KSB LCV Installation instructions

Installation/Operating Manual
2017.01 LCV [en-US]
Pump Type:
Pump Serial Number:
Date:
Purchaser:
Purchaser’s Order Number:
GIW / KSB Work Order Number:
Shipped To:
Include the pump’s serial number when ordering replacement parts
This is a standard maintenance manual provided for your convenience
This manual may include additional documentation not applicable to your specific pump
GIW INDUSTRIES, INC.
5000 Wrightsboro Road
Grovetown, GA 30813 USA
[phone]
FAX [phone]
www.giwindustries.com
KSB AG
Johann-Klein-Str. 9
D-67227 Frankenthal, Germany
[phone] .
FAX [phone]
www.ksb.com

LCV [en-US]
2
Legal Information/Copyright
Installation/Operating Manual LCV
Original operating manual (English)
In case of conflict between the local language version and the original operating manual, the original operating manual prevails.
A
ll rights reserved. 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 KSB´s express written consent.
Subject to technical modification without prior notice.
© GIW Industries, Inc

LCV [en-US]
3
Contents
Section Page Section Page
1General 5
2Safety 6
2.1Safety Markings 6
2.2Personnel Qualification and Training 6
2.3Non-compliance with Safety Instructions 7
2.4Safety Awareness 7
2.5Safety Instructions for Operators 7
2.6Safety Instructions for Maintenance, Inspection &
Installation 7
2.7Unauthorized Modification and Manufacture of Spare Parts 7
2.8Unauthorized Modes of Operation 7
2.9Assembly & Disassembly Safety 7
3Transport and Storage 9
3.1Transport & Handling Safety 9
3.2Storage Requirements 9
3.2.1Storage of New Pumps - Pumps under Warranty 9
3.2.2Pump Storage 9
3.2.3Pump Parts Storage 10
3.2.4Removal from Storage 11
3.3Recommended Lifting 12
4Description 13
4.1Technical Specification 13
4.2Designation 13
4.3Design Features 13
4.4Noise Characteristics 14
4.5Accessories 14
4.6Dimensions and Weights 14
4.7Forces and Moments at Nozzles 14
5Installation at Site 15
5.1Safety Regulations 15
5.2Foundation 15
5.3Installing the Baseplate and Pump 15
5.3.1Aligning the Pump / Drive Train for Horizontal Pump
Application 15
5.3.2Place of Installation 16
5.4Connecting the Piping 16
5.4.1Auxiliary Connections 16
5.5Safety Guards 17
5.6Oil Temperature Monitoring 17
5.7Final Check 17
5.8Connection to Power Supply 17
6Commissioning / Operation 18
6.1Commissioning / Return to Service 18
6.1.1Bearing Lubrication 19
6.1.2Shaft Seal Commissioning 19
6.1.3Checking the Direction of Rotation 19
6.1.4Cleaning the Plant Piping 19
6.1.5Suction Strainer 19
6.2Start-up 20
6.2.1Priming the Pump 20
6.3Shutdown 21
6.3.1Measures to be taken for Prolonged Shutdown 21
6.4Operating Limits 21
6.4.1Temperature Limits 21
6.4.2Switching Frequency 22
6.4.3Density of the Medium Handled 22
6.4.4ZW Pump Additional Limits 22
7Maintenance 23
7.1Supervision of Operation 23
7.2Drainage / Disposal 23
7.3Lubrication and Lubricant Change 23
7.4Procedures for Maximum Parts Life 24
7.5Operational Problems and Solutions 24
8Mechanical End 26
8.1Mechanical End Overview 26
8.2Mechanical End Disassembly 27
8.3Mechanical End Assembly 27
8.3.1Mounting the Bearings 28
8.3.2Back to Back Thrust Bearing Installation 28
8.3.3Face to Face Thrust Bearing Installation 29
8.3.4Installing End Covers and Seals 30
8.4Bearing Assembly Mounting 30
9Shaft Seal 31
9.1Seal Plate 31
9.1.1Seal Plate Assembly (LCV Only) 31
10Wet End 32
10.1Wet End Overview 32
10.2Wet End Disassembly 32
10.2.1Impeller Removal 32
10.2.2Impeller Break-Loose Device 32
10.2.3Impeller Removal with Impeller Lifting Device 33
10.2.4Casing Removal 33
10.3Wet End Assembly 33
10.3.1Mounting the Shaft Sleeve 33
10.3.2Mounting the Casing 33
10.3.3Impeller Installation 34
10.4Setting the Nose Gap 34
10.4.1Nose Gap Adjustment (Frame Size 1 & 2) 34
10.4.2Nose Gap Adjustment (Frame Size 3 & 4) 35
11Tooling 36
11.1Torque Requirements 36
11.2Spare Parts Stock 37
12Troubleshooting 38
14Notes 40

LCV [en-US]
4
Index
Section Page Section Page
Accessories 14
Alignment 15
Assembly Safety 7
Assembly, Mechanical End 27
Assembly, Wet End 33
Auxiliary Connections 16
Baseplate 15
Bearing Assembly Mounting 30
Bearing Installation 28
Bearing Lubrication, Commissioning 19
Casing 32
Casing Installation 33
Casing Removal 33
Cavitation / NPSH Performance 24
Commissioning 18
Commissioning / Return to Service 18
Commissioning, Bearing Lubrication 19
Density of the Medium Handled 22
Dimensions 14
Direction of Rotation 19
Disassembly Safety 7
Disassembly, Mechanical End 27
Disassembly, Wet End 32
Drainage / Disposal 23
End Covers and Seals, Installation 30
Foundation 15
Impeller 32
Impeller Installation 34
Impeller Removal 32
Impeller Removal, Break-Loose Device 32
Impeller Removal, Lifting Device 33
Impeller, Parts Life 24
Inspection, Safety 7
Installation 15
Installation, Location 16
Installation, Safety 7
Lifting 12
Lubricant Change 23
Maintenance Equipment 36
Maintenance, Safety 7
Mechanical End 26
Mechanical End Assembly 27
Mechanical End Disassembly 27
Mounting the Bearings 28
Noise Characteristics 14
Nose Gap Adjustment 34
Oil Temperature Monitoring 17
Operating Conditions of Flow and Head 25
Operating Limits 21
Operating Limits, ZW Pumps 22
Operation 18
Operation, Unauthorized Modes 7
Operational Problems and Solutions 24
Parts Life 24
Personnel 6
Piping System Design 24
Piping, Allowable Forces and Moments 14
Piping, Cleaning 19
Piping, Connecting 16
Power Supply 17
Priming the Pump 20
Pump Casing, Parts Life 24
Pump Description 13
Pump Design Features 13
Pump Designation 13
Pump Specification 13
RTD Installation 17
Safety Awareness 7
Safety Guards 17
Safety Markings 6
Safety, Final Check 17
Safety, Non-compliance 7
Safety, Operators 7
Safety, Regulations 15
Safety, Transport & Handling 9
Seal Plate 31
Seal Plate Assembly (LCV Only) 31
Shaft Seal 31
Shaft Seal, Commissioning 19
Shaft Sleeve, Mounting 33
Shutdown 21
Shutdown, Prolonged 21
Spare Parts Stock 37
Spare Parts, Unauthorized Modification 7
Start-up 20
Storage Requirements 9
Suction Liner, Parts Life 24
Suction Strainer 19
Sump Design 24
Switching Frequency 22
Temperature Limits 21
Thrust Bearing Installation (Back to Back) 28
Thrust Bearing Installation (Face to Face) 29
Tooling 36
Torque Requirements 36
Transport, Storage & Handling 9
Troubleshooting 38
Wear Problems and Solutions 24
Weights 14
Wet End 32
Wet End Assembly 33
Wet End Disassembly 32

LCV [en-US]
5
1 General
CAUTION
This manual contains important information for reliable, proper and efficient operation. Compliance with the
operating instructions is of vital importance to ensure reliability and long service life of the pump, and to avoid
any risks.
These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly
observed by all, including the personnel called in for installation.
WARNING
This pump / unit must not be operated beyond the limit values specified in the technical documentation for the
medium handled, capacity, speed, density, pressure, temperature and motor rating. Make sure that operation is
in accordance with the instructions given in this manual or in the contract documentation.
The nameplate indicates the type series / size, main operating data and serial number. Please quote this information in all
queries, repeat orders and particularly when ordering spare parts.
This manual may contain information not applicable to your pump/unit. Your pump/unit may not be equipped with all features or
auxillary components as described in this manual. Consult your pump/unit drawings and Bill of Materials for details.
If you need any additional information or instructions exceeding the scope of this manual or in case of damage, please contact
your GIW / KSB representative.

LCV [en-US]
6
2 Safety
These operating instructions contain fundamental information that must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible
trained personnel / operators prior to installation and commissioning, and it must always be kept close to the operating location
of the machine / unit for easy access.
Not only must the general safety instructions given in this chapter of "Safety" be complied with, but also the safety instructions
outlined under specific headings.
2.1 Safety Markings
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.
Instructions attached directly to the machine, such as:
 Arrow indicating the direction of rotation
 Marking for fluid connections must always be complied with and be kept in legible condition at all times.
2.2 Personnel Qualification and Training
All personnel involved in the operation, maintenance, inspection and installation of the machine must be fully qualified to carry
out the work involved.
Personnel responsibilities, competence and supervision must be clearly defined by the operator. If the personnel in question are
not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the
operator may commission the manufacturer / supplier to provide such training. In addition, the operator is responsible for
ensuring that the contents of the operating instructions are fully understood by the responsible personnel.

LCV [en-US]
7
2.3 Non-compliance with Safety Instructions
Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine itself. Non-
compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
Failure of important machine / unit functions
 Failure of prescribed maintenance and servicing practices
 Hazard to persons by electrical, mechanical and chemical effects
 Hazard to the environment due to leakage of hazardous substances.
2.4 Safety Awareness
It is imperative to comply with the safety instructions contained in this manual, the relevant national and local health and safety
regulations and the operator’s own internal work, operation and safety regulations.
2.5 Safety Instructions for Operators
 Any hot or cold components that could pose a hazard must be equipped with a guard by the operator.
 Guards that are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed while the
machine is operating.
 Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot) must be contained so as to
avoid any danger to persons and the environment. Pertinent legal provisions must be adhered to.
 Electrical hazards must be eliminated. (Refer to the relevant safety regulations applicable to different countries and /
or the local energy supply companies.)
 Mixing unsuitable media may cause a chemical reaction resulting in a pressure buildup and potential explosion.
2.6 Safety Instructions for Maintenance, Inspection & Installation
 The operator is responsible for ensuring that all maintenance, inspection and installation work is performed by
authorized and qualified personnel who are thoroughly familiar with the manual.
 Work on the machine must be carried out only during standstill. The shutdown procedure described in the manual for
taking the machine out of service must be adhered to without fail.
 Pumps or pump units handling media injurious to health must be decontaminated.
 Immediately following completion of the work, all safety / protective devices must be re-installed and / or re-activated.
 Please observe all instructions set out in the Section 6 "Commissioning" before returning the machine to service.
2.7 Unauthorized Modification and Manufacture of Spare Parts
Modifications or alterations of the machine are only permitted after consultation with the manufacturer. Original spare parts and
accessories authorized by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer
for damage or warranty.
2.8 Unauthorized Modes of Operation
Any warranty of the operating reliability and safety of the pump / unit supplied is only valid if the machine is operated in
accordance with its designated use as described in the following sections. The limits stated in the data sheet must not be
exceeded under any circumstances.
2.9 Assembly & Disassembly Safety
DANGER
Do not apply heat to the impeller hub or nose due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!
For sectional drawings and bills of material relating to your specific pump and equipment, locate an official copy of the
documentation provided by GIW / KSB. This may be shipped separately from the pump and will include drawings and bills
of material as attachments to this basic manual.
 Dismantling and reassembly must always be carried out in accordance with the rules of sound engineering practice
and the relevant sectional drawings. Any work on the motor, gear reducer, mechanical seal or other non-pump
equipment shall be governed by the specifications and regulations of the respective supplier.
 Before assembly thoroughly clean all dismantled part mating surfaces and check them for signs of wear. Damaged or
worn components are to be replaced by original equipment spare parts. Make sure that the seal faces are clean and
the o-rings and gaskets are properly fitted. It is recommended that new seal elements (o-rings and gaskets) be used
whenever the pump is reassembled. Make sure that new gaskets have the same thickness as the old ones.

LCV [en-US]
8
 Avoid the use of mounting aids as much as possible. Should a mounting aid be required, use a commercially available
contact adhesive. The adhesive should only be applied at selected points (three to four spots) and in thin layers. Do
not use cyanoacryiate adhesives (quick-setting adhesives). If in certain cases mounting aids or anti-adhesives other
than those described are required, please contact the sealing material manufacturer.
 The operator is responsible for ensuring that all maintenance inspection and installation work is carried out by
authorized, duly qualified staff who are thoroughly familiar with these operating instructions.
 A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure.
 Repair and maintenance work to the pump must only be carried out by specially trained personnel, using original
equipment spare parts.
WARNING
 Proper lifting, rigging and safety practices must be observed at all times. Do not attempt to lift heavy
components by hand as this may result in personal injury and damage to equipment.
 Work on the unit must only be carried out with the electrical connections disconnected and locked out.
Make sure that the pump set cannot be switched on accidentally.
 Pumps handling liquids posing health hazards must be decontaminated. When draining the medium
ensure there is no risk to persons or the environment. All relevant laws must be adhered to.
 Before dismantling or reassembly, secure the pump so as to make sure it cannot be switched on
accidentally. The shut-off elements in the suction and discharge nozzles must be closed. The pump
must have cooled down to ambient temperature, drained, and its pressure must be released.
 Before dismantling or reassembly of vertical cantilever pumps, remove the motor and pull the assembly
out of the sump.
 Upon completion of the work, all safety-related and protective equipment must be properly refitted
and/or reactivated before starting the pump set.
 Always ensure that lifting equipment does not bind the swivel hoist ring. Binding can cause the ring to
fail. When lifting a plate that contains two swivel hoist rings, do not allow the angle between the lines
of tension from the rings to exceed 120°. This could cause the hoist rings to fail.
Do NOT bind lifting equipment Do NOT exceed 120° between lines of tension
120
°

LCV [en-US]
9
3 Transport and Storage
3.1 Transport & Handling Safety
WARNING
 Proper rigging, lifting and safety practices must be observed at all times.
 If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage
to property.
 Follow proper lifting practice and safety rules at all times, including:
 Verification of the lift weight and load rating of the lift equipment.
 Suitability and stability of the attachment points.
 Be aware of the location of the center of gravity, which is usually NOT located at the physical center of the unit. In
general, the following guidelines will apply, although common sense and testing of the lift before movement should be
used to verify:
 Bare shaft pump (without motor): Near the shaft seal area.
 Pump with overhead mounted motor: Between the pump and motor, slightly behind (towards the drive end) of
the shaft seal.
 Vertical cantilever pump: between the pump and bearing assembly, but closer to the bearing assembly.
 Space the lifting points evenly about the center of gravity and as far apart as practical. This will result in the most stable
lift. Note that certain lift points on the pedestal or bearing housing may be intended for use in handling the pedestal or
bearing house alone and are not necessarily optimum balance points for the entire pump unit.
 See Section 3.3 or any addendums for suggested lifting methods. Actual safe lifting method will vary with pump
configuration and type of lifting equipment.
 Ensure secure attachments and test the lifting method for stability before moving pump.
 Ensure that the pump is firmly strapped down during shipment. Pump should be protected from direct contact with the
elements. Motors and gear reducers may require Immediate cover (consult manufacturer). After arrival on site, consult
GIW Pump Storage recommendations for further storage instructions.
 In corrosive environments be sure to remove all lifting devices from the pump and store in a non-corrosive environment
until needed.
 DO NOT: Use eyebolt or shackle locations on the bearing assembly, motor or pump plates. These are intended for
lifting those items alone and must not be used when lifting the entire pump.
 DO NOT: Place excessive side loads on cast lifting eyes. The side loading angle on any lifting eye should not exceed
30 degrees.
3.2 Storage Requirements
3.2.1 Storage of New Pumps - Pumps under Warranty
Consult your sales contract documents and/or your GIW / KSB representative for detailed instructions. Note that failure to follow
proper storage procedures will void your warranty.
3.2.2 Pump Storage
CAUTION
 In freezing environments, water must be prevented from collecting in the pump casing.
 Pumps with elastomer linings should be stored in a cool dark location free from electrical equipment
such as motors, or any other ozone generating devices. Exposure to direct sunlight or temperatures in
excess of 50°C (120°F) must be avoided.
 If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other
auxilarily equipment be sure to consult the manufacturer’s maintenance manual for any additional
storage instructions.
 Auxiliary systems should be regularly tested according to manufacturer’s recommendations.

LCV [en-US]
10
Storage Upon Receipt and up to 3 Months:
 Pump should stored indoors and out of the weather until ready for installation.
 In construction environments where indoor storage is not available, store the pump on blocks or pallets, build a frame
around it and cover with tarpaulin.
o Frame must be able to withstand snow and wind, anchored and built in a manner to last the entire time pump
is in storage. Shelter must be continuously maintained in a stable and leak free condition.
o Ensure the tarpaulin does not touch the pump, since this can lead to condensation. Leave the bottom open
for ventilation. Minimum Tarp requirements: 610gsm (18oz) Vinyl, 0.5mm (20mil) thick, Water proof & UV
(ultraviolet) resistant
Storage Exceeding 3 Months
 If pump is exposed to the weather at any time the frame requirements still stand.
 The Wet End pump parts should be drained and isolated from reaction vessel gasses.
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
 Check that the threaded holes are protected with grease and plugged.
 Grease lubricated bearing assemblies do not require monthly rotation.
 If the pump is fitted with a mechanical seal, precautions may need to be taken before rotating the shaft. Refer to the
seal manufacturer’s maintenance manual for instructions.
 Pumps with InPro/Seal® bearing isolators must be coated externally with white grease or petroleum jelly to seal the
gap between the rotor and stator. Units equipped with a vent kit must have the vents either removed and plugged, or
blocked to prevent air exchange.
 Vertical pumps should be stored horizontally, and the blocking on the shaft should be left in place until the pump is
ready to be installed.
Storage Exceeding 12 Months (Long Term Storage)
The following information on long term storage pertains to GIW pump assemblies only and does NOT cover any auxiliary
equipment such as motors, gearboxes, lube oil systems, etc... Long term storage for auxiliary equipment must be included in
the contract and negotiated with sub-vendors at time of order.
At 12 months storage and again at 24 months of storage, the following additional actions should be taken:
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
Installed Spares (Idle Pumps)
 After being idle to 1 or more months, shafts must be rotated through five (5) or more revolutions, either manually or by
a short duration start-up.
3.2.3 Pump Parts Storage
CAUTION
For proper storage ensure:
 All machined surfaces must be coated with rust protector
 Grease and plug all drilled and threaded holes
 Check monthly for paint breakdown on casting
 Check monthly for visible sign of rust on machine surface
 Check monthly forgeign matter buildup in drilled/threaded holes
 Remove rust with wire brush and recoat machined surfaces with a rust inhibitor as needed
 Remove rust with wire brush and repaint casting surfaces as needed
All pump parts must be stored indoors. The only exception is for large castings such as pedestals, pump casings,
impellers, etc… See chart below for details.