the permissible operating range.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
Switch off the pump (set) immediately.
Eliminate the causes before returning the pump set to service.
The system piping has been cleaned.
Pump, suction line and inlet tank, if any, have been vented and filled with the
fluid to be pumped.
The filling and venting lines have been closed.
CAUTION
Start-up against open discharge line
Motor overload!
Make sure the power reserve of the motor is sufficient.
Use a soft starter.
Use speed control.
1. Fully open the shut-off element in the suction head/suction lift line.
2. Close or slightly open the shut-off element in the discharge line.
3. Start up the motor.
4. Immediately after the pump has reached full rotational speed, slowly open the
shut-off element in the discharge line and adjust it to comply with the duty
point.
DANGER
Seal leakage at operating temperature
Hot or toxic fluid could escape!
After the operating temperature has been reached and/or in the event of
leakage, switch off the pump set and re-tighten the bolts between lantern and
casing.
Check the coupling alignment. Re-align the coupling if required.









6 Commissioning/Start-up/Shutdown
HPK-L 35 of 62
5. When the operating temperature has been reached and/or in the event of
leakage, switch off the pump set and re-tighten the bolts between lantern and
casing.
6. Check the coupling alignment and re-align the coupling, if required.
6.1.9 Checking the shaft seal
The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
Slight leakage at the seal is permissible and desirable.
If the leakage exceeds 8 l/h the seal is defective and needs to be replaced.
6.1.10 Shutdown
The shut-off element in the suction line is and remains open.
1. Close the shut-off element in the discharge line.
2. Switch off the motor and make sure the pump set runs down smoothly to a
standstill.
NOTE
If the discharge line is equipped with a non-return or check valve, the shut-off element
may remain open as long as there is back pressure.
NOTE
If shut-off is not possible, the pump will run in reverse direction.
The reverse runaway speed must be lower than the rated speed.
For prolonged shutdown periods:
1. Close the shut-off element in the suction line.
2. Close the auxiliary connections.
If the fluid to be pumped is fed in under vacuum, also supply the shaft seal with
barrier fluid during standstill.
Only turn off the cooling liquid supply after the pump has cooled down.
CAUTION
Risk of freezing during prolonged pump shutdown periods
Damage to the pump!
Drain the pump and the cooling/heating chambers (if any) or otherwise protect
them against freezing.
6.2 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature and speed
Hot or toxic fluid could escape!
Explosion hazard!
Comply with the operating data indicated in the data sheet.
Avoid prolonged operation against a closed shut-off element.
Never operate the pump at temperatures exceeding those specified in the data
sheet or on the name plate unless the written consent of the manufacturer has
been obtained.


Mechanical seal









6 Commissioning/Start-up/Shutdown
36 of 62 HPK-L
6.2.1 Ambient temperature
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
Table 14: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 40 C
Minimum See data sheet.
6.2.2 Frequency of starts
DANGER
Excessive surface temperature of the motor
Explosion hazard!
Damage to the motor!
In case of explosion-proof motors, observe the frequency of starts specified in
the manufacturer's product literature.
The frequency of starts is usually determined by the maximum temperature increase
of the motor. This largely depends on the power reserves of the motor in steady-
state operation and on the starting conditions (d.o.l., star-delta, moments of inertia,
etc). If the start-ups are evenly spaced over the period indicated, the following limits
can be used for orientation for start-up with the discharge-side gate valve slightly
open:
Table 15: Frequency of starts
Motor rating
[kW]
Maximum No. of start-ups
[Start-ups/hour]
up to 12 15
up to 100 10
more than 100 5
CAUTION
Re-start while motor is still running down
Damage to the pump (set)!
Do not re-start the pump set before the pump rotor has come to a standstill.
6.2.3 Flow rate
Unless specified otherwise in the characteristic curves or in the data sheets, the
following applies:
Short-time operation: Q
min
5)
=0.1xQ
opt
6)
Continuous operation: Q
min
5)
=0.3xQ
opt

6)
2-pole operation: Q
max
7)
=1,1xQ
opt

6)
4-pole operation: Q
max
7)
=1.25xQ
opt
6)
The data refer to water and water-like fluids. Longer operating periods with these
fluids and at the flow rates indicated will not cause an additional increase in the









5)
Minimum permissible flow rate
6)
Best efficiency point
7)
Maximum permissible flow rate

6 Commissioning/Start-up/Shutdown
HPK-L 37 of 62
temperatures on the pump surface. However, if the physical properties of the fluids
handled are different from water, the calculation formula below must be used to
check if an additional heat build-up may lead to a dangerous temperature increase at
the pump surface. If necessary, the minimum flow must be increased.
Table 16: Key
Symbol Description Unit
c Specific heat capacity J/kg K
g Gravitational constant m/s
H Pump head m
T
f
Temperature of the fluid handled C
T
o
Temperature at the casing surface C
Pump efficiency at duty point -
Temperature difference C
6.2.4 Density of the fluid handled
The power input of the pump increases in proportion to the density of the fluid
handled.
CAUTION
Excessive density of the fluid handled
Motor overload!
Observe the information on fluid density indicated in the data sheet.
Make sure the power reserve of the motor is sufficient.
6.2.5 Abrasive fluids
Do not exceed the maximum permissible solids content specified in the data sheet.
When the pump handles fluids containing abrasive substances, increased wear of the
hydraulic system and the shaft seal are to be expected. In this case, reduce the
intervals commonly recommended for servicing and maintenance.
6.3 Shutdown/storage/preservation
6.3.1 Measures to be taken for shutdown
The pump ( set) remai ns i nstal l ed
Sufficient fluid is supplied for the operation check run of the pump.
1. Start up the pump (set) regularly once a month or once every three months for
approximately five minutes during prolonged shutdown periods.
This will prevent the formation of deposits within the pump and the pump
intake area.
The pump ( set) i s removed from the pi pe and stored
The pump has been properly drained ( Section 7.3 Page 43) and the safety
instructions for dismantling the pump have been observed. ( Section 7.4.1 Page
43)
1. Spray-coat the inside wall of the pump casing, and in particular the impeller
clearance areas, with a preservative.
2. Spray the preservative through the suction and discharge nozzles.
It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).












6 Commissioning/Start-up/Shutdown
38 of 62 HPK-L
3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil and
grease, food-approved if required) to protect them against corrosion.
Observe the additional instructions. ( Section 3.2 Page 13)
If the pump set is to be stored temporarily, only preserve the wetted components
made of low alloy materials. Commercially available preservatives can be used for this
purpose. Observe the manufacturer's instructions for application/removal.
Observe any additional instructions and information provided. ( Section 3 Page 13)
6.4 Returning to service after storage
For returning the pump to service observe the sections on commissioning/start-up (
Section 6.1 Page 32) and the operating limits ( Section 6.2 Page 36) .
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. ( Section 7 Page 40)
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
As soon as the work is complete, re-install and/or re-activate any safety-relevant
and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer seals.





6 Commissioning/Start-up/Shutdown
HPK-L 39 of 62
7 Servicing/Maintenance
7.1 Safety regulations
DANGER
Improperly serviced pump set
Explosion hazard!
Damage to the pump set!
Service the pump set regularly.
Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.
The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly familiar
with the manual.
WARNING
Pump set started up inadvertently
Risk of injury by moving parts!
Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
Make sure that the pump set cannot be switched on accidentally.
WARNING
Fluids posing a health hazard or hot fluids
Risk of personal injury!
Observe all relevant laws.
When draining the fluid take appropriate measures to protect persons and the
environment.
Decontaminate pumps handling fluids posing a health hazard.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump (set) with a minimum of maintenance
expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service. Find
your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/
contact".
Never use force when dismantling and reassembling a pump set.
7.2 Servicing/inspection
7.2.1 Supervision of operation
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
Fire hazard!
Damage to the pump set!
Regularly check the lubricant level.
Regularly check the rolling element bearings for running noises.













7 Servicing/Maintenance
40 of 62 HPK-L
CAUTION
Increased wear due to dry running
Damage to the pump set!
Never operate the pump set without liquid fill.
Never close the shut-off element in the suction line and/or supply line during
pump operation.
CAUTION
Excessive fluid temperature
Damage to the pump!
Prolonged operation against a closed shut-off element is not permitted (heating
up of the fluid).
Observe the temperature limits in the data sheet and in the section on
Operating limits. ( Section 6.2 Page 36)
While the pump is in operation, observe and check the following:
The pump must run quietly and free from vibrations at all times.
Check the shaft seal.
Check the static seals for leakages.
Check the rolling element bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
Monitor the correct functioning of any auxiliary connections.
Cooling system
Take the pump out of service at least once year to thoroughly clean the cooling
system.
Monitor the stand-by pump.
To make sure that the stand-by pumps are ready for operation, start them up
once a week.
Monitor the bearing temperature.
The bearing temperature must not exceed 90 C (measured on the outside of the
bearing bracket).
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
The bearing temperature of the pump (set) must never exceed 90 C (measured
on the outside of the bearing bracket).
NOTE
After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is only
reached after a certain period of operation (up to 48 h depending on the conditions).
7.2.2 Inspection work
DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
Damage to the pump set!
Regularly check the coupling guard, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.








7 Servicing/Maintenance
HPK-L 41 of 62
7.2.2.1 Checking the coupling
Check the flexible elements of the coupling. Replace these parts in due time if there
is any sign of wear.
7.2.2.2 Checking the clearance gaps
To check the clearance gaps, remove the back pull-out unit.
If the clearance gap is larger than permitted (see the following table), replace casing
wear ring 502.01 with a new one.
The clearance gaps given refer to the diameter.
Table 17: Clearance gaps between impeller and casing / between impeller and casing
wear ring
HPK-LS/-LS4 HPK-LE/-LE4
up to DN 65 0.40 mm + 0.1 0.60 mm + 0.1
DN 80 to DN 200 0.50 mm + 0.1 0.60 mm + 0.1
DN 250 and above 0.65 mm + 0.1 0.75 mm + 0.1
All HPK-LS/-LS4 pumps are fitted with casing wear rings.
Table 18: Clearance gaps in the plain bearing
Bearing bracket Bearing clearance
LP02 0.03 mm + 0.045
LP03 0.05 mm + 0.045
LP04 0.05 mm + 0.045
LP05 0.05 mm + 0.05
LP06 0.05 mm + 0.05
NOTE
If the clearances given are exceeded by more than 1 mm (referring to the diameter)
replace the affected components or restore the original clearance by means of a casing
wear ring.
Contact KSB.
7.2.2.3 Cleaning filters
CAUTION
Insufficient inlet pressure due to clogged filter in the suction line
Damage to the pump!
Monitor contamination of filter with suitable means (e.g. differential pressure
gauge).
Clean filter in appropriate intervals.
7.2.3 Lubrication and lubricant change of rolling element bearings
7.2.3.1 Grease lubrication
The bearings are supplied packed with high-quality lithium-soap grease.
7.2.3.1.1 Grease quality
We recommend using Petro-Canada Peerless LLG high-temperature grease or an
equivalent product for lubrication. Under unfavourable operating conditions, e.g.
high room temperature, high atmospheric humidity, dust-laden air, aggressive
atmosphere etc., check the bearings earlier and, if required, clean and re-lubricate
them, preferably with Petro-Canada Peerless LLG.













7 Servicing/Maintenance
42 of 62 HPK-L
7.2.3.1.2 Grease quantities
Bearing bracket Bearings Grease qty. per single
bearing
LP02 7307 BG 6.5 to 8 g
LP03 7307 BG 6.5 to 8 g
LP04 7309 BG 13 to 15.5 g
LP05 7313 BG 23 to 26 g
LP06 7315 BG 29 to 33 g
The grease quantity indicated must be used for each single bearing of a bearing pair.
7.2.3.1.3 Intervals
Under suitable operating conditions the grease-lubricated 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) check
the bearings earlier and clean and re-lubricate them, if required.
Replace the rolling element bearings after 25,000 operating hours or 3 years of
continuous operation.
7.3 Drainage/disposal
WARNING
Fluids posing a health hazard
Hazardous to persons and the environment!
Collect and properly dispose of flushing liquid and any fluid residues.
Wear safety clothing and a protective mask, if required.
Observe all legal regulations on the disposal of fluids posing a health hazard.
If the fluids handled by the pump (set) leave residues which might lead to corrosion
when coming into contact with atmospheric humidity, or which might ignite when
coming into contact with oxygen, the pump (set) must be flushed through,
neutralised, and blown through with anhydrous gas for drying purposes.
Use connection 6B to drain the fluid handled (see auxiliary connections).
7.4 Dismantling the pump set
7.4.1 General notes/Safety regulations
DANGER
Insufficient preparation of work on the pump (set)
Risk of personal injury!
Properly shut down the pump set.
Close the shut-off elements in the suction and discharge line.
Drain the pump and release the pump pressure. ( Section 7.3 Page 43)
Close any auxiliary connections.
Allow the pump set to cool down to ambient temperature.











7 Servicing/Maintenance
HPK-L 43 of 62
WARNING
Unqualified personnel performing work on the pump (set)
Risk of personal injury!
Always have repair and maintenance work performed by specially trained,
qualified personnel.
WARNING
Hot surface
Risk of personal injury!
Allow the pump set to cool down to ambient temperature.
WARNING
Thin metal foil used as carrier material in gaskets/joint rings
Risk of injury (cuts)!
Wear protective clothing.
Always use an appropriate tool to remove gaskets/joint rings.
Observe the general safety instructions and information ( Section 7.1 Page 40).
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly observe the exploded views and the general
assembly drawing.
In the event of damage you can always contact our service staff.
NOTE
After a prolonged period of operation the individual parts may be hard to pull off the
shaft. If this is the case, use a brand name penetrating agent and/or - if possible - an
appropriate pull-off device.
NOTE
It is recommended to place a drip pan under the pump along its entire length to collect
any fluid escaping during dismantling.
7.4.2 Preparing the pump set
1. Disconnect the power supply (e.g. at the motor).
2. Disconnect and remove all auxiliary pipework.
3. Remove the coupling guard.
4. Remove the coupling spacer, if any.
7.4.3 Dismantling the motor
NOTE
For pump sets with spacer-type couplings, the back pull-out unit can be removed while
the motor remains bolted to the baseplate.
1. Disconnect the motor from the power supply.
2. Unbolt the motor from the baseplate.
3. Shift the motor to separate it from the pump.












7 Servicing/Maintenance
44 of 62 HPK-L
WARNING
Motor tipping over
Risk of squashing hands and feet!
Suspend or support the motor to prevent it from tipping over.
7.4.4 Removing the back pull-out unit
On pump sets without spacer-type coupling, the motor has been removed.
The notes and steps stated in ( Section 7.4.1 Page 43) to ( Section 7.4.3 Page
44) have been observed/carried out.
WARNING
Back pull-out unit tipping over
Risk of squashing hands and feet!
Suspend or support the bearing bracket at the pump end.
1. If required, suspend or support bearing bracket 330 to prevent it from tipping
over.
2. Unbolt support foot 183 from the baseplate.
3. Loop a rope tightly around the neck of bearing bracket 330.
4. Undo hexagon nut 920.01 at the volute casing.
5. Pull the back pull-out unit out of the volute casing.
6. If necessary, clean the threaded holes for forcing screws 901.31 and use forcing
screws.
7. Remove and dispose of joint ring 411.10.
8. Place the back pull-out unit on a clean and level surface.
7.4.5 Removing the impeller
The notes and steps stated in ( Section 7.4.1 Page 43) to ( Section 7.4.4 Page
45) have been observed/carried out.
The back pull-out unit is kept in a clean and level assembly area.
1. Undo hexagon nut 920.95.
2. Remove disc 550.87 from shaft 210.
3. Pull impeller 230 off shaft 210.
4. Remove keys 940.1.
7.4.6 Removing the plain bearing
The notes and steps stated in ( Section 7.4.1 Page 43) to ( Section 7.4.5 Page
45) have been observed/carried out.
1. 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.
7.4.7 Dismantling the bearings
The notes and steps stated in ( Section 7.4.1 Page 43) to ( Section 7.4.6 Page
45) have been observed/carried out.
The bearing is kept in a clean and level assembly area.
1. 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.
2. Loosen hexagon head bolts 901.84 and remove fan hood 832.












7 Servicing/Maintenance
HPK-L 45 of 62
3. 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
hexagon nuts 920.04 and pull bearing bracket 330 out of casing cover 161.
4. Undo socket head cap screws 914.02.
5. 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.
6. Pull taper lock ring 515.22 and bearing sleeve 529.21 off the shaft (unless this has
already been done).
7. Pull taper lock ring 515.22 and bearing sleeve 529.21 out of the bearing bracket
(unless this has already been done).
8. Bend open 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.
9. Undo grub screws 904.32.
10. Remove support disc 550.59 (LP02 and LP03 only) and O-ring 412.07.
11. Pull shaft sleeve 523 with mechanical seal 433.02 off shaft 210 towards the pump
end.
12. Pull out seat ring holder 476 with the seat ring of the mechanical seal towards
the pump end.
13. Take the seat ring out of seat ring holder 476.
14. Pull bearing 320.02 off the shaft. Remove thrower 507.12, spacer sleeve 525.03
and pump-end ring 500.32 from shaft 210.
NOTE
The bearings are packed with grease and must not be heated up for dismantling, or, if
heated up, they must be re-packed with grease!
7.4.8 Removing the mechanical seals
The notes and steps stated in ( Section 7.4.1 Page 43) to ( Section 7.4.7 Page
45) have been observed/carried out.
The bearing bracket is kept in a clean and level assembly area.
1. Undo grub screws 904.32.
2. Remove support disc 550.59 (LP02 and LP03 only) and O-ring 412.07.
3. Pull shaft sleeve 523 with mechanical seal 433.02 off shaft 210 towards the pump
end.
4. Remove seat ring holder 476 with the seat ring of the mechanical seal towards
the pump end.
5. Take the seat ring out of seat ring holder 476.
7.4.9 Removing the plain bearing bush
The notes and steps stated in ( Section 7.4.1 Page 43) to ( Section 7.4.8 Page
46) have been observed/carried out.
The bearing bracket is kept in a clean and level assembly area.
1. Remove circlip 932.05.
2. Completely pull bearing bush 545.21 and tolerance ring 500.61 out of the
bearing bracket.






7 Servicing/Maintenance
46 of 62 HPK-L
7.5 Reassembling the pump set
7.5.1 General notes/Safety regulations
CAUTION
Improper reassembly
Damage to the pump!
Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
Use original spare parts only.
Always reassemble the pump in accordance with the corresponding general assembly
drawing.
Gaskets
Always use new gaskets, making sure that they have the same thickness as
the old ones.
Always fit gaskets of asbestos-free materials or graphite without using
lubricants (e.g. copper grease, graphite paste).
O-rings
Never use O-rings that have been glued together from material sold by the
metre.
CAUTION
Contact of O-ring with graphite or similar material
Fluid could escape!
Do not coat O-ring with graphite or similar material.
Use animal fats or lubricants based on silicone or PTFE.
Assembly adhesives
For gaskets, avoid the use of assembly adhesives, if possible.
Should assembly adhesives be required after all, use a commercially available
contact adhesive (e.g. "Pattex").
Only apply adhesive at selected points and in thin layers.
Never use quick-setting adhesives (cyanoacrylate adhesives).
Coat the locating surfaces of the individual components and screwed
connections with graphite or similar before reassembly.
For reassembly, tighten all screws and bolts as specified in this manual. ( Section 7.6
Page 51)
7.5.2 Installing the bearings
The individual parts are kept in a clean and level assembly area.
All disassembled parts have been cleaned and checked for wear.
Any damaged or worn parts have been replaced by original spare parts.
The sealing surfaces have been cleaned.
1. Slip thrower 507.12, spacer sleeve 525.03 (for LP02 - LP04 only) and ring 500.32
onto shaft 210.
2. Press angular contact ball bearing 320.02 onto the shaft as far as it will go.
NOTE
Angular contact ball bearings must be installed in "O" arrangement. Angular contact ball
bearings installed in pairs must always be from the same manufacturer.



Sequence
Seal elements


Tightening torques




7 Servicing/Maintenance
HPK-L 47 of 62
NOTE
The bearings are packed with grease and must not be heated up for reassembly, or, if
heated up, they must be re-packed with grease!
3. Push spacer sleeve 525.24 onto shaft 210 and use a C-spanner 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 the
locknut. Then slip on lockwasher 931.01.
6. Tighten locknut 920.21 and bend back the lockwasher.
7.5.3 Installing the shaft seal
7.5.3.1 Installing the mechanical seal
The notes and steps stated in ( Section 7.5.1 Page 47) to ( Section 7.5.2 Page
47) have been observed/carried out.
The individual parts are kept in a clean and level assembly area.
All disassembled parts have been cleaned and checked for wear.
Any damaged or worn parts have been replaced by original spare parts.
The sealing surfaces have been cleaned.
NOTE
Only remove the protective wrapping of the contact faces immediately before assembly
takes place.
1. Insert the seat ring and the secondary seals of the mechanical seal into seat ring
holder 476 and push them onto the shaft from the pump end.
2. Push the rotating components of the mechanical seal (torque-transmitting
element, springs, spring-loaded ring, secondary seal, etc.) onto shaft sleeve 523 as
a complete sub-assembly. Push this sub-assembly until it will not go any further.
Then lock it with the grub screws.
3. For LP02 and LP03: Push shaft sleeve 523 onto shaft 210.
The shaft sleeve is correctly positioned on the shaft when its pump-end face ("S"
in the following Fig.) is aligned with the mark on the shaft ("M" in the following
Fig).
4. Guide O-ring 412.07 and support disc 550.59 carefully along the shaft and press
them into the recess of shaft sleeve 523.
5. Screw in grub screws 904.32 by several turns to hold the support disc in place.
6. For LP04, LP05 and LP06: Insert O-ring 412.07 into shaft sleeve 523. Carefully
guide the shaft sleeve along the shaft.
On pumps with bearing bracket size LP04 to LP06, no mark is provided on the
shaft; in this case, align the shaft sleeve with the shaft collar.
7. In doing so, the springs of the mechanical seal are compressed and the seal faces
are pressed against each other.
8. Firmly tighten all grub screws 904.32.
9. When all components have been mounted on the shaft, make sure that the
contact faces are slightly pre-loaded by the springs of the mechanical seal (see
the following Fig).
10. Verify the correct axial position of shaft sleeve 523 and mechanical seal 433.02 on
shaft 210.








7 Servicing/Maintenance
48 of 62 HPK-L
CAUTION
Incorrect position of the mechanical seal
Hot fluid or steam may spurt out during operation!
Make sure the mechanical seal is seated properly.
LP02,
LP03
LP04,
LP05,
LP06
Mechanical seal M = marking on the shaft; S = face of the shaft sleeve
Table 19: List of components of the mechanical seal (not available as individual
parts)
Part No. Description Part No. Description
412.1 O-ring 477 Spring
412.2 O-ring 485 Torque-transmitting
element
472 Spring-loaded ring 520 Sleeve
474 Thrust ring 904 Grub screw
475 Seat ring
7.5.4 Fitting the plain bearing bush
The notes and steps stated in ( Section 7.5.1 Page 47) to ( Section 7.5.3.1 Page
48) have been observed/carried out.
1. If bearing bush 545.21 needs to be replaced, also replace the tolerance ring
500.61 in the groove of the bearing bracket
2. Swiftly press bearing bush 545.21 evenly into the bearing carrier (risk of
fractures: do not subject it to any blows).
3. Insert ring 932.05 into the groove of the bearing carrier to secure the bearing
bush axially.
7.5.5 Fitting the bearing carrier
The notes and steps stated in ( Section 7.5.1 Page 47) to ( Section 7.5.4 Page
49) have been observed/carried out.
1. Place guard 680 onto the bearing bracket.
2. Fit O-ring 412.82 on the seat ring holder.
3. Push shaft 210 with all assembled components into the bearing bracket.
4. Fasten the bearing cover with socket head cap screws 914.02.
5. Carefully insert joint ring 411.11.
6. Place bearing bracket 330 into casing cover 161 and firmly tighten it with nuts
920.04.







7 Servicing/Maintenance
HPK-L 49 of 62
7.5.6 Fitting the plain bearing
The notes and steps stated in ( Section 7.5.1 Page 47) to ( Section 7.5.5 Page
49) have been observed/carried out.
1. Clean all parts of plain bearing (sleeve) 310.10 and make sure that there are no
dirt particles between the conical surfaces of the bearing parts. Otherwise, the
parts will not be centred correctly, which will result in failure of the plain
bearing.
2. Prior to reassembly check whether the bearing parts and the impeller can be
easily fitted on shaft 210.
3. Slip taper lock ring 515.22, bearing sleeve 529.21, taper lock ring 515.21 and cup
spring 950.23 onto the shaft.
Mount cup springs 950.23 in such a way that the outside diameter of the cup
spring rests against taper lock ring 515.21.
7.5.7 Fitting the impeller
The notes and steps stated in ( Section 7.5.1 Page 47) to ( Section 7.5.6 Page
50) have been observed/carried out.
1. Insert key 940.01 and push impeller 230 onto shaft 210.
2. Insert disc 550.87 and tighten hexagon nut 920.95 with a torque wrench.
-- Tighten evenly to prevent damage to the bearings. -- Rotate the shaft by hand
several times while tightening the nut (the shaft must be easy to rotate). Stop
the tightening procedure if the shaft seems to be blocked. Loosen the nut and
repeat the tightening procedure. If the shaft is blocked repeatedly, dismantle the
components again and check for cleanliness and correct dimensions.
3. 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.
7.5.8 Fitting the back pull-out unit
The notes and steps stated in ( Section 7.5.1 Page 47) to ( Section 7.5.7 Page
50) have been observed/carried out.
1. Carefully insert joint ring 411.10 into volute casing 102.
2. Guide the rotating pump assembly into volute casing 102 and tighten nut 920.01.
3. Check whether the rotor can easily be turned by hand.
4. Bolt support foot 183 to bearing bracket 330 and to the baseplate.
5. Mount fan hood 832 and fasten it together with guard 680, using hexagon head
bolts 901.84.
6. Insert key 940.02. Fasten the coupling half on the shaft.
7.5.9 Mounting the motor
NOTE
Steps 1 and 2 do not apply to versions with spacer-type coupling.
1. Shift the motor to connect it to the pump via the coupling.
2. Fasten the motor to the baseplate.
3. Align the pump. ( Section 5.7 Page 27)
4. Connect the motor to the power supply (refer to manufacturer's product
literature).










7 Servicing/Maintenance
50 of 62 HPK-L
7.6 Tightening torques
7.6.1 Tightening torques of volute casing/bearing carrier
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 hexagon nut for impeller fastening
920.95 and grub screws 904.32 for fastening the shaft sleeve must be tightened with
a torque wrench. Observe the tightening torques given in the table.
Table 20: Tightening torques for screwed connections [Nm]
Part number Screw Material / Stamp mark
902.01
902.04
Stud
DIN 939
1.7709+QT / GA Monix 3K / MM
920.01
920.04
Hexagon nut
ISO 4032
1.7218+QT+A2D / G Monix 3K / MM (M3K)
Thread Brand-new
threads
8)
-15 %
9)
-20 %
9)
Brand-new
threads
8)
-15 %
9)
-20 %
9)
M12 80 68 64 130 111 104
M16 190 162 152 320 272 256
M20 330 281 264 620 572 496
914.02 Socket head cap
screw
DIN 7984
8.8 / 8.8
Thread Brand-new threads
8)
-15 %
9)
-20 %
9)
M8 25 21 20
M10 35 30 28
M12 59 50 47
904.32 Grub screw
DIN 916
A4-50 / -
Thread
M6 5 - 9
920.95 Hexagon nut
ISO 8673
A4 / A4
Thread Brand-new threads -15 %
9)
-20 %
9)
M16x1.5 100 85 80
M20x1.5 120 102 96
M24x1.5 150 128 120
M30x2 350 298 280
7.7 Spare parts stock
7.7.1 Ordering spare parts
Always quote the following data when ordering replacement or spare parts:
Type series
Pump size
KSB order number
Material variant
Year of construction
Refer to the name plate for all data. ( Section 4.3 Page 17)






8)
These values are determined on the basis of a friction coefficient = 0.12.
9)
After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.

7 Servicing/Maintenance
HPK-L 51 of 62
Also supply the following data:
Part description
Part No.
Quantity of spare parts
Shipping address
Mode of dispatch (freight, mail, express freight, air freight)
Refer to the general assembly drawing for part numbers and descriptions. ( Section
9.1 Page 57)
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 21: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 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 %
310.10 Plain bearing (product-
lubricated)
2 3 4 5 6 8 100 %
320.02 Angular contact ball
bearing (set)
1 1 2 2 3 4 55 %
330 Bearing bracket - - - - - 1 2
433 Mechanical seal 1 1 2 2 2 3 25 %
502.01
10)
Casing wear ring 2 2 2 3 3 4 50 %
523 Shaft sleeve 1 1 1 2 2 2 20 %
545.21 Bearing bush (product-
lubricated)
2 3 4 5 6 8 100 %
--- Seal elements (set) 4 6 8 8 9 12 150 %
7.7.3 Interchangeability of pump components
Components featuring the same number in a column are interchangeable.
NOTE
Volute casing 102 and impeller 230 are not interchangeable between different pump
sizes.




10)
Provided as a standard feature on HPK-LS and HPK-LS4 only. Optional feature on HPK-LE and HPK-LE4

7 Servicing/Maintenance
52 of 62 HPK-L
Table 22: Interchangeability of pump components
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LP02 32-125 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1
25-160 2 25
32-160 2 1
40-160 2 2
50-160 3 3
25-200 2 3 25
32-200 3 1
40-200 3 2
50-200 3 3
LP03 65-160 3 4 2 2 2 2 2 7 2 2
80-160 5 9
65-200 4 5 8
80-200 5 10
100-200 6 12
32-250 5 5 6
40-250 5 5
50-250 5 4
65-250 6 8
80-250 7 11
40-315 6 6 5
50-315 7 7
LP04 100-250 5 8 3 2 3 2 3 3 13 2 3 2 2 2 2 2 2
125-250 9 15
150-250 10 16
65-315 6 8 9
80-315 9 12
100-315 9 14
125-315 10 16
80-400 7 10 27
100-400 10 14
125-400 11 15
LP05 200-250 8 13 4 3 4 4 3 4 4 17 3 4 3 3 3 3 3 3 3
150-315 9 12 18
200-315 13 19
250-315 16 5 21
150-400 10 12 18
200-400 13 20
150-500 11 14 18
200-500 17 28

7 Servicing/Maintenance
HPK-L 53 of 62
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LP06 250-400 12 17 6 4 5 5 4 5 5 22 4 5 4 4 4 3 3 3 4
250-500 13 15 23

7 Servicing/Maintenance
54 of 62 HPK-L
8 Trouble-shooting
Pump delivers insufficient flow rate
Motor overload
Excessive pump discharge pressure
Excessive bearing temperature
Leakage at the pump
Excessive leakage at the shaft seal
Vibrations during pump operation
Excessive rise of temperature inside the pump
Table 23: Trouble-shooting
A B C D E F G H Possible cause Remedy
11)
X Pump delivers against an excessively
high discharge pressure.
Re-adjust to duty point.
Check system for impurities.
Fit a larger impeller.
12)
Increase the speed (turbine, I.C. engine).
X X X Pump or piping are not completely
vented or primed.
Vent and/or prime.
X Supply line or impeller clogged Remove deposits in the pump and/or piping.
X Formation of air pockets in the piping Alter piping layout.
Fit a vent valve.
X X X Suction head is too high/NPSH
available
(positive suction head) is too low.
Check/alter fluid level.
Install pump at a lower level.
Fully open the shut-off element 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.
X Air intake at the shaft seal. Clean barrier fluid duct, supply external
barrier fluid, if necessary, or increase barrier
fluid pressure.
Fit new shaft seal.
X Wrong direction of rotation Interchange two of the phases of the power
cable.
X Speed is too low.
12)
- operation with frequency inverter
- operation without frequency inverter

- Increase voltage/frequency at the frequency
inverter within the permissible range.
- Check the voltage
X X Impeller Replace worn parts by new ones.
X X Pump back pressure is lower than
specified in the purchase order.
Re-adjust to duty point.
In the case of persistent overloading, turn
down impeller.
12)
X Density or viscosity of the fluid
pumped is higher than stated in the
purchase order.
Contact KSB.
X X Speed is too high. Reduce speed.
12)
X Use of unsuitable materials Change the material combination.
X Defective seal Fit new seal between volute casing and
discharge cover.
X Worn shaft seal Fit new shaft seal.
Check flushing liquid / barrier fluid.

A
B
C
D
E
F
G
H
11)
Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
12)
Contact KSB.

8 Trouble-shooting
HPK-L 55 of 62
A B C D E F G H Possible cause Remedy
11)
X X Score marks or roughness on shaft
protecting sleeve / shaft sleeve
Replace shaft protecting sleeve / shaft sleeve.
Fit new shaft seal.
X Dismantle to find out. Repair necessary.
X Vibrations during pump operation. Correct the suction conditions.
Re-align the pump.
Re-balance the impeller.
Increase the pressure at the pump suction
nozzle.
X X X The pump set is misaligned. Re-align.
X X X Pump is warped or sympathetic
vibrations in the piping.
Check pipeline connections and secure fixing
of pump; if required, reduce the distances
between the pipe clamps.
Fix the pipelines using anti-vibration material.
X Insufficient or excessive quantity of
lubricant or unsuitable lubricant.
Top up, reduce or change lubricant.
X Non-compliance with specified
coupling distance.
Correct distance according to the general
arrangement drawing.
X X Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
X Rotor is out of balance. Clean the impeller.
Re-balance the impeller.
X Defective bearing(s) Fit new bearing(s).
X X X Insufficient flow rate Increase the minimum flow rate.
X Incorrect inflow of circulation liquid Increase the free cross-section.
11)
Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

8 Trouble-shooting
56 of 62 HPK-L
9 Related Documents
9.1 General assembly drawing with list of components
Fig. 16: General assembly drawing HPK-LS/LE/LS4/LE4
Bearing bracket P04 Bearing bracket P05/P06
Part No. Description Scope of supply
102 Volute casing with joint ring 411.01/.02/.03/.04/.10, casing wear ring 502.01
13)
, Zylinderstift
561.01
13)
, stud 902.01, screwed plug 903.01/.02/.03/.04, hexagon nut 920.01
161 Casing cover with joint ring 411.11, hexagon head bolt 901.31, stud 902.04, hexagon nut
920.04
183 Support foot with hexagon head bolt 901.04, spring washer 930.01
*210 Shaft with disc 550.87, keywayed nut 920.21, hexagon nut 920.95, lockwasher
931.01, key 940.01/.02
230 Impeller
*310.10 Plain bearing (sleeve) with taper lock rings 515.21/.22, bearing sleeve 529.21, cup spring 950.23



13)
For HPK-LS/LS4 only

9 Related Documents
HPK-L 57 of 62
Part No. Description Scope of supply
*320.02 Angular contact ball
bearing

*330 Bearing bracket
330 Bearing bracket
(complete)
Comprising all parts marked *.
*360.02 Bearing cover
*411.20 Joint ring
*411.85 Joint ring
*433.02 Mechanical seal
*476 Seat ring holder
*500.32 Ring
*500.61 Tolerance ring
*507.12 Thrower
*523 Shaft sleeve with O-ring 412.07, support disc 550.59 (LP02 and LP03 only), grub screws
904.32
*525.03 Spacer sleeve
*525.24 Spacer sleeve
*545.21 Bearing bush
*550.87 Disc
*561.52 Grooved pin
*680 Guard
*720.22 Nipple joint
*831 Fan impeller
*832 Fan hood
* 901.84 Hexagon head bolt
*903.20 Screwed plug
*903.85 Screwed plug
*914.02 Socket head cap screw
*920.95 Hexagon nut
*932.05 Circlip
99-9 Set of seal elements with joint ring 411.01/.02/.03/.04/.10/.11/.20/.85, O-ring 412.07/.82

9 Related Documents
58 of 62 HPK-L
10 EC Declaration of Conformity

Manufacturer: KSB Aktiengesellschaft
Johann-Klein-Strae 9
67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

HPK-L

KSB order number: ...................................................................................................
is in conformity with the provisions of the following directives as applicable in their current version:
EC Machinery Directive 2006/42/EC
The manufacturer also declares that
the following harmonised international standards were applied:
ISO 12100-1/A1, ISO 12100-2/A1,
ISO 14121-1,
EN 809/A1

Pegnitz, 29 December 2009
...........................................................
Name
Function
Responsible for compiling the technical documentation
KSB Aktiengesellschaft
Bahnhofplatz 1
91257 Pegnitz (Germany)






10 EC Declaration of Conformity
HPK-L 59 of 62
11 Certificate of Decontamination

Type ................................................................................................................................
Order number/
Order item number
14)
................................................................................................................................

Delivery date ................................................................................................................................

Field of application: ................................................................................................................................

Fluid handled
14)
:
................................................................................................................................

Please tick where applicable
14)
:

radioactive explosive corrosive toxic


harmful bio-hazardous highly flammable safe

Reason for return
14)
:
................................................................................................................................

Comments: ................................................................................................................................

................................................................................................................................

The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing
at your disposal.
On sealless pumps, the rotor has been removed from the pump for cleaning.

No special safety precautions are required for further handling.
The following safety precautions are required for flushing fluids, fluid residues and disposal:

...............................................................................................................................................................

...............................................................................................................................................................

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with
the relevant legal provisions.


.................................................................... ....................................................... .......................................................
Place, date and signature Address Company stamp




14)
Required fields

11 Certificate of Decontamination
60 of 62 HPK-L
Index
A
Abrasive fluids 38
B
Bearing temperature 41
C
Certificate of decontamination 60
Clearance gaps 42
Commissioning/start-up 32
Coupling 42
Coupling alignment 27
D
Description of the fluid handled 16
Design 17, 19
Designation 16
Direction of rotation 31
Dismantling 44
Disposal 14
E
Explosion protection 11, 21, 26, 28, 29, 30, 33, 35, 37,
40, 41
F
Filling and venting 33
Filter 23, 42
Final check 34
Flow rate 37
Frequency of starts 37
Function 19
H
Heating speed 34
Heating up 34
I
Impeller type 17
Installation
Installation on foundation 21
Installation without foundation 22
Installation at site 21
Intended use 8
Interchangeability of pump components 52
K
Keeping the pump warm 34
M
Maintenance/repair 40
Mechanical seal 36
Misuse 9
Monitoring equipment 12
N
Noise characteristics 20
O
Operating limits 8
Order number 6
Ordering spare parts 51
Other applicable documents 6
P
Partly completed machinery 6
Permissible forces and moments at the pump nozzles
24
Piping 23
Preservation 14, 39
R
Reassembly 44
Return to supplier 14
Returning to service 39
Running noises 40, 41
S
Safety 8
Safety awareness 9
Scope of supply 20
Shaft seal 18
Shutdown 36, 39
Spare parts stock 52
Start-up 35
Storage 14, 39
T
Temperature difference 34
Temperature limits 11
Trouble-shooting 55


Index
HPK-L 61 of 62
KSB Aktiengesellschaft
P.O. Box 1361 91253 Pegnitz Bahnhofplatz 1, 91257 Pegnitz (Germany)
Tel. +49 9241 71-0 Fax +49 9241 71-1793
www.ksb.com
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