KSB 4K Series Installation instructions

KSB Mechanical Seal
4K / 4KD
For the KWP Type Series
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual 4K / 4KD
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
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.
© KSB SE & Co. KGaA, Frankenthal 27/03/2018

Contents
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Contents
1 General.................................................................................................................................................... 4
1.1 Principles ...........................................................................................................................................................4
1.2 Target group.....................................................................................................................................................4
1.3 Other applicable documents............................................................................................................................4
1.4 Symbols .............................................................................................................................................................4
1.5 Key to safety symbols/markings.......................................................................................................................5
2 Safety...................................................................................................................................................... 6
2.1 General..............................................................................................................................................................6
2.2 Intended use .....................................................................................................................................................6
2.3 Personnel qualification and training...............................................................................................................6
2.4 Consequences and risks caused by non-compliance with this manual .........................................................6
2.5 Safety awareness ..............................................................................................................................................7
2.6 Safety information for the user/operator.......................................................................................................7
2.7 Safety information for maintenance, inspection and installation ................................................................7
2.8 Unauthorised modes of operation..................................................................................................................7
3 Transport/Temporary Storage/Disposal............................................................................................... 8
3.1 Checking the condition upon delivery............................................................................................................8
3.2 Transport...........................................................................................................................................................8
3.3 Storage/preservation........................................................................................................................................8
3.4 Return to supplier.............................................................................................................................................9
3.5 Disposal ...........................................................................................................................................................10
4 Description............................................................................................................................................ 11
4.1 General description ........................................................................................................................................11
4.2 Designation.....................................................................................................................................................11
4.3 Materials .........................................................................................................................................................11
4.4 Design details..................................................................................................................................................11
4.5 Configuration and function...........................................................................................................................12
4.6 Flushing adapter.............................................................................................................................................12
5 Installation/Dismantling...................................................................................................................... 14
5.1 Permissible aids...............................................................................................................................................14
5.2 Prerequisites....................................................................................................................................................14
5.3 Installing the mechanical seal........................................................................................................................15
5.4 Removing the mechanical seal ......................................................................................................................17
5.5 Tightening torques.........................................................................................................................................18
6 Operation.............................................................................................................................................. 19
6.1 Safety instructions for operation...................................................................................................................19
6.2 Emissions .........................................................................................................................................................19
6.3 Operating limits..............................................................................................................................................20
7 Maintenance......................................................................................................................................... 21
7.1 Maintenance/inspection.................................................................................................................................21
8 Trouble-shooting.................................................................................................................................. 22
9 Related Documents.............................................................................................................................. 23
9.1 General assembly drawings with list of components...................................................................................23
9.1.1 4K ........................................................................................................................................................23
9.1.2 4K, tandem arrangement ..................................................................................................................24
9.1.3 4KXW ..................................................................................................................................................25
9.1.4 4KXW, tandem arrangement ............................................................................................................26
9.1.5 4KD, tandem arrangement ...............................................................................................................27
10 Certificate of Decontamination........................................................................................................... 28
Index ..................................................................................................................................................... 29

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The manual describes the proper and safe use of this equipment in all phases of
operation.
The order number and order item number of the pump clearly identify the
mechanical seal via the corresponding material number in the pump's parts list 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.
For any queries: [email protected]
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
in which the mechanical seal is installed.
General assembly drawing1) Description of the mechanical seal as part of the
sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.4 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.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1) If agreed to be included in the scope of supply

1 General
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1.5 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.
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 Safety
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2 Safety
!DANGER
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.
2.1 General
This operating manual contains general installation, dismantling, operating and
maintenance instructions that must be observed to ensure safe handling 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
▪Fitting direction
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
2.2 Intended use
▪This product must only be operated within the limit values stated in the technical
product literature for the ambient temperature, fluid handled, speed, density,
pressure, temperature and in compliance with any other instructions provided in
the operating manual or other applicable documents.
▪The product must not be used in potentially explosive atmospheres.
2.3 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the product 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 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 product must always be supervised by specialist technical personnel.
2.4 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

2 Safety
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2.5 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
2.6 Safety information for the user/operator
▪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 of hazardous fluids (e.g. explosive, toxic, hot) so as to avoid any
danger to persons and the environment. Observe all legal requirements.
▪The design of mechanical seals always produces a small amount of leakage.
▪Higher leakage may occur especially in the running-in phase. The leakage must
be drained off in a controlled way
2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the mechanical seal require 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 mechanical seal when the shaft is not rotating.
For mechanical seals installed in pump sets:
▪The pump (set) 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.
▪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.
▪Observe the relevant sections of the corresponding pump operating manual.
2.8 Unauthorised modes of operation
Never operate the mechanical seal outside the limits stated in the data sheet and in
this operating manual.
The warranty relating to the operating reliability and safety of the mechanical seal
supplied is only valid if the mechanical seal is used in accordance with its intended
use.
Any damage caused by dry running shall be excluded from the warranty.

3 Transport/Temporary Storage/Disposal
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
CAUTION
Improper transport
Damage to the mechanical seal!
▷Only transport the mechanical seal in suitable packaging.
▷Observe the weights, symbols and instructions indicated on the packaging.
▷Use suitable, permitted lifting accessories.
KSB's standard packaging is suitable for dry transport by forwarding agents (truck,
rail, air); special packaging can be provided if specified in the contractual agreement.
CAUTION
Removing transport locks too early
Damage to previously locked components during transport!
▷If transport locks are fitted, do not remove them too early.
3.3 Storage/preservation
We recommend taking the following measures for storing the mechanical seal:
CAUTION
Improper storage
Damage during storage due to humidity, dirt or vermin! Corrosion of and damage
to the mechanical seal!
▷Avoid outdoor storage.
▷Observe, check and record the storage conditions.
▷Regularly check the packaging for any damage.
▷Regularly check the humidity indicator of shrink-wrapped objects. (The relative
humidity should be <50%.)
▷If the relative humidity indicated for shrink-wrapped objects >50%, have the
equipment checked and repacked by the manufacturer.
CAUTION
Generation and presence of ozone
Risk of embrittlement! Damage to elastomers!
▷If the storage area is not sufficiently vented, avoid arc welding as well as the
use of high-voltage equipment, electric motors and mercury vapour lamps.

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CAUTION
Direct heat exposure
Damage to the mechanical seal!
Risk of embrittlement! Damage to elastomers!
▷Protect the mechanical seal from heat sources such as sun, heaters and heat
radiation.
CAUTION
UV light (ionising radiation)
Damage to the mechanical seal!
Risk of embrittlement! Damage to elastomers!
▷Protect the mechanical seal from light sources such as sunlight, arc welding,
fluorescent lamps or halogen lamps.
CAUTION
Wet, contaminated or damaged openings and connections
Damage to the mechanical seal!
Risk of embrittlement! Damage to elastomers!
▷Only open any closed screw plugs and connections at the mechanical seal at the
time of installation.
▷Avoid opening screw plugs, connections and similar before that time.
For storing the mechanical seal observe standards ISO2230 and DIN7716.
Store the mechanical seal in its original packaging, placed on a level surface in a dry,
protected room with constant conditions that meet the following requirements:
▪Relative humidity <65%
▪Temperature between 15°C and 25°C
▪Moderately vented atmosphere
▪Dust-free and vermin-free
If properly stored indoors, the equipment is protected for a maximum of 36months.
New mechanical seals are supplied by our factory duly prepared for storage.
3.4 Return to supplier
1. Remove the used mechanical seal from the system.
2. Always flush and clean the mechanical seal, particularly if it has been used for
handling noxious, explosive, hot or other hazardous fluids.
3. If the mechanical seal has handled fluids whose residues could lead to corrosion
damage in the presence of atmospheric humidity or could ignite upon contact
with oxygen, the mechanical seal must also be neutralised and dried with
anhydrous inert gas.
4. Always complete and enclose a certificate of decontamination when returning
the mechanical seal. Always 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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3.5 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 mechanical seal.
Collect greases and other lubricants during dismantling.
2. Separate and sort the mechanical seal materials, e.g. by:
- Metals
- Plastics
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.