KSB ITUR IFV-32 User manual

Instructions manual
MIF-3600/01-I [05-2008]
IFV
Vertical pumps for tanks
vortex impeller
This manual contains important instructions and warnings.
You must read them before mounting, making the electrical
connections and starting up. You must also comply with the
instructions for the components related to this pump.
You should also remember that it is essential to keep this
Manual close to the motor pump equipment.

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Index
1GENERAL.................................................................. 3
2SAFETY ..................................................................... 3
2.1 MARKING OF WARNINGS IN THIS MANUAL..................... 3
2.2 PERSONNEL QUALIFICATIONS AND INSTRUCTION.......... 3
2.3 RISKS OF FAILING TO COMPLY WITH THE SAFETY
INSTRUCTIONS................................................................. 3
2.4 CONSCIENTIOUS SAFETY AT WORK............................. 3
2.5 SAFETY INSTRUCTIONS FOR USERS AND SERVICE
PERSONNEL .................................................................... 3
2.6 SAFETY INSTRUCTIONS FOR MAINTENANCE,INSPECTION
AND ASSEMBLY WORK....................................................... 4
2.7 MODIFICATIONS AND ARBITRARY MANUFACTURE OF
SPARE PARTS .................................................................. 4
2.8 UNAUTHORISED OPERATION MODES ........................... 4
3TRANSPORT AND STORAGE.................................. 4
3.1 TRANSPORT AND HANDLING ...................................... 4
3.2 PROVISIONAL STORAGE/CONSERVATION ..................... 4
4GROUP DESCRIPTION............................................. 4
4.1 GENERAL DESCRIPTION ............................................ 4
4.2 DENOMINATION........................................................ 4
4.3 FORM OF CONSTRUCTION ......................................... 4
4.4 NOISE.PERMITTED LEVELS ....................................... 4
5INSTALLATION ......................................................... 5
5.1 CHECK BEFORE ASSEMBLY........................................ 5
5.2 GROUP POSITIONING ................................................ 5
5.2.1 Vertical groups...............................................5
5.3 PIPE JOINT .............................................................. 5
5.3.1 Auxiliary connections.....................................5
5.4 ELECTRICAL CONNECTION:........................................ 6
5.4.1 Motor connection...........................................6
5.4.2 Time relay adjustment ...................................6
5.4.3 Rotation direction. Check...............................6
6START UP.................................................................. 6
6.1 FIRST START-UP ...................................................... 6
6.1.1 Lubricant........................................................6
6.1.2 Filling (priming) of the pump..........................6
6.1.3 Final control...................................................7
6.1.4 Start-up..........................................................7
6.1.5 Shutdown.......................................................7
6.2 SERVICE LIMITS ....................................................... 7
6.2.1 Switching frequency ......................................7
6.2.2 Temperature of the liquid to be pumped........7
6.2.3 Density of the liquid to be pumped ................7
6.3 STARTING UP AFTER STORAGE .................................. 7
7MAINTENANCE/CONSERVATION............................7
7.1 GENERAL INSTRUCTIONS........................................... 7
7.2 MAINTENANCE/INSPECTION ....................................... 8
7.2.1 Checking instructions.................................... 8
7.2.2 Lubrication .................................................... 8
7.3 EMPTYING/DRAINAGE ............................................... 8
7.4 DI MANTLING........................................................... 8S
7.4.1 Fundamental instructions/observations......... 8
7.4.2 Coupling........................................................ 8
7.4.3 Pump ............................................................ 8
7.5 ASSEMBLY............................................................... 9
7.5.1 Coupling........................................................ 9
7.5.2 Pump ............................................................ 9
7.5.3 Tightening torque of the screws/nuts ............ 9
7.5.4 Tightening torque of the impeller nuts........... 9
7.6 RECOMMENDED SPARE PARTS ................................. 10
7.7 PREVENTATIVE MAINTENANCE.................................. 10
8TROUBLE-SHOOTING ............................................11
9ANNEXES.................................................................12
9.1 SECTIONAL PLANS .................................................. 12

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1 General
This KSB ITUR pump has been developed in
line with state-of-the-art technology,
manufactured with great care and put through continuous
Quality Control. The present Instructions Manual will provide
you with knowledge of the pump and the ways it can be
applied.
It contains important instructions to operate the pump
appropriately and profitably. It is important to comply with the
manual in order to guarantee reliability and a long useful life
for the pump, whilst avoiding any possible risks.
This manual does not include any local regulations or any
instructions with regards to assembly personnel, which the
user shall be responsible for.
This group cannot be used in conditions in excess of
those established in the technical documentation
with regards to the liquid to be pumped, flow, speed
(rpm), density, pressure and temperature, and with regards to
the motor power or anything else set out in the instructions
manual and contractual documentation. Check with the
manufacturer as appropriate.
The factory plate shows the model/size, the main service data
and the manufacture number of the pump. Please include
these data in any queries, subsequent orders or requests for
spare parts.
If you require any additional information or have problems with
regards to failures, please contact the nearest KSB ITUR
service.
2 Safety
This instructions manual contains fundamental instructions
which must be complied with in assembly, service and
maintenance. It must be read by assembly personnel,
competent technical personnel and users before installing and
starting up, and it must be available at all times at the place of
location of the machine.
Proceed not only in line with this main safety chapter, but also
observing the instructions described in other similarly
important safety points.
2.1 Marking of warnings in this manual
The instructions which may involve hazard if not observed are
highlighted with the following general symbols:
Safety instructions which may involve a hazard to
people and facilities if not complied with in
accordance with ISO 7000-0434.
Safety instructions to prevent electrical hazards in
accordance with IEC 417-5036.
Safety instructions which may affect the
equipment and its operation if not complied
with.
The details shown directly on the machine, such as:
- Rotation direction arrow
- Fluid connection identifications
These must be observed, and conserved in a manner which
ensures they are legible.
2.2 Personnel qualifications and instruction
All Service, Maintenance, Inspection and Assembly personnel
must be duly qualified. The terms regarding responsibility,
competence and supervision of personnel must be regulated
by the user in an exact manner.
Note
Any personnel lacking appropriate know-how must be duly
instructed. This preparation can be obtained upon request by
the machine user to the manufacturer or supplier of the
machine.
Finally, the user must ensure that all personnel have fully
understood the content of the instructions manual.
2.3 Risks of failing to comply with the safety
instructions
Failure to comply with the safety instructions may lead to risks
both for people, the environment and the machine, and may
lead to the loss of any entitlement to claims.
In particular, failure to comply may cause the following
hazards:
- Failure of important machine/facility functions.
- Failure of the prescribed maintenance and conservation
methods.
- Personal hazard resulting from electrical, mechanical or
chemical effects.
- Danger to the environment due to escaping noxious
products.
2.4 Conscientious safety at work
The safety instructions contained in this Manual must be
observed, as must international prescriptions on Health and
Safety at Work and any possible Safety Regulations at the
workplace of the user.
2.5 Safety instructions for users and service
personnel
- The installer must ensure that the parts of the machine
which may create danger due to heat or cold are
protected against accidental contact.
- The contact protections of moving parts (e.g. couplings)
must not be removed whilst the machine is in service.
- Any possible leaks (e.g. through the shaft sealing) of
hazardous products must be channelled in such a
manner as they do not present any risk to people or the
environment, in line with corresponding legislation.
- Electrical hazard must be avoided (see details in the
specific legislation of the country and/or the electricity
supply company).
Note

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2.6 Safety instructions for maintenance,
inspection and assembly work
The user must ensure that all maintenance, inspection and
assembly tasks are carried out by authorised, qualified,
specialised personnel who have been sufficiently informed
through careful study of the instructions manual.
The pump frame must have returned to environmental
temperature. It must then be depressurised and emptied of
liquid.
It is a fundamental principle that any work on the machine
must be carried only during standstill. It is essential to respect
the pump shutdown procedure described in the instructions
manual.
Series
Discharge nozzle DN
[mm]
Length of base plate to end
[mm]
All pumps or motor pumps which pump hazardous materials
must be decontaminated.
All safety and protection devices must be installed and put into
operation as soon as work concludes.
Before starting up again, all that described in the First Start-Up
section must be followed.
2.7 Modifications and arbitrary manufacture of
spare parts
The machine must not be modified or changed without prior
agreement with the manufacturer. Only original spare parts
and accessories approved by the manufacturer can guarantee
safety. The use of other components may terminate any
liability for consequences deriving from their use.
2.8 Unauthorised operation modes
The safe service of the supplied pump can only be guaranteed
through correct use, in line with section 4 of the Instructions
Manual. The operation limits established in the Datasheet
must not be exceeded under any circumstance.
3 Transport and storage
3.1 Transport and handling
The transport and handling of the equipment must
be carried out using suitable means in line with the
weight to be supported. The weight is generally
shown on the delivery note or on the data plate. If it is not, and
the equipment cannot be handled safely, please contact KSB
ITUR.
Remember that the equipment should never be lifted using the
ring bolts of each of the elements, e.g. the motor and pump
ring bolts, which are exclusively for independent transport.
It is also important not to use the pump and
pipe flanges or joining elements, e.g.
couplings.
If the equipment is to be lifted using straps,
these must always be run underneath the
motor and pump support.
When the pumps are dismounted from their transport
pallet, suitable means must be used to ensure the
stability of the equipment, until it is finally secured at
its definitive location.
3.2 Provisional storage/conservation
During provisional storage, it is only necessary to protect with
preservation products those low alloy parts in contact with the
liquid (e.g. grey cast, nodular cast, etc). Preservation products
available on the sector market can be used, in line with the
manufacturer's instructions on application and disposal.
The pump, or motor pump, shall be deposited in a dry site
where the relative humidity is as constant as possible.
When stored outside, it is necessary to keep the pump/motor
pump in an impermeable box, ensuring it does not come into
contact with external humidity.
Protect the stored product from humidity, dirt,
parasites and unauthorised access! All
openings must remain closed, and must not be opened until
necessary during assembly!
Note
The shiny (mechanised) parts and surfaces of the pump must
be protected from corrosion using silicone-free oil or grease.
The electric motor must be disconnected, the
connection cables removed and the terminal box
closed with its cover on.
The switchboards must be in vertical position and
disconnected.
4 Group description
4.1 General description
Vertical centrifugal pump designed for wells, ditches and
tanks. For sewage, dirty and other load-carrying waters.
4.2 Denomination
IFV- 32 / 1300
4.3 Form of construction
Spiral pump casing with axial suction and radial impulsion.
Vortex single-stage impeller.
The standard scope of supply does not include the discharge
pipe.
Sizes 32 and 50 are monobloc constructions with rigid
coupling. Size 100 is a free shaft construction with flexible
coupling.
Note
Bearings: All the sizes are fitted with a friction bearing. Size
100 is also fitted with a support with a ballbearing.
Note
Shaft sealing: The standard sealing system is by way of a lip
seal.
4.4 Noise. Permitted levels
The acoustic pressure level of these pumps is less than 95 dB
(A) at 1 m in any operation point within the operation range
without cavitation. The acoustic power is less than 105 dB (A)

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5 Installation
The electropump is dispatched totally mounted and prepared
for installation and operation (except for the few cases of the
motor being dispatched disassembled, as is the case of large,
heavy motors).
The design of the pipe systems, anchorings
and other installation areas corresponds to
other parties. KSB ITUR only offers details and comments as
a help, but does not assume any responsibility with regards to
the design, assembly and operation of any installation. We
recommend that customers check with a specialist in the
design of castings, pipes, wells, etc in order to interpret and
supplement the information given by KSB ITUR and to ensure
correct operation.
5.1 Check before assembly
Before positioning, check that the assembly base is in line with
the dimensional plan of the equipment.
The upper surface of the base must be horizontal and flat.
If the anchor pins are to be placed in existing holes, place the
anchor pins in their orifices suspended from the pump.
Do not connect the suction and impulsion nozzles until the
equipment is completely installed on its base.
5.2 Group positioning
5.2.1 Vertical groups
Levelling
Use a spirit level to level the equipment. Use wedges to alter
the height at different points. The maximum deviation
permitted is 0.2 mm/m.
The separation between the two coupling halves must be
maintained.
Pump - motor alignment
The equipment is aligned at factory, and this alignment will
never be lost. In case of dismantling of the motor and when
mounting again the motor following instructions must be
followed:
Check that the flange support surface of the motor support
and of the motor itself are perfectly clean and smooth.
- Check the correct separation between the two halves of
the coupling.
- Check that the alignment between both shafts is correct
by turning the equipment by hand.
5.3 Pipe joint
In no case can the pump be used as a fixed point for the
pipes.
The pipe system must at no time exercise force (due
to connection, thermal variation, etc.) in the pump.
The short pipes must be of at least the diameter of the pump
connections. The diameter of long pipes is, in some cases,
determined by economic criteria.
Transition pieces at larger diameters must have an extension
angle of around 8°, in order to prevent pressure drops.
The thermal expansions of the pipes must be offset with
suitable measurements, in order not to exceed the maximum
strains permitted on the pump.
The diameters of the pipes, valves and accessories must be
calculated in line with the load losses envisaged in the
installation, so that the fluid impulsion speeds in the pipes will
be from 2 to 3 m/s
Exceeding the admitted strains of the pipes may lead
to leaks in the pump and to the fluid escaping.
Hazard of death with hot liquids!
The suction and impulsion flange covers of the pump must be
removed before connecting the pipes.
Before starting up a new installation, it is necessary to
thoroughly clean the tanks, pipes and accessories by brushing
and blowing. Welding material, scales and other impurities are
often cast off some time after.
In order to prevent the rotation of the pumps
in inverse direction (danger of the impeller
breaking out), a retention valve must be placed in the
impulsion pipe.
Wet well. Suction conditions
It is not enough to simply submerge the pump in the well to
make it is primed. We need to pay attention to the suction of
the pump, since in this case good suction will depend more on
the environment surrounding the pump (physical conditions of
the well or sump) than on the pump itself.
As a general rule we can make some observations:
- The minimum liquid level in the well must be at the
distance indicated in the table in annex 9.2, save for
particular pump plans or datasheets showing other
greater or lower values for minimum submergence.
- The input of liquid to the well must be carried out gently,
without any fluctuation or turbulence which may harm the
pump suction, always aiming to achieve the most stable
flow possible.
- If several pumps are working in parallel in a single well,
they should be at a suitable distance from each other, or
precautions should be taken to ensure there is no
disturbance which may affect the suction conditions of
the pump.
The maximum liquid level must always be below the
base plate in order for it not to overflow.
5.3.1 Auxiliary connections
The equipment is normally delivered mounted and ready for
immediate operation, with only the hydraulic and exterior
electrical connections being necessary.
In the case of dirty or abrasive pumping liquids in which it is
necessary to connect the auxiliary refrigeration connections or
lubrication of the equipment, follow the instructions detailed in
7.2.2 or in annexes to this manual.
Auxiliary pipes are designed exclusively to
support internal strains due to the pressure of
the circulating fluid, to which end it is forbidden to subject
them to additional exterior strains (e.g. leaning on them, etc).
Note
Note
Note

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5.4 Electrical connection:
The electrical connection must be carried out by a
specialist electrician! Applicable regulations must be
complied with.
Check the mains voltage available with the factory plate data
and choose the appropriate connection.
The technical connection conditions and the conditions
of the local energy supply company must be observed
when carrying out the connections.
We strongly recommend the use of a safety circuit
breaker for the motor and a thermistor associated to a
trigger device.
These instructions apply to asynchronous three-phase
standard electric motors with a squirrel cage both in
horizontal and vertical execution, in IP-23, IP-54 and IP-55
protection grades, with frame sizes of between 56L and
355S, both inclusive, with voltages of 200 to 500 V
between phases.
5.4.1 Motor connection
Whilst connecting the cables, ensure it is not possible
for voltage to appear.
Check that the earth connection is in line with local
regulations.
Connection in single speed motors
Direct start-up:
In direct start-up the motor can be used in two different
connections:
The voltage and the connection, e.g. 400 VY, 240 VD is
stamped on the motor plate. This means that the motor can
connect at 400 volts in star connection (Y) or at 240 volts in
triangle connection (D).
Star connection Triangle connection
Star-triangle start-up:
In star-triangle start-up, the line voltage must coincide with the
voltage shown on the motor for triangle start up (D). The six
terminals indicated in the following diagram will be connected:
Connection to the star-triangle contactor
5.4.2 Time relay adjustment
In the star-triangle start-up of three-phase motors, it is
necessary to ensure that the switching from star to triangle
takes place quickly. Prolonged switchover periods may
damage the pump.
Time relay adjustment in the star-triangle connection:
Power
of the motor Time adjustment Y
≤30 kW < 3 sec.
> 30 kW < 5 sec.
5.4.3 Rotation direction. Check
Check the motor rotation direction by starting
up and immediately stopping. The rotation
direction must correspond with that shown by the pump arrow
located on the pump casing or support. If the rotation direction
is not correct, any two phases L1, L2 or L3 of the power cable
must be inverted in the motor terminal box.
Note
6 Start up
Start-up shall be carried out when all the necessary
mechanical, hydraulic, electrical and pneumatic connections
are complete.
Motor checks.
When making the electrical connection, ensure the
type of current and nominal voltage shown on the
motor's data plate concur with the type of current and
the mains voltage in the place of installation.
Follow the instructions described in the motor manual.
6.1 First start-up
6.1.1 Lubricant
BEARINGS:
Lubricated with grease. PUMP WITH LUBRICATORS: The
pump bearings are closed on both sides and have lifetime
lubrication. Lubricant is not required.
FRICTION BEARINGS:
Lubricated with pumping fluid: If the pumped fluid is clean
(without particles in suspension) and non-aggressive, the
friction bearings are lubricated with the pumped fluid.
Lubricant is not required.
Lubricated with external fluid PUMPS WITH
EXTERIOR AUXILIARY CONNECTION IN
THE BASE PLATE: If the pumped fluid is dirty, aggressive,
abrasive, etc, the PUMP HAS A CONNECTION for the
lubrication and cooling of the bearings through an exterior
means. Clean water or another fluid compatible with the
pumped fluid must be injected. See section 7.2.2.
Note
6.1.2 Filling (priming) of the pump
- Check that the level of liquid in the well is sufficient.
- Turn the pump shaft by hand in order to break any
adherence.

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6.1.3 Final control
Make the final check of the group alignment in accordance
with 5.2. The coupling/shaft must allow easy manual rotation.
Check all the auxiliary connections are
correct and functioning.
According to the rules on the prevention of
accidents at work, equipment cannot be started up
without protection for the coupling. If the buyer has
expressly requested that this protector be excluded from
supply, it must be provided by the user.
6.1.4 Start-up
Before starting up the group, check all the sections with
regards to chapter 6.
The start-up must be carried out with the impulsion valve
partially closed and, once the pump has reached its operation
speed, the operation point will be regulated by operating the
impulsion valve.
If the electric motor guard is triggered when starting up, close
the impulsion valve more until the equipment starts up
normally.
The pump must NEVER work with zero flow or flow
which is less than the operating minimum, as internal
recirculation will cause the fluid to heat up quickly,
leading to hazards (including explosion) as a result of the high
pressures reached within the frame. Check the minimum flow
in the operation curves.
6.1.5 Shutdown
Close the impulsion pipe valve.
If there is anti-return in impulsion with counter pressure, leave
the impulsion valve open.
- Shutdown the motor. Check that shutdown is normal.
- In prolonged periods of non-operation, close the suction
pipe valve (where fitted) and the auxiliary connection
valves.
- The pump must be protected from freezing whenever this
risk exists, and must be emptied in prolonged periods of
non-operation.
If, whilst the pump is in standstill, it must remain on standby
for service, start up at regular intervals for around 5 minutes
(see also 7.2.1)
- Fire pumps: 1x/month, at minimum.
- Drink-safe water pumps: 1x/48 hours, at minimum.
- Reserve pumps: 1x/week, at minimum (it is best to
change the operating pump every day).
The seal tightness and function of the auxiliary connections
must be examined during these start-ups.
6.2 Service limits
6.2.1 Switching frequency
In order to prevent abnormally high temperatures and
overloading of the motor, pump, coupling, seals, etc, the
switching frequencies shown below must not be exceeded:
Note
MOTOR POWER MAX. START-UPS/HOUR
Up to 3 kW 20
From 4 to 11 kW 15
From 11 to 45 kW 10
From 45 kW 5
6.2.2 Temperature of the liquid to be pumped
Never operate the pump at a temperature
higher than that shown in the data sheet
and/or data plate.
Note
6.2.3 Density of the liquid to be pumped
The power absorbed by the pump increases in direct
proportion to the density of the impelled liquid. In order to
prevent overloading in the motor, pump and coupling, this
density must not exceed that shown in the order.
6.3 Starting up after storage
If the storage and/or standstill of the pump has been for a
prolonged period of time (over 6 months), it is necessary to:
- Check the state of the joints.
- Check the levelling.
- Check all the auxiliary connections.
- Renew the lubrication of the bearings (where fitted).
- Change the packing (when fitted).
- After a short storage period, simply turn the pump shaft
manually to unlock the rotor equipment.
- Follow the specific post-short storage instructions in the
motor manuals and other items.
- Observe all the steps shown in the "Start-up" section.
If the equipment is to be in shutdown state for
a certain period of time and there is the
possibility of freezing temperatures, it is necessary to
completely drain the pump in order to prevent any
deterioration from the freezing of the contained fluid.
Note
7 Maintenance/Conservation
7.1 General instructions
Before dismounting, ensure that:
The motor cannot be operated accidentally, by
disconnecting from the electricity supply (e.g.
removing cut-outs, unplugging, disconnecting the
automatic circuit breaker, etc) or the start-up batteries
(disconnect operating energy).
The pump is free of pumped fluid, cleaning it
internally with appropriate liquid whenever it is a
hazardous fluid (hot, contaminant, inflammable,…)

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7.2 Maintenance/inspection
7.2.1 Checking instructions
During the first minutes of operation:
Check that there is no fluid leak through the support or pipe
joint. If this is so, proceed immediately to check and/or repair.
After a few hours operation:
Check the bearing temperature at the point in
the bearing location area. Normal
temperature can reach up to 40°C above environmental
temperature, but must never exceed 90°C.
Observe the possible anomalies shown in point 8 of this
manual.
The reserve pumps should be started up and shutdown once
a week, in order to ensure they are always in service
conditions.
7.2.2 Lubrication
Before lubricating the pump, ensure that
The pump is stopped and cannot be started up
accidentally.
The bearing support temperature is less than 40ºC,
in order to prevent burns to the hands. To do this,
measure the temperature with a thermocouple.
BEARINGS:
The type of lubrication of the bearings of the pump depends
on its size and construction:
SIZE Construction LUBRICATION
32 Monobloc Not applicable
50 Monobloc Not applicable
100 Support With lubricators
Lubricated with grease. PUMP WITH LUBRICATORS:
The pump leaves the factory with the bearings greased for
approximately 1000 hours of operation.
For lubrication, a chart is attached with the amount of grease
to be applied in each greaser, along with the regularity.
Pump size AMOUNT OF
GREASE [g] Regularity [h]
100 17 4000
Lubricant change
In order to completely change the grease, first dismount the
bearings and carefully clean their positions in the support in
order to remove old grease.
Type of grease:
We recommend using lytic-based lubrication grease with
antioxidant additives, of consistency 3 in line with DIN-51502
K3K.
FRICTION BEARINGS:
The friction bearings are found in the cover of pumps (always)
and also in case of double/triple intermediate pipe pumps, in
the intermediate couplings. These bearings must always be
lubricated and cooled. There are three types of lubrication:
1. Lubricated with pumping fluid: If the pumped fluid is clean
(without particles in suspension) and non-aggressive, the
friction bearings are lubricated with the pumped fluid.
Lubricant is not required.
2. Lubricated with external fluid PUMPS
WITH EXTERIOR AUXILIARY
CONNECTION IN THE BASE PLATE: For this purpose there
is an adapter in the base plate which the customer will inject
with clean water or another fluid compatible with the pumped
fluid at a pressure of approximately 3 kg/cm2 (manometer).
Note
Note
7.3 Emptying/Drainage
The emptying and drainage of pumps used to expel
liquids which are a health hazard must be carried out
in such a way as there is no risk to people or to the
environment, in line with legislation. If necessary, use
protective clothing and mask.
7.4 Dismantling
7.4.1 Fundamental instructions/observations
Before dismantling, ensure the pump cannot
be started up.
Note
The suction and impulsion valves must be closed.
The pump frame must have returned to environmental
temperature.
The pump frame must be emptied.
Comply with all safety measures in accordance with 7.1.
When working on the motor, also take into account the rules
and instructions of the manufacturer.
7.4.2 Coupling
Motor pump coupling
- Release the motor attachment screws and remove the
motor along with the male coupling.
- The rubber plugs can then be extracted from the female
coupling.
- If you need to release the coupling, use an extractor.
Never bang in order to extract, as this may cause serious
damage to the bearings.
7.4.3 Pump
For the extraction of ballbearings, shaft, bearings, etc., it is
necessary to dismantle the entire pump.
To do this, see the sectional plan and diagram with a
breakdown of the attached pieces.
Before dismounting the pump, remove it from its location:
- Release the pins which fix the attachment plate to the
support plate of the well.
First check that the lifting clamp bolts are securely in
place, as they will be used to lift the equipment. In
this position, leave to drain for a few moments to
discharge the fluid contained in the pump.
- Lay down or support the equipment on the edge of the
attachment plate, supporting the motor to ensure it does
not rest on it as a cantilever.

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DISMANTLING:
As a general guide to dismount the equipment, follow these
steps:
- Release the coupling if it is of rigid type.
- Release the attachment screws and remove the motor.
- Release the screws which join the pump casing and
support and extract the moving part.
- Release the impeller and extract it. The bearing bushing
is accessible at this moment.
- Extract the shaft bearing
7.5 Assembly
7.5.1 Coupling
Motor pump coupling
- Proceed in inverse order to assembly. It
is not necessary to check the alignment,
due to the design of the pump in which the concentricity
of the shafts is guaranteed by way of guides between the
motor and the pump support.
7.5.2 Pump
Proceed in reverse order to that described above, taking
special care:
- When mounting the shaft in the support, take care to
ensure it does not tilt and maintains the axial direction
with the support.
- To introduce the different elements, use a plastic
hammer, banging gently in order to prevent damage to
the ballbearings, seals and bearings.
- Do not forget to position new joints. There should be no
clearances and the joints should be perfect.
- Use your hand to check that the shaft rotates freely every
time a piece is mounted.
- If the friction bearing has been removed from its position
in the cover, clean the inside of the cover and the
exterior bearing surface before returning it, and use a
plastic hammer to hit an intermediate piece into place.
Do not forget to position the keep pin which fixes the
bearing to the pump cover.
- It is very important to check that the bearings are
perfectly aligned with the shaft, without any gaps which
may lead to the deviation of the shaft.
- Check the correct positioning of pieces,
especially seals, bushing and impellers.
7.5.3 Tightening torque of the screws/nuts
Steel
Stainless
steel
ISO Metric
thread Tightening Torque in [N·m]
(for non-lubricated thread)
M4 3.1 2.15
M5 6.1 4.25
M6 10.4 7.3
M8 25.2 17.7
M10 49.5 34.8
M12 85.2 59.9
M16 211 148
M20 412 290
M24 710 276
M27 1050 409
M30 1420 554
7.5.4 Tightening torque of the impeller nuts
Note Metric
thread Tightening Torque in [N·m] (for non-lubricated thread)
M14x1.5 38
M20x1.5 100
M27x1.5 250
M33x1.5 460
M52x1.5 2000
Note

IFV
10
7.6 Recommended spare parts
Recommended spare parts (1)
Piece denomination Reference Nº Start up 2 years 5 years
Joints (set) --- 1 2 5
Bearing (set) (2) 6 1 2
Lip seal (set) (2) 24 1 2
Felt ring 20 1 2
Shaft casing 9 1 2
Bearing (set) --- 1 2
Flexible coupling part (set) (2) --- 1 2
Impeller nut --- 1 2
Key (set) --- 1 2
Pump shaft(s) (set) 7 and 22 1
Impeller 11 and 14 1
Coupling (2) --- 1
(1) Amounts recommended for a continuous service pump.
(2) Only for size 100
7.7 Preventative maintenance
Nº DESCRIPTION OF THE OPERATION
TO BE CARRIED OUT PROCEDURE REGULARITY CONSEQUENCE
1 Check for lip seal seal leaks Visual inspection Quarterly 11
2 Check for leaks between the casing and
the cover Visual inspection Quarterly 12
3 Check for leaks between flanges and
connections Visual inspection Quarterly 12
4 Check for heating of the bearings With thermocouple Quarterly 7, 8, 13
5
Check tightness of connecting bolts for
motor, pump, cover/casing,
flanges/casing
Manually Quarterly 13
6 Check for wear of the impeller and rings Dismount casing, visual
inspection Yearly
7 Check for wear of the shaft and
bearings
Dismount support, Visual
inspection Yearly
8 Change the rubber coupling plugs See point 7.4.2 of the
manual Yearly
9 COMPLETE PUMP CHECK
Checking and
dismounting the pump.
See point 7.4.3 of the
manual
Yearly 1, 2, 3, 4, 5, 6, 7, 8,
10, 11, 12, 13, 14
10 Check functional characteristics loss Instrument reading In accordance
with use
Check the
installation, 9
11 Change the lip seal See point 7.4.3 of the
manual
When leaks are
detected
12 Change the joints Manually Every time they
are removed
13 Coupling check See point 5.2.1 of the
manual
Every time they
are removed
14 Check concentricity motor shaft and the
pump shaft
See point 5.2.1 of the
manual
Every time it is
removed

IFV
11
8 Trouble-shooting
The pump does not move the fluid
| Insufficient pressure or flow
| | Excessive absorbed power
| | | Excessive vibrations and noise
| | | | Excessive support temperature
| | | | | Cause Solution
x x Impulsion valves closed or poorly regulated Open them or search for a work point with the impulsion
valve
x Incorrect rotation direction Change the motor connections
x x
Maximum height generated by the pump lower
than that required by the installation or counter
pressure too high.
Increase the rotation speed. If this is not possible, a larger
impeller or larger pump needs to be assembled. Please ask
x Rotation speed incorrect Measure the speed, check the motor drive power supply
voltage
x Poorly primed Check the fluid level in the tank
x Pipe obstruction Clean the pipes
x x Impeller imbalanced or deteriorated Dismount the impeller and inspect, balance or change it
x Liquid viscosity or density greater than normal. Reduce the design point or change the motor
x x x Poor alignment between the pump and motor Check the coupling
x Obstruction inside the pump, impeller or flanges Dismount the pump and clean the impeller, inlets or pipe.
x
The real height to be generated by the pump is
lower than that of the design point, meaning the
flow and power are greater
Partially close the impulsion valve
x x x Ballbearings deteriorated, poorly assembled or
poorly lubricated
Check them, check the assembly or lubricate them, adjust
them properly in their positions.
x Excessive contact in rotating parts Dismount the pump and check elements are correctly
assembled and/or worn
x Misaligned or deformed shaft Dismount it and replace it
x Loose impeller support nuts Dismount the pump and tighten them
x x Pipe tensions on the pump Check the installation
x Lack of rigidity in the foundations or anchor bolts
loose Make new foundations or tighten the bolts
x x Pump cavitation Improve the suction. Please ask.
x Bearings excessively worn or deteriorated Change bearings
x Coupling plugs deteriorated Change the plugs
x Insufficient pipe diameters Larger diameter pipes, whenever possible
x
Poorly assembled coupling, without suitable
separation between its two parts Check the coupling

IFV
12
9 Annexes
9.1 Sectional plans
IFV-32 / IFV-50
Sectional C-355
Ref Denomination
1 Motor
2Key
3 Keep pin
4 Support pipe
5Key
6 Keep pin bushing
7 Shaft
8Key
9 Shaft protecting bushing
10 Bearing bushing
11 Support
12 Washer
13 Key
14 Impeller
15 Pump casing
16 Impeller clamping washer
17 Countersunk screw
18 Flange
19 Joint

IFV
13
IFV-100
Sectional C-356
Ref Denomination
1 Motor
2Key
3 Male sleeve
4Key
5 Bearing support nut
6 Bearing
7 Support pipe
8 Support
9 Bushing
10 Key
11 Impeller
12 Impeller clamping washer
13 Countersunk screw
14 Pump casing
15 Coupling flange
16 Joint
17 Bearing bushing
18 Bearing carrier support
19 Support cover
20 Felt washer
21 Keep pin
22 Pump shaft
23 Female sleeve
24 Lip seal

IFV
14
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IFV
15
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WARRANTY
KSB ITUR Spain, S.A. undertakes:
To repair or replace at any of its ASSOCIATED TECHNICAL SERVICE CENTRES or at its factory in Zarautz, free
of charge and for a period of 12 months as of the date of dispatch from our warehouses, any product which shows
manufacture defects. This warranty will be reduced to 6 months for continuous or permanent service pumps.
KSB ITUR Spain, S.A. shall not be liable for any direct or indirect damage which the product suffers as a result of
defective installation, lack of maintenance, negligent handling, handling by unauthorised personnel, overloading or
deficient functions.
The responsibility of KSB ITUR Spain, S.A. shall be limited to the replacement of the defective piece at the earliest
opportunity, without this giving any entitlement to claims for liability or compensation.
CERTIFICATE OF COMPLIANCE WITH
EC MACHINERY DIRECTIVE
KSB ITUR
P.O. Box 41 – 20800 ZARAUTZ (Gipuzkoa) Spain
PRODUCT UNDER CERTIFICATION. PUMPS SERIES: IFV
"EC" DECLARATION OF
CONFORMITY
KSB ITUR hereby declares, under its
responsibility, that its above-mentioned
products (when supplied with a motor), to
which this Declaration refers, are in line
with European Directive 98/37/CE,on the
approximation laws of the Member States
on machinery.
Applied harmonised standards:
EN 292 Part 1, EN 292 Part 2 and EN 809.
MANUFACTURER'S
DECLARATION
KSB ITUR hereby declares that its above-
mentioned products (when supplied
without a motor) are proposed for
incorporation in machinery or assembled
with other machines to form machinery
covered by Directive 98/37/CE.
Warning is hereby given that the
aforementioned products cannot be started
up until the machinery in which they are to
be incorporated has been declared to
conform to the dispositions of the
aforementioned Directive.
Applied harmonised standards:
EN 292 Part 1, EN 292 Part 2 and EN 809.
Zarautz, May 2008
Post Head of Engineering
Name Ángel Fernández
MIF-3600/01-I [05-2008]
KSB ITUR Spain, S.A.
P.O. Box 41 – 20800 ZARAUTZ (Gipuzkoa) Spain
Tel.: [phone] – Fax [phone]
E-mail:
p
ostventa
@
ksb-itur.es
–
www.itur.es