KSB WKLn Montageanleitung

Standardised Water Pump

WKLn

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual WKLn

Original operating manual

edited or processed for any other purpose, nor otherwise transmitted, published or made available to a

third party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

Contents

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Contents

1. Safety 4

1.1 4

1.2 4

1.3 4

1.4 5

1.5 5

1.6 5

1.7 5

1.8 6

1.9

General

Intended use

Personnel qualification and training

Consequences and risks caused by non-compliance with this manual

Safety awareness

Safety information for the operator/user

Safety information for maintenance, inspection and installation

Unauthorised modes of operation

Key to safety symbols/markings 6

2. Transport /Temporary Storage /Disposal 7

2.1 Checking the condition upon delivery 7

2.2 Transport 7

2.3 Storage / preservation 9

2.4 Return to supplier 9

2.5 Disposal 10

3. Installation at Site 11

3.1 Safety regulations 11

3.2 Mounting 12

3.3 Setting up the pump set 12

3.4 Alignment of Pump and Driver 13

3.5 Connecting the Piping 14

3.6 Auxiliary connections 15

3.7 Vacuum Balance Line 16

3.8 Minimum Flow 16

3.9 Coupling Guard 16

3.10 Final Check 16

4. Start-up / Commissioning, Shutdown 17

4.1 Preparations 17

4.1.1 Lubricants 17

4.1.2 Shaft Seal 17

4.1.3 Priming the Pump and associated Checks 17

4.1.4 Checking the Direction of Rotation 17

4.2 Start-up 18

4.3 Shutdown 19

5. Maintenance and Lubrication 20

5.1 Supervision of operation 20

5.2 Lubrication and Grease Change 20

5.2.2 Grease Change 20

6. Dismantling and Reassembly 22

6.1 General 22

6.2.1 Mechanical Seal 22

6.3 Bearings 23

6.4 Assembly 24

6.4.1 Pump 24

6.4.2 Shaft Seal 26

6.4.2.1 Packed Gland 26

6.4.2.2 Mechanical Seal 28

6.4.3 Setting Torques for the Tie bolts 28

6.5 Cooling Liquid (HW Design) 28

6.6 External Source Sealing Liquid (Vacuum Operation) 28

6.7 Spare Parts 29

6.7.1 Recommended List of Spare Parts 29

6.7.2 Alternatively keeping a complete Rotor in stock comprising: 29

6.8 Exploded Views and List of components 30

6.9 Faults 32

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1. Safety

All the information contained in this section refers to hazardous situations.

In addition to the present general safety information the action-related safety

information given in the other sections must be observed.

1.1 General

This operating manual contains general installation, operating and maintenance

instructions that must be observed to ensure safe operation of the system and

prevent personal injury and damage to property.

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

The operating manual must be read and understood by the responsible specialist

personnel/operators prior to installation and commissioning.

The contents of this operating manual must be available to the specialist personnel

at the site at all times.

Information attached directly to the product must always be complied with and 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 not

taken into account in this operating manual.

1.2 Intended use

▪The pump (set) must only be operated in the fields of application and within the

use limits specified in the other applicable documents.

▪Only operate pumps/pump sets which are in perfect technical condition.

▪Do not operate the pump (set) in partially assembled condition.

▪Only use the pump to handle the fluids described in the data sheet or product

literature of the pump model or variant.

▪Never operate the pump without the fluid to be handled.

▪Observe the minimum flow rates indicated in the data sheet or product literature

(to prevent overheating, bearing damage, etc).

▪Observe the minimum flow rate and maximum flow rate 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.

1.3 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain

and inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved in

transport, installation, operation, maintenance and inspection must be clearly

defined by the operator.

Deficits in knowledge must be rectified by means of training and instruction

provided by sufficiently trained specialist personnel. If required, the operator can

commission the manufacturer/supplier to train the personnel.

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

personnel.

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

▪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

1.5 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 regulations and safety regulations

▪Explosion protection regulations

▪Safety regulations for handling hazardous substances

▪Applicable standards, directives and laws

1.6 Safety information for the operator/user

▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪Do not remove any protective equipment (e.g. contact guards) during operation.

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

▪Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.

explosive, toxic, hot) so as to avoid any danger to persons and the environment.

Adhere to all relevant laws.

▪Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply

companies.)

▪If shutting down the pump does not increase potential risk, fit an emergency-

stop control device in the immediate vicinity of the pump (set) during pump set

installation.

1.7 Safety information for maintenance, inspection and installation

▪Modifications or alterations of the pump (set) are only permitted with the

manufacturer's prior consent.

▪Use only original spare parts or parts/components authorised by the

manufacturer. The use of other parts/components can invalidate any liability of

the manufacturer for resulting damage.

▪The operator ensures that maintenance, inspection and installation is performed

by authorised, qualified specialist personnel who are thoroughly familiar with

the manual.

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

▪Only perform work on the pump set when it has been disconnected from the

power supply (de-energised).

▪The pump (set) must have cooled down to ambient temperature.

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

▪Decontaminate pumps which handle fluids posing a health hazard.

▪As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service,

observe all instructions on commissioning.

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1.8 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.

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 EU Directive

2014/34/EU (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.

1.9 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

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2. Transport/Temporary Storage/Disposal

2.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and

notify KSB or the supplying dealer and the insurer about the damage in writing

immediately.

2.2 Transport

DANGER

The pump (set) could slip out of the suspension arrangement

Danger to life from falling parts!

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

▷Never attach the suspension arrangement to the free shaft end or the motor

eyebolt and/or the pump.

▷Observe the information on weights, centre of gravity and fastening points.

▷Observe the applicable local accident prevention regulations.

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

Table 3: Transporting the pump set

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Table 4: Transporting the pump on the baseplate

Table 5: Transporting the pump on a transport frame

Table 6: Transporting the pump on a transport frame (only if marked accordingly)

αα

Table 7: Transporting the pump without transport frame

ααα

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2.3 Storage/preservation

If commissioning is to take place sometime after delivery, we recommend that the

following measures be taken for pump (set) storage.

CAUTION

Damage during storage due to 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!

▷Clean and cover pump openings and connections as required prior to putting

the pump into storage.

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 three months.

New pumps/pump sets are supplied by our factory duly prepared for storage.

For storage periods exceeding three months, the pump set is preserved as specified in

the purchase order.

2.4 Return to supplier

1. Drain the pump as per operating instructions.

2. Flush and clean the pump, particularly if it has been used for handling noxious,

explosive, hot or other hazardous fluids.

3. If the pump has handled fluids whose residues could lead to corrosion damage

in the presence of atmospheric humidity or could ignite upon contact with

oxygen also neutralise the pump and blow through with anhydrous inert gas to

ensure drying.

4. Always complete and enclose a certificate of decontamination when returning

the pump.

Indicate any safety measures and decontamination measures taken.

NOTE

If required, a blank certificate of decontamination can be downloaded from the

following web site: www.ksb.com/certificate_of_decontamination

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2.5 Disposal

WARNING

Fluids handled, consumables and supplies which are hot and/or pose a health

hazard

Hazard to persons and the environment!

▷Collect and properly dispose of flushing fluid 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. Dispose of materials in accordance with local regulations or in another

controlled manner.

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