KSB Secochem-Ex User manual

Secochem-Ex
Original operating instructions
2939.8/10-EN
Explosion-proof Standardized
Chemical Pump
with canned motor
Connection dimensions to EN 22 858/ISO 2858
Explosion protection as per directive 94/9/EC
Order No.:
Type series:
These operating instructions contain fundamental
information and precautionary notes. Please read
the manual thoroughly prior to installation of unit,
electrical connection and commissioning. It is imperative
to comply with all other operating instructions referring to
components of individual units.
This manual shall always be kept close to the unit’s
location of operation or directly on the pump set.

Secochem-Ex
2
Contents
Page
1 General 4
2 Safety 4
2.1 Marking of instructions in the manual 4
2.2 Personnel qualification and training 4
2.3 Non-compliance with safety instructions 4
2.4 Safety awareness 4
2.5 Safety instructions for the operator / user 5
2.6 Safety instructions for maintenance,
inspection and installation work 5
2.7 Unauthorized modification and
manufacture of spare parts 5
2.8 Installation of partly completed machinery 5
2.9 Unauthorized modes of operation/intended use 5
2.10 Explosion protection 5
2.10.1 Marking 6
2.10.2 Unit fill 6
2.10.3 Drive 6
2.10.4 Checking the direction of rotation 6
2.10.5 Pump operating mode 6
2.10.6 Temperature limits 7
2.10.7 Technical design 7
2.10.8 Maintenance 7
3 Transport and interim storage 7
3.1 Transport 7
3.2 Interim storage / Preservation 7
4 Description of the product and
accessories 7
4.1 Technical specification 7
4.2 Designation 8
4.3 Design details 8
4.3.1 Functional description 9
4.3.2 Pump casing 9
4.3.3 Impeller type 9
4.3.4 Drive 9
4.3.5 Bearings 9
4.3.6 Noise characteristics 9
4.4 Permissible forces and moments at the pump
nozzles 10
4.5 Accessories 11
4.6 Dimensions and weights 11
5 Installation at Site 11
5.1 Safety regulations 11
5.2 Checks to be carried out prior to
installation 11
5.3 Installing the pump / unit 11
5.3.1 General 11
5.3.2 Installing pumps with motor sizes DE 90 /
DE 112 / DE 132 11
5.3.3 Installing pumps with motor sizes DE 160 and
DE 200 11
5.3.4 Place of installation 11
5.3.5 Connecting the piping 12
5.3.6 Auxiliary connections 12
5.4 Final check 12
Page
5.5 Electrical connection 12
5.5.1 Terminal box 12
5.5.2 Connecting the power cable 13
5.5.3 Connecting the control cables 13
5.5.4 Monitoring equipment 13
5.5.5 Potential equalisation 13
5.6 Pump operation with frequency inverter 13
6 Commissioning, start-up / shutdown 14
6.1 Commissioning 14
6.1.1 Priming the pump 14
6.1.2 Checking the direction of rotation 15
6.1.3 Cleaning the plant piping 15
6.1.4 Start-up strainer 15
6.1.5 Start-up 15
6.1.6 Shutdown 15
6.2 Operating limits 15
6.2.1 Temperature of the medium handled,
ambient temperature 15
6.2.2 Switching frequency 15
6.2.3 Density of medium handled 15
6.2.4 Abrasive media 15
6.2.5 Minimum/maximum flow 16
6.3 Shutdown / storage / preservation 16
6.3.1 Storage of new pumps 16
6.3.2 Measures to be taken for prolonged
shutdown 16
6.4 Returning to service after storage 16
7 Servicing / Maintenance 16
7.1 General instructions 16
7.2 Servicing / Inspection 16
7.2.1 Supervision of operation 16
7.2.2 Bearings 17
7.3 Drainage / Disposal 17
7.4 Dismantling 17
7.4.1 Fundamental instructions and
recommendations 17
7.4.2 Dismantling (general) 17
7.5 Reassembly 19
7.5.1 General instructions 19
7.5.2 Reassembly (General) 19
7.5.3 Tightening torques 20
7.5.4 Diametral clearances 21
7.6 Spare parts stock 21
7.6.1 Recommended spare parts stock for two years’
operation as per DIN 24296 21
8 Trouble-shooting 22
9 Lists of components and general
assembly drawings 24
9.1 Motors DE 90 24
9.2 Motors DE 112 26
9.3 Motors DE 160 28
9.4 Motors DE 200 30
9.5 Back pull-out unit with motors DE 90 32
9.6 Back pull-out unit with motors DE 112 34
9.7 Motor unit supplied as spare part 36
10 EC Declaration of Conformity 37
11 Certificate of Decontamination 38

Secochem-Ex
3
Index
Section Page
Abrasive media 6.2.4 15
Accessories 4.5 11
Auxiliary connections 5.3.6 12
Back pull-out unit with motors DE 112 9.6 34
Back pull-out unit with motors DE 90 9.5 32
Bearings 4.3.5 9
Bearings 7.2.2 17
Certificate of Decontamination 11 38
Checking the direction of rotation 2.10.4 6
Checking the direction of rotation 6.1.2 15
Checks to be carried out prior to
installation 5.2 11
Cleaning the plant piping 6.1.3 15
Commissioning 6.1 14
Commissioning, start-up / shutdown 6 14
Connecting the control cables 5.5.3 13
Connecting the piping 5.3.5 12
Connecting the power cable 5.5.2 13
Density of medium handled 6.2.3 15
Description of the product and
accessories 47
Design details 4.3 8
Designation 4.2 8
Diametral clearances 7.5.4 21
Dimensions and weights 4.6 11
Dismantling 7.4 17
Dismantling (general) 7.4.2 17
Drainage / Disposal 7.3 17
Drive 2.10.3 6
Drive 4.3.4 9
EC Declaration of Conformity 10 37
Electrical connection 5.5 12
Explosion protection 2.10 5
Final check 5.4 12
Functional description 4.3.1 9
Fundamental instructions and
recommendations 7.4.1 17
General 1 4
General 5.3.1 11
General instructions 7.1 16
General instructions 7.5.1 19
Impeller type 4.3.3 9
Installation at Site 5 11
Installation of partly completed machinery 2.8 5
Installing pumps with motor sizes DE 90 /
DE 112 / DE 132 5.3.2 11
Installing pumps with motor sizes DE 160 and
DE 200 5.3.3 11
Installing the pump / unit 5.3 11
Interim storage / Preservation 3.2 7
Lists of components and general
assembly drawings 924
Maintenance 2.10.8 7
Marking 2.10.1 6
Marking of instructions in the manual 2.1 4
Measures to be taken for prolonged
shutdown 6.3.2 16
Section Page
Minimum/maximum flow 6.2.5 16
Monitoring equipment 5.5.4 13
Motor unit supplied as spare part 9.7 36
Motors DE 112 9.2 26
Motors DE 160 9.3 28
Motors DE 200 9.4 30
Motors DE 90 9.1 24
Noise characteristics 4.3.6 9
Non-compliance with safety instructions 2.3 4
Operating limits 6.2 15
Permissible forces and moments at the pump
nozzles 4.4 10
Personnel qualification and training 2.2 4
Place of installation 5.3.4 11
Potential equalisation 5.5.5 13
Priming the pump 6.1.1 14
Pump casing 4.3.2 9
Pump operating mode 2.10.5 6
Pump operation with frequency inverter 5.6 13
Reassembly 7.5 19
Reassembly (General) 7.5.2 19
Recommended spare parts stock for two years’
operation as per DIN 24296 7.6.1 21
Returning to service after storage 6.4 16
Safety 2 4
Safety awareness 2.4 4
Safety instructions for maintenance,
inspection and installation work 2.6 5
Safety instructions for the operator / user 2.5 5
Safety regulations 5.1 11
Servicing / Inspection 7.2 16
Servicing / Maintenance 7 16
Shutdown 6.1.6 15
Shutdown / storage / preservation 6.3 16
Spare parts stock 7.6 21
Start-up 6.1.5 15
Start-up strainer 6.1.4 15
Storage of new pumps 6.3.1 16
Supervision of operation 7.2.1 16
Switching frequency 6.2.2 15
Technical design 2.10.7 7
Technical specification 4.1 7
Temperature limits 2.10.6 7
Temperature of the medium handled,
ambient temperature 6.2.1 15
Terminal box 5.5.1 12
Tightening torques 7.5.3 20
Transport 3.1 7
Transport and interim storage 3 7
Trouble-shooting 8 22
Unauthorized modes of operation/intended use 2.9 5
Unauthorized modification and
manufacture of spare parts 2.7 5
Unit fill 2.10.2 6
Weight 3.1 / 4.6 7 / 10

Caution
Secochem-Ex
4
1 General
This KSB product has been developed in
accordance with state-of-the-art technology; it
is manufactured with utmost care and subject to continuous
quality control.
These operating instructions are intended to facilitate
familiarization with the unit and its designated use.
The manual contains important information for reliable, proper
and efficient operation. Compliance with the operating
instructions is of vital importance to ensure reliability and a long
service life of the unit 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.
This pump / unit must not be operated beyond the limit
values for the medium handled, capacity, speed,
density, pressure, temperature and motor rating specified in the
technical documentation. Make sure that operation is in
accordance with the instructions laid down in this manual or in
the contract documentation. Contact the manufacturer, if
required.
All values stipulated for electrical connection of the unit as well
as instructions given for installation and maintenance must be
adhered to without fail.
All relevant regulations must be adhered to according to the
hazardous area classification.
The name plate indicates the type series / size, main operating
data and order number; please quote this information in all
queries, repeat orders and particularly when ordering spare
parts.
Carefully observe section 7.3, Drainage/disposal,
before returning the pump unit, in order to avoid any risk
both during transport and handling!
If you need any additional information or instructions exceeding
the scope of this manual or in case of damage please contact
KSB’s nearest customer service centre.
Noise characteristics see section 4.3.6.
2 Safety
These operating instructions contain fundamental information
which must be complied with during installation, operation,
monitoring 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 location of operation of the machine / unit for easy
access.
Not only must the general safety instructions laid down in this
chapter on ”Safety” be complied with, but also the safety
instructions outlined under specific headings, particularly if the
pump/unit is operated in hazardous areas (see section 2.10).
2.1 Marking of instructions in the manual
The safety instructions contained in this manual whose
non-observance might cause hazards to persons are specially
marked with the symbol
safety sign in accordance with DIN 4844 - W 9,
The electrical danger warning sign is
safety sign in accordance with DIN 4844 - W 8
and special instructions concerning explosion protection are
marked
The word
Caution
is used to introduce safety instructions whose non-observance
may lead to damage to the machine and its functions.
Instructions attached directly to the machine, e.g.
-- arrow indicating the direction of rotation
-- markings for fluid connections
must always be complied with and be kept in a perfectly legible
condition at all times.
2.2 Personnel qualification and training
All personnel involved in the operation, maintenance,
inspection and installation of the unit 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
is 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 take care of such training. In addition, the operator
is responsible for ensuring that the contents of the operating
instructions are fully understood by the responsible personnel.
2.3 Non-compliance with safety instructions
Non-compliance with safety instructions can jeopardize the
safety of personnel, the environment and the machine / unit
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 unit functions,
-- failure of prescribed maintenance and servicing practices,
-- hazard to persons by electrical, mechanical and chemical
effects as well as explosion,
-- 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 internationalexplosion
protection regulations, health and safety regulations and the
operator’s own internal work, operation and safety regulations.
Ex symbol relates to additional requirements which
must be adhered to when the pump is operated in
hazardous areas.

Secochem-Ex
5
2.5 Safety instructions for the operator / user
-- Any hot or cold components that could pose a hazard must
be equipped with a guard by the operator.
-- Guards which are fitted to prevent accidental contact with
moving parts must not be removed whilst the unit is
operating.
-- Leakages of hazardous media handled (e.g. explosive,
toxic, hot) must be contained so as to avoid any danger to
persons or the environment. All relevant laws must be
heeded.
-- Electrical hazards must be eliminated. (In this respect refer
to the relevant safety regulations applicable to different
countries and/or the local energy supply companies.)
-- If the pumps/units are located in hazardous areas, it
is imperative to make sure that unauthorized modes
of operation are prevented. Non-compliance may result in
the specified temperature limits being exceeded.
2.6 Safety instructions for maintenance,
inspection and installation work
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the manual.
The pump must have cooled down to ambient temperature and
pump pressure must have been released.The pump musthave
been de-energized and drained. If necessary, the applicable
explosion protection regulations must be heeded.
Work on the machine / unit must be carried out only during
standstill. The shutdown procedure described in the manual for
taking the unit out of service must be adhered to without fail.
Pumps or pump units handling media injurious to health must
be decontaminated.
Immediately following the completion of the work, all
safety-relevant and protective devices, including the
monitoring devices ensuring explosion protection (see 2.9)
must be re-installed and/or re-activated.
Please observe all instructions set out in the chapter on
“Commissioning” before returning the unit to service.
2.7 Unauthorized modification and
manufacture of spare parts
Modifications or alterations of the equipment supplied are only
permitted after consultation with the manufacturer and to the
extent permitted by the manufacturer. Original spare parts and
accessories authorized by the manufacturerensure safety. The
use of other parts can invalidate any liability of the manufacturer
for consequential damage.
Special regulations apply to repair work on explosion--proof
pumps. Modifications or alterations of the pump set may affect
explosion protection and are only permitted after consultation
with the manufacturer.
The actual dimensions of the flameproof joints are not
necessarily identical with those stipulated in EN 60079-1
Tables 1 and 2.
Repair work at the flameproof joints must only be performed in
accordance with the manufacturer’s instructions. Repair to the
values in tables 1 and 2 of EN 60079-1 is not permitted.
2.8 Installation of partly completed machinery
(back pull-out unit)
When installing partly completed machinery supplied by KSB
please refer to the relevant sub--sections regarding
servicing/maintenance,i.e. para.4 in section7.5.2 andsections
9.6 or 9.7.
The back pull--out unit is only available for sizes DE 90, DE 112
and DE 132.
2.9 Unauthorized modes of operation/Intended
use
The warranty relating to the operatingreliability andsafety ofthe
unitsupplied is only valid if the equipment is used inaccordance
with its designated use as described in the following sections.
The limits stated in the data sheetmust not be exceeded under
any circumstances.
Only operate pumps/pump sets which are in perfect
technical condition.
Do not operate partially assembled pumps/pump sets.
Only use the pump to handle the fluids specified in the data
sheet or product literature of the respective design variant.
Never operate the pump without the fluid to be handled.
Observe the minimumflow rates indicated in the data sheet
or product literature (to prevent overheating, bearing
damage, etc).
Observe the maximum flow rates indicated in the data
sheet or product literature (to prevent overheating,
mechanical seal damage, cavitation damage, bearing
damage, etc).
Do not throttle the flow rate on the suction side of the pump
(to prevent cavitation damage).
Consult the manufacturer about any use or mode of
operation not described in the data sheet or product
literature.
Prevention of foreseeable misuse
Never open the discharge--side shut--off elements further
than permitted.
-- The maximum flow rate specified in the data sheet or
product literature would be exceeded.
-- Risk of cavitation damage
Never exceed the permissible operating limits specified in
the data sheet or product literature regarding pressure,
temperature, etc.
Observe all safety information and instructions in this
manual.
2.10 Explosion protection
If the pumps/units are installed in hazardous areas, the
measures and instructions given in the following
sections 2.10.2 to 2.10.8 must be adhered to without fail, to
ensure explosion protection.
Suitable monitoring systems as well as suggested wiring
concepts are described in supplementary operating manual
1070.81-10.

Note
Secochem-Ex
6
2.10.1 Marking
Motor (electric) II 2G Ex de IIC T.. Gb
Temperature class (T..): T6, T5, T4 or T3
The temperature class for the Secochem-Ex (SCX) model
supplied depends on pump selection and is indicated in the
data sheet and on the pump name plate.
In case of special coatings with a total film thickness
exceeding 0.2 mm: II 2G Ex de IIB T..Gb.
Hydraulic system (mechanical) II 2G c TX
Note:
DIN EN 13463--1, 2009--07, section ”9.3.2 Marking of
equipment complying with this standard”, stipulates that
pumps must be marked ”TX”.
Reason:
Where the actual maximum surface temperature depends
not on the equipment itself but mainly on operating
conditions (like a heated fluid in a pump), the manufacturer
must not apply a temperature class or temperature
marking. In such cases, the note ”TX” must be included in
the marking, and the relevant information must be
contained in the operating manual.
2.10.2 Unit fill
It is assumed that the system of suction and discharge
lines and thus the wetted pump internals are completely
filled with the product to be handled at all times during pump
operation, so that an explosive atmosphere is prevented.
Ifthe operator cannotwarrant this condition, appropriate
monitoring devices must be used (Directive 94/9/EC,
Annex II, Section 1.5.5 and EN 1127-1).
In addition, itis imperative to make sure thatthe
rotor space is properly filled (particularly if
barrier liquid is used or filters are fitted upstream of the pump).
The same applies to heating and cooling systems.
2.10.3 Drive
The canned motors may be connected to electricallow-voltage
grids with nominal voltages and voltage tolerances to IEC 38 or
other grids or power supply facilities with max. nominal voltage
tolerances of +/- 10 %.
For explosion--proof pump sets, the maximum permissible
supply voltage deviation is ¦5 % of the rated voltage. The
voltage difference between the individual phases must not
exceed 1 %.
Appropriate steps shall be taken to protect the canned motor
against overload. Motor overload protection can be realized by:
Limiting the current (e.g. by means of a motor protection
switch)
In this case,the rated current (see Fig. 1, name plate) must
be set. The running motor must be cut out at 1.2 times the
rated current at the latest (EN 60079-14).
Limiting the temperature by means of PTC resistors
integrated in the stator.
The PTC resistors must be connected to a tripping unit
which meets the requirements stipulated by Directive
94/9/EC, Annex II, Section 1.5.5 and EN 1127-1.
Exception: not permitted for motor DE90.2--1,1 in
combination with temperature class T6; for this
combination, motor overload protection by means of a
motor protection switch is mandatory.
When reaching the temperature limit stipulated for compliance
with the temperature class, the canned motor must be cut out
by means of an approved tripping unit (to Directive 94/9/EC)
connected to the measuring points provided.
The following measuring points are provided on the motor:
Monitoring concept I:
Temperature sensor in the bearing carrier (Part No. 382,
see general assembly drawing in the annex)
or
Monitoring concept II:
PTC resistor on the can and/or in the stator (fitted in the
factory).
The cutout temperature indicated on the name plate (TEX)must
be adhered to without fail.
In the case of monitoring concept I
(field TEX shows a number, see illustration of name plate)
the temperature sensor in the bearing carrier must be
connected and the cutout temperature (TEX) must be set.
In the case of monitoring concept II
(Field TEX does not show a number, see Fig. 1, name
plate.)
the PTC resistors must be connected to a tripping unit (as
per Directive 94/9/EC, see above).
Cut-out temperature
of PT100
(number or --- )
Rated current
Explosion
protection
marking: Hydraulics
Explosion
protection
marking: Motor
Fig. 1 Name plate
The canned motors can also be operated on frequency
inverters. Make sure to observe the design data of the motor in
this case. To prevent an inadmissible heat build-up in the motor,
always use the motor version with PTC resistors integrated in
the stator when operating the pump unit with a frequency
inverter. The PTC resistors must be connected to a tripping unit
(also refer to sections 5.6 and 4.3.4).
If standstill heaters are used, make sure that the surface
temperatures of the canned motor do not exceed the
temperature class stated on the name plate.
The standstill heater offered by KSB is suited to the canned
motors described in this manual. Please observe the operating
manual supplied with the standstill heater.
2.10.4 Checking the direction of rotation (see also 6.1.2)
If the explosion hazard also exists during the installation
phase, the direction of rotation must never be checked
by starting up the unfilled pump unit, even for a short period, to
prevent temperature increases resulting from contact between
rotating and stationary components.
2.10.5 Pump operating mode
Make sure that the pump is always started up with the
suction-side shut-off valve fully open and the discharge-side
shut-off valve slightly open. However, the pump can also be
started up against a closed swing check valve. The
discharge-side shut-off valve shall be adjusted to comply with
the duty point immediately following the run-up process (see
6.1.5).

Note
Caution
Caution
Caution
Secochem-Ex
7
Pump operation with the shut-off valves in the suction
and/or discharge pipes closed is not permitted.
In this condition, there is a risk of the pump
casing taking on high surface temperatures
after a very short time, due to a rapid temperature rise in the
pumped product inside the pump.
Additionally, the resulting rapid pressure build-up inside the
pump may cause excessive stresses on the pump materials or
even bursting.
The minimum flows indicated in section 6.2.5 referto water and
water-like liquids. Longer operating periods with these liquids
and at the flow rates indicated will not cause an additional
increase in the temperatures on the pump surface. However, if
the physical properties of the media handled are different from
water, it is essential to check if an additional heat build-up may
occur and if the minimum flow rate must therefore be increased.
To check, proceed as described in section 6.2.5.
In addition, the instructions given in section 6 of this operating
manual must be observed.
Pump operation outside its specified operating
range may also result in dry running.
2.10.6 Temperature limits
a) Fluid temperature
The surface temperature at the pump casing
corresponds to the temperature ofthe mediumhandled.
If the pump is heated, it must be ensured that the temperature
classes stipulated for the plant are observed.
In the motor area, compliance with the surface temperature
stipulated is ensured by the monitoring facilities provided for
limiting the temperature in the rotor space and by the motor
overload protection device.
The motor surface must be freely exposed to the atmosphere.
In any case, responsibility for compliance with the
specified product temperature (operating temperature)lies
with the plant operator. The maximum permissible product
temperature depends on the temperature class to be
complied with.
Safety note:
The permissible operating temperature of the
pump in question is indicated on the data
sheet. If the pump is to be operatedat a higher temperature,the
data sheet is missing or if the pump is part of a pool of pumps,
the maximum permissible operating temperature must be
enquired from the pump manufacturer.
b) Ambient temperature for motor
DIN EN 60079--0 stipulates an ambient temperature for the
motor between --20 _C and 40 _C.
2.10.7 Technical design
Proper potential equalization between the pump unit
and the foundation must be provided for.
2.10.8 Maintenance
Only a pump unit which is properly serviced and maintained in
a perfect technical condition will give safe and reliable
operation.
Re-coating ofthe pump set to a film thickness of 200 ?m
is not permitted for Explosion Group IIC (risk of
electrostatic charging of pump set surface).
3 Transport and interim storage
3.1 Transport
Transport of the unit requires proper preparation and handling.
Fig. 2 Complete unit with sling points
Always make sure that the pump or the unit
remains in horizontal position during transport
and cannot slip out of the transport suspension arrangement.
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and damage
to property!
Refer to the weight of the pump set given in the general
arrangement drawing.
3.2 Interim storage (indoors) / Preservation
When the unit is temporarily put into storage, only the wetted
low alloy components (e.g. JS1025, etc.) must be preserved.
Commercially available preservatives can be used for this
purpose. Please observe the manufacturer’s instructions for
application/removal.
The relevant procedure is described in section 6.3.
The unit / pump should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.
Protect all stored goods against humidity, dirt,
vermin and unauthorized access! All openings
of the assembled unitcomponents are closed and must only be
opened when required during installation.
All blank parts and surfaces of the pump are coated with an
anti-corrosive.
4 Description of the product and
accessories
4.1 Technical specification
Horizontal, single-stage, seal-less volute casing pump in back
pull-out design with fully enclosed canned motor for handling
aggressive, flammable, toxic, volatile, explosive or valuable
liquids in the chemical and petrochemical industries, in
environmental and industrial engineering.
In addition, the Secochem-Ex (SCX) pump is suitable for
applications where low noise emissions, smooth running or
long service intervals (operating reliability) are required.

Secochem-Ex
8
Other applications:
refinery off-sites, the paper and cellulose industries, the food
and beverages industry, the sugar industry, sea water
desalination plants, absorption equipment (environmental
engineering), power stations, etc.
4.2 Designation
Secochem C H 32 - 200 / 7 2 Ex
Type series (code: SCX)
Material of pump casing
Additional code
Discharge nozzle DN
Nominal impeller dia. in mm
Rated motor power in kW
(rounded off to full kW)
Number of motor poles
Explosion-proof motor
Additional code
H = heatable version
Materials see data sheet
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code
12 DE 90.2-1.1
22 DE 90.2-2.2
42 DE 112.2-4
52 DE 112.2-5.5
72 DE 132.2-7.5
112 DE 132.2-11
152 DE 132.2-15
222 DE 160.2-22
302 DE 160.2-30
402 DE 200.2-40
552 DE 200.2-55
4.3 Design details
1
9468
5
11
78
2
3
10
Fig. 3 General assembly drawing Secochem-Ex (SCX)

L
Secochem-Ex
9
4.3.1 Functional description
The Secochem-Ex (SCX) pump is a seal-less canned motor
pump. Fig. 3 illustrates its general design.
The hydraulic system and the motor are firmly connected and
form a close-coupled unit. Both impeller (1) and rotor (2) are
arranged on a common shaft (3) running in plain bearings (4
and 5) which are lubricated by the medium handled. The rotor
space is sealed off towards the stator space by the can (6). The
can,made of corrosion-resistantmaterial,rests on the stator (7)
and the support sleeves (8) to compensate the forces resulting
from the pressure within the rotor space.
The bearings are lubricated by the medium handled in the rotor
space. When the pump is started up, the medium enters the
rotor space through the bores (9, 10) and vents the rotorspace
through a bore in the shaft.
The partialflow tapped from the medium flow through the bores
(9 u. 10) surrounds the rotor during pump operation and enters
an axialbore provided at the rear end ofthe rotorshaft.The axial
bore ends at the front face of the impeller-side shaft end.
The pressure difference between the bores (9 and 10) and the
outlet of the axial bore through the shaft at the impeller-side
shaftend results in a continuous partial flowof pumped product.
As this partial flow passes through the circular clearance
between the rotor and the can, it dissipates the heat losses
generated in the motor.
The intensive exchange ofliquid from the hydraulic space to the
rotor space and back to the suction side ofthe hydraulic system
at the same time ensures sufficient lubrication of the plain
bearings.
The pump set is connected to the electric power supply via the
terminal box (11).
Depending on the technical version,additional equipment such
as temperature sensors for monitoring the rotor space
temperature (PT100) and/or PTC resistors for monitoring the
winding temperature can be provided in the motor.
4.3.2 Pump casing
Radially split, consisting of volute casing and casing cover.
The connection dimensions at the volute casing are in
accordance with DIN EN 22858 / ISO 2858.
For handling combustible media, the pump casing must
be made of ductile material with a maximummagnesium
content of 7.5 % (see EN 13463-1). This is a standard feature
in all KSB supplies.
4.3.3 Impeller type
Closed radial impeller with multiple vanes. Axial thrust is
balanced by back vanes.
4.3.4 Drive
Explosion-proof three-phase asynchronous canned motor,
type of protection IP 55 (EN 60034-5). Explosion-protection as
per directive 94/9/EC and EN 60034-1. Stator space in
“flameproof enclosure”, terminal box in “increased safety”. The
rotor space must be filled with the liquid to be pumped at all
times.
The motors are suitable for frequency inverter operation in the
frequency range from 25 Hz (min.) to 50 or 60 Hz (max.),
depending on the nominal motor frequency they are designed
for. To ensure explosion protection, the PTC resistors in the
motor winding must be connected, This prevents an
inadmissible heat build-up in the motor.
General motor data:
Starting method: all motors d.o.l.
Voltages: 50 Hz: 400V, 500V, 690V 1)
60 Hz: 480V, 600V
Voltage tolerance: +/- 10 %
Explosion protection: directive 94/9/EC
Identification: II 2 G Ex de IIC T.. Gb 3)
Temperature class (T..): T6, T5, T4 or T3
Enclosure EN 60034: IP 55
Thermal class: H
Operating mode: S1 2)
Monitoring: PTC (optional)
Frequency inverter operation: possible in combination
with PTC:
Motor supply voltage limits:
du/dt < 1000 V/s
Û < 1000 V 4)
Ambient temperature of
motor: -- 2 0 _Cto+40_C
1) 690 V not available for motors 12, 22, 402 and 552
2) See also Section 6.2.2, ”Switching frequency”
3) See also Section 2.10.1, ”Marking”
4) At motor size DE 200: Û < 890 V
For specific motor data please refer to the data sheet!
4.3.5 Bearings
The shaft runs in product-lubricated plain bearings. Axial
movement of the rotor is limited by thrust bearings.
4.3.6 Noise characteristics
Motor code Motor size
DE
Surface sound pressure level
pA [dB] 1)
12 90.2-1.1 49
22 90.2-2.2 49
42 112.2-4 52
52 112.2-5.5 53
72 132.2-7.5 55
112 132.2-11 58
152 132.2-15 60
222 160.2-22 65
302 160.2-30 67
402 200.2-40 69
552 200.2-55 70
1) Spatial average value; as per ISO 3744 and EN 12639.
Applies within the operating range of the pump of Q/Qopt = 0.8 - 1.1and
in non-cavitating pump operation. If noise levels are to be guaranteed,
add an allowance of 3 dB for measurement and manufacturing
tolerance.

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4.4 Permissible forces and moments at the pump nozzles
The forces and moments were determined on the basis of API 610
(6th edition), table 2, doubled values.
The resulting permissible forces have been determined according to
Fres D ±Fx2+F
z2and Fres S ±Fy2+F z2
The data on forces and moments apply to static pipelines only. If the
limits are exceeded, they must be checked and verified. If a
computerized strength analysis is required, please contact KSB!
The values are only applicable if the pump is bolted to a rigid and level
foundation.
For temperatures exceeding 120 C, the values indicated must be
reduced in accordance with the above diagram.
Suction nozzle
Discharge nozzle
Fig. 4
Pump sizes Forces Moments
P
u
m
p
s
i
z
e
s
Suction nozzle in N Discharge nozzle in N SuctionnozzleinNm Discharge nozzle in
Nm
FxFyFzFres FxFyTens+FyCompr-FzFres MxMyMzMxMyMz
25-160
-200 1050 700 850 1100 500 350 650 450 700 550 450 300 400 300 200
32-160
-200
-250
1350 900 1100 1400 700 450 850 550 900 700 550 350 450 350 250
40-160
-200
-250
-315
1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 550 450 300
50-160
-200
-250
-315
2150 1400 1700 2200 1100 700 1350 900 1400 1450 1100 750 700 550 350
65-160
-200
-250
-315
2700 1750 2150 2750 1400 900 1750 1150 1800 2000 1500 1000 1150 850 600
80-160
-200
-250
-315
3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 750
100-200
-250
-315
3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000

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Secochem-Ex
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4.5 Accessories
The following accessories can be offered as required (cf.
section 7.2.1, Supervision of operation):
-- PTC tripping unit
(if thermal motor protection is used)
-- Level transmitter
-- Isolating amplifier
-- Resistance thermometer
-- Barrier
-- L i m i t s w i t c h
-- Pump power monitoring unit
-- Motor standstill heater
-- Main flow filter
The operating manuals and data sheets of the
accessories must be adhered to without fail.
Non-compliance can jeopardize the safety of personnel, the
environment and the machine itself.
It must be emphasized that spare parts not supplied by
the manufacturer and unauthorized accessories have
not been tested and approved by the manufacturer. Installation
and/or use of such products may therefore have an adverse
effect on the design-related properties of the pump. The
manufacturer cannot be held liable for damage resulting from
the use of non-original spare parts and unauthorized
accessories!
4.6 Dimensions and weights
For dimensions and weights please refer the general
arrangement drawing.
5 Installation at Site
5.1 Safety regulations
Electrical equipment operated in hazardous locations
must comply with the relevant explosion protection
regulations. This is indicated on the motor name plate.
If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and the
instructions given in section 2.10 must be complied with. The
EC type test certificate is supplied with the pump
documentation, if requested.
5.2 Checks to be carried out prior to
installation
All structural work required must have been prepared in
accordance with the dimensions stated in the dimension
table / general arrangement plan.
The concrete foundations shall have sufficient strength
(min. class X0) to ensure safe and functional installation in
accordance with DIN 1045 or equivalent standards.
Make sure that the concrete foundation has set firmly before
placing the unit on it. Its surface shall be truly horizontal and
even. The foundation bolts shall be inserted in the pump feet.
5.3 Installing the pump / unit
5.3.1 General
Depending on structural requirements and motor size, the
pump unit can be mounted on hard and even concrete, on
foundation rails or similar, or on a baseplate. The foundation
bolts or heavy-duty anchor bolts are not included in KSB’s
scope of supply.
The pump must be installed in horizontal position. Remove the
covers from the suction and discharge nozzle.
For low-noise operation contact KSB to check
whether the pump set can be installed on
anti-vibration mounts.
On request, the pump set can also be installed
in vertical position (i.e. with the motor below) in
accordance with the order--specific general arrangement
drawing.
5.3.2 Installing pumps with motor sizes DE 90 /
DE 112 / DE 132
Pump units combined with these motors can be installed
without an extra support under the motor.
They are secured by the foot bolts of the pump
casing. Therefore, a baseplate is not required
and very simple fastening methods like profile steel beams or
angle bars etc. allow space- and cost-saving installation.
The unit can also be installed on hard and even concrete, e.g.
with heavy duty anchor bolts. (Bores in the casing foot see
general arrangement drawing).
For installation, place the pump unit on the foundation
bolts/heavy duty anchor bolts and support it at the motor end in
such a way that the flange of the discharge nozzle is horizontal.
Before tightening the bolts firmly, remove the support underthe
motor to avoid distortions.
If a conventional baseplate is to be used, it must be truly
horizontal and secured as described in section 5.3.3.
5.3.3 Installing pumps with motor sizes DE 160 and
DE 200
These pump units have an extra support under the motor. A
baseplate is required, which is normally supplied mounted to
the pump.
Set the foundation bolts into the foundation using concrete in
line with the separately supplied general arrangement drawing
and allow the concrete to set.
The baseplate must be truly horizontal. Therefore, shims shall
be fitted between the baseplate/foundation frame and the
foundation itself (Fig. 5). They shall always be inserted to the
left and right of the foundation bolts and in close proximity to
these bolts. Tighten the foundation bolts evenly and firmly.
If a pump set as described above is to be mounted onto the
baseplate on site only, make sure that it can be bolted to the
baseplate without being subjected to any stresses or strains.
Shim Shim
Foundation bolts
800
Shim
Fig. 5 Fitting required shims
5.3.4 Place of installation
The pump unit takes on roughly the same temperature
as the medium handled. However, even if the product
temperature is relatively low, surface temperatures in the area
of the motor housing may still be high.
Take the necessary precautions to avoid burns!

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5.3.5 Connecting the piping
Never use the pump itself as an anchorage
point for the piping. The permissible pipeline
forces must not be exceeded (see section 4.4).
Suction lift lines shall be laid with a rising slope towards the
pump and suction head lines with a downward slope towards
the pump.The pipelines shall be anchored in close proximity to
the pump and connected without transmitting any stresses or
strains. The nominal diameters of the pipelines shall be at least
equal to the nominal diameters of the pump nozzles.
It is recommended to install check and shut-off elements in the
system, depending on the type of plant and pump. It must be
ensured, however, that the pump can still be drained and
dismantled without problems.
Thermal expansions of the pipelines must be compensated by
appropriate measures so as not to impose any extra loads on
the pump exceeding the permissible pipeline forces and
moments.
Expansion joints can be fitted between pump
and suction/discharge line.
An excessive, impermissible increase in the pipeline
forces may cause leaks on the pump where themedium
handled can escape into the atmosphere.
Danger of life when toxic or hot media are handled!
The flange covers on the pump suction and discharge nozzles
must be removed prior to installation in the piping.
5.3.6 Auxiliary connections
The dimensions and locations of the auxiliary connections (e.g.
barrier liquid) are indicated on the general arrangement
drawing or piping layout.
These connections are required for proper
functioning of the pump and are therefore of
vital importance!
5.4 Final check
Re-check the alignment and connections as described in
sections 5.2 and 5.3.
5.5 Electrical connection
The mains data must match the voltage and frequency data
indicated on the name plate. The motors shall be connected as
shown in the wiring diagram in the terminal box.
They are designed for d.o.l. starting. The motor winding has
been wired in star or delta in the factory. The wiring type is
shown on the name plate.
The connection of the motor and monitoring
equipment, as well as overload protection and
earthing shall be performed in accordance with the applicable
installation regulations.
If unexpected pump start-up can jeopardize the safety
of personnel, automatic re-starting of motor protection
devices is not permitted.
In addition to the general installation regulations, IEC 60079
(DIN VDE 0165) must be complied with. This regulation
stipulates overload protection by means of a motor protection
switch or equivalent protection device. Such devices also
include PTC resistors combined with a tripping unit.
5.5.1 Terminal box
The terminal box is fitted with power terminals (see Fig. 6) and
control terminals (see Fig. 7 and 8), depending on the pump
version. The side walls are provided with 2 bores each on the
left and right, which can be used as cable entries as required.
Fig. 6
Fig. 7
Fig. 8
Terminals – Power cables Terminals – Control cables
Motor size DE 90, 112, 132 DE 160 DE 200 DE 90, 112, 132, 160, 200
Rated voltage 1000 V 1000 V 630 V 380 V
Stripping length 11-- 12 mm 19--20 mm 22--24 mm 6--8 mm
Tightening torque 2Nm 3,5 Nm 6--8 Nm 0,5 Nm
Clamping range 0,5to16mm@2,5to35mm@25 to 50 mm@0,5to2,5mm@

Caution
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Caution
Earthing terminal
Motor housing
Secochem-Ex
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The motors have to be connected using cable and line entries
which meet the requirements of EN 50019 for terminal
compartments in type of protection “increased safety” and for
which separate test certificates have been issued.
All unused openings shall be closed with plugs which have also
obtained the requisite test certificates and are marked
accordingly.
5.5.2 Connecting the power cable
Electrical connection shall be effected by suitably
trained personnel only.
The power cable must be connected to the appropriate
terminals in the terminal box as shown on the wiring diagram in
the terminal box.
The correct direction of rotation of the motor is ensured by a
mains with a clockwise rotating field. If the motor has been
connected correctly, it would run in anti-clockwise rotation if it
could be viewed from the side of the bare shaft end (hydraulic
end).
When connecting the pump to the power supply, make sure to
observe the clearances between conductive components of
different potential stipulated by EN 60079-7.
Connection of the earthed conductors (terminal box and
motor housing) shall be in accordance with IEC 60079
(DIN VDE 0165) and IEC 60364 (DIN VDE 0100), depending
on the mains type.
5.5.3 Connecting the control cables
The wiring diagram supplied in the terminal box is limited to
motor connection and thermal monitoring by means of PTC
resistors. Other connections, e.g. an integrated PT100 sensor
for measuring the rotor space temperature, must be effected as
described in the supplementary operating manual of the
accessories in question (e.g. motor standstill heater).
If the motor is equipped with PTC resistors, control terminals
10/11 are connected and the information “PTC 180 / ---“ or“PTC
180 / 110” is shown on the name plate.
The PTC resistors must be connected to a tripping unit as
shown on the above-mentioned wiring diagram. If motor
overload protection as stipulated by IEC 60079(DIN VDE0165)
relies exclusively on PTC resistors, the tripping unit used must
be rated in accordance with Directive 94/9/EC, Annex II,
Section 1.5.5 and EN 1127-1, e.g. tripping unit with PTB
approval seal3.53 PTC/A.(The PTB approval seal3.53-PTC/A
confirms compliance of the electrical data at the interface
between the resistor circuit and the tripping unit and approval
of the tripping unit for use with PTC resistors for thermal
monitoring of explosion-proof electrical equipment.)
The tripping unit is not explosion-proof and
therefore has to be installed outside the
hazardous area.
5.5.4 Monitoring equipment
For installation and commissioning of the following monitoring
equipment
PTC monitoring
monitoring of rotor space temperature
monitoring of rotor space filling level
Please refer to the separate operating manuals.
If plant conditions are such that the pump could
run dry due to a lack of liquid,the plantoperator
must provide an appropriate monitoring device. See section
7.2.1.
Allmonitoring equipment must meetthe requirements of
Directive 94/9/EC, Annex II, Section 1.5.5, and
EN 1127--1. If any non--approved monitoring equipment is
used, successful functional testing must be demonstrated and
documented separately. Such equipment must be included in
the operator’s monitoring routines.
5.5.5 Potential equalisation
To avoid sparking, potential equilisation
must be ensured between the pump and
any metal objects located in the vicinity. Sparking may cause
explosion.
Providing potential equalisation
The screw terminal for the potential equalisation conductor is
fitted on the outside of the motor housing.
Motor sizes DE 90, 112 and 132
The terminal consists of a pressed--in square base with fitted
clamp and a screw (M6) with spring washer. The potential
equalisation terminal complies with VDE 0170 and is marked
with the earth symbol.
Fig. 9 Earth symbol
The conductor must be connected in a suitable manner as set
forth in EN 60999--1:2000
Nominal cross--section: 10 mm2
Max. tightening torque: 3,5 Nm
Fig. 10Connecting the PE conductor
Motor sizes DE 160 and 200
The conductor must be connected in a suitable manner as set
forth in EN 60999--1:2000
Nominal cross--section: 25 mm2
Max. tightening torque: 3,5 Nm
Earthing terminal Motor housing
Fig. 11 Connecting the PE conductor
5.6 Pump operation with frequency inverter
The canned motors can also be operated with
frequency inverters. Make sure to observe the design
data of the motor in this case. As frequency inverters generate
an additionaltemperature rise in the motor, the PTC resistors in
the motor winding have to be connected to safeguard explosion
protection. This prevents an inadmissible heat build-up in the
motor.
The motors are suitable for frequency inverter operation in the
frequency range from 25 Hz (min.) to 50 or 60 Hz (max.),
depending on the nominal motor frequency they are designed
for.

Caution
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Caution
Caution
Note
Secochem-Ex
14
Operating the pump unit with a frequency inverter entails the
risk of interference signals being emitted by the electrical
connection cable, which may affect the environment.
To eliminate such signals, shielded cables with concentric
copper braiding must be used. Make sure that the shield ends
have contact over a large area of the terminal compartments in
the motor and the frequency inverter.
The following limit values forthe voltagesupply
of the motor must not be exceeded:
Voltage ramp-up time du/dt < 1000 V/s
Voltage peaks Û < 1000 V 1)
1) At motor size DE 200: Û < 890 V
6 Commissioning, start-up / shutdown
It is imperative to fill the pump with the medium to be
handled prior to commissioning!
Dry running may cause severe damage!
Dry-running may result in high temperatures exceeding
the permissible temperature classes and must be
prevented.
Compliance with the following requirements is
of paramount importance. Damage resulting
from non-compliance shall not be covered by the scope of
warranty.
6.1 Commissioning
Before starting up the pump for the first time or returning it to
service, make sure that the following points have been checked
and fulfilled.
6.1.1 Priming the pump
Before start-up, the pump and the suction line must be primed
with the liquid to be pumped. Open the shut-off valves in the
suction line and the discharge line, respectively, and prime the
pump unit for approx. 5 minutes. Then close the shut-off valve
in the discharge line.
Ifa main flow filter is used, the pipe between the
motor housing and the main flow filter must be
laid with a steady rise so that the rotor space can be vented via
the filter.
Fig. 12Main flow filter
If, forhandling specific media, barrier liquid is to
be fed via connection 10 E, the pump set must
be filled with barrier liquid through this connection for 5 minutes
beforehand. The shut-off valve in the discharge line must be
open, the shut-off valve in the suction line must be closed while
this is done.
Fig. 13Pump set connections
After filling has been completed, turn off the barrier liquid feed
and proceed as follows:
For positive suction operation
Open the shut-off valve in the suction head line and vent the
system up to the discharge-side shut-off valve.
For suction lift operation
Open the shut-off valve in the suction lift line, evacuate the air
from the pump and the suction line. The min. permissible
pressure is 0.1 bar (absolute).
If necessary, an extension pipe is fitted to
connection 10 E and/or 10 B of vertically
installed pumps.
6.1.1.1 Heating
Heatable pump casing:
The pump casing can be heated with hot water or saturated
steam, for example.
To observe explosion protection regulations as per
Directive 94/9/EC, the surface temperature of the pump
casing has to be limited as well. The following supply
temperatures of the heating medium have to be observed:
Temperature class as
shown on pump
name plate
Tmax
Heating medium
T6 75 C
T5 90 C
T4 125 C
T3 150 C
Pmax = 10 bar
Motor standstill heater
The motor standstill heater is factory-set. In continuous
operation, the rotor space may be heated up to 80-100 C.
Temperature class T4 is observed in this case.
For operation at temperature classes T5 or T6, the
external temperature measuring point of the rotorspace
and/or the integrated PTC resistors must be used for tripping
the motor standstill heater.
The motor standstill heater is set to the rotor spacetemperature
required (T<100 C) by means of a control unit combined with
a measuring resistor fitted to the can of the rotor space.
Please refer to the separate operating manual supplied.

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Secochem-Ex
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6.1.2 Checking the direction of rotation
When the unit has been connected to theelectric power supply,
verify the following (local and national regulations have to be
taken into account separately):
For trouble-free operation of the pump, the
correct direction of rotation of the impeller is of
paramount importance. If running in the wrong direction of
rotation, the pump cannot reach its duty point; vibrations and
overheating will be the consequence. The pump set might be
damaged.
Before checking the direction of rotation make sure that
there is no foreign matterin the pump casing. The pump
set must be adequately secured against overturning.
Never hold your hands or any other objects into the pump!
Owing to the special design features of this pump set, the
direction of rotation can only be checked indirectly.
Proceed as follows:
-- Start up the pump as described in section 6.1.5.
Close the shut-off valve in the discharge line and check
whether the head achieved corresponds to the shutoff head
indicated in the pump performance curve. (Not longer than
1min.).
-- If the head achieved is more than 10 % lower than is to be
expected, switch off the pump set, take the necessary
precautions (disconnect the pump set from the power
supply, etc.), check the electrical connection as per section
5.5, and correct, if necessary.
-- Interchange terminals to determine whether a higher
pressure gauge reading is reached, which corresponds to
the correct direction of rotation.
6.1.3 Cleaning the plant piping
The cleaning operation mode and duration for flushing and
pickling service must be matched to the casing and seal
materials used.
6.1.4 Start-up strainer
Ifa start-up strainer has been fitted to protectthe pumps against
dirt and/or to retain contamination from the plant, the strainer’s
contamination level must be monitored by measuring the
differential pressure so as to ensure adequate inlet pressure for
the pump.
6.1.5 Start-up
Pump operation with the shut-off valves in the discharge
and suction pipes closed is not permitted. The
permissible pressure and temperature limits might be
exceeded. In extreme cases, the pump may burst.
Open the barrier liquid feed, if any, and adjust
the barrier liquid pressure in line with the data
sheet.
The proper functioning of the barrier pressure unit shall
be monitored.
Make sure that the pump is always started up with the
suction-side shut-off valve fully open and the discharge-side
shut-off valve slightly open! Only after the pump has reached
full rotational speed shall the shut-off valve in the discharge line
be opened further and adjusted to comply with the duty point.
Check the direction of rotation, if necessary (cf. 6.1.2).
6.1.6 Shutdown
Close the shut-off valve in the discharge line. If the discharge
line is equipped with a non-return or check valve, the shut-off
element may remain open if there is backpressure.
Switch off the pump unit, then shut down the barrier liquid
system (if connected).
For prolonged shutdowns, also close the shut-off valve in the
suction line.
In the event ofprolonged shutdowns, liquids which change their
physical condition due to changes in concentration,
polymerization, crystallization, solidification, etc. must be
drained from the pump and the motor. If applicable, flush the
pump via connection 11 E and close again in line with section
7.3.
6.2 Operating limits
The pump’s/unit’s application limits regarding pressure,
temperature, speed and motor data are stated on the
data sheet and must be strictly adhered to, also to safeguard
explosion protection.
If a data sheet is not available, contact KSB!
6.2.1 Temperature of the medium handled, ambient
temperature
Do not operate the pump at fluid temperatures (TM)
exceeding those specified in the data sheet or on the
name plate.
Motor power P2depends on the temperature of
the medium handled. It decreases as
temperatures increase. Damage resulting from disregarding
this warning will not be covered by the KSB warranty.
If the pump is used in hazardous areas, ambient
temperature shall be between -20 C and +40 C.
6.2.2 Switching frequency
A combination of temperature sensors embedded in the
winding (e.g. PTC thermistors) and tripping unit is
permitted as sole overload protection arrangement for motors
not operated in S1 mode.
To prevent high temperature increases in the motor and
excessive loads on the pump set, the switching frequency shall
not exceed the following number of start-ups per hour (S).
Motor rating (kW) max. S (start-ups/h)
up to 15 60
>15 to55 30
6.2.3 Density of medium handled
The power input of the pump will increase in proportion to the
density and viscosity of the medium handled. To avoid
overloading of the pump set, the density and viscosity of the
medium must comply with the data specified in the purchase
order.
6.2.4 Abrasive media
When the pump handles liquids containing abrasive
substances, increased wear of the wetted pump components
is to be expected.The intervals recommended for servicing and
maintenance shall be shortened.
If the medium handled contains magnetic particles,appropriate
measures (e.g. magnetic separator) shall be taken to prevent
them from entering the rotor space.

Caution
Secochem-Ex
16
6.2.5 Minimum/maximum flow
Unless specified otherwise in the characteristic curves or on the
data sheets, the following applies:
Qmin = 0.05 x Qopt for short operation
Qmin =0.3xQ
opt for continuous operation
Qmax =1.1xQ
opt for 2-pole operation
Qopt = optimum efficiency
The data refer to water and water-like liquids. However, if the
physical properties of the media handled are different from
water, the calculation formula below must be used to check if an
additional heat build-up may lead to a dangerous temperature
increase at the pump surface. If necessary, the minimum flow
must be increased.
To=Tf+
g*H
=*(1-)
c* 
c Specific heat [J / kg K]
g Acceleration due to gravity [m/s2]
H Pump head [m]
TfTemperature of medium handled [C]
TfTemperature of casing surface [C]
Pump efficiency at duty point [--]
 Temperature difference [C]
6.3 Shutdown / storage / preservation
Each KSB pump leaves the factory carefully assembled. If
commissioning is to take place some time after delivery, we
recommend that the following measures be taken for pump
storage.
6.3.1 Storage of new pumps
-- New pumps are supplied by our factory duly prepared for
storage. Maximum protection for up to 12 months, if the
pump is properly stored indoors.
-- Store the pump in a dry and protected location.
6.3.2 Measures to be taken for prolonged shutdown
1. The pump remains filled and installed (periodic check
of operation)
In order to make sure that the pump is always ready for
instant start-up, start up the pump set regularly once a
month or once every 3 months for a short time (approx.
5 minutes) during prolonged shutdown periods, provided
the medium does not change during pump shutdown
(freeze, polymerize, etc.). The instructions set forth in
section 6.1 ”Commissioning” shall be adhered to.
2. The pump is removed from the pipe and stored
Before putting the pump into storage, carry out all checks
specified in paragraphs 7.1 to 7.4. Then apply appropriate
preservatives:
-- Spray-coat the inside wall of the pump casing, and in
particular the impeller clearance areas, with a
preservative. Spray the preservative through the
suction and discharge nozzles. It is advisable to close
the pump nozzles (e.g. with plastic caps or similar).
-- Do not fill the pump with preservative!
6.4 Returning to service after storage
Before returning the pump to service, carry out all checks and
maintenance work specified in sections 7.1 and 7.2.
In addition, the instructions laid down in the sections on
”Installation at site” (5) and ”Commissioning”(6) mustbe
observed.
Immediately following completion of the work, all
safety-relevant and protective devices must be
re-installed and/or re-activated.
7 Servicing / Maintenance
7.1 General instructions
Sparks produced during servicing work
Explosion hazard!
The safety regulations in force at the place of
installation!
Always perform maintenance work on
explosion--proof pump sets outside potentially
explosive atmospheres.
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the manual.
If properly handled and operated in line with its design data,this
pump set is maintenance-free. The unit only has to be checked
in the case of rough running, noise, vibrations > 3.0 mm/s veff,
motor cutout or similar.
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 and work.
The pump must have cooled down to ambient
temperature, pump pressure must have been
released and the pump must have been drained.
Work on the unit must only be carried out with the
electrical connections disconnected. Make sure
that the pump set cannot be switched on accidentally
(danger of life!).
Pumps handling liquids posing health hazards
must be decontaminated. When draining the
medium see to it that there is no risk to persons or the
environment. All relevant laws must be adhered to (danger
of life)!
7.2 Servicing / Inspection
7.2.1 Supervision of operation
The pump must run quietly and free from
vibrations at all times.The pump must neverbe
allowed to run dry.
Examples ofmonitoring systems in the plantwhich may prevent
the pump from running dry if liquid feed should be interrupted:
1. Pressure switch
2. Flow control unit
3. Level control unit (for rotor space)
4. Level control unit (for plant system)
5. Pump power monitoring unit
6. Current control unit
In most cases, a well-proven monitoring system is already
installed in the plant.

Secochem-Ex
17
Prolonged operation against a closed shut-off valve is
not permitted. When operating the pump set against a
closed shut-off valve in the discharge line for a short period of
time, the permissible pressure and temperature limits must not
be exceeded.
The shut-off elements and the auxiliary feed lines must not be
closed during operation.
Check all flange connections for tightness and re-tighten, if
necessary.
7.2.2 Bearings
The plain bearings only need to be checked if vibrations
exceeding 3.0 mm/s veff, unusual noise and an increase in
power input occur while operating conditions remain
unchanged.
7.3 Drainage / Disposal
If the pump was used for handling liquids posing health
hazards, see to it that there is no risk to persons or the
environment when draining the medium. All relevant laws must
be heeded. If required, wear safety clothing and a protective
mask!
If the media handled by the pumps leave residues which might
lead to corrosion when coming into contact with atmospheric
humidity, or which might ignite when coming into contact with
oxygen, then the unit must be flushed through, neutralized,and
then for drying purposes anhydrous gas must be blown through
the pump.
Before draining the pump, secure it so as to make sure
it cannot be switched on accidentally. The shut-off
valves in the suction and discharge lines as well as the auxiliary
feed lines (e.g. barrier liquid) must be closed.
The pump must have cooled down to ambient temperature.
To drain the medium handled from the standard pump design
(internal circulation), use connection 6 B, or connection 10 B to
also drain the rotor space of pumps with barrier liquid feed
(motor cooling by means of external liquid feed or partial flow
from main flow filter). See Fig. 14.
Fig. 14(without temperature measuring point in the rotor
space)
Fig. 15(with temperature measuring point in the rotor space)
After drainage, the pump set can be flushed through. To flush
the pump, also open connection 11 E and connect the flushing
device.
Connection 11 E (G 1/2) see Fig. 14
Connection 11 E (G 1/4) see Fig. 15
Flush the pump set towards the suction side for a few minutes.
Assess the condition of the drained liquid with a view to the
safety regulations governing the application in question
(concentration, colour, smell, etc.). The pumped product is
largely removed from the pump in this way. Refer to the liquid
contents of the drive section given in table 7.3 for orientation.
Liquid content of the drive section (rotor space)
Motor size DE Content (litres)
90.2-1.1 0.3
90.2-2.2 0.3
112.2-4 1.1
112.2-5.5 0.8
132.2-7.5 1.7
132.2-11 1.7
132.2-15 1.2
160.2-22 2.8
160.2-30 2.8
200.2-40 7.6
200.2-55 5.5
Table 7.3
Prior to sending the unit in for inspection/repairs, if any,
or dismantling it (cf. 7.4), make sure it is flushed
carefully, and see to it that any liquid residues are drained and
properly disposed of.
For further details please refer to the certificate of
decontamination in Section 11, which must be completed and
added to the shipping documents.
7.4 Dismantling
7.4.1 Fundamental instructions and recommendations
Repair and maintenance work to the pump mustonly be carried
out by specially trained personnel, using original spare parts.
Important information on the dimensions of the flameproof
joints: section 2.7, page 5.
Observe the safety regulations laid down in section 7.1.
Dismantling and reassembly must always be carried out in
accordance with the relevant general assembly drawing.
The general assembly drawing and other relevant
documents are found in the annex. The dismantling
sequence can be derived from the general assembly
drawing.
In case of damage you can always contact our service
departments.
7.4.2 Dismantling (general)
1. Disconnecting the electrical connections
Remove the cover of the terminal box. Then disconnect
the main and auxiliary connections.
Unscrew the screwed inserts of the two cable glands (one
half remains in the base of the terminal box) and remove
the cables.
2. Removing the pump set/back pull-out unit from the
piping and dismantling the pump casing
After draining and flushing the pump set as described in
section 7.3, close connections 11 E, 6 B and, if applicable,
10 B again.
If the complete pump set is to be removed from the piping,
proceed as described in para. 2a.
If the pump casing is to remain installed in the piping,
however, and only the back pull-out unit is to be removed,
proceed as described in para. 2b.

Note
Note
Caution
Secochem-Ex
18
2.a Removing the pump set from the piping
-- Undo the flanged connections.
-- Undo the pump foot bolts, if applicable.
-- Remove the pump from the piping and place on a
clean and level surface.
Fluid residues may escape! Risk of personal
injury! Collect and properly dispose of any fluid
residues which might escape!
-- Set the pump set down onto the motor section and the
pump foot and secure against tipping over.
2.b Removing the back pull-out unit
-- Undo hexagon nuts 920.01.
-- Use forcing screws to push the complete back pull--out
unit out of casing 102.
-- Take care to prevent the impeller from colliding with the
sides of the pump casing.
Watch out for possibly hazardous medium
residues (protective clothing). Collect and
properly dispose of any medium residues which might
escape!
-- Set the back pull--out unit down on the motor section
onto a clean surface in such a way that the impeller and
the shaft/rotor do not touch the surface. Secure the back
pull--out unit against tipping over.
2.c Dismantling the pump casing
If the complete pump set has been removed from the
piping, dismantle the pump casing as follows:
-- Place the pump set in a clean and level assembly area.
-- Undo hexagon nuts 920.01 and remove the pump
casing.
Watch out for possibly hazardous medium
residues (protective clothing). Collect and
properly dispose of any medium residues which might
escape!
Both for safety reasons and for easier
handling, we recommend to place the
motor section vertically (impeller pointing upwards)onto
a suitable base when dismantling the unit. Close drain
connection 11 E.
Make sure the unit cannot tip over during
dismantling and reassembly! Risk of personal
injury!
3 Dismantling the impeller
Hold the impeller with a belt wrench at the impeller eye.
Undo impeller nut 920.95 and disc 550.87. Then remove
the impeller with a suitable pull-off device.
4. Dismantling the rotor
-- M o t o r s D E 9 0
Pull off cup springs 950.23 and thrust bearing 314.01.
Undo hex. nuts 920.04 and pull off casing cover 161. Take
off taperlock ring 515.04.Remove U-ring 411.87. Pullrotor
818 carefully out of the rotor space.
-- Motors DE 112 and 132
Undo nuts 920.15 and take casing cover 161 off bearing
bracket lantern 344, remove taper lock ring 515.04. Pull
cup springs 950.23 and thrust bearing 314.01 off the rotor.
Undo nuts 920.04 and remove bearing bracket lantern
344. Remove U-rings 411.11/.87. Pull rotor 818 carefully
out of the rotor space.
-- Motors DE 160 and 200
Pull off cup springs 950.23 and thrust bearing 314.01.
Remove socket head cap screws 914.07. Use jacking
thread to pull bearing ring carrier 391.01 out of casing
cover 161.
Undo hex. nuts 920.04 and lift off casing cover 161.
Remove U-ring 411.87. Pull rotor 818 carefully out of the
rotor space.
General:
Do not tilt the rotor when pulling it out, to prevent damage
to the motor end plain bearing or the can. Larger motors
are best dismantled in vertical position. For this purpose,
a lifting eye nut is fitted to the rotor instead of impeller nut
920.95. A crane can be used now to pull the rotor carefully
out of the rotor space.
5. Dismantling the bearings
Pull bearing sleeve 529.21 and thrust bearing 314.02 off
the rotor.
Remove hex. socket head cap screw 914.80 or hex. nut
920.80 on DE 160/200 (Caution! Left-hand thread!)as well
as cup springs 950.11.
Pull taper lock rings 515.23, 515.24 and bearing sleeve
529.06 off the shaft end.
Remove nut 920.36 and pull off bearing carrier 382.
(Caution! Left-hand thread!)
Remove U-ring 411.48 and O-ring 412.22.
6. Checking the can and the motor winding
Inspectthe can for damage after having removed therotor.
Use a suitable measuring instrument to measure the
insulation resistance of the motor winding (e.g. 1000 V
magneto). The resistance towards ground shall not be
lessthan5M.
If the can is found to be damaged and/or the insulation
resistance of the motor winding is too low, there may be
leaks in the can.
If no damage can be found, proceed as described in
item 9.
Watch out for possibly hazardous medium
residues (protective clothing). Collect and
properly dispose of any medium residues which might
escape!
Both for safety reasons and for easier
handling, we recommend to place the
motor section vertically (impeller pointing upwards) onto a
suitable base when dismantling the unit. Close drain
connection 11 E.
Further dismantling of the drive section will affect
the flameproof enclosure of the motor and result in
the temporary suspension of the explosionproof status of
the pump set. The applicable regulations of EC directive
94/9/EC shall be observed.
Further dismantling, e.g. of terminal box
base 81-36 and cover 812, is only
required if the can or winding have been damaged and
other unit components have to be cleaned.
Normally, the motor unit should not be re-used in this
case.
In the event of a can defect, hazardous vapours
and liquids may escape from the stator space!
Take the necessary precautions (wear protective
glasses/clothes, collect residues) when removing
terminal box base 81-36 and cover 812.

Note
Caution
Note
Secochem-Ex
19
7. Opening the stator space
Undo socket head cap screws 914.57/.84 and lift off
terminal box base 81-36.
If the electrical connection is to be removed completely,
the connectors between cable gland 834 and motor unit
80-1 must be cut.
Make sure that the conductor markings to the right and left
of the cut are retained, so that the motor can be wired
correctly during re-assembly.
8. Removing the cover
Undo socket head cap screws 914.38 and remove cover
812.
Dispose of any liquid residues, taking the necessary
precautions (see section 6).
9. Cleaning, checking
Clean and check the dismantled components. Damaged
parts should be re-worked or replaced by new original
spare parts.
For checking the dimensions of components, please refer
to the clearances table in section 7.5.4.
The bores located in the following parts shall be inspected
for cleanliness and free passage, and cleaned, if
necessary:
thrust bearing 314.01/.02, bearing carrier 382, rotor 818,
casing cover 161, bearing bracket lantern 344, socket
head cap screw 914.80 (not on DE 160/200).
7.5 Reassembly
7.5.1 General instructions
The pump shall be reassembled in accordance with the rules
of sound engineering practice.
Clean all dismantled components and check them for signs of
wear. Damaged or worn components are to be replaced by
original spare parts. Make sure that the seal faces are clean
and that the sealing elements are properly fitted. Always use
new sealing elements whenever the pump is reassembled.
Components with flameproof joints must be inspected
for damage. They are identified in the applicable
sectional general assembly drawings in the annex. Damaged
components with flameproof joints mustnever be re-workedbut
have to be replaced by new original spare parts. Never apply
paint or other agents which alter the shape and dimensions of
components to flameproof joints.
Reassembly is effected in reverse order to dismantling. Use the
general assembly drawing and the list of components for
orientation.
All screws and bolts must be properly tightened during
assembly. For the required torques please refer to table
7.5.3.
7.5.2 Reassembly (General)
1. Fitting the bearings
1.a Motor-side bearing sleeve at the rotor
-- Motors DE 90, 112 and 132
For fitting the motor-side bearing sleeve of the rotor, slip
the components in the correct sequence of taper lock ring
515.23, bearing sleeve 529.06, taper lock ring 515.24 and
cup springs 950.11 (pointing in the same direction) onto
the free shaft end. The highest pointof the cup spring pack
shall point towards the head of socket head cap screw
914.80. Screw in socket head cap screw 914.80 and
tighten slightly by hand.
Slightly turn the plain bearing sleeve 529.06 in the conical
seat, then tighten socket head cap screw 914.80 with the
torque given in table 7.5.3. (Warning! Left-hand thread!)
Push thrust bearing 314.02 and bearing sleeve 529.21
onto the pump-side shaft end until it will not go any further.
-- Motors DE 160 and 200
For fitting the motor-side bearing sleeve of the rotor, slip
the components in the correct sequence of taper lock ring
515.23, bearing sleeve 529.06, taper lock ring 515.24 and
cup springs 950.11 onto the free shaft end. The highest
point of the cup spring shall point towards hex. nut 920.80.
Screw on hex. nut 920.80 and tighten slightly by hand.
Slightly turn plain bearing sleeve 529.06 to and fro in the
conical seat, then tighten hex. nut 920.80 with the torque
given in table 7.5.3. (Warning! Left-hand thread!)
Push thrust bearing 314.02 onto the pump-side shaft end
until it will not go any further.
1.b Motor-side bearing bush; Motor unit supplied as
spare part
Motor units supplied as spare parts
come with the bearing carrier already
fitted. Proceed as described in para. 2.
Place U-ring 411.48 into the groove of bearing carrier 382.
Fit O-Ring 412.22.
Always use new sealing elements in
the materials given in the relevant list
of components and compatible with the medium
handled for re-assembly. The inside/outside diameter
of the U-rings has a bevel of 10. Make sure the U-ring
is inserted in the groove accordingly!
Push bearing carrier 382 with bearing bush into motor
housing cover 812. Assemble nut 920.36. Hold bearing
carrier382 with an engineer’s wrench when tightening nut
920.36. (Caution! Left-hand thread!)
Check the contact faces of the plain bearings for
cleanliness or damage.
2. Fitting the rotor and the main bearing
Carefully insert the rotor into the rotor space until the
motor-side bearing sleeve is held and guided by the
bearing bush.
General:
Do not tilt the rotor when fitting it into the rotor space, to
prevent damage to the motor-end plain bearing or the can.
Larger motors are best reassembled in vertical position.
For this purpose, a lifting eye nut(M 16 x 1,5) is fitted tothe
rotor instead of impeller nut 920.95. A crane can be used
now to insert the rotor carefully into the rotor space.
-- M o t o r s D E 9 0
Push taper lock ring 515.04 onto the motor housing. Push
casing cover 161 with U-ring 411.87 into the centering
recess of the motor housing, until the U-ring willnot go any
further. Screw on nuts 920.04 and tighten in accordance
with table 7.5.3.
Screwed plug 903.16 must point
vertically upwards when the motor is
installed in the system, to ensure unimpaired venting
and drainage of the rotor space.
Pull the rotor towards the pump end by the free shaft end
until thrust bearing ring 314.02 rests against the face of the
bearing bush.
Push thrust bearing ring 314.01 and cup spring pack
950.23 onto the free shaft collar, until the thrust bearing
ring rests against the bearing bush.

Caution
Note
Caution
Note
Caution
Caution
Caution
Secochem-Ex
20
The cup springs 950.23 must be
mounted pointing in the same
direction. The highest point of the cup spring pack is
at the inside diameter and must point towards the
impeller side.
-- Motors DE 112 and 132
Push bearing bracket lantern 344 with U-rings 411.11/.87
into the centering recess of the motor housing, until the
U-rings will not go any further.
Screwed plug 903.16 must point
vertically upwards when the motor is
installed in the system, to ensure unimpaired venting
and drainage of the rotor space.
Screw on nuts 920.04 and tighten in accordance with table
7.5.3.
Pull the rotor towards the pump end by the free shaft end
until the rotor will not go any further.
Push thrust bearing ring 314.01 and cup spring pack
950.23 onto the free shaft collar, until the thrust bearing
ring rests against the bearing bush.
The cup springs 950.23 must be
mounted pointing in the same
direction. The highest point of the cup spring pack is
at the inside diameter and must point towards the
impeller side.
Push taper lock ring 515.04 onto the bearing bracket
lantern or motor housing. Place casing cover 161 onto
bearing bracketlantern 344. Align the marking (groove) on
the casing cover with screwed plug 903.16.
Screw on nuts 920.15 and tighten in accordance with table
7.5.3.
-- Motors DE 160 and 200
Push casing cover 161 with U-ring 411.87 but without
bearing ring carrier 391.01 into the centering recess of the
motor housing, until the U-ring will not go any further.
Screw on nuts 920.04 and tighten in accordance with table
7.5.3.
Screwed plug 903.16 must point
vertically upwards when the motor is
installed in the system, to ensure unimpaired venting
and drainage of the rotor space.
Place bearing ring carrier 391.01 into casing cover 161
and tighten socket head cap screws 914.07 until the two
components rest against each other. Tightening torque
seetable7.5.3.
Push bearing sleeve 529.21 onto the pump-side shaftend
up to the stop. Place the motor in horizontal position now.
Pull the rotor towards the pump end by the free shaft end
until thrust bearing ring 314.02 rests against the face of the
bearing bush.
Push thrust bearing ring 314.01 and cup spring pack
950.23 onto the free shaft collar, until the thrust bearing
ring rests against the bearing bush.
Cup springs 950.23 must be mounted
pointing in the same direction. The
highest point of the cup spring pack is at the inside
diameter and must point towards the impeller side.
3. Fastening the impeller
Place key 940.01 into the shaft keyway, slip on impeller
230 and disc 550.87, and screw on shaft nut 920.95.
Use a torque wrench to tighten the shaftnut in accordance
with the torques given in table 7.5.3.
Hold the impeller with belt wrench
when tightening the impeller nut,
moving the impeller slightly to and fro.
When tightening the impeller nut, you
will notice some resistance due to the
pre-loaded cup springs, before complete contact of all
parts is established. If there is no resistance, check
whether the cup springs are mounted correctly and
repeat the steps described above.
4. Assembling the pump casing with the back pull-out
unit
Place joint ring 411.10 into the centering recess on the
pump casing. Insert the studs in pump casing 102 into the
holes on taper lock ring 515.04 or casing cover 161. Screw
on nuts 920.01 and tighten in accordance with table 7.5.3.
5. Final checks
Insert screwed plug 903.91 with gasket 411.91 on motor
housing cover 812 and tighten.
Close the pump flanges and screwed plugs and check
tightness with dry compressed air or nitrogen at 2 bar
(duration: approx. 30 minutes).
Rotate the impeller by hand - use a socket wrench on
impeller nut 920.95, if necessary - and check if it rotates
easily. If rotating the impeller proves difficult or grinding
noises can be heard, open the pump and eliminate the
causes.
7.5.3 Tightening torques
Part No. Thread Material Tightening torque
Nm
914.07 M10 A4-70 35
914.38
914.38
M10
M16
8.8
8.8
50
150
914.57/.84
914.57/.84
M10
M16
8.8
8.8
50
150
914.80 M12LH A4-70 45
914.81 M6 8.8 10
914.85
914.85
M8
M12
A4-70
A4-70
18
60
920.01
920.01
920.01
920.01
M12
M16
M12
M16
A4-70
A4-70
1.7709
1.7709
55
155
80
190
920.04
920.04
920.04
M8
M10
M12
A4-70
A4-70
A4-70
18
35
60
920.15 M10 A4-70 35
920.36 M 35x1,5 LH 11 H 200
920.80 M 24x1,5 LH 1.4462 120
920.95
920.95
M 16x1,5
M 20x1,5
1.4462
1.4462
100
120
Table 7.5.3
The torques given apply to the initial tightening of brand-new
threads. After repeated tightening of the threads and in case of
good lubrication the values shall be reduced by 15 to 20 %.
They do not apply, if general assembly drawings or other
instructions state different values.