KSB WKLn Installation instructions

Standardised Water Pump
WKLn
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual WKLn
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 04/06/2018

Contents
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Contents
1. Safety 4
1.1 4
1.2 4
1.3 4
1.4 5
1.5 5
1.6 5
1.7 5
1.8 6
1.9
General
Intended use
Personnel qualification and training
Consequences and risks caused by non-compliance with this manual
Safety awareness
Safety information for the operator/user
Safety information for maintenance, inspection and installation
Unauthorised modes of operation
Key to safety symbols/markings 6
2. Transport /Temporary Storage /Disposal 7
2.1 Checking the condition upon delivery 7
2.2 Transport 7
2.3 Storage / preservation 9
2.4 Return to supplier 9
2.5 Disposal 10
3. Installation at Site 11
3.1 Safety regulations 11
3.2 Mounting 12
3.3 Setting up the pump set 12
3.4 Alignment of Pump and Driver 13
3.5 Connecting the Piping 14
3.6 Auxiliary connections 15
3.7 Vacuum Balance Line 16
3.8 Minimum Flow 16
3.9 Coupling Guard 16
3.10 Final Check 16
4. Start-up / Commissioning, Shutdown 17
4.1 Preparations 17
4.1.1 Lubricants 17
4.1.2 Shaft Seal 17
4.1.3 Priming the Pump and associated Checks 17
4.1.4 Checking the Direction of Rotation 17
4.2 Start-up 18
4.3 Shutdown 19
5. Maintenance and Lubrication 20
5.1 Supervision of operation 20
5.2 Lubrication and Grease Change 20
5.2.2 Grease Change 20
6. Dismantling and Reassembly 22
6.1 General 22
6.2.1 Mechanical Seal 22
6.3 Bearings 23
6.4 Assembly 24
6.4.1 Pump 24
6.4.2 Shaft Seal 26
6.4.2.1 Packed Gland 26
6.4.2.2 Mechanical Seal 28
6.4.3 Setting Torques for the Tie bolts 28
6.5 Cooling Liquid (HW Design) 28
6.6 External Source Sealing Liquid (Vacuum Operation) 28
6.7 Spare Parts 29
6.7.1 Recommended List of Spare Parts 29
6.7.2 Alternatively keeping a complete Rotor in stock comprising: 29
6.8 Exploded Views and List of components 30
6.9 Faults 32

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1. Safety
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
1.1 General
This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪Arrow indicating the direction of rotation
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
1.2 Intended use
▪The pump (set) must only be operated in the fields of application and within the
use limits specified in the other applicable documents.
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate the pump (set) in partially assembled condition.
▪Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model or variant.
▪Never operate the pump without the fluid to be handled.
▪Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪Observe the minimum flow rate and maximum flow rate indicated in the data
sheet or product literature (to prevent overheating, mechanical seal damage,
cavitation damage, bearing damage, etc).
▪Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
1.3 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.

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1.4 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
1.5 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
1.6 Safety information for the operator/user
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
1.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪Only carry out work on the pump (set) during standstill of the pump.
▪Only perform work on the pump set when it has been disconnected from the
power supply (de-energised).
▪The pump (set) must have cooled down to ambient temperature.
▪Pump pressure must have been released and the pump must have been drained.
▪Decontaminate pumps which handle fluids posing a health hazard.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.

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1.8 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
1.9 Key to safety symbols/markings
Table3: Definition of safety symbols/markings

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2. Transport/Temporary Storage/Disposal
2.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
2.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷Always transport the pump (set) in the specified position.
▷Never attach the suspension arrangement to the free shaft end or the motor
eyebolt and/or the pump.
▷Observe the information on weights, centre of gravity and fastening points.
▷Observe the applicable local accident prevention regulations.
▷Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
Table 3: Transporting the pump set
α
α

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Table 4: Transporting the pump on the baseplate
α
α
Table 5: Transporting the pump on a transport frame
α
Table 6: Transporting the pump on a transport frame (only if marked accordingly)
αα
Table 7: Transporting the pump without transport frame
ααα

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2.3 Storage/preservation
If commissioning is to take place sometime after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage due to humidity, dirt or vermin
Corrosion/contamination of the pump (set)!
▷For outdoor storage cover the pump (set) or the packaged pump (set) and
accessories with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump!
▷Clean and cover pump openings and connections as required prior to putting
the pump into storage.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
If properly stored indoors, the pump set is protected for three months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storage periods exceeding three months, the pump set is preserved as specified in
the purchase order.
2.4 Return to supplier
1. Drain the pump as per operating instructions.
2. Flush and clean the pump, particularly if it has been used for handling noxious,
explosive, hot or other hazardous fluids.
3. If the pump has handled fluids whose residues could lead to corrosion damage
in the presence of atmospheric humidity or could ignite upon contact with
oxygen also neutralise the pump and blow through with anhydrous inert gas to
ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump.
Indicate any safety measures and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
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2.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Hazard to persons and the environment!
▷Collect and properly dispose of flushing fluid and any fluid residues.
▷Wear safety clothing and a protective mask if required.
▷Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set).
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.
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3. Installation at Site
3.1 Safety regulations
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
Damage to the pump set!
▷Comply with the applicable local explosion protection regulations.
▷Observe the information in the data sheet and on the name plates of pump and
motor.
WARNING
Pump with long-term preservation: Harmful preservatives in drinking water
systems
Danger of poisoning!
▷Flush the system prior to commissioning.
▷If necessary, dismantle the pump and thoroughly remove the preservative from
all wetted components.
▷Observe the data given in the order confirmation.
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3.3 Setting up the pump set
DANGER
Static charging due to insufficient potential equalisation
Explosion hazard!
▷Make sure that the connection between pump and baseplate is electrically
conductive.
CAUTION
Warped baseplate or pump
Damage to the pump!
▷Align the baseplate and the pump accurately and carefully when installing the
pump set.
▷Ensure the baseplate is flat and level.
3.2 Mounting
Position the pump set on the foundation and align using a precision spirit level (on
the shaft/discharge nozzle). Ensure that the gap between the two coupling halves is
as given on the general arrangement drawing.
Shims should always be fitted to the left and right of the bolts in close proximity to
the bolts, between the baseplate/base frame and foundation. If the bolts are more
than 800mm apart, position extra shims equal distant between them. All shims must
seat perfectly flush.
Fig. 2 Fitting shims
Uniformly tighten up the bolts.
Grout in the baseplate (non-shrinking mortar is highly recommended), ensuring no
cavities remain.
NOTE
For low-noise operation contact KSB to check whether the pump set can be
installed on anti-vibration mounts. In this case, the baseplate should not be
grouted.
NOTE
Expansion joints can be fitted between the pump and the suction/discharge line.
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3.4 Alignment of Pump and Driver
After the baseplates has been fixed in position carefully check the coupling and, if
necessary, realign the pump set.
The coupling must also be checked and the pump set realigned even if the pump and
driver are supplied ready mounted on a common baseplate.
The pump set can be considered correctly aligned when the gap (a or b, see Fig 3)
between each shaft and a straight edge placed axially over both half couplings is the
same at all points in the circumference.
Furthermore, the gap between the two coupling halves must be the same at all
points on the circumference. This can be measured with callipers or a feeler gauge
(see Fig. 3 and 4)
Fig. 3 Aligning a non-spacer type flexible coupling Fig. 4 Aligning a flexible spacer coupling
The axial ad radial deviation between the two coupling halves must not exceed
0.1mm.
DANGER
Inadmissible temperatures at the coupling or bearings due to misalignment of the
coupling
Explosion hazard!
Risk of burns!
▷Make sure that the coupling is correctly aligned at all times.
CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷Always check the coupling after the pump has been installed and connected to
the piping.
▷Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
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3.5 Connecting the Piping
Suction lift lines should be run with a rising slope towards the pump, positive
suction lines with a downward slope towards the pump.
The pump must not bear the weight of the piping.
The nominal bores of the pipes should be the same as or larger than those of the
pump nozzles. We recommend installing non-return devices and shut-off valves,
depending on the type of installation.
Before commissioning a new installation, thoroughly clean, flush and blow
through all vessels, piping and connections. As welding beads, scale and other
impurities frequently only become dislodged after a certain period of time, it is
necessary to fit a strainer should be three times the cross-section of the piping in
order to avoid excessive pressure loss across the strainer due to clogging.
The conical strainer consists of a coarse strainer fronted by a fine strainer with a
2,0mm mesh and 0,5mm wire, made of corrosion-resistant material. See DIN 4181
1. Strainer holder
2. Fine strainer
3. Coarse strainer
4. Pump suction nozzle
5. Differential pressure gauge
Fig. 5 Conical strainer for suction line
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DANGER
Impermissible loads acting on the pump nozzles
Danger to life from escaping hot, toxic, corrosive or flammable fluids!
▷Do not use the pump as an anchorage point for the piping.
▷Anchor the pipes in close proximity to the pump and connect them properly
without transmitting any stresses or strains.
▷Observe the permissible forces and moments at the pump nozzles.
▷Take appropriate measures to compensate for thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷Never earth the electric welding equipment on the pump or baseplate.
▷Prevent current flowing through the rolling element bearings.
NOTE
Installing check and shut-off elements in the system is recommended, depending on
the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
3.6 Auxiliary Connections
The size and location of all auxiliary connections for sealing, circulation, balance and
leakage liquid are shown in the general arrangement drawing or piping diagram.
DANGER
Risk of potentially explosive atmosphere by incompatible fluids mixing in the
auxiliary piping
Risk of burns!
Explosion hazard!
▷Make sure that the barrier fluid, quench liquid and/or cooling liquid and fluid
handled are compatible.
WARNING
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing
liquid, etc.)
Risk of injury from escaping fluid!
Risk of burns!
Malfunction of the pump!
▷Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the quantity, dimensions and locations of auxiliary
connections.
▷Use the auxiliary connections provided.
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3.7 Vacuum Balance Line
If the pump has to pump liquid out of a vessel under vacuum it is advisable to fit a
vacuum balance line. This line should have a minimum N.B. of 25 mm and should be
arranged to lead back into the vacuum vessel at a point above the highest
permissible liquid level.
An additional line from the pump discharge nozzle facilitates pump venting prior to
start-up.
A Main shut-off valve
B Vacuum balance line
C Shut-off valve
E Vacuum-tight shut off valve
R Non-return flap valve
V Vacuum vessel
Z Intermediate flange
Fig. 6 Suction line and vacuum balance line
3.8 Minimum Flow
If it is possible that the pump will have to operate against a closed discharge valve, a
manual or continuous bypass or a bypass check valve must be provided.
3.9 Coupling Guard
Safety regulations specify that the pump must be fitted with a coupling guard. If
the purchaser specifically states that he does not want us to supply guard, this must
be provided by the operator.
3.10 Final Check
Re-check alignment as described in 3.4 It must be possible to rotate the coupling
easily by hand. Check the integrity of all connections.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷Observe all relevant regulations for selecting a coupling guard.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!!
▷Choose a coupling guard material that is non-sparking in the event of
mechanical contact.
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4.Start-up/Commissioning, Shutdown
4.1 Preparations
4.1.1 Lubricant
The grease-lubricated bearings have already been packed with grease.
4.1.2 Shaft Seal
Check seal (6.4.2)
•Single cartridge seal
•Elastomer bellows
•Independent of direction of rotation
•Stationery seat, rotating spring
•Bellows and spring free from torsion
4.1.3 Priming the Pump and associated Checks
The shutoff valve in the suction line must be fully open.
Fully open all auxiliary connections (flushing, sealing and cooling fluids). Check the
flow. Open the shut-off valve in the vacuum line (if fitted) and close the vacuum-
tight shut-off valve “E” (Fig 6)
4.1.4 Checking the Direction of Rotation
•Align the pump and driver
•Do not connect the coupling between the pump and driver
•Start driver, the direction of rotation must correspond to the
arrow on the pump.
•Connect coupling
•Fit coupling guard
DANGER
Formation of a potentially explosive atmosphere inside the pump
Explosion hazard!
▷Before starting up the pump set, vent the pump, mechanical seal housing and
suction line, and prime them with the fluid to be handled.
CAUTION
Increased wear due to dry running
Damage to the pump set!
▷Never operate the pump set without liquid fill.
▷Never close the shut-off element in the suction line and/or supply line during
pump operation.
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4.2 Start-up
Start the set up against a closed discharge valve only. Slowly open the discharge
valve to obtain the required duty point after the pump has reached full speed.
N.B.
After the pump has reached its working temperature and/or if the pump leaks, shut
the set down and tighten the tie bolts.
DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid
handled
Explosion hazard!
Damage to the pump set!
▷Never operate the pump set without liquid fill.
▷Prime the pump as per operating instructions.
▷Always operate the pump within the permissible operating range.
WARNING
The suction casing, discharge casing, stage casing, seal housing and seal cover take
on the same temperature as the fluid handled.
Risk of burns!
▷Do not touch hot components.
WARNING
The temperature at the bearing bracket can exceed 60°C during operation.
Risk of burns!
▷Do not touch hot components.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷Switch off the pump (set) immediately.
▷Eliminate the causes before returning the pump set to service.
CAUTION
Start-up against open discharge line
Motor overload!
▷Make sure the motor has sufficient power reserves.
▷Use a soft starter.
▷Use speed control.
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4.3 Shutdown
Close the discharge valve.
The discharge valve can remain open if the discharge line incorporates a non-return
valve, provided there is back pressure.
Switch off the driver, making sure the pump set runs smoothly and evenly down to
a standstill.
If the pump set is to remain out of service for long periods, close the shut-off valve
in the suction line. Close off the auxiliary connections.
Do not shut off the flow of cooling fluid, if applicable, until the pump has cooled
down.
On pumps supplied with product under vacuum, sealing liquid must be supplied to
the shaft seal even during stand-still.
If there is a danger of freezing and/or if the pump is to be out of service for long
periods, drain the pump or otherwise protect against freezing
CAUTION
Heat build-up inside the pump
Damage to the shaft seal!
▷Depending on the type of installation, the pump set requires sufficient after-
run time – with the heat source switched off – until the fluid handled has
cooled down.
CAUTION
Backflow of fluid handled is not permitted
Motor or winding damage! Mechanical seal damage!
▷Close the shut-off elements.
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5.Maintenance and Lubrication
5.1 Supervision of operation
The pump must run quietly and evenly at all times.
Avoid dry-running of the pump.
Do not run the pump for a long period against a closed discharge valve.
The bearing temperature may exceed ambient temperature by up to 50°C, but must
not exceed 90°C (measured externally on the bearing housing).
The shut-off valves in the auxiliary lines must remain open while the pump is
running.
If the pump has a gland packing this should leak slightly during operation. The
gland nuts should only be lightly tightened.
If the pump has a mechanical seal this experiences only minor leakage or no visible
leakage (flashing) during operation. It is maintenance free.
Any standby pumps should be started up then shut down immediately, at least once
a week, to ensure they are in constant readiness for operation. Check the integrity
of the auxiliary connections.
The flexible coupling elements should be regularly checked and replaces as soon as
they show signs of wear.
5.2 Lubrication and Grease Change
5.2.1 Lubrication
The anti-friction bearings are grease-lubricated.
5.2.2 Grease Change
The initial fill of grease-lubricated anti-friction bearings should be changed after
3000 operating hours or 2 years, whichever is the sooner.
Grade:
Use high-quality lithium soap grease, resin and acid-free not liable to crumble, with
good rust preventative properties. It must have a penetration number between 2
and 3, corresponding to a worked penetration between 220 and 295 mm/10. Its drop
point must be above 175°C.
WARNING
Unintentional starting of the pump set
Risk of injury by moving components and shock currents!
▷Ensure that the pump set cannot be started unintentionally.
▷Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Risk of injury!
▷Observe all relevant laws.
▷When draining the fluid take appropriate measures to protect persons and the
environment.
▷Decontaminate pumps which handle fluids posing a health hazard.
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