Process Pump

CHTR
100 bar
Rolling Element Bearings

Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual CHTR

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 Aktiengesellschaft, Frankenthal 30.09.2013

Contents

Contents

1 General ..................................................................................................7
1.1 Principles ...........................................................................................................7
1.2 Installation of partly completed machinery .................................................... 7
1.3 Target group ..................................................................................................... 7
1.4 Other applicable documents ............................................................................ 7
1.5 Symbols .............................................................................................................8

2 Safety .....................................................................................................9
2.1 Key to safety symbols/markings ....................................................................... 9
2.2 General .............................................................................................................. 9
2.3 Intended use .....................................................................................................9
2.4 Personnel qualification and training ............................................................. 10
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 10
2.6 Safety awareness ............................................................................................11
2.7 Safety information for the operator/user ..................................................... 11
2.8 Safety information for maintenance, inspection and installation work ..... 11
2.9 Unauthorised modes of operation ................................................................ 11
2.10 Explosion protection ...................................................................................... 12

3 Transport/Temporary Storage/Disposal .............................................14

3.1 User information ............................................................................................14
3.2 Checking the condition upon delivery .......................................................... 14
3.3 Transporting the packaged components of the pump set .......................... 14
3.4 Transport ......................................................................................................... 15
3.5 Storage/preservation ...................................................................................... 20
3.6 Return to supplier ........................................................................................... 21
3.7 Disposal ...........................................................................................................22

4 Description of the Pump (Set) ............................................................23

4.1 User information ............................................................................................23
4.2 General description ........................................................................................ 23
4.3 Designation ..................................................................................................... 23
4.4 Name plate ...................................................................................................... 23
4.5 Design details .................................................................................................. 23
4.6 Configuration and function ........................................................................... 24
4.7 Order specifications ........................................................................................ 26

5 Installation at Site ...............................................................................27

5.1 User information ............................................................................................27
5.2 Safety regulations ........................................................................................... 27
5.3 Checks to be carried out prior to installation ............................................... 27
5.4 Unpacking the pump set components ..........................................................28

CHTR 3 of 168
 Contents

5.5 Removing the preservation ............................................................................ 28

5.6 Transporting the pump set components to the place of installation ......... 29
5.7 Dismantling the coupling guard/cover .......................................................... 29
5.8 Mounting the coupling hubs ......................................................................... 30
5.9 Preparing the levelling screws ....................................................................... 32
5.10 Installing the pump set .................................................................................. 33
5.11 General information for alignment .............................................................. 34
5.12 Checking the coupling alignment ................................................................. 35
5.13 Alignment Corrections on the Pump ............................................................. 38
5.14 Drilling the holes for fastening the feet ....................................................... 39
5.15 Fastening the baseplate to the foundation .................................................. 40
5.16 Piping .............................................................................................................. 41
5.17 Electrical connection ...................................................................................... 46
5.18 Final installation of the pump set .................................................................47
5.19 Installing or connecting the measuring instruments ................................... 48
5.20 Preservation for standstill .............................................................................. 49
5.21 Check list for installation ...............................................................................50

6 Commissioning/Start-up/Shutdown ...................................................51
6.1 User information ............................................................................................51
6.2 General information ....................................................................................... 51
6.3 Work to be carried out prior to commissioning/start-up ............................. 51
6.4 Commissioning/start-up ................................................................................. 61
6.5 Checklist for commissioning/start-up ............................................................ 65
6.6 Operation ........................................................................................................ 65
6.7 Operating limits .............................................................................................. 67
6.8 Measures to be taken for shutdown ............................................................. 69
6.9 Work after shutdown ..................................................................................... 71
6.10 Preservation for standstill .............................................................................. 73
6.11 Returning to service ...................................................................................... 74

7 Servicing/Maintenance .......................................................................75
7.1 User information ............................................................................................75
7.2 Supervision ...................................................................................................... 75
7.3 Maintenance ................................................................................................... 77
7.4 Dismantling the pump ...................................................................................80
7.5 Reassembling the pump ................................................................................. 95
7.6 Installing the pump into the system ............................................................ 113
7.7 Fastening the pump feet ............................................................................. 114
7.8 Fitting the piping and instruments ............................................................. 114
7.9 Fitting the contact guards ........................................................................... 114
7.10 Maintenance of the other pump set components ..................................... 114
7.11 Spare parts stock ........................................................................................... 115

4 of 168 CHTR
Contents

8 Trouble-shooting .............................................................................117
8.1 Trouble-shooting .......................................................................................... 117

9 Related Documents ..........................................................................121

9.1 User information .......................................................................................... 121
9.2 Technical information .................................................................................. 121
9.3 Pump signage ............................................................................................... 134
9.4 Assembly drawings/instructions ................................................................... 137

10 EC Declaration of Conformity ..........................................................165

11 Certificate of Decontamination .......................................................166

CHTR 5 of 168
 Glossary

Glossary

Certificate of decontamination has been properly drained to eliminate any

environmental and health hazards arising from
A certificate of decontamination is enclosed by
components in contact with the fluid handled.
the customer when returning the product to
the manufacturer to certify that the product
Discharge line
The line which is connected to the discharge
nozzle

6 of 168 CHTR
1 General

1 General

1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the pump (set) and serve as identification for all further business
processes.
KSB specialist personnel must be called in for installation, commissioning/start-up and
maintenance. KSB will only assume responsibility for faultless execution of the work
and for the safety of the personnel involved if dismantling/reassembly and
maintenance have been performed by KSB’s specialist team.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics (⇨ Section 9.2.1 Page 121)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, refer to the sub-sections
under Servicing/Maintenance.

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (⇨ Section 2.4 Page 10)

1.4 Other applicable documents

In addition to this instruction manual, it is important to observe further product-
specific information and technical documents of the other pump set components.
The relevant documents can be found in (⇨ Section 9 Page 121) . Depending on the
scope of supply the following documents are available:
▪ Data sheet
▪ General arrangement drawing
▪ Excerpt from DIN 1045
▪ List of measuring points
▪ Bolt tightening torques
▪ P&I diagram
▪ List of valves and fittings
▪ Table of weights
▪ Diametral clearances
▪ General assembly drawings/Drawings for assembly
▪ Product literature on the coupling
▪ Product literature on the drive
▪ Product literature on minimum flow system and minimum flow valve
▪ Minimum flow diagram
▪ Product literature on valves and equipment
▪ Product literature on the instruments
▪ Product literature on gear or variable speed coupling

CHTR 7 of 168
 1 General

1.5 Symbols
Table 1: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product

8 of 168 CHTR
 2 Safety

2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
2.1 Key to safety symbols/markings
Table 2: Definition of safety symbols/markings
Symbol Description
! DANGER DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
! WARNING WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EC Directive
94/9/EC (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.

2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
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 manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits described 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.

CHTR 9 of 168
 2 Safety

▪ The pump must only be operated with the components selected by KSB.
▪ Never operate the pump without the fluid handled.
▪ Observe the minimum flow 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

▪ The pressure of the fluid handled must not exceed the maximum permissible
pump discharge pressure.
▪ The temperature of the fluid handled must not exceed the permissible maximum
value.
▪ Observe the information on minimum flow rates specified in the data sheet (to
prevent overheating, damage to seal elements, damage to bearings, etc).
▪ Observe the information on maximum flow rates specified in the data sheet (to
prevent overheating, damage to seal elements, cavitation damage, damage to
bearings, etc).
▪ Take appropriate measures in compliance with the local regulations to prevent
operation above or below the operating limits due to operating errors,
malfunctions or procedural errors.
▪ The pump must only be operated when in perfect technical condition.
Immediately remedy any faults which could compromise the safety.
▪ The pump must not be operated in partially assembled condition.
▪ The pump or its components must not be altered in any way.
▪ Regularly check that all monitoring and alarm equipment is in perfect condition.
▪ Generally observe the operating limits given.

2.4 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.

2.5 Consequences and risks caused by non-compliance with these operating

instructions
▪ 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

10 of 168 CHTR
2 Safety

– Hazard to the environment due to leakage of hazardous substances

2.6 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 and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards and laws

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any 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.)
▪ As long as shutting down the pump does not increase potential risk, provide for
an emergency-stop control device in the immediate vicinity of the pump (set)
during pump set installation.
▪ Minimise exposure in the pump set’s danger area.

2.8 Safety information for maintenance, inspection and installation work

▪ Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪ Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪ The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪ If maintenance work is carried out in potentially explosive atmospheres, the
operator is responsible for taking all required precautionary measures.
▪ Only carry out work on the pump (set) during standstill of the pump.
▪ The pump casing must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pump set out of service always adhere to the procedure
described in the manual.
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning.

2.9 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.

CHTR 11 of 168
 2 Safety

2.10 Explosion protection

Always observe the information on explosion protection given in this section when
! DANGER operating an explosion-proof pump set.

Sections of the manual marked by the Ex symbol apply to explosion-proof pump sets
also when temporarily operated outside potentially explosive atmospheres.
Only pumps/pump sets marked as explosion-proof and identified as such in the data
sheet must be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof pump sets in accordance
with EC Directive 94/9/EC (ATEX).
Especially adhere to the sections in this manual marked with the Ex symbol.
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
Never operate the pump (set) outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.

2.10.1 Marking
Pump The marking on the pump refers to the pump part only.
Example of such marking: II 2 G c TX
Refer to the Temperature Limits table for the temperatures permitted for the
individual pump variants.
Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor The motor must be considered separately.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected at the
surface of the pump casing, at the shaft seal and in the bearing areas.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated, the operator of the system is responsible for
observing the specified temperature class and fluid temperature (operating
temperature).
The table below lists the temperature classes and the resulting theoretical
temperature limits of the fluid handled. (A possible temperature rise in the shaft seal
area has been taken into account).
Table 3: Temperature limits
Temperature class to EN 13463-1 Maximum permissible fluid
temperature
T1 Pump temperature limit
T2 Pump temperature limit
T3 185 °C
T4 120 °C
T5 85 °C
Temperature class T4 In the area of the rolling element bearings, based on an ambient temperature of
40 °C and assuming proper service and operation, compliance with the requirements
of temperature class T4 is warranted. If the ambient temperature exceeds 40 °C,
contact the manufacturer.
Temperature classes T5 / A special design is required to comply with the requirements of temperature classes T
T6 5 / T6 in the bearing area.
Misuse, malfunctions or non-compliance with the instructions may result in
substantially higher temperatures. If the pump is to be operated at a higher
temperature or if there is no data sheet, contact the pump manufacturer and ask for
the maximum permissible operating temperature.

12 of 168 CHTR
2 Safety

2.10.3 Monitoring equipment

The pump (set) must only be operated within the limits specified in the data sheet
and on the name plate.
If the system operator cannot warrant compliance with these operating limits,
appropriate monitoring devices must be used.
Check whether monitoring equipment is required to ensure that the pump set
functions properly.
Contact KSB for further information on monitoring equipment.

2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.7.3.1 Page 68) refer to water and water-
like fluids handled. Longer operating periods with these fluids and at the flow rates
indicated will not cause an additional increase in the temperatures at the pump
surface. However, if the physical properties of the fluids handled differ from those of
water, it is essential to check whether additional heat build-up may occur and if the
minimum flow rate must therefore be increased. The calculation formula in
(⇨ Section 6.7.3.1 Page 68) can be used to check whether additional heat build-up
may lead to a dangerous temperature increase at the pump surface.

2.10.5 Repair
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.

CHTR 13 of 168
 3 Transport/Temporary Storage/Disposal

3 Transport/Temporary Storage/Disposal

3.1 User information

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

3.2 Checking the condition upon delivery

Check each packaging unit for damage before it is stored In the event of in-transit
damage, assess the exact damage, document it and notify KSB about the damage in
writing immediately.

3.3 Transporting the packaged components of the pump set

✓ The weights of the individual components to be transported have been
identified in the packing list.
✓ Suitable lifting equipment has been selected.
1. Attach the handling gear and/or transport ropes as shown on the packaging.
Observe the markings for fastening points and the centre of gravity.

Fastening points Centre of gravity

Transport the transport boxes as indicated.

NOTE
The angle α depends on the lifting tackle; however it must never be wider than
120°.

Fig. 1: Hoisting the transport box

14 of 168 CHTR
3 Transport/Temporary Storage/Disposal

3.4 Transport

DANGER
The pump or individual components could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump or components in the specified position.
▷ Refer to the weights indicated for the individual components.
▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
▷ Never attach the suspension arrangement to the free shaft end of the pump.
▷ Observe the applicable local accident prevention regulations.
▷ Use appropriate personal protective equipment.

DANGER
Improper transport
Risk of injury from lifting heavy components!
▷ Select lifting accessories which are suitable for the component weight.
▷ Always use the attachment points provided for the lifting accessories.
▷ Comply with the applicable health and safety regulations.

WARNING
Lack of stability
Serious injuries due to parts tipping over!
▷ Place the pump only on an area designed for this purpose.
▷ Comply with the requirements to be met by the load-bearing capacity of the
floor. Check the load-bearing capacity of the floor. Consult the building
drawing and general arrangement drawing.
▷ Give due attention to the position of the centre of gravity of the pump set.
▷ Refer to the table of weights for the weight of the pump (set) or packaging
unit.

CAUTION
Improper transport
Damage to the pump components!
▷ Always protect pump components from direct contact with chains or steel
ropes.
▷ Protect built-on accessories and pipes.
To determine the lifting capacity, give due consideration to the position of the centre
of gravity, the angle of spread and permissible bending radii of the lifting accessories
attached to the load to be lifted.
To transport the pump/pump set suspend it from the lifting tackle as shown below.

NOTE
The angle α depends on the lifting tackle; however it must never be wider than
120°.

CHTR 15 of 168
 3 Transport/Temporary Storage/Disposal

Transporting the pump set

a°

Fig. 2: Centreline pump feet

Fig. 3: Transport using a transportation beam

Transporting the pump on the baseplate

Fig. 4: Separate baseplate for pump

16 of 168 CHTR
3 Transport/Temporary Storage/Disposal

a°

Fig. 5: Common baseplate for pump and drive

Transporting the pump on a transport frame

Fig. 6: Pump on transport frame

Transporting the pump without transport frame

Fig. 7: Transport of a pump without transport frame

CHTR 17 of 168
 3 Transport/Temporary Storage/Disposal

3.4.1 Transporting the pump rotor

DANGER
The pump rotor could slip out of the suspension arrangement.
Danger to life from falling parts!
▷ Never use steel ropes or chains for transport.
▷ Use manila ropes or plastic ropes.
▷ Transport the pump rotor in horizontal position.
Transport the pump rotor as shown.

Fig. 8: Transporting the pump rotor

Observe the following instructions for transporting the pump rotor:
▪ Attach transport ropes which are suitable for the length of the rotor.
▪ When placing the pump rotor down, support it adequately to prevent it from
any damage.
▪ Secure the pump rotor against overturning or rolling.

3.4.2 Transporting the pump set accessories

CAUTION
Improper transport of strainers/filters
Damage to the strainer/filter through lifting tackle!
▷ Do not exert pressure on the strainer element and strainer meshes or damage
them.
▷ Transport pump set accessories by hand, if possible. If this is not an option
because of the weight, observe the transport options described in this manual.

18 of 168 CHTR
3 Transport/Temporary Storage/Disposal

Attach the lifting accessories as shown and/or in accordance with the relevant
manufacturer’s documentation.

α α
α

1 2 3

α α
α

4
6
Fig. 9: Transporting the pump set accessories
1 Conical strainer 2 Strainer housing
3 Basket strainer 4 Y-strainer
5 Cylindrical strainer 6 Minimum flow valve

3.4.3 Transporting the cartridge

WARNING
Lack of stability
Serious injuries due to parts tipping over!
▷ Place the cartrdige only on an area designed for this purpose.
▷ Comply with the requirements to be met by the load-bearing capacity of the
floor. Check the load-bearing capacity of the floor. Consult the building
drawing and general arrangement drawing.
▷ Give due attention to the position of the centre of gravity of the cartridge.
▷ Refer to the table of weights for the weight of the pump (set) or packaging
unit.

CHTR 19 of 168
 3 Transport/Temporary Storage/Disposal

DANGER
The cartridge could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Never use steel ropes or chains for transport.
▷ Always use hemp or plastic ropes.
▷ Transport the cartridge in a horizontal position.

<120°

Fig. 10: Transporting the cartridge

3.5 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storage:

CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.

CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
▷ Only remove caps/covers from the openings of the pump set at the time of
installation.

CAUTION
Improper storage
Impairment of O-rings' sealing function!
▷ Do not store O-rings together with chemicals, solvents, fuels, acids, etc.
▷ Protect O-rings from light, in particular from direct sun exposure and strong
artificial light high in ultraviolet rays.
▷ Check the O-rings for damage before they are fitted.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.

20 of 168 CHTR
 3 Transport/Temporary Storage/Disposal

Preservation

WARNING
Improper handling of materials and supplies
Risk of injury due to contact with hazardous substances!
▷ Observe the relevant safety instructions for the handling of hazardous
substances (wear safety goggles and protective gloves, for example).
Period of storage up to 12 The pump is supplied preserved for storage of up to 12 months. (Standard
months preservation)
Table 4: Measures taken for preservation
Type of preservation Preservative To be preserved
External preservation Tectyl 502-C made by All blank and uncoated
Valvoline GmbH, Hamburg parts (e.g. shaft ends,
couplings and flange faces)
Internal preservation Tectyl 502-C, made by All blank internal parts of
Valvoline GmbH, Hamburg the pump (e.g casing
(not applicable for pumps inside, shafts, impellers and
made of non-corroding diffusers)
materials)
Period of storage longer If the requisite preservation measures have not been performed by KSB (special
than 12 months preservation), they must be discussed with and approved by KSB prior to putting the
pump into storage.
Table 5: Measures to be taken for preservation
Type of preservation Preservative To be preserved
External preservation Tectyl 502-C made by All blank and uncoated
Valvoline GmbH, Hamburg parts (e.g. shaft ends,
couplings and flange faces)
Internal preservation Glycol/water mixture Fill pump interior
All blank internal parts of
the pump (e.g casing
inside, shafts, impellers and
diffusers)

WARNING
In the case of storage periods of more than 5 years, the sealing function of O-rings
may be impaired.
Rick of injury from leakage of hot, pressurised fluid handled!
▷ After a storage period of more than 5 years, the pump must be dismantled
before it is installed, and the O-rings must be replaced.
▷ Check the O-rings for damage before they are fitted.

3.6 Return to supplier

1. Drain the pump as per operating instructions.
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the pump set has handled fluids whose residues could lead to corrosion in the
presence of atmospheric humidity or could ignite upon contact with oxygen,
the pump set must also be neutralised, and anhydrous inert gas must be blown
through the pump to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump (set).
Always indicate any safety and decontamination measures taken. (⇨ Section 11
Page 166)

CHTR 21 of 168
 3 Transport/Temporary Storage/Disposal

NOTE
If required, a blank certificate of decontamination can be downloaded from the
KSB web site at: www.ksb.com/certificate_of_decontamination

3.7 Disposal

WARNING
Fluids, consumables and supplies which are hot or pose a health hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷ 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.

22 of 168 CHTR
 4 Description of the Pump (Set)

4 Description of the Pump (Set)

4.1 User information

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

4.2 General description

Pump for handling hydrocarbons, boiler feed water, clean cold or hot water or
aqueous solutions employed in refineries, refinery off-sites and in the petrochemical
industry.
▪ Process pump to API 610
▪ High-pressure multistage barrel-type pump

4.3 Designation
Example: CHTR 5 / 6 or CHTR 5 / 1+5
Table 6: Key to the designation
Code Description
CHT Type series
R Additional code
5 Size
6 Number of stages (single-entry inlet)
1+5 Number of stages (double-entry inlet)

4.4 Name plate

8
1
9
Ord.-No. Year 10
2
3 Ser.-No. Type 11
4 Item-No. Test pressure bar 12
5 Q m3/h H m 13
6 n 1/min t °C
7 ρ kg/dm3 14
MAWP bar MAWP @ °C
Bearings
ZN 3823 - E231

Fig. 11: Name plate (example)

1 KSB order number 2 Item number
3 Flow rate 4 Rated speed
5 Density of the fluid handled 6 Maximum operating pressure
7 Bearings 8 Manufacturer's name and address
9 Year of construction 10 Type series, size
11 Test pressure 12 Head
13 Application temperature 14 Maximum operating pressure @
temperature

4.5 Design details

Design ▪ Horizontal installation
▪ Radially split pump with radial impellers

CHTR 23 of 168
 4 Description of the Pump (Set)

▪ Single-entry or double-entry
▪ Multistage
▪ Sealing between the casings by means of O-rings or gaskets
▪ Nozzle positions
– Suction nozzle: radial, vertically to the top
– Discharge nozzle: radial, vertically to the top
– Tapping nozzle: Radial, possible in all stage casings, in various directions
Bearings Depending on pump size and design:
▪ Radial bearing
– Rolling element bearing, uncooled, oil ring lubrication
– Rolling element bearing, cooled, oil ring lubrication
– Rolling element bearing, oil mist lubrication
– Plain bearing, forced-feed lubrication
▪ Thrust bearing
– Rolling element bearing, cooled, oil ring lubrication
– Rolling element bearing, oil mist lubrication
– Plain bearing, forced-feed lubrication
Balancing device ▪ Axial thrust balancing by hydraulic balancing device on discharge side
▪ Balancing by drum or double drum
Shaft seal Depending on pump size and design:
▪ Mechanical seal, uncooled, mating ring cooling, injection or circulation
▪ Shaft equipped with a replaceable shaft sleeve in the shaft seal area
Flanges ▪ Mating dimensions to ASME

4.6 Configuration and function

1 2 3 4 5

6 7 8 9 10 11 12 13 14 15 16

Fig. 12: Sectional drawing

1 Thrust bearing 2 Shaft seal housing
3 Barrel casing 4 Inlet ring
5 Radial bearing 6 Bearing housing
7 Throttle bush 8 Balance drum

24 of 168 CHTR
 4 Description of the Pump (Set)

9 Diffuser, last stage 10 Stage casing

11 Casing wear ring 12 Clearance
13 Impeller 14 Diffuser
15 Shaft seal 16 Shaft
Function The fluid enters the pump via the suction nozzle of the barrel casing (3) and the inlet
ring (4) and is accelerated by the (suction) impeller (13) in a cylindrical flow towards
the discharge nozzle. In the flow passage of the diffuser (14) inserted in the stage
casing (10) the kinetic energy of the fluid is converted into pressure energy and the
fluid is routed to the next impeller (13) via the return guide vanes of the diffuser.
This process is repeated in all stages until the fluid has passed the last stage diffuser
(9) from where it leaves the pump.
The clearance gap (12) at the casing wear ring (11) prevents any fluid from flowing
back from the stage casing (9) into the suction area of the previous impeller. A
balancing device consisting of balance drum (8) and throttle bush (7) is fitted behind
the last impeller, providing axial thrust balancing by means of hydraulic forces.
Behind the balancing device and the inlet ring, the fluid area is closed off by a shaft
seal housing (2) through which the shaft (16) passes. The shaft passage through the
shaft seal housing (2) is sealed to the atmosphere by a dynamic shaft seal (15). The
drive shaft (16) is supported by a thrust bearing (1) and a radial bearing (5) located in
the bearing housing (6).

CHTR 25 of 168
 4 Description of the Pump (Set)

4.7 Order specifications

Project: BANGGAI AMMONIA PLANT
KSB order number: 9973056397-100, 200.

Type series, size: CHTR 2/7+1B

Item number: 110-J/JA

Table 7: Technical data

Characteristic Value Unit
Fluid handled WATER WITH DISSOLVED CO2 -
Operating 40 °C
temperature
Head 433.5 m
Flow rate 26.76 m³/h
Speed 2970 rpm
Direction of rotation CLOCKWISE SEEN FROM DRIVE END -
Drive rating 94 kW
Table 8: Forces and moments
Pump nozzle Size Forces and moments
Suction nozzle ASME B16.5 DN80 CL600 RF Values as per API 610 table 2-1 A/B
Discharge nozzle ASME B16.5 DN50 CL600 RF Higher values as per API 610 Appendix
F are permissible (if required)

110 Dynamic balancing

NOTE
Whenever dynamic rotor balancing has to be performed at site, this should be done
at 80 % of the critical speed, without fluid, by means of a balancing machine.

Table 9: Bearing
Pump end Size
Drive end NU 310 C3
Non-drive end 7310B-G
Table 10: Relevant drawings
Description Drawing number Comment
General arrangement drawing F30459B
Sectional drawing PR75525A
Piping & instrumentation drawings PR75593 C
Table 11: Illustrations for the removal/assembly of components
Description Drawing number Comment
Scaffolding UA3 37814 01 Cartridge removal
Puller & pusher kit Removal of throttle bush 542, rolling
UA3 37819 01
element bearings and balance drum
603.
As-built dimensions UA3 37818 01
Clamping kit UA3 37816 01

26 of 168 CHTR
5 Installation at Site

5 Installation at Site

5.1 User information

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

5.2 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.

DANGER
Unprotected floor openings and/or foundations
Danger of death from falling!
▷ Secure the danger zone.
▷ Observe the applicable local occupational safety and accident prevention
regulations.

5.3 Checks to be carried out prior to installation

Place of installation

WARNING
Installation on mounting surface which is unsecured and cannot support the load
Personal injury and damage to property!
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN 206-1.
▷ The mounting surface must have set and must be completely horizontal and
even.
▷ Observe the weights indicated.

DANGER
Insufficient stability of pump set as a result of incorrect dimensioning and fastening
of the baseplate (unless included in KSB's scope of supply)
Risk of pump tipping over!
▷ Prior to commissioning, provide proof that the baseplate is adequately
dimensioned to ensure the pump set’s stability, and proof of compliance with
the maximum permissible vibration level.
▷ Make sure that the vibrations do not exceed the specified limits.
✓ Proper illumination is available at the place of installation.
✓ Suitable alignment devices are available.
✓ In the area of the baseplate grouting and at the side walls of the holes for the
foundation bolts, the foundation has rough surfaces to allow for better bonding.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.

CHTR 27 of 168
 5 Installation at Site

5.4 Unpacking the pump set components

DANGER
Improper transport
Danger to life from falling parts!
▷ Use a stable mounting frame.
▷ Always coordinate all unpacking work with the responsible site management/
operator.
▷ Use personal protective equipment.

WARNING
Parts falling down during unpacking
Risk of crushing injuries!
▷ Secure loose parts (e.g. box lids) against falling down.

CAUTION
Open or closed connections and openings
Damage to the pump!
▷ During installation, do not open connections and openings earlier than
necessary. (All openings and connections are closed at the factory.)
▷ Prior to commissioning/start-up, check on the basis of the information given in
(⇨ Section 6 Page 51) whether the openings and connections must be open or
closed.
▪ Do not unpack the pump set components until immediately before the
installation work starts. Take care not to damage the cable.
▪ The consignee of the components supplied is responsible for disposal of the
packaging.
▪ Completely cover the unpacked pump set components on site to protect them
against dirt, moisture, spark discharge, grinding dust and other harmful ambient
influences. Take special care to adequately protect instruments, electric cables
and wiring ducts.
▪ Spare parts and parts which are not immediately needed must be stored.

NOTE
If components of the pump set became damaged, wet or dirty, inform KSB.

5.5 Removing the preservation

NOTE
If the pump has been specially preserved for storage of more than 12 months or sea
transport, the necessary measures for removal of preservation prior to installation
must be carried out. (⇨ Section 6.3.1 Page 51)

28 of 168 CHTR
 5 Installation at Site

5.6 Transporting the pump set components to the place of installation

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

5.7 Dismantling the coupling guard/cover

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

5.7.1 Dismantling the coupling guard

Dismantle the coupling guards mounted to the pump set and store, if required.

Coupling guard (example) Coupling cover (example)

1 Bottom plate 2 Foot fastening (lock strip)
1. Undo and remove the bottom plate.
2. Undo the foot fastening.
3. Remove the coupling guard upwards.
4. Store coupling guard, if required.

CHTR 29 of 168
 5 Installation at Site

5.7.2 Dismantling the coupling cover (if applicable)

WARNING
Risk of hot oil escaping as a result of an improperly mounted/dismantled coupling
cover
Risk of burns!
Damage to the coupling!
▷ Do not damage the seal elements and sealing surfaces.
▷ Never operate the coupling without a lubricant.
▷ Prior to putting the coupling into service, check the coupling cover for correct
installation and sealing.
1. Remove all pipe connections on the cover.
2. Remove the taper pins and screws of the cover split joints.
3. Unscrew the screws in the upper part of the coupling cover.
4. Remove the upper half of the coupling cover.
5. Remove the internal injection lines.
6. Disconnect the lower half of the coupling cover from the flange and remove
this half.

5.7.3 Dismantling the coupling spacer

Dismantle and store the coupling spacer as described in the manufacturer’s product
literature.

5.8 Mounting the coupling hubs

WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.

CAUTION
Improper dismantling
Damage to bearings and coupling parts!
▷ Remove coupling hubs using a puller.
▷ Never strike the coupling hubs.

WARNING
Falling coupling parts
Risk of crushing from falling parts!
▷ Secure coupling parts against falling down.
▷ Wear safety shoes.

CAUTION
Improper mounting of elastomers
Elastomers' sealing function reduced!
▷ Never use elastomeric parts again which have been heated.
▷ As a general rule, always use new elastomeric parts.

30 of 168 CHTR
5 Installation at Site

Mount all coupling hubs which have not been fitted.

Make sure that the markings on all coupling components to be connected are
identical.

5.8.1 Checking the shaft ends for run-out

Fig. 13: Checking the shaft ends for run-out

NOTE
Observe the marking between coupling hub and shaft. (⇨ Section 7.4.4 Page 83)

1. Permissible tolerance at the pump shaft ≤ 0.03 mm/ 0.0012 inch. If this value is
exceeded, inform KSB.
2. After every 90° turn, read measured values again.
3. Permissible tolerance at the motor shaft, see the data provided by the
manufacturer.

5.8.2 Fitting the coupling hubs (with key)

1. Carefully clean the shaft ends and bores of the coupling hubs and check them
for dimensional accuracy.
2. Slightly deburr the hub keyways and insert the key.

Fig. 14: Clearance between keyway and key

3. Check the protruding dimension of the key. Observe tolerance in accordance
with the figure "Clearance between keyway and key".

WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
4. To facilitate fitting, the coupling hubs may be heated uniformly to a
temperature of 80 °C max. Elastomeric parts must be removed before heating.
Elastomeric parts which have been heated must not be used any more.

CHTR 31 of 168
 5 Installation at Site

Fig. 15: Fit coupling hub (example)

Pump size Thread size X
2 M12
3 M12
4 M16
5 M16 or M20
5. Fit the coupling hubs until the shaft end and the hub face are in alignment.

Fig. 16: Coupling hub with grub screw

A Grub screw
6. Securely tighten the grub screws.
7. Fit the retaining ring, if applicable, to the coupling hub.

5.9 Preparing the levelling screws

Prepare the levelling screws and position them on either side of the foundation bolts
as shown in the sketch.

Fig. 17: Preparing the levelling screws (example)

1 Foundation centreline 2 Levelling screws
3 Foundation holes 4 Baseplate
5 Foundation H max. 47 mm / min. 35 mm

32 of 168 CHTR
5 Installation at Site

5.10 Installing the pump set

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

5.10.1 Securing the baseplate with foundation bolts

1. Lift the baseplate.
2. Place the foundation bolts into the baseplate holes and screw on the nuts until
the bolt thread projects by about 10 mm.
3. Place the baseplate onto the levelling screws and align the baseplate using the
screws. Check the alignment in relation to the foot supporting surfaces both
parallel to and 90° to the foundation centreline using a spirit level (accuracy <
0.3 mm/m). The foundation bolts must be suspended freely in the foundation
holes.
4. Position on the baseplate the pump set components which are not already
mounted on it. Observe the manufacturer's product literature.
5. Check the baseplate alignment once again in relation to the foot supporting
surfaces both parallel to and 90° to the foundation centreline using a spirit level
(accuracy < 0.3 mm/m). Correct any deviations which might have occurred under
the load of the components using the levelling screws.

5.10.2 Securing the baseplate with bonded anchors

1. Lift the baseplate and place it onto the levelling screws. Position the baseplate
so that the holes for the bonded anchors in the foundation may be rough-
drilled.
2. Align the baseplate using the levelling screws. Check the alignment in relation
to the foot supporting surfaces both parallel to and 90° to the foundation
centreline using a spirit level (accuracy < 0.3 mm/m).
3. Position on the baseplate the pump set components which are not already
mounted on it. Observe the manufacturer's product literature.
4. Check the baseplate alignment once again in relation to the foot supporting
surfaces both parallel to and 90° to the foundation centreline using a spirit level
(accuracy < 0.3 mm/m). Correct any deviations which might have occurred under
the load of the components using the levelling screws.
5. Spot-drill the holes for the bonded anchors.
6. Lift the baseplate again.
7. Finish-drill and clean the holes.
8. Insert the bonded anchors.
9. Allow time for curing of the bonded anchors. Then place the baseplate onto the
levelling screws and align the baseplate using the screws. Check the alignment
in relation to the foot supporting surfaces both parallel to and 90° to the
foundation centreline using a spirit level (accuracy < 0.3 mm/m).

5.10.3 Securing the baseplate with special foundation bolts

1. Lift the baseplate.
2. Place the special foundation bolts into the baseplate holes and screw on the
nuts until the bolt thread projects by about 10 mm.
If the crane hook height is not sufficient, insert the special foundation bolts

CHTR 33 of 168
 5 Installation at Site

from the foundation side through the special foundation bolt holes into the
baseplate holes and screw on the nuts until the bolt thread projects by about 10
mm.
3. Place the baseplate onto the levelling screws and align the baseplate using the
screws. Check the alignment in relation to the foot supporting surfaces both
parallel to and 90° to the foundation centreline using a spirit level (accuracy <
0.3 mm/m). The foundation bolts must hang freely in the foundation holes.
4. Set the pump set components which are not mounted on the baseplate in place
on the baseplate as described in the manufacturer’s product literature. If
coupling hubs are mounted on the pump set components, the markings on the
coupling parts to be connected must be identical.
5. Check the baseplate alignment once again in relation to the foot supporting
surfaces both parallel to and 90° to the foundation centreline using a spirit level
(accuracy < 0.3 mm/m). Correct any deviations which might have occurred under
the load of the components using the levelling screws.
6. Fasten the plates and nuts of the special foundation bolts at the bottom side of
the foundation to the special foundation bolts.
The plates for the special foundation bolts must rest evenly on the foundation.
7. Tighten the nut of the special foundation bolts. Refer to the general
arrangement drawing for bolt tightening torque.

5.11 General information for alignment

DANGER
Impermissible temperatures at the coupling or bearings caused by misalignment of
the coupling
Explosion hazard!
▷ Make sure that the coupling is correctly aligned at all times.

WARNING
Improper coupling alignment
Overloading or destruction of coupling!
Risk of injury from parts flying off!
▷ Align the coupling properly.
▷ When performing alignment, take into account any thermal expansion of the
machines to be coupled.

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.

CAUTION
Increased wear due to dry running
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▪ Align the pump set components in accordance with the manufacturer’s product
literature.
▪ Coupling alignment starts with the drive which is the reference point for aligning
all other pump set components.
The pump is the last component to be aligned.
Exception:

34 of 168 CHTR
5 Installation at Site

Pumps equipped with feet underneath the pump body which are already fitted
and pinned to the baseplate cannot be aligned laterally. In this case the pump is
the reference point for alignment of the other pump set components; the drive is
the last component to be aligned.
▪ In the case of motors with axial tolerance, their rotors must be placed in the
magnetic centre as described in the manufacturer’s documentation. This rotor
position must not be altered during the full duration of alignment work.

Fig. 18: Pump rotor position

▪ Move the pump shaft towards the suction casing until the rotor abuts.
▪ Check the distance between the coupling hubs for compliance with the general
arrangement drawing and adjust it, if required.

Fig. 19: Fit spacer plates

▪ If using gear couplings, fasten the coupling sleeves with spacer plates (included
with the supply) to the hubs.

5.12 Checking the coupling alignment

DANGER
Impermissible temperatures at the coupling or bearings caused by misalignment of
the coupling
Explosion hazard!
▷ Make sure that the coupling is correctly aligned at all times.

5.12.1 Checking the coupling hubs for run-out

CAUTION
Incorrect measurement results and damage to the alignment device
Coupling misalignment!
Damage to the pump set!
▷ Never turn the coupling by means of the alignment device.

CHTR 35 of 168
 5 Installation at Site

5.12.1.1 Coupling hubs with outside step

Fig. 20: Run-out check with outside step (example)

Check each coupling hub for run-out using a dial gauge.
The run-out must not exceed 0.03 mm; if it is exceeded, contact KSB.

5.12.1.2 Coupling hubs without outside step

Fig. 21: Run-out check without outside step (example)

Check each coupling hub for run-out using a dial gauge.
The run-out must not exceed 0.03 mm; if it is exceeded, contact KSB.

5.12.2 Checking the coupling alignment with a dial gauge

Perform the alignment with dial gauges in accordance with the manufacturer’s
product literature.

Fig. 22: Checking the alignment of a coupling with spacer (example)

A Coupling hub used as a reference B Coupling hub to be aligned
point for alignment

36 of 168 CHTR
5 Installation at Site

A B
Fig. 23: Checking the alignment of a coupling without spacer (example)
A Coupling hub used as a reference B Coupling hub to be aligned
point for alignment

5.12.3 Checking the coupling alignment with a laser device

Coupling alignment can optionally be checked using a laser device.
To this end observe all warnings in the laser manufacturer’s operating instructions.

5.12.4 Permissible misalignment of pump and drive

The high temperature of the fluid handled and the fact that the pump set
components heat up during operation cause displacements of the coupling hub in
different directions. Such displacements must be taken into consideration when
aligning the cold pump set components at the coupling.
Always observe the radial displacement and angular misalignment as well as the axial
distance indicated by the coupling manufacturer.

5.12.4.1 Radial displacement

Va

VR

Fig. 24: Radial displacement (example)

The radial displacement VR must not deviate more than 0.03 mm from the nominal
value, measured at a distance of 90°.

CHTR 37 of 168
 5 Installation at Site

5.12.4.2 Angular misalignment

SMax.
Va
SMax. - SMIN
VW =
2

VR

SMin.

Fig. 25: Angular misalignment (example)

The angular misalignment Vw is calculated according to the equation. Observe the
permissible values indicated by the coupling manufacturer.

5.12.4.3 Axial distance

The axial distance Va of the different coupling types varies. Refer to the general
arrangement drawing and the manufacturer's product literature for the permissible
tolerances.

5.13 Alignment Corrections on the Pump

5.13.1 Correcting the height of the pump

The height correction is performed by means of shims underneath the pump feet.

Fig. 26: Height correction using shims (example)

1 Pump foot 2 Nut
3 Disc 4 Shims
5 Stud 6 Baseplate

38 of 168 CHTR
5 Installation at Site

5.13.2 Lateral correction of the pump

1 2 3

Fig. 27: Lateral correction - centreline pump feet

1 Guide casing 2 Nut
3 Adjusting screw
1. Loosen the nuts (2) of the bolts used for fastening the feet.
2. Perform the lateral correction using the adjusting screws (3).
3. Do not yet tighten the nuts (2) of the adjusting screws (3) and fastening bolts
firmly because coupling alignment still has to be repeated several times.

5.13.3 Correcting the alignment of the pump set components

The alignment corrections on the other pump set components shall be performed in
accordance with the relevant manufacturer’s product literature.

5.14 Drilling the holes for fastening the feet

If the baseplate is not provided with tapped holes for fastening the pump set
components, use the holes in the feet of the pump set components as templates.
Because of the thermal expansion of the pump and the associated displacement of
the pump feet, the position of the holes must be marked accordingly.

Fig. 28: Position of the fastening studs on the pump feet

1 Centre of foot (drive end) 2 Centre of foot (non-drive end)
3 Stud 4 Hole in pump foot
✓ Pump set component is positioned on the baseplate
1. Use the holes in the feet of the pump set components as template.
2. Determine the position of the holes. Pay attention to offset between stud and
hole in the pump foot.
3. Drill the holes.

CHTR 39 of 168
 5 Installation at Site

5.15 Fastening the baseplate to the foundation

5.15.1 Securing the baseplate with foundation bolts

1. Grout the foundation bolt holes with non-shrinking concrete, compressive
strength class C 25/30, grain size ≤ 8 mm (see Appendix (⇨ Section 9.2.7 Page
127) ).
Produce flowability with the help of a solvent.
2. When the grouting compound has set (setting time as indicated by
manufacturer), tighten the nuts of the foundation bolts with the tightening
torque given in the general arrangement drawing.
3. Check coupling alignment and re-align, if necessary.
4. Grouting the baseplate with concrete:
- Prepare the concrete shuttering for the baseplate and foundation pedestals up
to the planned grouting height as shown in the general arrangement drawing.
- Make provisions for the grouting compound to bond with the foundation
concrete.
- Fill at least 1/3 of each field of the baseplate with non-shrinking grouting
compound (e.g. Pagel concrete grout), minimum compressive strength class C
25/30, grain size ≤ 8 mm. The remaining 2/3 of the fields may be filled with
standard concrete of this quality. KSB recommends that all fields be completely
grouted with non-shrinking concrete grout. Produce flowability with the help
of a solvent. Complete grouting without major interruptions.
- In order to avoid cavities, the grouting compound must be compacted.
5. When the grouting compound has set, check the nuts of the foundation bolts
for tight fit once again using a torque wrench.
Observe the tightening torque!
6. Check coupling alignment and re-align, if necessary.

5.15.2 Securing the baseplate with bonded anchors

1. After the curing of the bonded anchors , tighten the nuts of the bonded
anchors with the tightening torque given in the general arrangement drawing.
2. Check coupling alignment and re-align, if necessary.
3. Grouting the baseplate with concrete:
- Prepare the concrete shuttering for the baseplate and foundation pedestals up
to the planned grouting height.
- Make provisions for the grouting compound to bond with the foundation
concrete.
- Fill at least 1/3 of each field of the baseplate with non-shrinking grouting
compound (e.g. Pagel concrete grout), minimum compressive strength class C
25/30, grain size ≤ 8 mm. The remaining 2/3 of the fields may be filled with
standard concrete of this quality. KSB recommends that all fields be completely
grouted with non-shrinking concrete grout. Produce flowability with the help
of a solvent. Complete grouting without major interruptions.
- In order to avoid cavities, the grouting compound must be compacted.
4. When the grouting compound has set, check the nuts of the bonded anchors
for tightness once again using a torque wrench.
Observe the tightening torque!
5. Check coupling alignment and re-align, if necessary.

5.15.3 Securing the baseplate with special foundation bolts

1. Fill the special foundation bolt holes with dry sand.
2. Insulate the special foundation bolts in the area between the upper edge of the
foundation and the lower edge of the baseplate with Styrofoam or a similar
material.
3. Grouting the baseplate with concrete:
- Prepare the concrete shuttering for the baseplate and foundation pedestals up
to the planned grouting height as shown in the general arrangement drawing.

40 of 168 CHTR
5 Installation at Site

- Fill at least 1/3 of each field of the baseplate with non-shrinking grouting
compound (e.g. Pagel concrete grout), minimum compressive strength class C
25/30, grain size ≤ 8 mm. The remaining 2/3 of the fields may be filled with
standard concrete of this quality. KSB recommends that all fields be completely
grouted with non-shrinking concrete grout. Produce flowability with the help
of a solvent. Complete grouting without major interruptions.
- In order to avoid cavities, the grouting compound must be compacted.
4. When the grouting compound has set, check the nuts of the special foundation
bolts for tightness once again using a torque wrench. Observe the tightening
torque!
5. Check coupling alignment and re-align, if necessary.

5.16 Piping

DANGER
Improper connection of auxiliary lines
Explosion hazard from escaping leakage or fluid!
▷ Correctly install the auxiliary lines.
▷ Observe the maintenance and monitoring schedules.

5.16.1 Prerequisites
▪ The pump set has been earthed.
▪ The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
▪ With short pipelines, the nominal diameters should be at least equal to the
nominal diameters of the pump nozzles. For long pipelines, the most economical
nominal diameter has to be determined from case to case.
▪ Adapters to larger diameters should have a diffuser angle of approximately 8° in
order to avoid any pressure losses caused by the formation of air pockets.
▪ The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
▪ The general arrangement drawing shows which pipes, valves and instruments are
included in our scope of supply and how they are arranged.
▪ All pipes in the baseplate area have been completely mounted at the factory.
▪ Make and adapt any possibly required connecting pipes in accordance with the
general arrangement drawing (offset at flange connections and pipe unions is
not permitted.).
▪ Pipes supplied by KSB have been cleaned and closed. Nevertheless their interior
must be checked for impurities which might have been caused afterwards and be
cleaned, if required.
▪ As a general rule, pipes made on site must be cleaned prior to final mounting.
▪ Do not remove blind flanges or covers on pump nozzles and pipe connections
including any packaging with desiccants possibly attached to them until
immediately before the relevant pipes are connected.

CHTR 41 of 168
 5 Installation at Site

5.16.2 Cleaning the piplines

CAUTION
Solids inside the pump or in the pipelines.
Increased wear or blockages!
▷ When flushing the piping, the pump must as a rule be protected against
welding beads, scale and other impurities.
▷ Use pipe bypasses or filters to prevent solids from entering the pump.

CAUTION
Cleaning with a high-pressure steam-jet air ejector
Destruction of plastic parts through high-pressure steam-jet air ejector.
▷ Never clean the cooling circuit with a high-pressure steam-jet air ejector.
Permissible cleaning methods:
▪ The pipes may be blown through with compressed air.
▪ If the pipes have been welded with forming gas, they may be cleaned using a
high-pressure steam-jet air ejector at a steam temperature of at least 110 °C.

5.16.3 Cleaning the oil pipes

WARNING
Fluids posing a health hazard
Hazard to persons and the environment!
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
▷ Observe the relevant safety instructions for the handling of hazardous
substances (wear protective clothing and mask, if required).

CAUTION
Caustic damage to auxiliary systems
Leaks on flexible pipe parts!
▷ Never pickle flexible pipe parts.
Pickle oil pipes with dilute hydrochloric acid.
Neutralise oil pipes with a 0.5 % soda solution (500 g of soda/100 l of water).
Composition of the pickling solution for 100 litres:
▪ 30 l of concentrated hydrochloric acid (37% concentration)
▪ 70 l of water
▪ Temperature: Ambient temperature
1. Screw off the oil pipes and close one side.
2. Fill the pipes with the pickling solution and allow it to react until the inside pipe
surfaces are cleaned to bright metal, however 4 hours as a maximum.
After this procedure there must be no rust or scale particles left; remove
tenacious scale residues, if any, using a bottle brush.
3. Drain the pipes and flush them thoroughly with cold water.
4. Neutralise any possibly existing acid residues by filling the pipes with a soda
solution in a 0.5 % concentration.
5. After about 1 or 2 hours drain the pipes and flush them thoroughly with cold
water.
6. Immediately blow hot air through the pipes and dry them.
7. Immediately afterwards coat the pipes with the oil intended for this purpose,
for example by spray-coating, or filling and subsequent draining.

42 of 168 CHTR
5 Installation at Site

5.16.4 Fitting a strainer/filter

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

NOTE
The strainer in the inlet line is destined to stop welding beads, scale and other
impurities (that come off the piping with time) from entering the pump. It is not
destined to remove any inadmissible particles entrained in the fluid handled due to
an excessive solids content.
For installing the strainer refer to the manufacturer's product literature.

CAUTION
Improper transport of strainers/filters
Damage to the strainer/filter through lifting tackle!
▷ Do not exert pressure on the strainer element and strainer meshes or damage
them.
▷ Transport pump set accessories by hand, if possible. If this is not an option
because of the weight, observe the transport options described in this manual.
1. Prior to installation, perform a visual inspection of the inlet pipe between
strainer and pump. Clean it, if required.
2. Install the strainer in the inlet line as close to the pump nozzle as possible.
3. For differential pressure monitoring a drilled hole is provided upstream and
downstream of the strainer insert or at the strainer housing.

Fig. 29: Fitting a strainer/filter

A Inlet line B Suction line, pump
C Connection, differential pressure D Strainer housing
monitoring
H approx. 300 mm

CHTR 43 of 168
 5 Installation at Site

5.16.5 Minimum flow system

Minimum flow system
1. Arrange the minimum flow system (if applicable) as shown on the P + I diagram.
2. Perform the installation as described in the manufacturer’s product literature.

Minimum flow valve

1. Fit the minimum flow valve (if applicable) to the pump’s discharge nozzle as
stated in the manufacturer’s product literature.

5.16.6 Connecting the piping

DANGER
Impermissible loads acting on the pump nozzles
Danger to life from leakage of hot, toxic, corrosive or flammable fluids!
▷ Do not use the pump as an anchorage point for the piping.
▷ The pipelines have been anchored in close proximity to the pump and
connected without transmitting any stresses or strains.
▷ Observe permissible forces and moments at the pump nozzles.
▷ Take appropriate measures to compensate 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
It is recommended to install check and shut-off elements in the system, depending
on the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the
suction and discharge nozzles of the pump.

CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Free the piping from any impurities.
▷ If necessary, install a filter.
▷ Comply with the instructions set out in (⇨ Section 5.16.4 Page 43) .

44 of 168 CHTR
5 Installation at Site

CAUTION
Inadmissible forces at the flange connections
Overloaded pump nozzles and leakage!
▷ It must be possible to insert all bolts of the flange into their respective holes
and to remove them without becoming bolt bound (off-set holes).
▷ It must be possible to bring the pipes into their mounting position with one
hand.
▷ It must be possible to prise apart the pump nozzle flanges by approx. 300 mm.
(Fitting the flange seal)
▷ Never use flange bolts to tighten the flanges.
3. If the flange seal has not yet been fitted, insert flange seal. For this purpose, use
an appropriate tool to prise apart the flanges in order to fit the flange seal.
4. Connect the pump nozzles with the piping.

CAUTION
Aggressive flushing and pickling agents
Damage to the pump!
▷ Match the cleaning operation mode and duration for flushing and pickling
service to the casing and seal materials used.

5.16.6.1 Permissible forces and moments at the pump nozzles

See the general arrangement drawing.

5.16.6.2 Vacuum balance line (if applicable)

NOTE
Where fluid has to be pumped out of a vessel under vacuum, it is recommended to
install a vacuum balance line.

The following rules apply to vacuum balance lines:

▪ Minimum nominal line diameter 25 mm.
▪ The line extends above the highest permissible fluid level in the vessel.

CHTR 45 of 168
 5 Installation at Site

1 2 3 4

5 6
Fig. 30: Vacuum balance system
1 Vessel under vacuum 2 Vacuum balance line
3 Shut-off element 4 Swing check valve
5 Main shut-off element 6 Vacuum-tight shut-off element

NOTE
An additional line (from the pump discharge nozzle to the balance line) fitted with
a shut-off element facilitates venting of the pump before start-up.

5.16.7 Bypass and balancing lines

CAUTION
Impermissible piping layout
Damage to the balancing system
▷ When installing the bypass line and the balancing line, the minimum flow
diagram and/or P + I diagram must be observed.
▷ Install an orifice immediately ahead of the inlet vessel to avoid vaporisation.

5.17 Electrical connection

DANGER
Incorrect electrical installation
Explosion hazard!
▷ For electrical installation, also observe the requirements of IEC 60079-14.
▷ Always connect explosion-proof motors via a motor protection switch.

DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

46 of 168 CHTR
5 Installation at Site

WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method.

NOTE
A motor protection device is recommended.

5.17.1 Earthing

DANGER
Electrostatic charging
Explosion hazard!
Fire hazard!
Damage to the pump set!
▷ Connect the PE conductor to the earthing terminal provided.

5.17.2 Connecting the motor

NOTE
In compliance with IEC 60034-8, three-phase motors are always wired for clockwise
rotation (looking at the motor shaft stub).
The pump's direction of rotation is indicated by an arrow on the pump.
1. Match the motor's direction of rotation to that of the pump.
2. Observe the manufacturer's product literature supplied with the motor.

5.18 Final installation of the pump set

▪ Check coupling alignment and re-align, if necessary.
Consider height and lateral displacements in accordance with the assembly
sketch. (⇨ Section 9 Page 121)
If the connection of the pipe has altered the pump set’s alignment, the pipe is
not free from stresses or strains.
▪ Record the final measurement results in the coordinate system of the alignment
data sheet/transfer log of the coupling.

5.18.1 Fastening the pump feet

1. Tighten the nuts on the suction side/drive end in accordance with the
specifications on how to fasten the pump feet. Observe the tightening torque!
2. Tighten the nuts on the discharge side/non-drive end so that the discs may still
be moved by means of slight hammer blows.
3. Lock all nuts using an additional nut.
4. Tighten the adjusting screws on the guide casing.

CHTR 47 of 168
 5 Installation at Site

5.18.2 Pinning the pump feet

Fig. 31: Pinning the pump feet

If the pump feet have not been pinned at the factory, the holes for the parallel pins
C have to be drilled at the place of installation and the parallel pins must be fitted.
▪ The other pump set components shall be fastened and pinned as described in the
relevant manufacturer’s product literature.
▪ Have the tightening torques of all fastening bolts and foundation bolts checked
and confirmed by the responsible site management.
▪ Have the alignment data sheet/transfer log confirmed by the responsible site
management.

5.19 Installing or connecting the measuring instruments

DANGER
Lack of necessary monitoring and alarm equipment
Failure of pressurised components!
Explosion hazard
Risk of injury in the event that the hot, pressurised fluid handled escapes!
▷ Mount the monitoring and alarm equipment necessary to ensure operating
reliability.

General
▪ Choose a pressure gauge with an adequate measuring range!
▪ Do not remove the screwed plugs of the connection points until immediately
before mounting.
Pressure gauges
▪ Insert the sealing washer and screw the pressure gauge into place with a
clamping nut.
Thermometer (bearing)
▪ Insert the seal element. Screw in the thermometer.
Oil sight gauge or constant-level oiler
▪ Screw in the oil sight gauge or constant-level oiler including sealing tape or
liquid seal. Lengthening pieces, if required, are included in the delivery.
Resistance thermometer or thermocouple
▪ When installing standard resistance thermometers observe the assembly
instructions. (⇨ Section 9 Page 121)
▪ For the feeler length and the threaded connection required for the respective
measuring point, please refer to the list of measuring points and check the
length at the place of installation.
▪ Insert the seal element. Screw in the resistance thermometer or thermocouple.

48 of 168 CHTR
5 Installation at Site

▪ Run the electric connecting cables in cable conduits until just before reaching the
measuring point and have them connected by authorised personnel.
Differential pressure monitoring
1. Fasten the differential pressure monitoring equipment to the holder provided
on the baseplate.
2. Fasten the instrument leads at the intended connection points and install them
according to the constraints on site.
3. Run the electric connecting cables in cable conduits until just before reaching
the measuring point and have them connected by authorised personnel.
Vibration sensors and shaft trajectory measurement
1. For information on the sensor for the respective measuring point, please refer
to the list of measuring points and check at the place of installation.
2. Install in accordance with the manufacturer’s instructions.
3. Run the electric connecting cables in cable conduits until just before reaching
the measuring point and have them connected by authorised personnel.

5.20 Preservation for standstill

If the pump is not commissioned immediately after its installation, carry out the
measures for preservation.

CHTR 49 of 168
 5 Installation at Site

5.21 Check list for installation

NOTE
The manufacturer’s product literature is binding for all work performed on the
pump/set

NOTE
Items on this check list that are not found in the instruction manual do not apply.

Table 12: Checklist for installation

Steps Work required Comments:
1 Check the supplied pump/pump set(s) and
accessories for completeness and damage
incurred in transit; (⇨ Section 3 Page 14)
(⇨ Section 5 Page 27)
2 Check the condition and dimension of the
foundation for compliance with the general
arrangement drawing; (⇨ Section 5 Page 27)
3 Pre-align the foundation (adjusting screws/
shims); (⇨ Section 5 Page 27)
4 Mount the foundation bolts on the baseplate.
4a Mount the anchor bolts; (⇨ Section 5 Page 27)
5 Place the baseplate and readily mounted
components of the set onto the foundation;
(⇨ Section 5 Page 27)
6 Mount the drive; (⇨ Section 5 Page 27)
7 Pre-align the components; (⇨ Section 5 Page 27)
8 Grout the foundation bolts.
8a Grout the anchor bolts.
9 Allow the concrete to set; (⇨ Section 5 Page 27)
10 Align the pump set components; (⇨ Section 5
Page 27)
11 Tighten the anchor bolts; (⇨ Section 5 Page 27)
12 Grout the baseplate; (⇨ Section 5 Page 27)
13 Mount all pipes, valves, fittings; (⇨ Section 5
Page 27)
14 Check the parallelism for all pipe connections;
(⇨ Section 5 Page 27)
15 Fine align all components making up the set(s)
using dial gauge with 0.1 mm scale divisions.
Record readings in KSB alignment record;
(⇨ Section 5 Page 27)
16 Pin the pump (set) to the baseplate; (⇨ Section 5
Page 27)
17 Check the variable spring hanger for proper
functioning, remove locking device; (⇨ Section 5
Page 27)

50 of 168 CHTR
6 Commissioning/Start-up/Shutdown

6 Commissioning/Start-up/Shutdown

6.1 User information

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

6.2 General information

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.

DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained electrician.
▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof models,
EN 60079.
▷ The pump set's electrical equipment must comply with the general
requirements of the EN 60204-1 standard.

6.3 Work to be carried out prior to commissioning/start-up

6.3.1 Removing the preservation

WARNING
Fluids, consumables and supplies which are hot or pose a health hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

6.3.1.1 Internal preservation

If the pump has been filled with a glycol/water mixture for preservation, this mixture
has to be drained prior to any further work.

CHTR 51 of 168
 6 Commissioning/Start-up/Shutdown

NOTE
Observe the manufacturer's instructions for application/removal of the preservative.

✓ A container for collecting the preservative is on hand.

1. Open the drain (6B) of the pump.
2. Drain the pump.
3. Collect the drained fluid in a suitable container and dispose of it in accordance
with the environmental regulations.
4. Close the drain (6B) of the pump.
5. Flush the pump sufficiently to remove all residues of the preservative.
6. Remove the grease on the outsides of all pump set components.

6.3.1.2 External preservation

Remove the preservation of the pump set components in accordance with the
relevant manufacturer’s product literature.
1. Clean the preserved exterior parts using appropriate cleaning agents.

6.3.2 Work to be carried out prior to restart after standstill > 12 months
1. Dismantle the pump-end coupling hub.
2. Dismantle the bearings.
3. Remove the mechanical seal and check it in accordance with the manufacturer’s
product literature.
If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise
a new mechanical seal must be installed.
4. Re-mount the bearings and lift the pump rotor if the pump is equipped with
plain bearings.
5. Re-mount the pump-end coupling hub.

6.3.3 Connecting the oil mist lubrication (if applicable)

Connect the oil mist lubrication, see chapter 9.

6.3.4 Flushing the lube oil circuit with oil (if applicable)

DANGER
Ignition of lubricant leakage on hot pump surfaces
Explosion hazard!
▷ The ignition temperature of the lubricant should exceed the maximum surface
temperature of the pump by at least 50 K.

Oil quality When operating the pumps in potentially explosive atmospheres, lubricants have to
be selected whose ignition temperature / flash point exceeds the maximum surface
temperature of the pump by at least 50 K. Recommended oil quality (⇨ Section 9
Page 121)

52 of 168 CHTR
6 Commissioning/Start-up/Shutdown

CAUTION
Incorrect commissioning/start-up
Damage to the bearings!
▷ Do not perform oil flushing until immediately before commissioning/start-up.
▷ If commissioning/start-up is delayed by more than one month, repeat the oil
flushing.
1. Dismantle the pump-end coupling hub.
2. Dismantle the bearings.
3. For oil flushing, mount the bearing housings including existing labyrinth rings
and the thrower, but without internal bearing parts (bearing shell, bearing
segment carriers, thrust bearing plate, etc.).
4. Check whether all connections on the bearing housings and covers are closed
with plugs.
5. Mount the coupling cover, if applicable.
6. Check all the connection points of the oil circuit; connect and seal if required.
7. Close the oil supply ports of the coupling cover, if applicable.
8. Fully open all throttle valves in the oil supply pipes.
9. Switch on the oil supply unit or auxiliary oil pump and check for leakage.
10. Check the oil flow at the oil sight gauge in the oil return lines.
11. Check the oil level of the oil reservoir and top up, if required.
When the cooling circuits and pipes are filled and vented, the oil level shall be
in the middle between the minimum and maximum mark of the oil sight
gauges.
12. Change over and clean the filters of the oil circuits frequently, see the
manufacturer’s catalogue.
13. Switch off the oil supply unit or auxiliary oil pump when the oil filters are free
from dirt for at least eight hours.
14. Check the oil quality. If required, clean or replace the oil.
15. Re-install the pump bearings and lift the pump rotor.
16. Re-mount the pump end coupling hub.

6.3.5 Filling in lubricants (if applicable)

DANGER
Ignition of lubricant leakage on hot pump surfaces
Explosion hazard!
▷ The ignition temperature of the lubricant should exceed the maximum surface
temperature of the pump by at least 50 K.

CAUTION
Incorrect oil level in bearing housing
Damage to the pump!
▷ Check the oil level only during standstill of the pump!

CHTR 53 of 168
 6 Commissioning/Start-up/Shutdown

CAUTION
Unsuitable time for flushing with oil
Damage to the bearings!
▷ Do not perform oil flushing of the oil lines until immediately before
commissioning/start-up.
▷ If commissioning/start-up is delayed by more than one month, repeat the oil
flushing.

General information
▪ During operation, the oil level in the bearing housing drops.
▪ An excessive oil level leads to a temperature rise and to leakage of the fluid
handled or oil.
▪ An inadequate oil level results in insufficient lubrication and bearing damage.
▪ Refer to the technical specifications section for the oil quantity/quality.
▪ Filter the oil prior to filling it in; filter mesh size 30 µm.
▪ After a standstill of more than 12 months, check the quality of the oil. Clean or
replace the oil if necessary.
▪ Fill the pump set components with lubricant in accordance with the
manufacturer’s product literature.
▪ Observe the permissible ambient temperatures. (⇨ Section 6.7.2 Page 68)
For recommended oil quality, oil quantity and oil change intervals refer to: (⇨ Section
9.2.8 Page 128)

6.3.5.1 Oil sight gauge

1. Remove vent plug 913 with gasket 400.05.
2. Fill oil through the opening until the oil level is between the minimum and
maximum marks of the oil sight gauge 639.
3. Re-insert vent plug 913 with gasket 400.05.

6.3.5.2 Constant-level oiler

Fig. 32: Constant-level oiler

✓ The constant-level oiler is fitted in the bearing housing on the relevant side (see
figure Constant-level oiler).
1. Remove vent plug 913 with gasket 400.05.
2. Press together clamp on constant-level oiler 638 and pull the reservoir of the
constant-level oiler upwards.

54 of 168 CHTR
6 Commissioning/Start-up/Shutdown

3. Fill the reservoir of constant-level oiler 638 with oil and return it to its operating
position.
4. Re-insert vent plug 913 with gasket 400.05.
5. After a short time check whether the oil level in the reservoir has dropped.
It is important to keep at least one third of the reservoir filled at all times. If the
oil level is too low, top it up with oil.

6.3.6 Checking the direction of rotation

DANGER
Temperature increase resulting from contact between rotating and stationary
components
Explosion hazard!
Damage to the pump set!
▷ Never check the direction of rotation by starting up the unfilled pump set.
▷ Separate the pump from the motor to check the direction of rotation.

CAUTION
Pump and motor running in the wrong direction of rotation
Damage to the bearing and shaft seal!
▷ Pay attention to the rotation arrow on the drive end bearing housing.
▷ The direction of rotation of the drive must correspond to the direction
indicated in the general arrangement drawing.
If the pump set is driven by an electric motor, the direction of rotation of the motor
must be checked prior to commissioning/start-up.
Prerequisites
▪ Check the direction of rotation prior to the final assembly of the coupling (motor
alone is running).
▪ Observe the manufacturer’s documentation.
▪ The electric motor is provided with a lubricant.

6.3.6.1 Checking the direction of rotation with a phase-sequence indicator

The direction of rotation of the motor can be checked by means of an
electromagnetic phase-sequence indicator.

6.3.6.2 Checking the direction of rotation without phase-sequence indicator

DANGER
Mistake in the electrical connections
Danger of death from electric shock!
Short circuit, motor damage or pump is running in the wrong direction!
▷ Mark the connections in the terminal box.

WARNING
Starting of the motor for checking the direction of rotation
Risk of injury due to contact with unprotected or rotating parts or parts flying off!
▷ Remove or fasten any movable parts on the motor shaft.
▷ Never touch any unprotected, rotating parts.

CHTR 55 of 168
 6 Commissioning/Start-up/Shutdown

CAUTION
Incorrect axial clearance
Damage to the bearings!
▷ In the case of electric motors with axial tolerance, re-align the motor shaft
coupling hub in line with the actual magnetic centre, if required. If the coupling
has a spacer, it must be possible to mount and remove it.

Fig. 33: Installing the spacer plates (example)

1. In the case of toothed couplings, fix the drive-end coupling sleeve on the hub
using spacer plates (supplied loose).
2. Have the electric motor switched on by authorised personnel for a short period
of time.
3. Have the electric motor switched off again immediately before the operating
speed is reached.
4. Check the direction of rotation. If necessary, have the terminal connections
reversed by authorised personnel and check the direction of rotation once
again.

WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
5. Secure the drive against unintentional start-up.

6.3.7 Rotatability of the pump rotor

Fig. 34: Rotatability of the pump rotor

A approx. 150 mm
▪ In the case of toothed couplings, fix the pump-end coupling sleeve on the hub
using spacer plates (supplied loose).
▪ Prior to performing the work, check the oil level in the bearing housings.

56 of 168 CHTR
6 Commissioning/Start-up/Shutdown

▪ It must be possible to rotate the pump rotor by hand, and it may only be rotated
in the direction of rotation of the pump. If necessary, attach an appropriate tool
at the coupling hub.
▪ If the pump is fitted with a balance disc without lift-off device, move the pump
rotor towards the non-drive end by approx. 1 mm before you turn it by hand.

6.3.8 Mounting the coupling

✓ All installation work has been completed.
✓ The lubricant has been filled in/topped up.
✓ The direction of rotation has been checked and is correct.
1. Mount and align the spacer (if any) of the coupling as described in the
manufacturer’s product literature.
2. Connect coupling hubs to spacer sleeve. For this purpose, insert and tighten the
main assembly bolts.
Observe the tightening torques.

6.3.9 Fitting the protective equipment

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

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.
At the end of all preparatory work to be carried out for start-up, mount all protective
equipment (e.g. coupling guard, contact guard, etc.) and check for correct
functioning.
Operate the pump (set) only after all protective equipment has been fitted.

CHTR 57 of 168
 6 Commissioning/Start-up/Shutdown

6.3.9.1 Mounting the coupling guard

Fig. 35: Coupling guard (example)

1 Bottom plate 2 Foot fastening (lock strip)
1. Align the coupling guard over the coupling.
2. Make sure the distance to both shaft ends and the coupling components is
sufficient.
3. Fasten the lock strips of the coupling guard to the floor.
4. Fasten the bottom plate with the respective screws.

6.3.9.2 Mounting the coupling cover (if applicable)

WARNING
Risk of hot oil escaping as a result of an improperly mounted/dismantled coupling
cover
Risk of burns!
Damage to the coupling!
▷ Do not damage the seal elements and sealing surfaces.
▷ Never operate the coupling without a lubricant.
▷ Prior to putting the coupling into service, check the coupling cover for correct
installation and sealing.

Fig. 36: Coupling cover

1. Meticulously clean the locating and sealing surfaces.
2. Fit the gasket and O-ring.
3. Mount the lower coupling cover half and fasten it to the adapter.

58 of 168 CHTR
6 Commissioning/Start-up/Shutdown

Fig. 37: Adjusting the injection nozzles

4. Adjust the injection nozzles (see figure Adjusting the injection nozzles).
5. Coat the sealing surfaces of the cover flanges with a liquid, oil and temperature
resistant sealing agent (up to 120° C).
6. Use the eyebolt as a transport aid as shown in figure Coupling cover.
7. Fit the upper coupling cover half to the adapter.
8. Fix the upper and lower halves with 2 taper pins and fasten with screws.
9. Connect the pipes to the cover.

6.3.9.3 Fitting the contact guard for the shaft seal

Fasten the contact guard to the bearing housing by means of screws.

6.3.9.4 Mounting the sound insulating hood

If applicable, mount the sound insulating hood as described in the manufacturer’s
product literature.

6.3.10 Functional test and adjustment of the instruments

DANGER
Overload due to incorrectly set monitoring and alarm equipment
Seal failure!
Explosion hazard
Rick of injury resulting from leakage of hot or pressurised fluid.
▷ Connect and activate all monitoring and alarm equipment installed.
▷ Check all instruments in accordance with the manufacturer's product literature
for correct measuring data and adjust the instruments, if required.
▷ Set the warning and shutdown values in cooperation with control engineering
specialists.

6.3.11 Checking the shaft seal

DANGER
Improper connection of auxiliary lines
Explosion hazard from escaping leakage or fluid!
▷ Correctly install the auxiliary lines.
▷ Observe the maintenance and monitoring schedules.

CHTR 59 of 168
 6 Commissioning/Start-up/Shutdown

▪ Check the mechanical seal’s readiness for operation.

▪ Remove the assembly fixtures, if required.
▪ Check all the required connections are correctly fitted (see general assembly
drawing or seal manufacturer's product literature).
Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
Observe the manufacturer’s product literature.

6.3.12 Setting the lube oil supply (if applicable)

The functional test of the pressure switches is possible by throttling the valve even
during standstill of the pump.

CAUTION
Improper maintenance
Damage to the pump set!
Insufficient lubrication!
▷ Only make adjustments when oil operating temperature has been reached.
▷ No oil is allowed to escape between labyrinth ring (423) and shaft (210)!
1. Set the switching points of the pressure switches for switching the auxiliary oil
pump on and off as well as for enabling and switching off the drive.
2. Adapt the pre-drilled orifice plates on the lube oil outlets to the gear or
variable speed coupling and operate in accordance with the relevant
manufacturer's documentation.
3. Check the oil level and top up, if required.
4. Switch on the oil supply unit or auxiliary oil pump and check the oil pressure.
5. Adjust the throttle valves in the supply lines of the thrust and radial bearings of
the pump with the help of auxiliary pressure gauges.
6. Screw the auxiliary pressure gauges in the throttle valves.
7. Secure the adjustment of the throttle valves with locking screws.
8. Switch off the oil supply unit or auxiliary oil pump, remove the auxiliary
pressure gauges and close the connection carefully.

6.3.13 Priming the pump and piping

DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.

CAUTION
Increased wear due to dry running
Damage to the pump (set)/bearings!
▷ Never operate the pump set without liquid fill.
▷ Never operate the pump set in incompletely primed or incompletely vented
condition.
▷ Never close the shut-off element in the suction line and/or supply line during
pump operation.

60 of 168 CHTR
6 Commissioning/Start-up/Shutdown

✓ All preparatory measures have been completed.

1. Close all drains and drain lines.
2. Completely open the cooling water main valve and all cooling water throttle
valves.
3. Vent the entire cooling water circuit.
4. If applicable, vent the entire barrier fluid system of the mechanical seal.
5. Monitor the cooling water flow by means of sight glasses and/or flow
indicators.

NOTE
Do not cool down cooling chambers and heat exchangers with aggressive raw
water.

6. If fitted, check the filter in the barrier fluid system of the mechanical seal. Clean
it, if required.
7. Open the valves in the minimum flow system.
8. Check the oil levels and top up with oil, if required.
9. Fully open the valve in the inlet pipe.
10. Fill the inlet pipe, pump and discharge pipe with the fluid handled. If the
discharge pipe is equipped with a check valve, the shut-off element in the
discharge pipe may remain open as long as there is some back pressure.
11. Vent all pressure gauge lines until there is no more air to escape.
12. Fully open the shut-off element in the inlet pipe.
13. Check whether inlet pressure is available.

NOTE
For design-inherent reasons, the existence of some spaces not filled with liquid after
the pump has been filled prior to commissioning cannot be excluded. However,
once the drive is started up the pumping effect will immediately fill these spaces
with the fluid handled.

6.4 Commissioning/start-up

6.4.1 Prerequisites for commissioning/start-up

▪ Installation and alignment have been performed in accordance with good
engineering practice, recorded and accepted by the operator.
▪ The rotatability of the pump rotor has been checked.
▪ The drive has been checked in accordance with the manufacturer’s product
literature.
▪ The direction of rotation of the drive has been checked.
▪ All other pump set components have been checked in accordance with the
relevant manufacturer’s product literature.
▪ All contact guards preventing accidental contact have been mounted.
▪ All pipes have been cleaned and connected.
▪ All instruments have been fitted and checked for correct functioning.
▪ The pump, supply lines and circuits have been primed and vented.
▪ Monitor the bearing oil temperature. Make sure that the limits are not exceeded.
(⇨ Section 6.7.2 Page 68)

CHTR 61 of 168
 6 Commissioning/Start-up/Shutdown

6.4.2 Checks prior to commissioning/start-up

WARNING
Leakage caused by improper fitting of pipes and/or flanges
Risk of injury resulting from leakage of hot or pressurised fluid or vapour!
▷ Check all screws/bolts, screw/bolt and pipe connections as well as pipes and
flanges for leakage or damage prior to and during commissioning/start-up.
▷ Close all unused connections.
▪ Prior to and during starting of the pump check all connections, pipes, flanges,
screw/bolt connections and pipe unions for leakage and damage.
▪ All unused connections must be closed.
▪ The inlet vessel is in operational condition.
▪ The inlet line, pump and discharge line have been primed and vented.
▪ The shut-off element in the inlet line is fully open.
▪ The shut-off element in the discharge line is closed. If the discharge line is
equipped with a check valve, the shut-off element in the discharge line may
remain open as long as there is some back pressure.
▪ The connection for tapping, if applicable, is closed.
▪ The shut-off elements in the bypass line are open.
▪ The cooling water system is ON.
▪ The cooling liquid pressure at the inlet must not exceed 6 bar.
▪ The cooling liquid temperature at the outlet must not exceed 55 °C.
▪ All temperatures indicated are below the limit values.
▪ In the case of a pump set with variable speed coupling, check the scoop tube
position for compliance with the manufacturer’s product literature and re-adjust,
if required.
▪ Check all guards for correct fastening.
▪ Monitor the bearing oil temperature. Make sure that the limits are not exceeded.
(⇨ Section 6.7.2 Page 68)

6.4.3 Start-up and trial run

DANGER
Non-compliance with operating limits for pressure, temperature, fluid handled and
speed
Hot or toxic fluid could escape!
Explosion hazard!
▷ Comply with the operating data indicated in the data sheet.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures exceeding those specified in the data
sheet or on the name plate unless the written consent of the manufacturer has
been obtained.

WARNING
Sound pressure level above 85 dB(A) when starting up the pump set
Injury to or impairment of hearing!
▷ Wear ear protection.
▷ Access to the pump set is permitted to authorised specialist personnel only.
▷ Observe the applicable local occupational health and safety regulations.

62 of 168 CHTR
6 Commissioning/Start-up/Shutdown

WARNING
Failure of seal elements on suction and discharge nozzles and other pressurised
parts
Risk of personal injury in the event that hot, pressurised fluid handled escapes!
▷ Wear safety goggles.
▷ Check seal elements regularly.
▷ Access to the pump is permitted to authorised specialist personnel only.

WARNING
Hot surfaces - Pump and piping take on the temperature of the fluid handled.
Risk of burns!
▷ Do not touch hot surfaces.

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
Off-design operating data
Damage to the pump set by cavitation!
▷ The minimum discharge head of 150 m must not be underrun, except in the
start-up and stopping phase.
▷ The minimum speed of n = 1000 min-1 may only be underrun in the start-up and
stopping phase.
▷ The minimum speed (< 5 s) must be reached quickly.

NOTE
Should warning signals or problems occur during starting or trial run, proceed as
described in the chapter "Trouble-shooting"

6.4.3.1 Pump set with electric motor

1. Switch the drive on as described in the manufacturer’s product literature.
2. For pump set with variable speed coupling:
- The motor is running; due to the scoop tube position, the pump is operating
at a minimum speed of n = 1000 rpm or a minimum head of Hmin = 150 m.
- Switch on the cooling water (if applicable).
- Adjust the pump to minimum flow by changing the scoop tube position.
3. Check the temperature and smooth running of the bearings. Observe the
information given in "Interlock criteria for rolling element and plain bearings
and permissible vibrations at the bearing housings".
4. Check the pump pressures and differential pressures.
5. Monitor the minimum flow valve to make sure it works (hydrodynamic noise).
6. Check the mechanical seal. Mechanical seals must not drip.
7. Slowly open the shut-off valve of the discharge line until it is completely open.
When starting against an open shut-off valve in the discharge line, consider the
higher power input required.
8. Continuously monitor the pump set’s operating behaviour.

CHTR 63 of 168
 6 Commissioning/Start-up/Shutdown

9. For mechanical seals with circulation cooling:

- If a magnetic separator is available, check whether the temperature of the
circulation liquid remains constant after its commissioning/start-up.
- If a continuous venting system is not available, vent the mechanical seal circuit.

6.4.3.2 Turbine-driven pump set

CAUTION
Blocking of rotor
Damage to the rotor!
▷ In the event of a turning gear failure and pump standstill (n = 0 rpm), the pump
has to cool down until the pump casing temperature is ≤ 60 ℃ before it is
returned to service.
1. If a pump is primed with a fluid which has a temperature greater than 60° C, let
the pump casing cool down to 60° C.
2. Switch on the turning gear, if any, and observe the turbine manufacturer’s
instructions on starting of the pump set.
3. If pre-warming is provided, open the valve in the pre-warming line.
4. Switch on the cooling water (if applicable).
5. Check the temperature and smooth running of the bearings. Observe the
information given in "Interlock criteria for rolling element and plain bearings
and permissible vibrations at the bearing housings".
6. Check the pump pressures and differential pressures.
7. Monitor the minimum flow valve to make sure it works (hydrodynamic noise).
8. Check the mechanical seal. Mechanical seals must not drip.
9. Increase the pump speed until the operating speed is reached.
10. Slowly open the shut-off valve of the discharge line until it is completely open.
When starting against an open shut-off valve in the discharge line, consider the
higher power input required.
11. Continuously monitor the pump set’s operating behaviour.

64 of 168 CHTR
 6 Commissioning/Start-up/Shutdown

6.5 Checklist for commissioning/start-up

NOTE
The manufacturer’s product literature is binding for all work performed on the
pump/set

Table 13: Checklist for commissioning/start-up

Steps Work required Comments:
1 In the case of rolling element bearings, fill in
the oil to the level specified and fill the
constant level oiler.
2 Fill in oil. Flush oil filter; (⇨ Section 6 Page 51)
3 Adjust oil throttling valves (pressure, flow
rate); (⇨ Section 6 Page 51)
4 Check the direction of rotation of the drive;
(⇨ Section 6 Page 51)
5 Check the alignment; (⇨ Section 6 Page 51)
6 Mount coupling and coupling guard;
(⇨ Section 6 Page 51)
7 Check the strainer/filter in the suction pipe;
(⇨ Section 6 Page 51)
8 Prime and vent the system; (⇨ Section 6 Page
51)
9 Prepare the pump(s)/set(s) for operation,
ensure quantity of oil fills, check shaft seals,
start up auxiliary circuits; (⇨ Section 6 Page
51)
10 Check all instruments for proper functioning;
(⇨ Section 6 Page 51)
11 Set the oil flow to the correct flow rate;
(⇨ Section 6 Page 51)
12 Check and adjust all interlocking systems.
Check turning gear (active time: from pump
standstill until start of turning gear);
(⇨ Section 6 Page 51)
13 Check valve position. Check the minimum
flow valve; (⇨ Section 6 Page 51)
14 Start up pump set; (⇨ Section 6 Page 51)

6.6 Operation

6.6.1 Safety Instructions for Operation

DANGER
Non-compliance with the permissible pressure and temperature limits if the pump is
operated with the suction and/or discharge line closed.
Explosion hazard!
Leakage of hot or toxic fluids!
▷ Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷ Only start up the pump set with the discharge-side shut-off element slightly or
fully open.

CHTR 65 of 168
 6 Commissioning/Start-up/Shutdown

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 specified.
▷ Always operate the pump within the permissible operating range.

DANGER
Improper or no earthing
Risk of personal injury from electric shock!
Damage to the pump set!
▷ Ensure proper earthing of the pump set and check regularly.

WARNING
Excessive temperatures as a result of bearings running hot or defective bearing seals
Fire hazard!
Damage to the pump set!
▷ Regularly check the oil level and tightness of the bearings.
▷ Regularly check the temperature and smooth running of the bearings.

WARNING
Unprotected, rotating parts
Risk of injury from parts flying off!
Risk of injury by rotating shafts!
▷ Operate the pump set only after all protective equipment has been fitted.
▷ Never remove any guards while the pump is running.
▷ Regularly check all guards for correct fastening.

WARNING
Sound pressure level above 85 dB(A) when starting up the pump set
Injury to or impairment of hearing!
▷ Wear ear protection.
▷ Access to the pump set is permitted to authorised specialist personnel only.
▷ Observe the applicable local occupational health and safety regulations.

WARNING
Failure of seal elements on suction and discharge nozzles and other pressurised
parts
Risk of personal injury in the event that hot, pressurised fluid handled escapes!
▷ Wear safety goggles.
▷ Check seal elements regularly.
▷ Access to the pump is permitted to authorised specialist personnel only.

WARNING
Hot surfaces - Pump and piping take on the temperature of the fluid handled.
Risk of burns!
▷ Do not touch hot surfaces.

66 of 168 CHTR
6 Commissioning/Start-up/Shutdown

CAUTION
Excessive density of the fluid handled
Motor overload!
▷ Observe the information on fluid density in the data sheet.
▷ Make sure the motor has sufficient power reserves.

6.7 Operating limits

DANGER
Non-compliance with operating limits for pressure, temperature, fluid handled and
speed
Explosion hazard!
Hot or toxic fluid could escape!
▷ Comply with the operating data indicated in the data sheet.
▷ Never use the pump for handling fluids it is not designed for.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures, pressures or rotational speeds
exceeding those specified in the data sheet or on the name plate unless the
written consent of the manufacturer has been obtained.

6.7.1 Frequency of starts

DANGER
Excessive surface temperature of the motor
Explosion hazard!
Damage to the motor!
▷ In case of explosion-proof motors, observe the frequency of starts specified in
the manufacturer's product literature.

CAUTION
Excessive frequency of starts
Damage to the balancing device!
▷ Do not exceed the values for the frequency of starts.

CAUTION
Re-starting while motor is still running down
Damage to the pump (set)!
▷ Do not re-start the pump set before the pump rotor has come to a standstill.

NOTE
The values indicated for the frequency of starts apply to the pump only.
The frequency of starts is usually determined by the maximum temperature increase
of the motor. This largely depends on the power reserves of the motor in steady-
state operation and on the starting conditions (DOL, star-delta, moments of inertia,
etc). Observe the manufacturer’s instructions. (⇨ Section 9 Page 121)

▪ The permissible number of start-ups per day is 25.

▪ If the pump is fitted with a balance disc without lift-off device: max.15 starts per
day.
▪ In systems with more than one pump ensure an even distribution of the pump
operating hours (pump changeover).

CHTR 67 of 168
 6 Commissioning/Start-up/Shutdown

6.7.2 Ambient temperature

CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
▷ Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
Table 14: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 50 °C
Minimum - 20 °C
For operation at temperatures outside the permissible limits, contact KSB.
Bearing oil temperature The minimum permissible bearing oil temperature when starting the pump depends
upon the quality of oil used:

DANGER
Temperature increase due to insufficient lubrication
Explosion hazard!
Damage to the pump set!
▷ Always observe the minimum permissible bearing oil temperature when
starting the pump.

If lower bearing temperatures are expected, special bearings should be used.

Table 15: Bearing oil temperature
Oil quality Bearing oil temperatures
ISO – VG 32 10 °C
ISO – VG 46 15 °C

6.7.3 Fluid handled

6.7.3.1 Flow rate

The data refer to water and water-like fluids. Longer operating periods with these
fluids and at the flow rates indicated will not cause an additional increase in the
temperatures at the pump surface. However, if the physical properties of the fluids
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.
Flow rate Unless specified otherwise in the characteristic curves or data sheets, the following
applies:
Qmax. 1): See characteristic curves
Qmin. 2) = 0.3 x Qopt.3)

To = Tf + ΔT
gxH
ΔT = c x η x (1 - η)

Fig. 38: Calculation formula

1) Maximum permissible flow rate

2) Minimum permissible flow rate
3) Best efficiency point

68 of 168 CHTR
6 Commissioning/Start-up/Shutdown

Table 16: Key

Symbol Description Unit
c Specific heat capacity J/kg K
g Gravitational constant m/s2
H Head m
Tf Temperature of the fluid handled °C
To Temperature at the casing surface °C
η Pump efficiency at duty point -
ΔT Temperature difference °C

6.7.3.2 Density of the fluid handled

The pump input power changes in proportion to the density of the fluid handled.

CAUTION
Impermissibly high density of the fluid handled
Motor overload!
▷ Observe the information on fluid density indicated in the data sheet.
▷ Make sure the motor has sufficient power reserves.

6.7.3.3 Abrasive fluids

Do not exceed the maximum permissible solids content specified in the data sheet.
When the pump handles fluids containing abrasive substances, increased wear of the
hydraulic system and shaft seal are to be expected. In this case, reduce the commonly
recommended inspection intervals.

6.8 Measures to be taken for shutdown

CAUTION
Off-design operating data
Damage to the pump set by cavitation!
▷ The minimum discharge head of 150 m must not be underrun, except in the
start-up and stopping phase!
▷ The minimum speed of n = 1000 rpm may only be underrun in the start-up and
stopping phase.
▷ The minimum speed (< 5 s) must be reached quickly.

WARNING
Hot surfaces - Pump and piping take on the temperature of the fluid handled.
Risk of burns!
▷ Do not touch hot surfaces.

6.8.1 Shutdown with the pump set remaining ready for operation

6.8.1.1 Pump set with electric motor

1. Close the shut-off element in the discharge line. If the discharge line is
equipped with a check valve, the shut-off element in the discharge line may
remain open as long as there is some back pressure.
2. Make sure the minimum flow valve works.
3. For pump sets with variable speed coupling:
Reduce the speed until the minimum head or minimum speed is reached.
4. Switch off the drive, making sure it runs smoothly down to a standstill.

CHTR 69 of 168
 6 Commissioning/Start-up/Shutdown

5. Note the run-down time.

NOTE
The cooling water system remains ON!

6.8.1.2 Turbine-driven pump set with synchronised turning gear

CAUTION
Blocking of rotor
Damage to the rotor!
▷ In the event of a turning gear failure and pump standstill (n = 0 rpm), the pump
has to cool down until the pump casing temperature is ≤ 60 ℃ before it is
returned to service.
▪ If the speed of the pump set drops to the speed of the turning gear, the turning
gear takes over rotating of the rotor.
▪ The pre-warming unit (if any) remains in operation.
▪ The cooling unit (if applicable) remains in operation.

6.8.1.3 Turbine-driven pump set with non-synchronised turning gear

▪ Following standstill of the pump set (n = 0 rpm) the turning gear must take over
the turning of the rotor within a period of 10 seconds..

CAUTION
Blocking of rotor
Damage to the rotor!
▷ If the turning gear does not begin operation after a period of 10 seconds, the
pump has to cool down until the pump casing temperature is ≤ 60 ℃ before it is
returned to service.
▪ If it cannot be ensured that the turning gear turns the rotor within a period of 10
seconds after standstill of the pump set (n = 0 rpm), solenoid valves for example
have to be installed for the jacket cooling.
▪ If the pump set reaches a speed of n = 500 rpm, the solenoid valves, for example,
stop the jacket cooling.
▪ One minute after putting into service of the turning gear, the jacket cooling has
to be activated by means of solenoid valves, for example.
▪ The pre-warming unit (if any) remains in operation.
▪ Close the shut-off element in the discharge line. If the discharge line is equipped
with a check valve, the shut-off element in the discharge line may remain open
as long as there is some back pressure.
▪ Monitor the minimum flow valve to make sure it works.

NOTE
The cooling water system remains ON!

6.8.2 Shutdown for maintenance of the pump set or prolonged standstill

6.8.2.1 Pump set with electric motor

1. Close the shut-off element in the discharge line.
2. Monitor the minimum flow valve to make sure it works.

70 of 168 CHTR
6 Commissioning/Start-up/Shutdown

3. For pump sets with variable speed coupling:

Reduce the speed until the minimum head or minimum speed is reached.
4. Switch off the drive, making sure it runs smoothly down to a standstill.
5. Note the run-down time.

CAUTION
Unintentional starting of pump set
Damage to the shaft!
▷ Secure the drive against unintentional start-up, e. g. by disconnecting the
motor.
6. Close the shut-off valve in the minimum flow line.
7. Close the shut-off element in the inlet line.
8. Turn off the cooling water supply when the casing temperature (measured at
the pump nozzles) is lower than 50 °C.
9. Close all other pipes.

6.8.2.2 Turbine-driven pump set

✓ Observe the instructions concerning the turning gear. (⇨ Section 6.4.3.2 Page 64)
(⇨ Section 6.8.1.2 Page 70) (⇨ Section 6.8.1.3 Page 70)
✓ Operate the pump set by means of the turning gear until the pump casing
temperature is ≤ 80 ℃.
1. Close the shut-off element in the discharge line.
2. Make sure the minimum flow valve works.
3. Switch off the drive, making sure it runs smoothly down to a standstill.
4. Note the run-down time.

CAUTION
Pump set started up inadvertently
Damage to the pump!
▷ Secure drive against unintentional start-up, e. g. by disconnecting the motor.
5. Close the shut-off valve in the minimum flow pipe.
6. Close the shut-off element in the inlet pipe.
7. Turn off the cooling water when the casing temperature (measured at the
pump nozzles) is lower than 50 °C.
8. Close all other pipes.

6.9 Work after shutdown

6.9.1 Work after shutdown with the pump set remaining ready for operation
General Information
If the period of standstill during readiness for instant start-up is longer than 2 weeks,
the pump set components such as gear or motor must be protected against water
ingress and humidity as described in the manufacturer’s preservation instructions.
Every 4 to 6 weeks
▪ Start up the pump set. (⇨ Section 6.4 Page 61)
▪ After approximately 10 minutes shut down the pump set. (⇨ Section 6.8 Page 69)
▪ Check whether the pump rotor runs down smoothly to a standstill.
Every two months (in the case of pump set with variable speed coupling)
▪ If the scoop tube actuator was used during stand-by operation, re-lubricate the
guide bush. Comply with the manufacturer’s product literature.

CHTR 71 of 168
 6 Commissioning/Start-up/Shutdown

6.9.2 Work after shutdown for standstill - Pump not ready for operation

CAUTION
Danger of frost/freezing
Damage to the pump!
▷ If there is any risk of freezing or in the event of prolonged standstill, drain and
preserve the pump.
In the case of danger of frost and standstill > 2 weeks, drain and preserve the pump.
General information
▪ Make sure that the drive cannot be switched on.
▪ Secure all valves against opening.
▪ Close all openings and supply lines.
If the period of standstill is longer than 2 weeks, the pump set components such as
gear or variable speed coupling must be protected against water ingress and
humidity as described in the manufacturer’s preservation instructions.

6.9.3 Work after shutdown for maintenance

WARNING
Fluids posing a health hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing liquid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of substances posing a health
hazard.

DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set.
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure.
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.

WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
General information
▪ Make sure that the drive cannot be switched on.
▪ Secure all valves against opening.
▪ Open all drains and/or drain pipes.
▪ Collect the fill in an appropriate container and dispose of according to the local
anti-pollution regulations.
If the period of standstill is longer than 2 weeks, the pump set components such as
gear or variable speed coupling must be protected against water ingress and
humidity as described in the manufacturer’s preservation instructions.

72 of 168 CHTR
 6 Commissioning/Start-up/Shutdown

6.10 Preservation for standstill

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

WARNING
Pump parts falling down during dismantling and reassembly.
Risk of injury from falling parts!
▷ Use appropriate means to secure the parts, if possible.
▷ Wear safety shoes.
▷ Observe the applicable local accident prevention regulations.
Preservation for standstill is required if:
▪ The pump set is not commissioned immediately after its installation
▪ The standstill time of the pump set exceeds two weeks
▪ There is any risk of freezing
Preservative Use a preservative which fulfils the following criteria:
▪ Mixture of glycol and water, ratio 1:1

NOTE
This mixture ensures protection against freezing down to approximately - 42 °C.

✓ The pump set has been shut down. (⇨ Section 6.8 Page 69)
✓ All necessary work after shutdown has been performed. (⇨ Section 6.9.3 Page 72)
✓ The drive has been secured against start-up.
✓ The pump has been drained, if required.
✓ A container for collecting the fluid is on hand.
✓ Sufficient preservative is available.
1. Secure all shut-off elements against opening.
2. Place suitable containers under the drain holes.
3. Open all drains and/or drain lines.
4. Collect and properly dispose of the fluid.
5. Close all drains and drain lines.
6. Fill the pump with preservative.
7. Dismantle and store the coupling guard.
8. Dismantle and store the spacer of the coupling as described in the
manufacturer’s documentation.
9. If required, fill the bearing housing with oil.
10. Rotate the pump rotor once or twice a month to prevent a separation of the
preservation fill.
11. Check the fill level of the preservative once or twice a month; top it up, if
required.

CHTR 73 of 168
 6 Commissioning/Start-up/Shutdown

6.11 Returning to service

WARNING
In the case of storage periods of more than 5 years, the sealing function of O-rings
may be impaired.
Rick of injury from leakage of hot, pressurised fluid handled!
▷ After a storage period of more than 5 years, the pump must be dismantled
before it is installed, and the O-rings must be replaced.
▷ Check the O-rings for damage before they are fitted.
For returning the pump to service, observe the items on commissioning/start-up
(⇨ Section 6.4 Page 61) .
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (⇨ Section 7 Page 75)

74 of 168 CHTR
7 Servicing/Maintenance

7 Servicing/Maintenance

7.1 User information

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

7.2 Supervision

DANGER
Improperly serviced pump set
Explosion hazard!
Damage to the pump set!
▷ Service the pump set regularly.
▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.

NOTE
During the warranty term, pumps/pump sets must only be dismantled or
reassembled by KSB personnel!

The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly familiar
with the manual.

WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.

WARNING
Fluids posing a health hazard and/or hot fluids
Risk of personal 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.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump (set) with a minimum of maintenance
expenditure and work.

NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".
Never use force when dismantling and reassembling the pump set.

CHTR 75 of 168
 7 Servicing/Maintenance

7.2.1 Supervision plan

This supervision plan contains the minimum scope of work recommended by KSB. Do
not exceed the time intervals indicated; shorter intervals serve to improve the
operating reliability.
Table 17: Supervision plan
What/where How Value to be met Interval
Radial plain bearing Check the temperature. 4) Weekly
Tilting-pad thrust bearing Check the oil level Middle between the Weekly
(only designs with oil ring minimum and maximum
Radial rolling element lubrication). marks
bearing Check smooth running. The pump must run quietly Weekly
Rolling element thrust and free from vibrations.
bearing
Mechanical seal Check for leakage. 4) 4)

Or see manufacturer's Or see manufacturer's

product literature product literature
Mechanical seal/ Check the temperature. 4) 4)

Temperature measurement Or see manufacturer's Or see manufacturer's

(if applicable) product literature product literature
Differential pressure meter, Check the differential 4) Weekly
strainer - inlet pipe pressure.
(if applicable)
Differential pressure meter, Check the differential 4) Weekly
duplex filter pressure.
(if applicable)
Measuring instrument, Check the pressure. 4) Weekly
suction side ps (instrument
holer)
(if applicable)
Measuring instrument, Check the pressure. 4) Weekly
discharge side pd (instrument
holer)
(if applicable)
Measuring instrument, Check the pressure. 4) Weekly
tapping (instrument holder)
(if applicable)
Measuring instrument, Check the pressure. 4) Weekly
balancing water pE
(instrument holer)
(if applicable)
Thermometer (suction/ Check the temperature. 4) Weekly
discharge nozzle)
(if applicable)
Cooling water line (supply Check the temperature. Δt ≤ 10 °C Daily
and return line)
(if applicable)
Sight glass (cooling water Check the cooling water Water flows. Daily
line) flow.
(if applicable)
Sight glass (oil line) Check the oil flow. Oil flows. Weekly
(if applicable)
Oil pressure gauge Check the pressure. 4) Weekly
(instrument holder)
(if applicable)
Vibration measurement Check. 4) Weekly
device
(if applicable)
Shaft position monitoring Check. 4) Weekly
(if applicable)

4) See list of measuring points, interlock criteria or manufacturer’s product literature

76 of 168 CHTR
 7 Servicing/Maintenance

What/where How Value to be met Interval

Oil sight glass (oil supply Checking the oil level 4) Weekly
system) (if applicable)
Drive See manufacturer's product See manufacturer's product See manufacturer's
literature literature product literature
Static seals, general Check tightness. The static seal shall be dry. Weekly
Static seals, pressure body Check tightness. The static seal shall be dry. Daily
Coupling guard Check Contact-free installation Monthly
Earth conductor Check. Earth conductor must be Monthly
connected and marked.
Alarm signals Check proper functioning. See the manufacturer’s Daily
product literature or the
documentation on the
monitoring system
In the case of deviations, proceed in accordance with the "Trouble-shooting" table.
(⇨ Section 8.1 Page 117)

7.3 Maintenance

7.3.1 General instructions for maintenance

DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Explosion hazard!
Fire hazard!
Damage to the pump set!
▷ Regularly check the lubricant level.
▷ Regularly check the rolling element bearings for running noises.

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.

CAUTION
Impermissibly high temperature of fluid handled
Damage to the pump!
▷ Prolonged operation against a closed shut-off element is not permitted
(heating up of the fluid).
▷ Observe the temperature limits in the data sheet and in the section on
operating limits. (⇨ Section 6.7 Page 67)

While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.
▪ In case of oil lubrication, ensure the oil level is correct.
▪ Check the shaft seal.
▪ Check the static seals for leakages.
▪ Check the rolling element bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
▪ Monitor the correct functioning of any auxiliary connections.

CHTR 77 of 168
 7 Servicing/Maintenance

▪ Monitor the stand-by pump.

To make sure that the stand-by pumps are ready for operation, start them up
once a week.
▪ Monitor the bearing temperature.
▪ Regularly check all guards for correct fastening.

7.3.2 Pump servicing plan

Prerequisite:
▪ The pump set has been taken out of service.
▪ Any protective equipment mounted on the pump set has been dismantled or
removed
The intervals indicated in the servicing plan apply to normal operating conditions at
trouble-free operation. Adapt the servicing plan to the actual operating conditions,
for example the dirt accumulation, frequency of starts, load, etc.
In the case of problems and unusual operating conditions that present electric and
mechanical overloads of the pump set, off-schedule servicing must be performed.

NOTE
Perform a visual inspection of the pump set — as far as accessible — about 500
operating hours after commissioning/start-up.

Table 18: Servicing plan

What/where Check Work to be performed Intervals
Bearing Oil level, oil quality See the section on oil First oil change after 500
Oil ring lubrication lubrication. operating hours
(if applicable) Subsequent oil changes
every 3000 operating hours
or yearly, whichever is
shorter.
Bearing Oil level, oil quality Check after 500 operating
Forced oil lubrication hours
(if applicable) First oil change after 8,000
operating hours, after 2
years at the latest
Coupling Fill with oil or grease (if See manufacturer's product See manufacturer's product
applicable). literature. literature.
Check the axial movability. See manufacturer's product After approx. 8,000
literature. operating hours
Drive See manufacturer's product See manufacturer's product See manufacturer's product
literature. literature. literature.
Instruments Perfect condition and Replace defective See manufacturer's product
(if applicable) proper functioning equipment; literature.
see manufacturer’s product
literature
Mechanical seal See manufacturer's product See manufacturer's product See manufacturer's product
literature. literature. literature.
Pressure gauges Perfect condition: no Replace defective Every three months;
(if applicable) mechanical damage. equipment; see manufacturer's product
If applicable: electrical see manufacturer’s product literature
connections intact. Proper literature
functioning: local measured
value indication available.
Differential pressure gauge Perfect condition: no
(if applicable) mechanical damage;
electrical connections intact
Check the switching points.

78 of 168 CHTR
 7 Servicing/Maintenance

What/where Check Work to be performed Intervals

Temperature measuring Perfect condition: no
instruments mechanical damage.
(if applicable) If applicable: electrical
connections intact.
Proper functioning: local
measured value indication
available
Check the switching points.
Vibration measurement Perfect condition: no
(if applicable) mechanical damage.
If applicable: electrical
connections intact.
Proper functioning: local
measured value indication
available
Shaft position monitoring Perfect condition: no
(if applicable) mechanical damage;
if applicable: electrical
connections intact. Proper
functioning: local measured
value indication available

7.3.3 Maintenance work

7.3.3.1 Changing the oil (if applicable)

After a standstill > 12 months, check the oil quality. If required, clean or replace the
oil.

Oil sight gauge

1. Remove the screwed plug (13 B.1 and/or 13 B.2), completely drain off the oil fill
and dispose off in accordance with the local anti-pollution regulations.
2. Screw the screwed plug incl. seal in again.
3. Remove vent plug 913.
4. Fill in oil through the opening until the oil level is between the minimum and
maximum markings of the oil sight gauge 639.01/639.02.
5. Re-insert vent plug 913 with gasket 400.05.

Constant-level oiler

Fig. 39: Constant-level oiler

CHTR 79 of 168
 7 Servicing/Maintenance

✓ The constant-level oiler is fitted in the bearing housing on the relevant side (see
figure Constant-level oiler).
1. Remove vent plug 913 with gasket 400.05.
2. Press together clamp on constant-level oiler 638 and pull the reservoir of the
constant-level oiler upwards.
3. Fill the reservoir of constant-level oiler 638 with oil and return it to its operating
position.
4. Re-insert vent plug 913 with gasket 400.05.
5. After a short time check whether the oil level in the reservoir has dropped.
It is important to keep at least one third of the reservoir filled at all times. If the
oil level is too low, top it up with oil.

7.3.3.2 Re-lubrication (if applicable)

(⇨ Section 6.3.5 Page 53)

7.3.3.3 Servicing other pump set components

Fill with oil in accordance with the manufacturer’s product literature.

7.3.3.4 Servicing the coupling

1. Perform all maintenance work in accordance with the manufacturer’s product
literature.
2. Observe all dismantling and reassembly steps for the coupling. (⇨ Section 7.4.4
Page 83)

7.4 Dismantling the pump

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

7.4.1 General information/Safety regulations

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

DANGER
Unprotected floor openings and/or foundations
Danger of death from falling!
▷ Secure the danger zone.
▷ Observe the applicable local occupational safety and accident prevention
regulations.

WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.

80 of 168 CHTR
7 Servicing/Maintenance

WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.

WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.

WARNING
Pump parts falling down during dismantling and reassembly.
Risk of injury from falling parts!
▷ Use appropriate means to secure the parts, if possible.
▷ Wear safety shoes.
▷ Observe the applicable local accident prevention regulations.

WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
Observe the general safety instructions and information.
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly observe the exploded views and the general
assembly drawing.

DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set.
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure.
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.

NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".

NOTE
After a prolonged period of operation the individual components may be hard to
pull off the shaft. If this is the case, use a brand name penetrating agent and/or - if
possible - an appropriate puller.

CHTR 81 of 168
 7 Servicing/Maintenance

NOTE
This type of pump design allows the cartridge to be removed from the barrel casing
with minimum dismantling (Removal of pump cartridge: (⇨ Section 7.4.9 Page 92) ).

7.4.2 Prerequisites for dismantling

▪ The pump set has been taken out of service in accordance with the instructions.
(⇨ Section 6.8 Page 69) (⇨ Section 6.9 Page 71)
▪ All spare parts required are available.
▪ Proper lifting accessories and means of transport are available and ready for use.
▪ Sufficient room space and appropriate tools are available.
▪ The drive has been secured against unintentional starting.

7.4.3 Dismantling guards

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

7.4.3.1 Sound insulation hood

If applicable, dismantle the sound insulating hood as far as necessary as described in
the manufacturer’s product literature.

7.4.3.2 Coupling guard

Dismantle and store the coupling guard.

7.4.3.3 Contact guard for shaft seal

Dismantle and store the contact guard.

82 of 168 CHTR
7 Servicing/Maintenance

7.4.4 Dismantling the coupling

7.4.4.1 Dismantling the coupling spacer

1

2
3

Fig. 40: Coupling

1 Coupling hub (pump end) 2 Intermediate piece
3 Coupling hub (drive end) X Marking
✓ The coupling guard has been dismantled.
1. Mark the coupling to prevent any confusion at a later stage.
2. Dismantle the spacer of the coupling as described in the manufacturer’s product
literature.

7.4.4.2 Pulling off the coupling hub

WARNING
Falling coupling parts
Risk of crushing from falling parts!
▷ Secure coupling parts against falling down.
▷ Wear safety shoes.

WARNING
Coupling hub coming off suddenly
Risk of crushing fingers/hands at the puller
▷ Never put fingers/hands in the spaces between coupling hub and tool during
dismantling.
▷ Use appropriate personal protective equipment.

CAUTION
Improper dismantling
Damage to bearings and coupling parts!
▷ Remove coupling hubs using a puller.
▷ Never strike the coupling hubs.

CAUTION
Improper mounting of elastomers
Elastomers' sealing function reduced!
▷ Never use elastomeric parts again which have been heated.
▷ As a general rule, always use new elastomeric parts.
1. Dismantle the retaining rings, if applicable, from the coupling hub.

CHTR 83 of 168
 7 Servicing/Maintenance

1 2

Fig. 41: Marking of coupling parts

1 Shaft 2 Coupling hub
2. Mark the coupling hub's position relative to the shaft in circumferential
direction. If no marking exists, mark the position by stamping. (Maintaining the
balancing grade for reassembly)
3. Remove the grub screws.

WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
4. To facilitate removal, the coupling hubs may be heated uniformly to a
temperature of 80 °C max. Elastomeric parts must be removed before heating.
Elastomeric parts which have been heated must not be used any more.

Fig. 42: Pulling off the coupling hub

5. Remove the coupling hub as shown in the figure.
6. Mark and then remove the key.

84 of 168 CHTR
7 Servicing/Maintenance

7.4.4.3 Checking the shaft ends for run-out

Fig. 43: Checking the shaft ends for run-out

NOTE
Observe the marking between coupling hub and shaft. (⇨ Section 7.4.4 Page 83)

1. Permissible tolerance at the pump shaft ≤ 0.03 mm. If this value is exceeded,
contact KSB.
2. Permissible tolerance of the motor shaft, see the data provided by the
manufacturer.

7.4.5 Removing the pump from the system (if necessary)

7.4.5.1 Dismantling the piping and instruments

1. Have a container on hand for both the fluid handled and the supplies and, if
required, place it underneath the connections of the pipes to be dismantled.
2. Secure inlet and discharge lines.
3. Undo the connections between discharge nozzle and discharge line and
between suction nozzle and suction line.
4. Dismantle the minimum flow valve, if installed.
5. Disconnect the tapping pipe, if applicable.
6. Detach and dismantle any auxiliary lines such as balancing liquid, circulation,
cooling liquid and oil pipes or measuring lines as far as necessary.
7. Dismantle the measuring instruments as far as necessary, and store them
appropriately.
8. If required, dismantle the shaft seal cooler including support.
9. Dispose of the fluid handled and the supplies in compliance with environmental
standards.
10. Close the openings of all dismantled pipes.

CHTR 85 of 168
 7 Servicing/Maintenance

7.4.5.2 Removing the pump from the baseplate

1 2 3

8 9 10

4 5 6 7

Fig. 44: Fastening of the pump feet (example)

1 Pump foot 2 Nut
3 Disc 4 Parallel pin
5 Baseplate 6 Stud
7 Shim 8 Guide casing
9 Nut 10 Adjusting screw
1. Unscrew the fastening studs on the pump feet.
2. Remove the parallel pins.
3. Undo the adjusting screws on the guide casing.
4. Mark the matching shims (between the pump feet and baseplate) so that they
can be inserted in the same place on subsequent reassembly, and store them
appropriately.
5. Lift the pump off the baseplate.

7.4.5.3 Transporting the pump to the place of dismantling

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

7.4.6 Dismantling the bearings

CAUTION
Improper dismantling/installation
Damage to the shaft and bearings!
▷ When the bearings are dismantled ensure that the shaft never rests on the
bearing housings or labyrinth rings or is rotated.
▷ Mark the bearings to ensure their correct assignment to the bearing housings.

86 of 168 CHTR
7 Servicing/Maintenance

CAUTION
Installation of defective or damaged bearings
Damage to the pump!
▷ Re-use only bearings which are in perfect condition.
▷ In the case of slight discolourations or any damage, the bearings must be
replaced.
▷ After washing the bearings out, immediately spray them with oil.

7.4.6.1 Dismantling the bearings - Preparations

1. Prior to dismantling, drain the oil fill of the bearing housings.
2. Dismantle the oil supply pipes as far as necessary.
3. Dismantle measuring instruments as far as necessary and store properly.
4. If available, remove hexagon head bolts 901.05, discs 550.14 to dismantle
bearing guard 680.03.

7.4.6.2 Dismantling the non-drive end bearing

1. Remove hexagon head bolts 901.02, discs 550.02 and fan hood 832.01.
2. Remove circlip 932.02 from shaft 210.
3. Remove adapter 82-5 with fan impeller 831.
4. Remove key 940.06 from shaft 210.
5. Loosen hexagon head bolts 901.03 and remove fan hood 832.02 as well as
bearing cover 360.01 including O-ring 412.09 and labyrinth seal 423.02. If a
tapered roller bearing is used, remove parallel pin 562.10, if any.
6. Remove oil ring 644.02 from the groove of spacer sleeve 525.05.
7. Loosen hexagon socket head cap screw 914.06 including disc 550.06 and remove
slotted nut 920.12 using an appropriate tool as described in the relevant work
instructionUA3 37819 01.
8. Pull spacer sleeve 525.05 off shaft 210.
9. Take labyrinth seal 423.01 out of bearing housing 350.02. If applicable, observe
the information on the removal of INPRO labyrinth seal 423.01. (⇨ Section
7.4.6.4 Page 88)
10. Loosen and remove nuts 920.05 including discs 550.05 located on studs 902.05
to dismantle bearing housing 350.02.
11. Fasten bearing housing 350.02 to the crane by means of eyebolt and rope.
12. Take off bearing housing 350.02 including the two angular contact ball
bearings 320 or the two tapered roller bearings 324 using an appropriate tool
as described in the relevant work instruction UA3 37819 01.
13. For further dismantling, pull spacer ring 504.01, segmental ring 501.04, if any,
and inner labyrinth seal 423.01 off shaft 210.
14. It is not necessary to dismantle cooling insert 442.01 or 442.02 fitted to drive or
non-drive end bearing housing 350.01 or 350.02 every time.
15. If required, remove nuts 920.07 including discs 550.07 from studs 902.07 or
902.08.
16. Water cooling design: Remove cooling chamber cover 165.04 including O-ring
412.27 and cooling insert 442.02 including O-ring 412.16 from bearing housing
350.02.
Air cooling design:Remove cooling insert 442.02 including O-ring 412.16 from
bearing housing 350.02.

CHTR 87 of 168
 7 Servicing/Maintenance

7.4.6.3 Dismantling the drive end bearings

1. Undo hexagon head bolts 901.01 and remove bearing cover 360.02 including O-
ring 412.09 and labyrinth seal 423.01.
2. Undo grub screw 904.16 on spacer sleeve 525.01.
3. Remove oil ring 644.01 from the groove of spacer sleeve 525.01. Pull spacer
sleeve 525.01 from shaft 210 using an appropriate puller as described in the
relevant work instructionUA3 37819 01.
4. Undo and remove nuts 920.05 and discs 550.05 located on studs 902.01.
5. Push bearing housing 350.01 including outer ring, cage and rolling elements of
cylindrical roller bearing 322 and, if applicable, INPRO labyrinth seal 423.01 out
of seal housing 441.01 using the screws as described in work instruction
UA3 37819 01.
6. If applicable, refer to drawing UA1 37858 02 for the removal of INPRO labyrinth
seal 423.01.
7. If required, pull outer ring of cylindrical roller bearing 322 from bearing
housing 350.01.
8. Pull spacer ring 504.03 and the inner ring of the bearing from shaft 210 using
an appropriate puller as described in the relevant work instruction UA3 37819
01.
9. For further dismantling, remove circlip 932.01, if applicable, and then the inner
labyrinth ring 423.01 from shaft 210.
10. If required, remove nuts 920.07 including discs 550.07 from studs 902.07 or
902.08.
11. Water cooling design: Remove cooling chamber cover 165.03 including O-ring
412.19 and cooling insert 442.01 including O-ring 412.19 from bearing housing
350.01.
Air cooling design: Remove cooling insert 442.01 including O-ring 412.19 from
bearing housing 350.01.

7.4.6.4 Dismantling the INPRO labyrinth seal from the non-drive end bearing
housing (if applicable)

CHTR 2-3
✓ Observe the disassembly sketches of the INPRO labyrinth seal in work instruction
UA1 37858 02.
1. Loosen hexagon nuts 920.05 including discs 550.05 to remove bearing housing
350.02 from cooling chamber cover 165.01.
2. Remove bearing housing 350.02 including bearings 320/324 and labyrinth seal
423.01 using forcing screws 901.73 as shown in the work instruction
UA3 37819 01.
3. Continue the removal of the bearing housing until labyrinth seal 423.01
separates from the bearing housing by striking against segmental ring 501.04.
4. Pull spacer ring 504.01, segmental ring 501.04 from shaft 210. Gently remove
INPRO labyrinth seal 423.01 from the shaft by pushing it or using a mallet.

CHTR 4-5
✓ Observe the disassembly sketches of the INPRO labyrinth seal in work instruction
UA1 37858 02.
1. Loosen hexagon nuts 920.05 including discs 550.05 to remove bearing housing
350.02 from cooling chamber cover 165.01.
2. Remove bearing housing including bearings using forcing screws 901.73 as
shown in the work instruction UA3 37819 01.

88 of 168 CHTR
7 Servicing/Maintenance

3. Continue the removal of the bearing housing until it can be pulled from the
shaft along with INPRO labyrinth seal 423.01, bearings 320/324 and spacer ring
504.01.

7.4.7 Dismantling the shaft seal

7.4.7.1 Preparations
Disconnect all cooling liquid, barrier fluid, circulation or injection pipes as far as
necessary.

7.4.7.2 Removing the mechanical seal

WARNING
Damaged shaft sleeve and mechanical seals
Risk of personal injury in the event that hot, pressurised fluid handled escapes!
▷ Replace damaged shaft sleeves and mechanical seals by new components.

Fig. 45: Locking sleeve (example)

A Locking sleeve B Locking screw
C Shrink disc D Shaft sleeve
E Shaft
▪ Observe the general drawings of the mechanical seal and the manufacturer’s
product literature.
1. Dismantle any cooling liquid, sealing liquid, circulation or injection pipes, as far
as necessary.
2. Place thick spacers on any four studs (902.01 for DE and 902.05/902.23 for NDE)
at 90° and tighten four nuts (920.05 for DE and/or 920.04 for NDE).
3. Engage the locking discs in the groove of the shaft sleeve and fasten them on
the seal cover using hexagon head bolts.
4. Loosen the grub screws which fasten the mechanical seal shaft sleeve to the
shaft 210 or on the shrink disc.

CAUTION
Incorrect handling of locking screws
Damage to the shaft seal!
▷ Never loosen locking screws in diagonally opposite sequence.
▷ Never screw out the individual locking screws completely in a single go.
5. Loosen the locking screws of the locking sleeve (A) uniformly and one after the
other by a quarter turn, see figure Locking sleeve.
6. Loosen the locking screws further in a second run or any further run, however,
do not screw them out.
7. Remove dirt from shaft sleeve.
8. Remove locking sleeve (A) from shaft sleeve (D).

CHTR 89 of 168
 7 Servicing/Maintenance

9. Undo and remove hexagon nuts 920.10.

10. Use screws to force off the seal cover along with the shaft sleeve and
mechanical seal and pull them off the shaft completely.
11. Check the mechanical seal.
If the seal faces are clean and undamaged, the mechanical seal may be re-
installed. Otherwise a new seal must be installed.

7.4.7.3 Disassembling the mechanical seal

▪ see the manufacturer's product literature.

7.4.7.4 Removing casing components

7.4.7.4.1 CHTR 2-5 (100 bar)

1. Loosen and remove the thick spacers on the studs (902.01 for DE and 902.05 for
NDE) (⇨ Section 7.4.7.2 Page 89) .
2. Undo and remove nuts 920.04 and discs 550.04 on the non-drive end studs
902.04.
3. If required, remove cooling chamber cover 165.01 or 165.02 including O-ring
412.11 and 412.03.
4. Attach shaft seal housing 441.01, DE, and 441.02, NDE, including O-rings 412.06,
DE, and 412.07, NDE, or joint rings 411.06, DE, and 411.07, NDE, to crane and
rope by means of eyebolt, force off with screws and remove it.

7.4.7.4.2 CHTR 2-5 (250 bar)

1. Loosen and remove the thick spacers on the studs (902.01 for DE and 902.05 for
NDE) (⇨ Section 7.4.7.2 Page 89) .
2. Undo and remove nuts 920.04 and discs 550.04 on the non-drive end studs
902.04.
3. If required, remove cooling chamber cover 165.01 or 165.02 including O-ring
412.11 and 412.03.
4. Attach shaft seal housing 441.02 including O-ring 412.07 or joint rings 411.07 to
crane and rope by means of eyebolt, force off with screws and remove it.

7.4.8 Dismantling the balancing device

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

CHTR 2-3
1. Undo and remove shaft nut 921.
2. Use an appropriate device as described in the work instruction UA3 37819 01 to
remove balance drum 603.01 with spacer ring 504.02 and O-ring 412.02 or joint
ring 411.02 from shaft 210.
3. Undo socket head cap screws 914.14 and push throttle bush 542.01 with screws
out of cover 160.01. Also remove O-ring 412.05 or joint ring 411.05 and O-ring
412.04.
4. Check balance drum 603.01 and throttle bush 542.01 for damage.

90 of 168 CHTR
7 Servicing/Maintenance

CHTR 4-5
1. Undo socket head cap screws 914.10 and pull off loose collar 505.01.
2. Remove segmental ring 501.01 from shaft groove and spacer ring 504.02 from
shaft 210.
3. Use an appropriate device as described in the work instruction UA3 37819 01 to
remove balance drum 603.01 with O-ring 412.02 or joint ring 411.02 from shaft
210.
4. Undo socket head cap screws 914.14 and push throttle bush 542.01 with screws
out of cover 160.01. Also remove O-ring 412.05 or joint ring 411.05 and O-ring
412.04.
5. Check balance drum 603.01 and throttle bush 542.01 for damage.

7.4.8.1 Measuring the overall clearance

NOTE
An exact measurement of the rotor clearances is only possible with the pump set
dismantled!
If the pump body is not dismantled, only an approximate radial clearance can be
measured.

Fig. 46: Measuring the approximate radial clearance

1. Place the dial gauge holder on a firm base (for example cover) and position the
dial gauge on the seat of the balance drum as shown in the figure: Measuring
the approximate radial clearance.
2. Carefully lift the shaft until it abuts on top. Prevent increased shaft deflection
(incorrect measurement).
3. The diametral clearance determined this way must not exceed 1.4 mm; if it
does, the pump must be dismantled and overhauled.

CHTR 91 of 168
 7 Servicing/Maintenance

7.4.9 Removing the pump cartridge from the barrel casing

7.4.9.1 General information

NOTE
The pump cartridge may only be dismantled by trained specialist personnel.
In case of maintenance, the pump cartridge must be clamped together axially in
accordance with the assembly instruction UA3 37816 01 or UA3 37817 01, and, if
necessary, sent to KSB Service Center or KSB with dismantled components.

7.4.9.2 Prerequisites
▪ All pipes, add-on parts and measuring instruments which have to be dismantled
for pump cartridge removal are dismantled.
▪ Only use the special tools (tool cradle) included in the scope of supply as shown
in the assembly sketch (CHTR 2:UA3 37814 01; CHTR 3-5: UA3 37815 01).
▪ Prior to dismantling, mark the exact positions of component parts and
connection holes to one another.

7.4.9.3 Preparations
CHTR 2
1. Dismantle the drive end bearing housing (⇨ Section 7.4.6 Page 86) and the shaft
seal (⇨ Section 7.4.7 Page 89) .
2. Fit the dummy bearing housing 350.81 along with ring 500.81 and secure in
position using four discs 550.05 and four hexagon nuts 920.05, if applicable.
3. Loosen hexagon head bolts 901.06 and remove guide piece 897.

CHTR 3-5
1. Dismantle drive end bearing cover 360.02 or labyrinth ring 423.01. (⇨ Section
7.4.6 Page 86)
2. If applicable, loosen hexagon nut 920.07 and remove cooling insert 442.01
including O-ring 412.19, discs 550.07 and stud 902.07 or 902.08.
3. Loosen hexagon head bolts 901.06 and remove guide piece 897.

CHTR 4-5 with double suction impellers (i.e. pump types CHTR N /1+X)
1. Dismantle drive end bearing cover 360.02 or labyrinth ring 423.01. (⇨ Section
7.4.6 Page 86)
2. If applicable, loosen hexagon nut 920.07 and remove cooling insert 442.01
including O-ring 412.19, discs 550.07 and stud 902.07 or 902.08.
3. Remove hexagon nuts 920.15 and 920.19 with discs 550.15 and 550.19 including
studs 902.15 and 902.19 from barrel casing 10-3 and inlet ring 131.02 and
remove the two-piece ring (500).

7.4.9.4 Clamping together the drive end

1. Slide pipe 710.81 over pump shaft and fasten to bearing housing 350.81 or
350.01 using disc 550.88 and hexagon head bolt 901.87.
2. Clamp pipe 710.81 to shaft 210 with disc 550.85 and hexagon head bolt 901.85.
3. Screw together pipes 710.82, 710.83 and 710.84, if applicable, using tommy bar
99-5.
4. Remove protective casings 13-16, if any.

92 of 168 CHTR
7 Servicing/Maintenance

7.4.9.5 Fitting the tool cradle

7.4.9.5.1 Non-drive end

CHTR 2-5 (100 bar), CHTR 2-4 (250 bar)
1. Loosen and remove 12 of the 16 or 8 of the 12 hexagon nuts 920.01, taking care
that the remaining four fasteners are equispaced.
2. Fix the support feet 183.81 to the pump feet or baseplate using hexagon head
bolts 901.83, strips 575.83 and hexagon head bolts 901.84 as shown in the
assembly sketch UA3 37814 01 or UA3 37815 01.
3. Mount the supporting device comprising grub screws 904.81, strips 575.82, discs
550.81 and nuts 920.81.
4. Fasten strips 575.81 to cover 160.01 or 160.02 by means of hexagon head bolts
901.81.
5. Insert pin 564.81 and slide on the rolls 59-30.81 along with deep groove ball
bearings 321.81.
6. Secure with grub screws 904.82.
7. Align the supporting device by means of hexagon head bolts 901.82 and nuts
920.81.

CHTR 5 (250 bar)

1. Undo hexagon nuts 920.01, discs 550.01 and socket head cap screws 914.19 and
remove cover 160.02.
2. Fix the support feet 183.81 to the pump feet and the baseplate using the
hexagon head bolts 901.83, strips 575.83 and hexagon head bolts 901.84 as
shown in the assembly sketch UA3 37815 01.
3. Mount the supporting device comprising grub screws 904.81, strips 575.82, discs
550.81 and nuts 920.81.
4. Fasten strips 575.81 to casing insert 13-6 by means of hexagon head bolts
901.81.
5. Insert pin 564.81 and slide on the rolls 59-30.81 along with deep groove ball
bearings 321.81 and secure with grub screws 904.82.
6. Align the supporting device by means of hexagon head bolts 901.82 and nuts
920.81.

7.4.9.5.2 Drive end

CHTR2 (100 bar)
1. Fasten rail 593.81 to pump base frame using studs 902.81, discs 550.82 and
hexagon nuts 920.82 as shown in the assembly sketch UA3 37814 01.
2. Fasten trestle 895.81 to rail 593.81 using hexagon head bolts 901.89.
3. Slide roll 59-30.81 along with deep groove ball bearing 321.81 over pin 564.82
and insert into trestle.
4. Align pump cartridge by means of hexagon head bolts 901.88 and secure with
hexagon head bolts 901.90.

CHTR 3-5, CHTR 2 (250 bar)

1. Fasten rail 593.81 to barrel casing 10-3 using studs 902.81, discs 550.82 and
hexagon nuts 920.82 as shown in the assembly sketch UA3 37815 01.
2. Fasten trestle 895.81 to rail 593.81 using hexagon head bolts 901.89.
3. Slide roll 59-30.81 along with deep groove ball bearing 321.81 over pin 564.82
and insert into trestle.
4. Align pump cartridge by means of hexagon head bolts 901.88 and nuts 920.88
and secure with hexagon head bolts 901.90.

CHTR 93 of 168
 7 Servicing/Maintenance

7.4.9.6 Withdrawing the pump cartridge from the barrel casing

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.
1. Screw eyebolt 59-47.2 into cover 160.01/160.02 or casing insert 13-6.
2. Loosen and remove the remaining four hexagon nuts 920.01, if applicable.
3. Fasten strips 575.84 to barrel casing 10-3 using hexagon head bolts 901.91 and
sleeve 520.81, if applicable. Screw in hexagon head bolts 901.86.
4. Uniformly force pump cartridge out of barrel casing 10-3 by tightening hexagon
head bolts 901.86.
5. Remove pump cartridge from barrel casing 10-3. If necessary, lift the pump
cartridge using hexagon nuts 920.81 and hexagon head bolts 901.82 on the
non-drive end, or hexagon head bolts 901.88 on the drive end so that the pump
cartridge can be withdrawn from the barrel casing without knocking against it.

NOTE
It must be possible to easily withdraw the pump cartridge from the barrel casing
without tilting. If this is not possible, contact KSB.

6. Attach transport rope as shown in the assembly sketch UA3 37814 01 or UA3
37815 01.
7. If there is enough clearance for removal, transport the complete pump
cartridge including lengthening pipes to the place of dismantling and place
down on assembly supports.
If space is not sufficiently available, disconnect pipes 710.82, 710.83 and 710.84,
if applicable, from pipe 710.81 using tommy bar 969.75 and remove them.
8. Lift the pump cartridge off the tool cradle.
9. Transport the pump cartridge to the place of dismantling (⇨ Section 3 Page 14)
and place it down on assembly supports.
10. Remove gasket 400.03, O-ring 412.01 or joint ring 411.01 and gaskets 400.08
and spacer discs 551.01, if fitted.

7.4.9.7 Dismantling the pump cartridge

Dismantle the non-drive end bearings (⇨ Section 7.4.6 Page 86) , shaft seal (⇨ Section
7.4.7 Page 89) and balancing device (⇨ Section 7.4.8 Page 90) as described in the
relevant chapters.

7.4.9.8 Clamping together the pump cartridge

CHTR 2-5 (100 bar)
✓ Observe assembly instructions UA3 37816 01.
1. Slide first gasket 400.81 and then disc 550.84 over inlet ring 131 or 131.02.
2. Fasten inlet ring 131 or 131.2 (with gasket 400.81 and disc 550.84) to cover
160.01 using tie bolts 905.81, discs 550.86 and 550.87 and hexagon nuts 920.86.
3. Axially clamp together the pump cartridge using nut 920.86, taking into
account reference dimension A as specified in the assembly instructions
UA3 37818 01.

CHTR 2-3 (250 bar)

✓ Observe assembly instructions UA3 37817 01.

94 of 168 CHTR
7 Servicing/Maintenance

1. Slide first gasket 400.81 and then disc 550.84 over inlet ring 131.03.
2. Fasten inlet ring 131.03 (with gasket 400.81 and disc 550.84) to cover 160.01
using tie bolts 905.81, discs 550.86 and 550.87 and hexagon nuts 920.86.
3. Axially clamp together the pump cartridge using nut 920.86, taking into
account reference dimension A as specified in the assembly instructions
UA3 37818 01.

CHTR 4-5 (250 bar)

✓ Observe assembly instructions UA3 37817 01.
1. For CHTR 4 (250 bar) only: Undo socket head cap screw 914.19 and remove
cover 160.02. (Re-use socket head cap screw and cover for reassembly.)
2. Slide first gasket 400.81 and then disc 550.84 over inlet ring 131.03.
3. Slide disc 550.85 over casing insert 13-6. Fasten casing insert (with disc 550.85)
to disc 550.84 using tie bolt 905.81, discs 550.86 and hexagon nuts 920.86.
4. Axially clamp together the pump cartridge using nut 920.86, taking into
account reference dimension A as specified in the assembly instructions
UA3 37818 01.

7.5 Reassembling the pump

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

7.5.1 General information/Safety regulations

WARNING
Pump parts falling down during dismantling and reassembly.
Risk of injury from falling parts!
▷ Use appropriate means to secure the parts, if possible.
▷ Wear safety shoes.
▷ Observe the applicable local accident prevention regulations.

WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.

WARNING
O-rings in contact with oil or grease
Risk of injury in the event that the hot, pressurised fluid handled escapes!
▷ Do not take the O-rings out of their original packagings until immediately
before they are fitted and protect them from mineral oil and grease.
▷ Do not fit the O-rings in dry condition: Observe the specifications on auxiliary
materials for assembly outlined by KSB and the manufacturer of the mechanical
seal.
▷ Check the O-rings for damage before they are fitted.

CHTR 95 of 168
 7 Servicing/Maintenance

WARNING
Damage to locating and sealing surfaces through improper reassembly or
dismantling.
Risk of injury in the event that the hot, pressurised fluid handled escapes!
▷ Do not damage the locating and sealing surfaces.

CAUTION
Improper reassembly
Damage to the pump!
▷ Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
▷ Use original spare parts only.

NOTE
Check dismantled parts for damage. The installation of damaged parts leads to
increased wear or to failure of the balancing device, which results in damage to the
pump rotor.
▪ Reassembly must be performed in accordance with the rules of sound mechanical
engineering practice.
▪ Meticulously clean all dismantled parts, in particular the locating and sealing
surface areas.
▪ If required, remove any lime and incrustation from the cooling chambers.
▪ Check all dismantled parts for damage.
▪ Prior to reassembly coat the screw/bolt connections and pipe unions as well as
the fits of the individual components using the respective specified lubricating
agent as described in the work instruction UA4 28699 01.
Sequence Always reassemble the pump in accordance with the corresponding general assembly
drawing.
Seal elements ▪ Gaskets
– Always use new gaskets, making sure that they are of the same thickness and
material as the old ones.
▪ O-rings
– Always use new O-rings, making sure that they are of the same thickness and
material as the old ones.
– Never use O-rings that have been glued together from material sold by the
metre.
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.

7.5.2 Prerequisites
▪ Mounting of the pump cartridge may only be performed with the special tools
included in the supply (tool cradle) as shown in the assembly sketch
UA3 37814 01 or UA3 37815 01.
▪ The spare cartridge (if any) has been clamped together with assembly tools at the
factory as described in the assembly instruction UA3 37816 01 or UA3 37817 01.
▪ Refer to the outline drawingUA3 37818 01 for the dimensions of the spare
cartridge, see chapter 9.
▪ The sealing and locating surfaces of the barrel casing and the components to be
mounted must not exhibit any damage.

96 of 168 CHTR
7 Servicing/Maintenance

7.5.3 Fitting the pump cartridge in the barrel casing

7.5.3.1 Preparations
1. Measure dimension ‘L2’ as shown on the dimensional record UA3 37818 01 and
calculate the actual dimension ‘A’.
2. Fit the tool cradle, if required. (⇨ Section 7.4.9.5 Page 93)

7.5.3.2 Spare cartridge components

If a spare cartridge is installed, the original components as listed in chapter 9
"Original components to be re-installed when a spare cartridge is used" (Pump
Technical Information) are to be re-used.
For CHTR 4 (250 bar) only:
If a spare cartridge is used, disc 550.85 must be replaced.
Put original cover 160.02 on the casing insert 13-6 and fit the socket head cap screws
914.19. Observe
assembly sketch UA3 37816 01.
The components must be cleaned and free from damage.

7.5.3.3 Inserting the pump cartridge into the barrel casing

1. Loosen hexagon head bolt 901.91 and remove from barrel casing 10-3 together
with strip 575.84, sleeve 520, if applicable, and hexagon head bolt 901.86.
2. If there is enough clearance for installation, mount pipes 710.82, 710.83, and
710.84, if applicable, on the drive end.
3. Insert gasket 400.03, gaskets 400,08 with spacer discs 551.01 and O-ring 412.01
or joint ring 411.01, if applicable.

DANGER
Pump cartridge tipping over
Risk of crushing hands and feet!
▷ Secure pump cartridge against tipping over.
4. Attach transport rope as shown in the assembly sketch UA3 37814 01 or UA3
37815 01.
5. Lift the pump cartridge from the assembly supports and transport it to the
barrel casing.
Observe the assembly sketch UA3 37814 01 or UA3 37815 01.
6. If pipes 710.82, 710.83, and 710.84, if applicable, have not been mounted
during the dismantling of the original pump cartridge, screw pipes 710.82,
710.83 and 710.84 together with pipe 710.81 using tool 969.75.
7. Introduce pump cartridge into barrel casing 10-3 as far as the point where rolls
59-30.81 rest on support feet 183.81, and pipe 710.83 or 710.84 rests on rolls
59-30.81 mounted on trestle 895.81.
8. Remove the transport ropes from the pump cartridge.

CAUTION
Incorrect installation
Damage to the sealing faces!
▷ It must be possible to easily insert the pump cartridge into the barrel casing
without tilting.
▷ The O-ring joints must not be damaged.
▷ Should problems arise, contact KSB.

CHTR 97 of 168
 7 Servicing/Maintenance

9. Slide pump cartridge into barrel casing 10-3.

If necessary, lift the pump cartridge using hexagon nuts 920.81 and hexagon
head bolts 901.82 on the non-drive end, or hexagon head bolts 901.88 on the
drive end so that the pump cartridge can be easily inserted into the barrel
casing without knocking against it.

NOTE
The orientation of the opening in the inlet ring 131, 131.01, 131.02, 131.03, if
applicable, must coincide with that of the suction nozzle.

10. If applicable, the slot in the inlet ring 131 or 131.02 or 131.03 should
accommodate guide piece 897. If a hole is provided instead of a slot, then the
hole in the inlet ring 131 or 131.02 or 131.03 should engage the cylindrical pin
562.12 and also engage the hexagon bolt 901.06.
11. Remove the pipes 710.82 to 710.84 one after the other depending on the
position of the cartridge from shaft 210.
12. Remove lifting lug 59-47.2 from cover 160.01 or 160.02.
13. Dismantle strips 575.81 including pins 564.81 and rolls 59-30.81 from cover
160.01 or 160.02 or casing insert 13-6.
14. For CHTR 5 (250 bar) only:Fit original cover 160.02 and socket head cap screws
914.19.
15. Fit four of the twelve/sixteen discs 550.01 and hexagon nuts 920.01 at
equispaced locations and tighten.
16. Completely dismantle the tool cradle on the drive end.
17. Fit and tighten the remaining discs 550.01 and hexagon nuts 920.01 as
described in the relevant work instruction UA3 37821 01 or UA3 37821 02. For
tightening sequence, follow the usual good engineering practices.

CHTR 2
1. Remove dummy bearing housing 350.81 from shaft 210.
2. Fit bearing and bearing housing.

CHTR 2-5
1. Fasten the guide piece 897 to barrel casing 10-3 with hexagon head bolt 901.06
applying the tightening torque given in the relevant work instruction UA3
37821 01.

CHTR 4-5 with double suction impellers (i.e. type series CHTR N /1+X)
1. Fit studs 902.15 and 902.19 to barrel casing 10-3 and inlet ring 131.02 or 131.03.
2. Fit ring 500 to barrel casing 10-3 and inlet ring 131.02 or 131.03 using parallel
pins 562.12 and 562.22.
3. Fit discs 550.15 and 550.19 and hexagon nuts 920.15 and 920.19 on studs 902.15
and 902.19 applying the tightening torque given in the relevant work
instruction UA3 37821 01.

7.5.3.4 Dismantling the tool cradle

Non-drive end
1. If needed, loosen hexagon bolts 901.84 to remove support feet 183.81 and
completely disassemble all other parts of the tool cradle.

7.5.3.5 Fitting the pump components

1. If applicable, fasten cooling insert 442.01 including O-ring 412.19 to bearing
housing 350.01 using studs 902.07 or 902.08, discs 550.07 and hexagon nuts
920.07 applying the tightening torque given in the relevant work instruction.

98 of 168 CHTR
7 Servicing/Maintenance

2. Fit balancing device (⇨ Section 7.5.5 Page 106) on the non-drive end and on the
drive and non-drive ends of both shaft seal (⇨ Section 7.5.6 Page 107) and
bearings (⇨ Section 7.5.7 Page 109) .

7.5.4 Checking the dimensions and sizing the components

WARNING
Pump parts falling down during dismantling and reassembly.
Risk of injury from falling parts!
▷ Use appropriate means to secure the parts, if possible.
▷ Wear safety shoes.
▷ Observe the applicable local accident prevention regulations.

7.5.4.1 Balancing device for pump sizes 2-5

NOTE
The work described below is only necessary if throttle bush 542.01 or balance drum
603.01 require reworking or replacement.

Carry out this work with special care in order not to damage the internal pump parts.

CHTR 2-5
1. Refer to figure "Adapting the balance drum". Measure the distance “d” for the
total length of throttle bush 542.01. Measure distance "b" for total length, and
distance "c" of balance drum 603.01.
2. Determine distance "a": a=d-b. (Note: "a” can be either positive or zero.)

Fig. 47: Dimensions of throttle bush and balance drum

3. Insert parallel pin 562.03 into cover 160.01, if applicable.
4. Fit throttle bush 542.01 without O-rings or joint ring. The parallel pin 562.03
must engage in the groove of throttle bush 542.01.
5. Push the last stage impeller towards the suction side using appropriate means.

Fig. 48: Adjusting the pump rotor position

1 Discharge side 2 Suction side

CHTR 99 of 168
 7 Servicing/Maintenance

6. Refer to figure "Adjusting the pump rotor position". Move the pump rotor
towards the discharge side until it abuts and then move it back to the suction
side by a distance = SL1. (For SL1 refer to Table of Clearances ). (⇨ Section 9.2.3
Page 122) ).
7. This rotor adjustment must not be changed during the entire process of
measuring the balancing device!
8. Slide balance drum 603.01 onto shaft 210 until it abuts with the last stage
impeller hub.
9. Refer to figure "Adapting the balance drum". Adapt balance drum 603.01.

Fig. 49: Adapting the balance drum

10. Measure the distance “a1” from the face of throttle bush 542.01 to the face of
balance drum 603.01.
11. Remachine the step length in balance drum 603.01 to the dimension ”c1” in
accordance with the figure Adapting the balance drum:
c1 = c + (a-a1) + SL2. (For SL2 refer to Table of Clearances (⇨ Section 9.2.3 Page
122) ).
12. Always consider (a-a1) value as +ve (i.e. absolute).
13. Adapt spacer ring 504.02. Refer to figure "Adapting the spacer ring".

Fig. 50: Adapting the spacer ring

14. Ensure proper position of last stage impeller by using a sleeve!
15. Measure the distance ”x” from the end of the impeller hub to the step on shaft
210.
16. Determine the dimension ”h” between the ends of balance drum 603.01.
17. Shorten the spacer ring 504.02 to the dimension “f”: f = x-h-SL2. The maximum
permissible deviation from plane parallelism is 0.02 mm/0.0008 in.
If required, use new spacer ring 504.02.

100 of 168 CHTR

 7 Servicing/Maintenance

7.5.4.2 Positioning the thrust bearings - CHTR 2-5

CAUTION
Incorrect measurement values due to improperly installed temperature measuring
instrument.
Damage to the pump (set)!
▷ When mounting the bearings, the holes for measuring the temperature in the
bearing segments and the associated temperature measuring instrument
connections in the bearing housings and/or bearing covers must be in
alignment.

CAUTION
Incorrect adjustment of rotor position
Damage to the pump (set)!
▷ Never change the rotor position when measuring the balancing device.

Angular contact ball bearings CHTR 2-3

1. Dismantle all components including balance drum 603.01 and throttle bush
542.01 in reverse order and move pump rotor to non-drive end.
2. Fit non-drive end shaft seal housing 441.02 and cooling chamber cover 165.01
to cover 160.01, without O-rings.
3. Position rotor. (⇨ Section 7.5.4.1 Page 99)
4. Measure the distance "d" from the contact face of the angular contact ball
bearing 320 in bearing housing 350.02 to the outer face of the bearing housing.
5. Fit non-drive end bearing housing 350.02.

n 504.01
350.02
m

501.04

184.73
OIM_CHTR 012

Fig. 51: Adjusting the thrust bearings CHTR 2-3 (angular contact ball bearings)
Z Unmachined
b Machined
6. Fit segmental ring 501.04 and spacer ring 504.01 along with the shaft. Ensure
proper engagement of spacer ring and segmental ring using clamping ring
184.73, stud 902.72 and nut 920.72 as shown in the figure. Measure the distance
"m" on the clamping ring and the distance "n" from the outer face of the
bearing housing to the face of the clamping ring (see figure: Adjusting the
thrust bearings CHTR 2-3).

CHTR 101 of 168

 7 Servicing/Maintenance

NOTE
Machine the contact face of spacer ring 504.01 abutting against clamping ring
184.73.

7. Shorten spacer ring 504.01 to the dimension "b" , where b = Z-[(n + d)-m].
"Z" is the unmachined length of spacer ring 504.01.
The maximum permissible deviation from plane parallelism for spacer ring
504.01 is 0.02 mm/0.0008 in.

Angular contact ball bearings CHTR 4-5

1. Dismantle all components including balance drum 603.01 and throttle bush
542.01 in reverse order and move pump rotor to non-drive end.
2. Fit non-drive end shaft seal housing 441.02 and cooling chamber cover 165.01
to cover 160.01, without O-rings.
3. Position rotor. (⇨ Section 7.5.4.1 Page 99)
4. Measure the distance "d" from the contact face of the angular contact ball
bearing 320 in bearing housing 350.02 to the outer face of the bearing housing.
5. Fit non-drive end bearing housing 350.02.

902.71 504.01
n d
350.02
m

Z 504.01
b

920.71 184.74

320

CHTR 4-5 OIM_CHTR 013

Fig. 52: Adjusting the thrust bearings CHTR 4-5 (angular contact ball bearings)
Z Unmachined
b Machined
6. Slide spacer ring 504.01 over shaft until it abuts against the shaft collar.
7. Ensure proper abutment of spacer ring against shaft collar using clamping ring
184.74, stud 902.71 and nut 920.71 as shown in the figure. Measure the distance
"m" on the clamping ring and the distance "n" from the outer face of the
bearing housing to the face of the clamping ring as shown in the figure:
Adjusting the thrust bearing CHTR 4-5 (angular contact ball bearing)).
8. Shorten spacer ring 504.01 to the dimension "b" , where b = Z-[(n + d)-m].
The maximum permissible deviation from plane parallelism is 0.02 mm/0.0008
in.

Tapered roller bearings CHTR 2-3

1. Dismantle all components including balance drum 603.01 and throttle bush
542.01 in reverse order and move pump rotor to non-drive end.

102 of 168 CHTR

7 Servicing/Maintenance

2. Fit non-drive end shaft seal housing 441.02 and cooling chamber cover 165.01
to cover 160.01, without O-rings.
3. Position rotor. (⇨ Section 7.5.4.1 Page 99)
4. Measure distances L1, L2, l1, l2 and X (as shown in the figure: Bearing
dimensions).

L1 X L2

l1 l2
c

OIM_CHTR 018

Fig. 53: Bearing dimensions

5. Measure and add the (axial) length of both inner rings = l1 + l2.
6. Measure and add the (axial) length of both outer rings = L1 + L2.
7. Measure the (axial) length of the intermediate bearing ring = X.
8. Determine the distance "c" as follows: c = [(L1 + L2 + X) – (l1 + l2)] / 2.
9. Measure the distance "d" from the contact face of tapered roller bearing 324 in
bearing housing 350.02 to the outer face of the bearing housing.
10. Fit non-drive end bearing housing 350.02.
11. Fit segmental ring 501.04 and spacer ring 504.01 along with the shaft.

CHTR 103 of 168

 7 Servicing/Maintenance

n 504.01
350.02
m

Z c
b
501.04

184.73
324

OIM_CHTR 019
CHTR 2-3
Fig. 54: Adjusting the thrust bearings CHTR 2-3 (tapered roller bearings)
12. Ensure proper engagement of spacer ring and segmental ring using clamping
ring 184.73, stud 902.72 and nut 920.72 as shown in the figure: Adjusting the
thrust bearing CHTR 2-3 (tapered roller bearing)). Measure the distance "m" on
the clamping ring and the distance "n" from the outer face of the bearing
housing to the face of the clamping ring as shown in the figure. Shorten spacer
ring 504.01 to the dimension "b", where b = Z-[(n + d)-m]+c.
"Z" is the unmachined length of spacer ring 504.01. The maximum permissible
deviation from plane parallelism for spacer ring 504.01 is 0.02 mm/0.0008 in.

Tapered roller bearings CHTR 4-5

1. Dismantle all components including balance drum 603.01 and throttle bush
542.01 in reverse order and move pump rotor to non-drive end.
2. Fit non-drive end shaft seal housing 441.02 and cooling chamber cover 165.01
to cover 160.01, without O-rings.
3. Position rotor. (⇨ Section 7.5.4.1 Page 99)
4. Measure distances L1, L2, l1, l2 and X (as shown in the figure: Bearing
dimensions).
5. Measure and add the (axial) length of both inner rings = l1 + l2.
6. Measure and add the (axial) length of both outer rings = L1 + L2.
7. Measure the (axial) length of the intermediate bearing ring = X.
8. Determine the distance "c" as follows: c = [(L1 + L2 + X) – (l1 + l2)] / 2.
9. Measure the distance "d" from the contact face of tapered roller bearing 324 in
bearing housing 350.02 to the outer face of the bearing housing.
10. Fit non-drive end bearing housing 350.02.

104 of 168 CHTR

 7 Servicing/Maintenance

902.71 504.01
n d 350.02

m
c

Z 504.01
b

920.71 184.74

324

OIM_CHTR 020
CHTR 4-5
Fig. 55: Adjusting the thrust bearings CHTR 4-5 (tapered roller bearings)
11. Slide spacer ring 504.01 over shaft until it abuts against the shaft collar.
12. Ensure proper abutment of spacer ring against shaft collar using clamping ring
184.74, stud 902.78 and nut 920.78 as shown in the figure: Adjusting the thrust
bearing CHTR 4-5 (tapered roller bearing). Measure the distance "m" on the
clamping ring and the distance "n" from the outer face of the bearing housing
to the face of the clamping ring as shown in the figure: Adjusting the thrust
bearing CHTR 4-5 (tapered roller bearing).
13. Shorten spacer ring 504.01 to the dimension "b", where b = Z-[(n + d)-m] + c.
"Z" is the unmachined length of spacer ring 504.01. The maximum permissible
deviation from plane parallelism is 0.02 mm/0.0008 in.

CHTR 105 of 168

 7 Servicing/Maintenance

7.5.4.3 Positioning the cylindrical roller bearings - CHTR 2-5

Fig. 56: Adjusting the cylindrical roller bearings

1. Fit drive end shaft seal housing 441.01 and cooling chamber cover 165.01 to
inlet ring 131/131.02, without O-rings.
2. Fit drive end bearing housing 350.01. Fit circlip 932.01 and spacer ring 504.03.
3. Measure the distance "a" between the contact face of rolling element bearing
(cylindrical roller bearing) 322 in bearing housing 350.01 and spacer ring 504.03.
4. Shorten spacer ring 504.03 to the dimension "b": b = x - a.
(x= unmachined length of spacer ring 504.03)
The maximum permissible deviation from plane parallelism is 0.02 mm/0.0008
in.

7.5.5 Mounting the balancing device

CAUTION
Insufficient face contact
Damage to the pump (set)!
▷ If throttle bush 542.01 or balance drum 603.01 have been remachined or
replaced, check the dimensions and adapt the size of the components, if
required. (⇨ Section 7.5.4 Page 99)

CHTR 2-5
1. Insert parallel pin 562.03 into cover 160.01, if applicable.
2. Fit throttle bush 542.01 including O-ring 412.05 or joint ring 411.05 and/or O-
ring 412.04. Parallel pin 562.03, if applicable, must engage in the groove of
throttle bush 542.01. Fasten with socket head cap screws 914.14. (Tightening
torque as per work instruction UA3 37821 01)

106 of 168 CHTR

7 Servicing/Maintenance

Fig. 57: Adjusting the pump rotor position

1 Discharge side 2 Suction side

CAUTION
Incorrect installation
Damage to the pump rotor through incorrect tightening torques!
▷ Apply tightening torque as per work instruction UA3 37821 01.
3. For the adjustment of the rotor position refer to figure Adjusting the pump
rotor position.
4. Move the pump rotor towards the discharge side until it abuts and then move it
back to the suction side by a distance = SL1. (For SL1 refer to Table of Clearances
(⇨ Section 9.2.3 Page 122) ).
5. Fit O-ring 412.02 or joint ring 411.02 into groove of balance drum 603.01. Slide
balance drum 603.01 onto shaft 210 until key 940.04 snaps into place.
6. Slide spacer ring 504.02 onto shaft 210.
7. Place key 940.04 on shaft 210.

CHTR 2-3
1. Tighten shaft nut 921 on shaft 210 using an appropriate tool as described in the
work instruction UA3 37819 01.

CHTR 4-5
1. Insert segmental ring 501.01 into shaft groove. Slide loose collar 505.01 over
them and fasten to balance drum 603.01 using socket head cap screws 914.10;
for tightening torque refer to the relevant work instruction UA3 37821 01.

7.5.6 Fitting the shaft seal

DANGER
Improper connection of auxiliary lines
Explosion hazard from escaping leakage or fluid!
▷ Correctly install the auxiliary lines.
▷ Observe the maintenance and monitoring schedules.

WARNING
Damaged shaft sleeve and mechanical seals
Risk of personal injury in the event that hot, pressurised fluid handled escapes!
▷ Replace damaged shaft sleeves and mechanical seals by new components.
▪ Observe the tightening torques.
▪ Observe the direction of rotation of the seal components.
▪ Observe the general drawings of the mechanical seal and the manufacturer’s
product literature.

CHTR 107 of 168

 7 Servicing/Maintenance

Preparations on the drive end

1. If studs 902.01 have been removed, re-insert them.
2. Fit shaft seal housing 441.01 along with neck bush 456.01 and grub screw
904.06 including parallel pin 562.08 and O-rings 412.06 or joint ring 411.06,
depending on the variant, to inlet ring 131 or 131.02. Parallel pin 562.17 must
engage in the groove of shaft seal housing 441.01.
3. Fit cooling chamber cover 165.01 including O-rings 412.03 and 412.11. Parallel
pin 562.08 must engage in the groove of cooling chamber cover 165.01. Place
thick spacers on any four studs 902.01 at 90 degrees and tighten four nuts
920.05 on them.
4. Place studs 902.10 in position.

Preparations on the non-drive end

1. If studs 902.04 have been removed, re-insert them (if applicable).
2. Fit shaft seal housing 441.02 along with neck bush 456.02 and grub screw
904.06 including parallel pin 562.09 and O-rings 412.07 or joint ring 411.07,
depending on the variant, to cover 160.01. Parallel pin 562.07 must engage in
the groove of shaft seal housing 441.02.
3. If applicable, fit discs 550.04 and hexagon nuts 920.04 and tighten them.
Tightening torques, see the relevant work instruction.
4. Fit cooling chamber cover 165.01 including O-rings 412.03 and 412.11. Parallel
pin 562.09 must engage in the groove of cooling chamber cover 165.01.
5. Place thick spacers on any four studs 902.05 at 90 degrees and tighten four nuts
920.05 on them.
6. Place studs 902.10 in position.

7.5.6.1 Installing the mechanical seal

WARNING
Damaged shaft sleeve and mechanical seals
Risk of personal injury in the event that hot, pressurised fluid handled escapes!
▷ Replace damaged shaft sleeves and mechanical seals by new components.
▪ Observe the tightening torques.
▪ Observe the direction of rotation of the seal components.
▪ Observe the general drawings of the mechanical seal and the manufacturer’s
product literature.

Fig. 58: Locking sleeve (example)

A Locking sleeve B Locking screw
C Shrink disc D Shaft sleeve
E Shaft
1. Mount the seal cover along with shaft sleeve and mechanical seal cartridge
assembly 433.01 and 433.02 over the shaft 210, and gently push till the seal
cover abuts the shaft seal housing 441.02. Ensure proper rotor position.

108 of 168 CHTR

7 Servicing/Maintenance

2. Fit the hexagon nuts 920.10 and tighten; for tightening torque see the relevant
work instruction.
3. Lock the mechanical seal shaft sleeve on the shaft 210 with the grub screws.

NOTE
Do not tighten the locking screws prior to sliding on the locking sleeve, otherwise
the locking sleeve or shaft sleeve cannot be mounted.

4. Slide the locking sleeve (A) over the shaft sleeve (D) and join with the locking
screw as shown in the figure: Locking sleeve (example)).
5. In the area of the locking sleeve seat, the outer surface of the shaft sleeve may
be greased.

CAUTION
Improper reassembly
Destruction of the locking screws or insufficient preload!
▷ Do not tighten the locking screws in diagonally opposite sequence.
6. Tighten the locking screws uniformly and one after the other in anti-clockwise
direction. The tightening torque for the locking screws is stamped on the
locking sleeve.
7. At the end of the mounting process, the faces of locking sleeve and shrink disc
must be in alignment.

7.5.7 Installing the bearings

CAUTION
Improper dismantling/installation
Damage to the shaft and bearings!
▷ When the bearings are dismantled ensure that the shaft never rests on the
bearing housings or labyrinth rings or is rotated.
▷ Mark the bearings to ensure their correct assignment to the bearing housings.

CAUTION
Installation of defective or damaged bearings
Damage to the pump!
▷ Re-use only bearings which are in perfect condition.
▷ In the case of slight discolourations or any damage, the bearings must be
replaced.
▷ After washing the bearings out, immediately spray them with oil.

CAUTION
Improper reassembly
Damage to the rotor parts!
▷ Adjustment work may only be effected by trained specialist personnel!
▷ Carry out the work with special care.
For mounting the bearings observe the relevant assembly drawing UA3 37819 01.

7.5.7.1 Fitting the bearing housing

1. Fasten the bearing housing to the crane by means of eyebolt and rope.
2. Remove the hexagon nuts 920.05 and the thick spacers from the stud 902.01 or
902.05 on the drive end.

CHTR 109 of 168

 7 Servicing/Maintenance

3. If cooling chamber cover 165.01 and O-rings 412.03 and 412.11 have been
removed, place them back in position on the drive and non-drive ends.
4. Fit bearing housing 350.01 and/or 350.02 including labyrinth seal 423.01 and
parallel pin 562.10, if applicable. If applicable, observe the information on the
installation of INPRO labyrinth seal 423.01. (⇨ Section 7.5.7.1.2 Page 110) (⇨
Section 7.5.7.1.1 Page 110)
5. Fit discs 550.05 and hexagon nuts 920.05. Tighten hexagon nuts applying the
tightening torque indicated in the relevant work instruction.
6. Fit bearing guard 680.03 with discs 550.14 and hexagon head bolt 901.05 to
bearing housing 350.01.
7. Water cooling design: Insert cooling chamber cover 165.03 and/or 165.04
including O-ring 412.19 and/or 412.27 and cooling insert 442.01 and/or 442.02
including O-ring 412.19 into bearing housing 350.01 and/or 350.02.
Air cooling design: Insert cooling chamber cover 165.03 and/or 165.04 including
O-ring 412.19 and/or 412.27 and cooling insert 442.01 and/or 442.02 including
O-ring 412.19 into bearing housing 350.01 and/or 350.02.
8. Fit nuts 920.07 with discs 550.07 on studs 902.07 or 902.08 and tighten.

7.5.7.1.1 Fitting INPRO labyrinth seal into non-drive end bearing housing (if
applicable)

WARNING
Incorrect installation
Damage to the mechanical seal!
▷ Do not remove the assembly fixtures of mechanical seal before the assembly of
pump is completed.
✓ Observe work instruction UA1 37858 01 for the installation of the INPRO
labyrinth seal.
1. Fit labyrinth seal 423.01, spacer ring 504.01 and segmental ring 501.04 on shaft
210.
2. Slide bearing housing 350.02 over spacer ring 504.01 and segmental ring 501.04
to fit it into cooling chamber cover 165.01.
3. Position the bearing housing on studs 902.05. Engage the outer diameter of
labyrinth seal 423.02 into the inner diameter of bearing housing 350.02.
Tighten nuts 920.05 on studs 902.05 until bearing housing 350.02 along with
labyrinth seal 423.02 moves close enough to the face of mechanical seal 433.02
so that segmental ring 501.20 can be inserted tightly into the gap between the
face of labyrinth seal 423.02 and the face of mechanical seal 433.02.
4. Continue tightening hexagon nuts 920.05 to fasten bearing housing 350.02 to
cooling chamber cover 165.01 until the outer diameter of labyrinth seal 423.02
engages completely into the inner diameter of bearing housing 350.02.
5. Loosen hexagon nuts 920.05 and remove bearing housing 350.02 until
segmental ring 501.20 is loosened and can be removed.
6. Again tighten hexagon nuts 920.05 to fasten bearing housing 350.02 to cooling
chamber cover 165.02.

7.5.7.1.2 Fitting INPRO labyrinth seal into drive end bearing housing (if applicable)

CAUTION

Damage to the mechanical seal!

▷ Do not remove the assembly fixtures of mechanical seal before the assembly of
pump is completed.
▷ Observe work instruction UA1 37858 01 for the installation of the INPRO
labyrinth seal.

110 of 168 CHTR

7 Servicing/Maintenance

1. Fit labyrinth seal 423.01, spacer ring 504.03 and circlip 932.01 on shaft 210.
2. Slide bearing housing 350.01 over spacer ring 504.03 to fit it into cooling
chamber cover 165.01.
3. Position the bearing housing on studs 902.01. Engage the outer diameter of
labyrinth seal 423.01 into inner diameter of bearing housing 350.01. Tighten
nuts 920.05 on studs 902.01 until bearing housing 350.01 along with labyrinth
seal 423.01 moves close enough to the face of mechanical seal 433.01 so that
segmental ring 501.20 can be inserted tightly into the gap between the face of
labyrinth seal 423.01 and the face of mechanical seal 433.01.
4. Continue tightening hexagon nuts 920.05 to fasten bearing housing 350.01 to
cooling chamber cover 165.01 until the outer diameter of labyrinth seal 423.01
engages completely into the inner diameter of bearing housing 350.01.
5. Loosen hexagon nuts 920.05 and remove bearing housing 350.01 until
segmental ring 501.20 is loosened and can be removed.
6. Again tighten hexagon nuts 920.05 to fasten bearing housing 350.01 to cooling
chamber cover 165.02.

7.5.7.2 Fitting the thrust bearing

CAUTION
Incorrect measurement values due to improperly installed temperature measuring
instrument.
Damage to the pump (set)!
▷ When mounting the bearings, the holes for measuring the temperature in the
bearing segments and the associated temperature measuring instrument
connections in the bearing housings and/or bearing covers must be in
alignment.
1. Fasten thrust bearing housing 350.02 to the crane by means of eyebolt and
rope.
2. Position rotor. (⇨ Section 7.5.5 Page 106)
3. For CHTR 2-3, insert segmental ring 501.04. Slide appropriately machined spacer
ring 504.01 onto shaft 210. (⇨ Section 7.5.4 Page 99)
As a general rule, always use a new spacer ring 504.01! This will ensure correct
positioning of the thrust bearing.

Fig. 59: Adjusting the thrust bearings

CHTR 111 of 168

 7 Servicing/Maintenance

WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
4. To facilitate fitting, the inner rings of the two angular contact ball bearings or
the two tapered roller bearings respectively may be heated uniformly to a
temperature of 110-120°C/230-248°F.
5. Use an appropriate device as described in assembly sketch UA3 37819 03 E to
slide the angular contact ball bearings 320 or tapered roller bearings 324 in
pairs onto shaft 210 and insert them into bearing housing 350.02.
6. Slide spacer sleeve 525.05 onto shaft 210.
7. Place slotted nut 920.12 onto the shaft. Tighten with normal hammer
tightening. Fit disc 550.06 and hexagon socket head cap screw 914.06 and
tighten with the tightening torque indicated in the relevant work instruction.
8. If applicable, insert oil ring 644.02 into the designated groove of spacer sleeve
525.05.

NOTE
If a tapered roller bearing is used, ensure parallel pin 562.04 is fitted between the
bearing housing and the non-drive end bearing cover.

9. Fit bearing cover 360.01 including labyrinth seal 423.02 and O-ring 412.09 along
with fan hood part 832.02. If a tapered roller bearing is used, parallel pin 562.10
must engage in the corresponding groove of bearing cover 602.01. Tighten
hexagon head bolts 901.03 uniformly; for tightening torque, see the relevant
work instruction.
10. Fit key 940.06 into the keyway of shaft 210.
11. Fit adapter 82-5 with assembled fan impeller 831 on the shaft, engaging key
940.06.
12. Place circlip 932.02 in its designated groove on shaft 210.
13. Fit fan hood 832.01 and secure in place using hexagon head bolts 901.02 and
discs 550.02.

NOTE
The bearing cover and the bearing housing have cast-on markings. Ensure during
assembly of the angular contact ball bearings that both markings coincide. They
need not coincide for the assembly of the tapered roller bearings.

NOTE
Zero axial clearance is required between bearing cover and bearing housing face!
Refer to work instructions (UA4 37827 01 and UA4 37828 01) (⇨ Section 9.4 Page
137)

7.5.7.3 Mounting the radial bearings

1. Slide circlip 932.01 into position and insert appropriately machined spacer ring
504.03 onto shaft. (⇨ Section 7.5.4 Page 99)
2. Slide inner ring of cylindrical roller bearing 322 onto shaft 210.

112 of 168 CHTR

7 Servicing/Maintenance

WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
3. To facilitate fitting, the inner ring of the cylindrical roller bearing 322 may be
heated uniformly to a temperature of 110-120°C/230-248°F.
4. Insert the outer ring of cylindrical roller bearing 322 including rollers and cage
in bearing housing 350.01.
5. Slide spacer sleeve 525.01 over the shaft 210. Tighten grub screws 904.16, secure
them with Loctite 221, and place oil ring 644.01 in the designated groove of
bearing sleeve 525.01.
6. Fit bearing cover 360.02 including O-ring 412.09 and labyrinth seal 423.01.
Tighten hexagon head bolts 901.01 uniformly; for tightening torque, see the
relevant work instruction.

NOTE
The bearing cover and the bearing housing have cast-on markings. Ensure during
assembly that both markings coincide.

NOTE
An axial clearance of about 0.5 to 1 mm/0.0197 to 0.0394 in is required between
bearing cover and bearing housing.

7.6 Installing the pump into the system

7.6.1 Transporting the pump to the place of installation

DANGER
Improper transport
Danger to life from falling parts!
▷ Observe the safety regulations for transport work. (⇨ Section 2 Page 9)
(⇨ Section 3 Page 14)
▷ Observe the applicable local occupational safety and accident prevention
regulations.

7.6.2 Aligning the pump set components

▪ See manufacturer's product literature

7.6.3 Mounting the coupling hubs

see (⇨ Section 5.8 Page 30)

7.6.3.1 Checking the shaft ends for run-out

see (⇨ Section 5.8.1 Page 31)

7.6.3.2 Fitting the coupling hubs (with key)

see (⇨ Section 5.8.2 Page 31)

CHTR 113 of 168

 7 Servicing/Maintenance

7.6.4 Aligning the coupling

Checking the coupling alignment, see (⇨ Section 5.12 Page 35)
Alignment corrections on the pump (⇨ Section 5.13 Page 38)

7.6.5 Fitting the coupling spacer

1

2
3

Fig. 60: Coupling with spacer

1 Coupling hub (pump end) 2 Intermediate piece
3 Coupling hub (drive end) X Marking
✓ The coupling guard has been dismantled.
1. Fit the spacer of the coupling as described in the manufacturer’s product
literature.

7.7 Fastening the pump feet

▪ according to (⇨ Section 5.18.1 Page 47)
Drive, see manufacturer's product literature

7.8 Fitting the piping and instruments

▪ Re-mount all pipes and instruments which have been dismantled in connection
with maintenance work.

7.9 Fitting the contact guards

▪ according to (⇨ Section 6.3.9 Page 57)

7.10 Maintenance of the other pump set components

Coupling
▪ See manufacturer's product literature

Drive
▪ See manufacturer's product literature

Minimum flow system/valve

▪ See manufacturer's product literature

Instruments and valves

▪ Maintenance is not required; in the case of malfunction, the instruments are
replaced.

114 of 168 CHTR

 7 Servicing/Maintenance

Oil supply system etc. (if applicable)

▪ See manufacturer's product literature

Gear/variable speed coupling (if applicable)

▪ See manufacturer's product literature

7.11 Spare parts stock

7.11.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:
▪ Type series or pump set components
▪ KSB order number
▪ Order item number
▪ Consecutive number
Refer to the name plate for all data. (⇨ Section 4.4 Page 23)
Also specify the following data:
▪ Description
▪ Part No.
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)
Refer to the general assembly drawing for part numbers and descriptions. (⇨ Section
9 Page 121)

7.11.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 19: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 10 and
more
210.01/.02 Shaft (complete with small 1 1 1 2 2 2 20 %
parts)
230 Impeller (set) 1 1 1 2 2 2 20 %
314 Thrust bearing5) 1 1 2 2 3 4 50 %
320 Rolling element bearing (set)5) 1 1 2 2 2 3 25 %
322 Radial roller bearing5) 1 1 2 2 2 3 25 %
324 Thrust roller bearing5) 1 1 2 2 2 3 25 %
370 Bearing shell5) 1 1 2 2 3 4 50 %
384 Thrust bearing plate 1 1 2 2 3 4 50 %
388 Counter thrust bearing plate5) 1 1 2 2 3 4 50 %
400 Gasket (set) 4 6 8 8 9 10 100 %
411 Joint ring 4 6 8 8 9 10 100 %
412 O-ring (set) 4 6 8 8 9 10 100 %
420.01 Shaft seal ring 4 6 8 8 9 10 100 %
423.01 Labyrinth ring 4 6 8 8 9 10 100 %
433 Mechanical seal5) 1 1 2 2 2 3 25 %
456 Neck bush5) 1 1 2 2 2 3 30 %
501.01 Segmental ring 1 1 2 2 3 4 50 %
502.01/.02 Casing wear ring 2 2 2 3 3 4 50 %
503.01/.02 Impeller wear ring5) 1 1 2 2 3 4 50 %
/.04

5) if applicable for pump variant selected

CHTR 115 of 168

 7 Servicing/Maintenance

Part No. Description Number of pumps (including stand-by pumps)

2 3 4 5 6 and 7 8 and 9 10 and
more
504.01/.02 Spacer ring 1 1 2 2 3 4 50 %
505.01 Loose collar 1 1 2 2 3 4 50 %
522.01 Throttle sleeve 1 1 2 2 3 4 50 %
523.01/.02 Shaft sleeve5) 2 2 2 3 3 4 50 %
525.01/.02 Spacer sleeve5) 1 1 2 2 3 4 50 %
542.01/.02 Throttle bush5) 1 1 2 2 3 4 50 %
541 Interstage bush 2 2 2 3 3 3 30 %
603.01/.02 Balance drum5) 1 1 2 2 3 4 50 %

116 of 168 CHTR

 8 Trouble-shooting

8 Trouble-shooting
This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

8.1 Trouble-shooting
If problems occur that are not described in the following table, consultation with
KSB’s customer service is required.
Table 20: Trouble-shooting
Fault/malfunction Possible cause Remedy
Pump flow rate < specified Pump delivers against an Keep opening the shut-off element in the discharge
value excessively high pressure line until the duty point is reached.
Excessive back pressure Mount larger impeller(s).
Contact KSB’s service centre.
Increase the speed of the turbine or the combustion
engine.
Check system for impurities.
Pump and/or piping not Vent and/or prime.
completely vented and/or
primed
Inlet pipe or impeller(s) clogged. Remove deposits in the pump and/or piping.
Formation of air pockets in the Alter piping layout.
piping Fit a vent valve.
NPSHavailable (positive suction Check/alter the fluid level.
head) is too low Fully open the shut-off element in the inlet pipe.
Change inlet pipe if the friction losses in the inlet
pipe are too high.
Check any strainers installed.
Excessive speed of pressure fall Observe permissible speed of pressure fall.
Suction head too high Clean the strainer element and inlet pipe.
Correct/alter the fluid level.
Change the inlet pipe.
Check any strainers installed.
Wrong direction of rotation Interchange 2 phases of the power supply.
Speed is too low Increase the speed.
Increase the voltage.
Contact KSB’s service centre.
Internal parts worn Replace defective parts.
Contact KSB’s service centre.
Motor is running on two phases Replace defective fuses.
only. Check the power cable connections.
Pump discharge pressure pd Speed is too high Alter the impeller diameter.
> specified value Contact KSB’s service centre.
Inlet pressure ps < specified Damaged measuring instrument Replace the measuring instrument.
value Differential pressure in strainer Dismantle and clean the strainer element.
element too high
Shut-off element in the inlet Open the shut-off element.
pipe not fully open
Pressure in the inlet vessel too Check the inlet vessel and/or increase the pressure.
low
Pump discharge pressure pd Damaged measuring instrument Replace the measuring instrument.
< specified value Speed is too low Check the drive.
Inlet pressure too low Check the inlet pressure and inlet vessel.
Temperature of the medium Increase/reduce the temperature.
pumped is too low or too high.
Defective minimum flow system Check the minimum flow system.
Leakage at the shaft seal Defective shaft seal Check; replace, if required.
Score marks or roughness on Check shaft sleeve 523; replace, if required.
shaft sleeve 523
Seal cover tightened incorrectly Check.

CHTR 117 of 168

 8 Trouble-shooting

Fault/malfunction Possible cause Remedy

Pump set alignment Check the coupling; re-align, if required.
Pump warped Check piping connections and secure fixing of pump.
Insufficient cooling liquid Increase cooling liquid quantity.
Dirty cooling liquid chamber or Clean the cooling liquid chamber and/or cooler.
cooler Check the cooling liquid; clean, if required.
Fault in the circulation liquid Increase the free cross-section.
pipe. Check piping.
Excessive surface pressure at the Check installation dimensions.
sealing clearance, lack of Contact KSB’s service centre.
lubricant/circulation liquid
Excessive bearing Defective bearing(s) Check; replace, if required.
temperature Oil quantity Check the oil quantity; top up or replace, if required.
Oil quality Check.
Increased axial thrust Check the casing wear rings/balancing device;
replace, if required.
Contact KSB’s service centre.
Internal parts worn Replace defective parts.
Contact KSB’s service centre.
Pump rotor is out of balance Clean the pump rotor.
Balance the pump rotor.
Pump set misaligned Check the coupling and re-align, if required.
Pump warped Check piping connections and secure fixing of pump.
Coupling hub distance Check the coupling hub distance for compliance with
the general arrangement drawing; correct, if
required.
Lubricating ring cannot move Prior to commissioning check whether the
freely lubricating ring can move freely via the inspection
hole in the bearing housing. For this purpose, rotate
the pump rotor by hand. If necessary, restore the
rotor's free movement.
Temperature of pump > Pump and/or piping not Vent and/or prime.
specified value completely vented and/or
primed
NPSHavailable (positive suction Check/alter the fluid level.
head) is too low Fully open the shut-off element in the inlet pipe.
Change inlet pipe if the friction losses in the inlet
pipe are too high.
Check any strainers installed.
Excessive speed of pressure fall Observe permissible speed of pressure fall.
Flow rate < specified value Flow rate ≥ Qmin
Loose tie bolts Re-tighten.
Contact KSB’s service centre.
Pump leakage Defective O-rings and/or metallic Fit new O-rings and/or re-machine the metallic
sealing surfaces sealing surfaces.
Contact KSB’s service centre.
Tie bolts have worked loose. Re-tighten.
Contact KSB’s service centre.
Pump runs rough Pump and/or piping not Vent and/or prime.
completely vented and/or
primed
NPSHavailable (positive suction Check/alter the fluid level.
head) is too low Fully open the shut-off element in the inlet pipe.
Change inlet pipe if the friction losses in the inlet
pipe are too high.
Check any strainers installed.
Excessive speed of pressure fall Observe permissible speed of pressure fall.
Internal parts worn Replace defective parts.
Contact KSB’s service centre.
Pump back pressure is lower Adjust duty point accurately by means of the shut-
than specified in purchase order off element in the discharge line.
In the case of persistent overloading, turn down the
impeller(s), if necessary.

118 of 168 CHTR

 8 Trouble-shooting

Fault/malfunction Possible cause Remedy

Contact KSB’s service centre.
Pump set alignment Check the coupling; re-align, if required.
Pump warped Check piping connections and secure fixing of pump.
Oil quantity Check the oil quantity; top up or replace, if required.
Oil quality Check; replace, if required.
Pump rotor is out of balance Clean the pump rotor.
Balance the pump rotor.
Defective bearing(s) Replace.
Flow rate < specified value Flow rate ≥ Qmin
Cavitation noise in the Damaged inlet pipe Check the inlet pipe.
pump and/or piping Shut-off element in the inlet Open shut-off element in the inlet pipe.
pipe not fully open
Pressure in the inlet vessel too Check the inlet vessel and/or increase the pressure.
low
NPSHavailable/NPSHrequired too low Check the inlet pipe.
Change the inlet pipe.
Excessive speed of pressure fall Observe permissible speed of pressure fall.
Air intake at seal elements, Check the piping; check shaft seal for leakage.
valves and shaft seal
Pump and/or piping are not Vent and/or prime.
completely vented
Temperature of fluid handled Reduce the temperature.
too high
Pump suddenly blocks. Mechanical blocking of the rotor Interrupt the energy supply, interlock and
depressurise the pump.
Contact KSB’s service centre.
Fluctuating balancing Pump and/or piping not Vent and/or prime.
liquid pressure/quantity completely vented and/or
primed
NPSHavailable (positive suction Check/alter the fluid level.
head) is too low Fully open the shut-off element in the inlet pipe.
Change inlet pipe if the friction losses in the inlet
pipe are too high.
Check any strainers installed.
Excessive speed of pressure fall Observe permissible speed of pressure fall.
Internal parts worn Replace defective parts.
Contact KSB’s service centre.
Increased axial thrust Check the casing wear rings/balancing device;
replace, if required.
Contact KSB’s service centre.
Change in cross-section of Check the mode of operation.
balancing liquid pipe; excessive Check return line.
friction losses; joining of several
pipes near the pump Check the pump pressures.
Balance flow leakage - balance Check the rotor clearances and balancing device.
disc seat/final stage diffuser
Wear of the balancing device Check the rotor clearances and balancing device.
Drive is overloaded Internal parts worn Replace defective parts.
Contact KSB’s service centre.
Pump back pressure is lower Re-adjust to duty point by means of the shut-off
than specified in purchase order element in the discharge line.
In the case of persistent overloading, turn down the
impeller(s), if necessary.
Contact KSB’s service centre.
Density or viscosity of the fluid Contact KSB’s service centre.
handled higher than specified in
the purchase order.
Gland follower tightened Correct.
excessively or cocked
Speed is too high Alter the impeller diameter.
Contact KSB’s service centre.
Reduce the speed of the drive.

CHTR 119 of 168

 8 Trouble-shooting

Fault/malfunction Possible cause Remedy

Pump warped Check piping connections and secure fixing of pump.
Supply voltage is too low. Check the power cable connections.
Motor is running on two phases Replace defective fuses.
only. Check the power cable connections.

120 of 168 CHTR

 9 Related Documents

9 Related Documents

9.1 User information

This section forms a part of the installation / operating manual and is not complete
by itself. The installation / operating manual must be read and understood in its
entirety.

9.2 Technical information

9.2.1 Noise characteristics

NOTE
The specified noise characteristics are based on proper installation of the pump (set)
in accordance with this manual. Improper isolation of pump (set) and building/plant
or an inappropriate piping layout may increase noise emission and/or the vibration
level.

100
LpA

90

80

70

60

2900 rpm
50
1 10 100 1000 10000 PN
Fig. 61: Noise characteristics
LpA6) Surface sound pressure level
PN Rated power input

9.2.2 Lubricants for plain bearings

Oil quality High quality oil of ISO viscosity grade VG 46 to DIN 51519 or ISO 3448, TD 46 to DIN
(recommendated) 51515 or of similar quality.

6) Measured at a distance of 1 m from the pump outline (as per DIN 45635 Parts 1 and 24)

CHTR 121 of 168

 9 Related Documents

9.2.3 Clearances

9.2.3.1 Clearance

Fig. 62: Clearance between inlet ring and shaft

Fig. 63: Clearance between balance drum and throttle bush

Fig. 64: Clearance between double balance drum, balance disc seat and throttle bush

122 of 168 CHTR

 9 Related Documents

Fig. 65: Impeller clearance

Table 21: Clearances S3 - S4
Size S3 S4
Operating temperature Operating temperature Operating temperature Operating temperature
< 260 °C > 260 °C < 260 °C > 260 °C
[mm/inch] [mm/inch] [mm/inch] [mm/inch]
2 0.45 - 0.563/ 0.6 - 0.713/ 0.4 - 0.496/ 0.5 - 0.596/
0.0177 - 0.0221 0.0236 - 0.0280 0.0157 - 0.0195 0.0196 - 0.0234
3 0.45 - 0.563/ 0.6 - 0.713/ 0.4 - 0.504/ 0.55 - 0.654/
0.0177 - 0.0221 0.0236 - 0.0280 0.0157 - 0.0198 0.0216 - 0.0257
4 0.45 - 0.622/ 0.6 - 0.722/ 0.55 - 0.654/ 0.55 - 0.654/
0.0177 - 0.0244 0.236 - 0.0303 0.216 - 0.257 0.0216 - 0.0257
5 0.5 - 0.672/ 0.65 - 0.772/ 0.55 - 0.654/ 0.55 - 0.654/
0.0196 - 0.0264 0.0255 - 0.0303 0.216 - 0.257 0.0216 - 0.0257
Maximum 1.0 / 0.0394 1.0 / 0.0394
permissible
clearance gap
Table 22: Clearances S5 - S9
S5 S6 S7 S9
Hydraulic system

[mm/inch] [mm/inch] [mm/inch] [mm/inch]

Size

2 3 0.3 - 0.355 / 0.25 - 0.335 / 0.35 - 0.44 / 0.7 - 0.9 /

4 0.0118 - 0.0139 0.0098 - 0.0131 0.0137 - 0.0173 0.0275 - 0.0354
3 5 0.3 - 0.360 / 0.30 - 0.35 / 0.45 - 0.546 /
6 0.0118 - 0.0141 0.0118 - 0.0137 0.0177 - 0.0214
4 7 0.3 - 0.350 / 0.35 - 0.40 / 0.45 - 0.499 /
8 0.0118 - 0.0137 0.0137 - 0.0157 0.0177 - 0.0196
5 9 0.4 - 0.480 / 0.35 - 0.40 / 0.45 - 0.502 /
0.0157 - 0.0180 0.0137 - 0.0157 0.0177 - 0.0197
10 0.45 - 0.50 /
0.0177 - 0.0196
Maximum 1.0 / 1.0 / 1.0 - 1.2 / 1.4 /
permissible 0.0394 0.0394 0.0394 - 0.0472 0.0551
clearance gap

CHTR 123 of 168

 9 Related Documents

Table 23: Clearances SL2/SL3

Size SL2 SL3
[mm/inch] [mm/inch]
2 0.6 - 0.75 / 0.15 - 0.20 /
0.0236 - 0.2095 0.0059 - 0.00787
3 0.20 - 0.30 /
4 0.00787 - 0.0118
5

9.2.3.2 Plain bearing clearance

Fig. 66: Plain bearing clearance

Table 24: Plain bearing clearance
Size Pressure Bearing clearance SLG3 (diametral
[bar] clearance)
[mm] [inch]
2 250 0.059 - 0.1 0.0023 - 0.0039
3, 4, 5 250 0.1 - 0.135 0.0039 - 0.0053
5 100 0.09 - 0.166 0.0035 - 0.0065

124 of 168 CHTR

 9 Related Documents

9.2.3.3 Tilting-pad thrust bearing clearance

CHTR sizes 3 to 5 (250 bar) Sizes CHTR 5 (100 bar), CHTR 2 (250 bar),
Table 25: Tilting-pad thrust bearing clearances
Size Pressure Bearing clearance SLG 2 (diametral
[bar] clearance)
[mm] [inch]
2, 3, 4, 5 250 0.40 - 0.60 0.0157 - 0.0236
5 100 0.30 - 0.50 0.0118 - 0.0196

9.2.3.4 Total theoretical axial clearances

Table 26: Total theoretical axial clearances
Size Hydraulic SA1 + SA2 SL1
system [mm] [inch] [mm]
2 3 8.0 - 8.5 0.315 - 0.335 5.5
4 6.0 - 6.5 0.236 - 0.256 3.5
3 5 8.0 - 8.5 0.315 - 0.335 5.5
6 5.5 - 6.0 0.217 - 0.236 3.0
4 7 6.5 - 8.0 0.256 - 0.315 3.5
8
5 9 8.5 - 10.0 0.335 - 0.394 4.5
10

9.2.4 Tightening torques

CHTR 2-5
Prerequisites 1. The threads of the screw/bolt and nut are not damaged.
2. The threads and bearing surfaces of the screws/bolts and nuts are plane,
deburred and cleaned thoroughly.
3. The threads move smoothly.
4. The washers are plane, deburrred and cleaned thoroughly.
Pump Observe the tightening torques for the screwed/bolted connections. (⇨ Section 9.4
Page 137)
Table 27: Tightening torques for pump feet fastening studs
Thread size Tightening torques MA
[Nm] [ftlb]
M20 190 140
M24 330 244

CHTR 125 of 168

 9 Related Documents

Thread size Tightening torques MA

[Nm] [ftlb]
M30 660 486
M36 1160 855
Flanged connection The tightening torques specified in this chapter apply to flange connection bolts
included in KSB’s scope of supply.
Foundation bolts and Tightening torques for foundation bolts and special foundation bolts, see general
special foundation bolts arrangement drawing.
Flange connection bolts The tightening torques only apply to bolts and screws included in KSB’s scope of
(suction nozzle, discharge supply.
nozzle and tapping Table 28: Tightening torques for flanges as per ANSI
nozzle)
Nominal diameter Nominal pressure Tightening torques Tightening torques
DN PN class MA MA
[inch] [Nm] [ftlb]
1" 600 80 59
1500 240 177
1.5" 600 140 103
1500 350 258
2" 600 90 66
1500 240 170
2.5" 600 140 103
1500 270 200
3" 600 120 88
1500 490 361
4" 600 210 155
1500 650 480
6" 600 350 258
1500 830 612
8" 600 460 339
1500 1350 995
10" 600 650 479
1500 1480 1092

9.2.5 Interlock criterion for rolling element and plain bearings (only applicable if
resistance thermometers or thermocouples are used)

NOTE
Do not open bearing temperature measuring connections 4M.7 and 4M.8 while the
pump is running. All values indicated are based on normal ambient temperatures.

Permissible temperature limits for rolling element bearings

▪ Radial rolling element bearing and rolling element thrust bearing
▪ Oil lubrication: Oil ring lubrication
▪ Minimum start-up temperature in oil sump: 10 °C / 50 °F (ISO-VG 32/ ISO-VG 15)
Table 29: Temperature limits/Tripping (rolling element bearings)
Temperature Alarm Tripping
measurement
At outer bearing ring 100 °C / 212 °F 110 °C / 230 °F
In oil sump 90 °C / 194 °F 100 °C / 212 °F

Permissible temperature limits for plain bearings

▪ Radial plain bearing and plain thrust bearing
▪ Oil lubrication: Forced-feed lubrication
▪ Minimum start-up temperature in reservoir: 10 °C / 50 °F (ISO-VG 32)

126 of 168 CHTR

 9 Related Documents

▪ Minimum start-up temperature in oil sump: 15 °C / 59 °F (ISO-VG 46)

Table 30: Temperature limits/Tripping (plain bearings)
Temperature Alarm Tripping
measurement
At outer bearing shell 90 °C / 194 °F 100 °C / 212 °F
At oil outlet 80 °C / 176 °F 90 °C / 194 °F

9.2.6 Permissible vibrations at the bearing housings (pump variants with plain or
rolling element bearings and grouted baseplates)

NOTE
The specified vibration values are based on proper installation of the pump (set) in
accordance with this manual. Improper isolation of pump (set) and building/plant or
an inappropriate piping layout may increase noise emission and/or the vibration
level.

Limits7) for unfiltered vibrations (vibration level) in the preferred operating range:
Q = 0.5 X Qopt to 1.25 X Qopt
Table 31: Vibration velocity RMS
Standard Alarm Tripping
Measuring mm/s inch/s mm/s inch/s mm/s inch/s
point
At the 3 0.12 ≥ 7.1 ≥ 0.28 ≥ 10.92 ≥ 0.43
bearing
housing

NOTE
An increase in vibration is allowed at flows outside the preferred operating range
but within the allowable operating range of 30 % of the values specified.

Limit value (guaranteed value) for vibration velocity:

Limit values for guaranteed effective vibration velocity Veff is 4.5 mm/s (RMS). 8)

Measuring point properties:

▪ The arrangement of measuring points is in accordance with DIN ISO 10816-1.
▪ For the type and quantity of the measuring instruments please refer to the P+I
diagram and the relevant list of measuring points in chapter 9.
▪ The frequency range shall be between 10 Hz and 1000 Hz (Class 3 to DIN ISO
10816-1:1997-08).
▪ Larger drives and other large machines with rotating mass, positioned on rigid
and heavy foundations which are relatively stiff in the direction of the vibrations
measured.

9.2.7 Concrete quality

Admixtures
Admixtures are substances which are added to the concrete and which, by chemical
or physical action or both, change the properties of the concrete, e.g. its workability,
hardening or setting. They provide negligible bulk.

7) As per API 610/10, values Table 7; these values do not apply to minimum flow operation.
8) The values correspond to the limit value stipulated for zone B in part III of DIN ISO 10816-1 (August 1997 edition).

CHTR 127 of 168

 9 Related Documents

Strength class to DIN 1045

Table 32: Strength classes for concrete
Exposure Minimum Clylinder compressive Cube compressive strength
class compressive strength
class [N/mm²] [lb/sq in] [N/mm²] [lb/sq in]
XC4 C25/30 25 3626 30 4351

Admixtures
For concrete and cement mortar - also for fixing any anchoring parts in position -
only admixtures as per item 2 and exhibiting a valid test symbol must be used, and
only under the conditions stated in the test certificate. Chlorides, chloride-containing
or other substances expediting the corrosion of steel must not be added to
reinforced concrete as well as concrete and mortar coming into contact with
reinforced concrete.

Minimum cement content allowing for admixtures

Table 33: Minimum cement content
Minimum compressive Minimum cement content Water cement value ω for
class of compacted concrete Z 35
[kg/m3]
B25/30 270 / 455 ≤ 0.60

Consistency of concrete
Concrete of consistency class F2, propagation value 35 to 41 cm (14 to 16 in) shall be
used.

9.2.8 Lubrication for rolling element bearings (oil ring lubrication)

Oil High-quality oil to ISO Class VG 32 to DIN 51519 or ISO 3448, TD32 to DIN 51515, or
quality(recommendation) equivalent.
Oil quantity Table 34: Oil quantity
Size Oil quantity [l/bearing housing]
2 0.75
3
4 1.85
5
4/1+ 1.85
5/1+
Intervals Table 35: Oil change intervals
First oil change All subsequent oil changes
After 500 operating hours Every 3000 operating hours and at least
once per year

9.2.9 Weights

NOTE
The weights indicated in the tables below are for orientation. The actual pump set
weight is indicated on the plate at the barrel casing.

128 of 168 CHTR

9 Related Documents

9.2.9.1 Weights 100 bar

Table 36: Weights for CHTR 2 (100 bar)
Part No. Description Weight (approx.)
[kg]
10-3 Barrel casing for 5 stages 415
Each additional stage 49
108 Stage casing 16
131 Inlet ring 55
160 Cover 100
171 Diffuser 6.4
210 Shaft for 5 stages 29.1
Each additional stage 0.6
230 Impeller 4.1
350 Bearing housing (suction side) 31
Bearing housing (discharge side) 31
441 Shaft seal housing (suction side) 16
Shaft seal housing (discharge side) 20
542 Throttle bush 7.15
603 Balance drum 11
- Rotor for 5 stages 62
- Each additional stage 5
- Pump cartridge for 5 stages 595
- Each additional stage 80
Table 37: Weights for CHTR 3 (100 bar)
Part No. Description Weight (approx.)
[kg]
10-3 Barrel casing for 5 stages 690
Each additional stage 73
108 Stage casing 27
131 Inlet ring 83
160 Cover 162
171 Diffuser 15
210 Shaft for 5 stages 43
Each additional stage 3
230 Impeller 7.5
350 Bearing housing (suction side) 31
Bearing housing (discharge side) 31
441 Shaft seal housing (suction side) 16
Shaft seal housing (discharge side) 32
542 Throttle bush 11.3
603 Balance drum 22
- Rotor for 5 stages 105
- Each additional stage 10.5
- Pump cartridge for 5 stages 1170
- Each additional stage 144
Table 38: Weights for CHTR 4 (100 bar)
Part No. Description Weight (approx.)
[kg]
10-3 Barrel casing for 5 stages 1299
Each additional stage 138
108 Stage casing 53.5
131 Inlet ring 91
160 Cover 320
171 Diffuser 15
210 Shaft for 5 stages 83
Each additional stage 5
230 Impeller 12.5
350 Bearing housing (suction side) 57

CHTR 129 of 168

 9 Related Documents

Part No. Description Weight (approx.)

[kg]
Bearing housing (discharge side) 57
441 Shaft seal housing (suction side) 36
Shaft seal housing (discharge side) 64
542 Throttle bush 22
603 Balance drum 31
- Rotor for 5 stages 169
- Each additional stage 17.5
- Pump cartridge for 5 stages 1741
- Each additional stage 230
Table 39: Weights for CHTR 4/1+ (100 bar)
Part No. Description Weight (approx.)
[kg]
10-3 Barrel casing for 5 stages 1571
Each additional stage 138
108 Stage casing 53.5
131 Inlet ring 151
160 Cover 320
171 Diffuser 15
210 Shaft for 5 stages 83
Each additional stage 5
230 Impeller 12.5
350 Bearing housing (suction side) 57
Bearing housing (discharge side) 57
441 Shaft seal housing (suction side) 36
Shaft seal housing (discharge side) 64
542 Throttle bush 22
603 Balance drum 31
- Rotor for 5 stages 169
- Each additional stage 17.5
- Pump cartridge for 5 stages 1754
- Each additional stage 230
Table 40: Weights for CHTR 5 (100 bar)
Part No. Description Weight (approx.)
[kg]
10-3 Barrel casing for 5 stages 2125
Each additional stage 230
108 Stage casing 89
131 Inlet ring 183
160 Cover 610
171 Diffuser 30
210 Shaft for 5 stages 111
Each additional stage 7
230 Impeller 20
350 Bearing housing (suction side) 57
Bearing housing (discharge side) 57
441 Shaft seal housing (suction side) 43
Shaft seal housing (discharge side) 77
542 Throttle bush 41
603 Balance drum 68
- Rotor for 5 stages 280
- Each additional stage 27
- Pump cartridge for 5 stages 2790
- Each additional stage 360

130 of 168 CHTR

9 Related Documents

Table 41: Weights for CHTR 5/1+ (100 bar)

Part No. Description Weight (approx.)
[kg]
10-3 Barrel casing for 5 stages 2529
Each additional stage 230
108 Stage casing 89
131 Inlet ring 260
160 Cover 610
171 Diffuser 30
210 Shaft for 5 stages 108
Each additional stage 7
230 Impeller 20
350 Bearing housing (suction side) 57
Bearing housing (discharge side) 57
441 Shaft seal housing (suction side) 43
Shaft seal housing (discharge side) 77
542 Throttle bush 41
603 Balance drum 68
- Rotor for 5 stages 300
- Each additional stage 27
- Pump cartridge for 5 stages 2786
- Each additional stage 360

9.2.9.2 Weights 250 bar

Table 42: Weights for CHTR 2 (250 bar)
Part No. Description Weight (approx.
kg)
10-3 Barrel casing for 5 stages 925
Each additional stage 95
108 Stage casing 16
131 Inlet ring 62
160 Cover 235
171 Diffuser 6.4
210 Shaft for 5 stages 31.6
Each additional stage 1.6
230 Impeller 4.1
350 Bearing housing (suction side) 38
Bearing housing (discharge side) 38
441 Shaft seal housing (discharge side) 47
542 Throttle bush 5
602 Balance disc seat 5.5
603 Balance drum 8.8
- Rotor for 5 stages 66
- Each additional stage 5
- Pump cartridge for 5 stages 1111
- Each additional stage 126
Table 43: Weights for CHTR 3 (250 bar)
Part No. Description Weight (approx.
kg)
10-3 Barrel casing for 5 stages 1440
Each additional stage 148
108 Stage casing 27
131 Inlet ring 110
160 Cover 342
165 Cooling chamber cover 30
171 Diffuser 15
210 Shaft for 5 stages 67
Each additional stage 3

CHTR 131 of 168

 9 Related Documents

Part No. Description Weight (approx.

kg)
230 Impeller 7.5
350 Bearing housing (suction side) 75
Bearing housing (discharge side) 130
441 Shaft seal housing (discharge side) 80
542 Throttle bush 6
602 Balance disc seat 12
603 Balance drum 18.7
- Rotor for 5 stages 134
- Each additional stage 10.5
- Pump cartridge for 5 stages 2144
- Each additional stage 205
Table 44: Weights for CHTR 4 (250 bar)
Part No. Description Weight (approx.
kg)
10-3 Barrel casing for 5 stages 2861
Each additional stage 269
108 Stage casing 53.5
13-6 Casing insert 223
131 Inlet ring 121
160 Cover 313
165 Cooling chamber cover 92
171 Diffuser 15
210 Shaft for 5 stages 99.4
Each additional stage 5
230 Impeller 12.5
350 Bearing housing (suction side) 75
Bearing housing (discharge side) 138
361 Non-drive end bearing cover 42
441 Shaft seal housing (discharge side) 142
542 Throttle bush 6.6
602 Balance disc seat 15.2
603 Balance drum 28.6
- Rotor for 5 stages 196
- Each additional stage 17.5
- Pump cartridge for 5 stages 2461
- Each additional stage 358
Table 45: Weights for CHTR 4/1+ (250 bar)
Part No. Description Weight (approx.
kg)
10-3 Barrel casing for 5 stages 3305
Each additional stage 270
108 Stage casing 53.5
13-6 Casing insert 223
131 Inlet ring 151
160 Cover 313
165 Cooling chamber cover 92
171 Diffuser 15
210 Shaft for 5 stages 106
Each additional stage 5
230 Impeller 12.5
350 Bearing housing (suction side) 75
Bearing housing (discharge side) 138
361 Non-drive end bearing cover 42
441 Shaft seal housing (discharge side) 142
542 Throttle bush 6.6
602 Balance disc seat 15.2
603 Balance drum 28.6
- Rotor for 5 stages 221

132 of 168 CHTR

9 Related Documents

Part No. Description Weight (approx.

kg)
- Each additional stage 17.5
- Pump cartridge for 5 stages 2659
- Each additional stage 358
Table 46: Weights for CHTR 5 (250 bar)
Part No. Description Weight (approx.
kg)
10-3 Barrel casing for 5 stages 3888
Each additional stage 409
108 Stage casing 89
13-6 Casing insert 325
131 Inlet ring 228
160 Cover 472
165 Cooling chamber cover 119
171 Diffuser 25
210 Shaft for 5 stages 135
Each additional stage 7
230 Impeller 21.5
350 Bearing housing (suction side) 137
Bearing housing (discharge side) 240
361 Non-drive end bearing cover 45
441 Shaft seal housing (suction side) 83
Shaft seal housing (discharge side) 187
542 Throttle bush 14
602 Balance disc seat 18.5
603 Balance drum 48
- Rotor for 5 stages 303
- Each additional stage 27
- Pump cartridge for 5 stages 3635
- Each additional stage 552
Table 47: Weights for CHTR 5/1+ (250 bar)
Part No. Description Weight (approx.
kg)
10-3 Barrel casing for 5 stages 4900
Each additional stage 409
108 Stage casing 89
13-6 Casing insert 325
131 Inlet ring 228
160 Cover 472
165 Cooling chamber cover 119
171 Diffuser 25
210 Shaft for 5 stages 120
Each additional stage 7
230 Impeller 20
350 Bearing housing (suction side) 75
Bearing housing (discharge side) 240
361 Non-drive end bearing cover 45
441 Shaft seal housing (discharge side) 187
542 Throttle bush 14
602 Balance disc seat 18.5
603 Balance drum 48
- Rotor for 5 stages 323
- Each additional stage 27
- Pump cartridge for 5 stages 3764
- Each additional stage 552

CHTR 133 of 168

 9 Related Documents

9.2.10 Original components to be re-installed when a spare cartridge is installed

If a spare cartridge is used, the following original components must be re-installed
during reassembly:
Table 48: Original components to be re-installed
Part No. Description CHTR 100 bar CHTR 250 bar
2 3 4 5 4/1 5/1 2 3 4 5 4/1 5/1
+ + + +
160.02 Cover - - - - - - - - ✘ ✘ ✘ ✘

500 Ring - - - - ✘ ✘ - - - - ✘ ✘
550.01 Disc ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘
550.15 Disc - - - - ✘ ✘ - - - - ✘ ✘
550.19 Disc - - - - - - - - - - ✘ ✘

897 Guide piece ✘ ✘ ✘ ✘ - - ✘ ✘ ✘ ✘ - -

901.06 Hexagon head bolt ✘ ✘ ✘ ✘ - - ✘ ✘ ✘ ✘ - -

902.02 Stud ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘
902.15 Stud - - - - ✘ ✘ - - - - ✘ ✘
902.19 Stud - - - - - - - - - - ✘ ✘

914.19 Hexagon socket head cap screw - - - - - - - - ✘ ✘ ✘ ✘

920.01 Nut ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘ ✘
920.15 Nut - - - ✘ ✘ - - - - - ✘ ✘
920.19 Nut - - - - - - - - - - ✘ ✘

9.3 Pump signage

Observe the following signs at the pump (set).

NOTE
Always observe all signs at the pump (set).
Keep signs, plates and labels in a perfectly legible condition at all times.
Immediately replace any damaged or illegible signs, plates or labels by new ones.

134 of 168 CHTR

9 Related Documents

Fig. 67: Pump signage

1 Warning sign: Observe the 2 Warning sign: Observe the
instruction manual. specified temperature! (if
applicable)
3 Company plate 4 Weight
5 Name plate 6 ATEX marking (if applicable)
A Drive end

Warning sign: Observe the instruction manual.

! ! ! !
DE Betriebshandbuch beachten.

EN Observe the instruction manual.

FR Observer le manuel d‘instructions.

ES
Obsérvense el manual de
instrucciones.

PT
Observar instrucões do Manual de
Servico.
IT Osservare il manuale di istruzioni.

NL Bedrijfshandleiding opvolgen.
DK Vær opmærksom på driftshånbag.

EL Προσεζτε το βιβλιο με τιξ οδηγεξ.

SV Observera instruktionshandboken.
FI Käsikirjan ohjeita on noudatettava.

CS Dodržuj provozni předpis

Mat.No.: 01040645 ZN 3827 - 21 M

Fig. 68: Example: Warning sign:

CHTR 135 of 168

 9 Related Documents

Warning sign: Observe the specified temperature!

Fig. 69: Example: Warning sign:

1 Maximum temperature at the 2 Safety distance in [cm]
pump

136 of 168 CHTR

 9 Related Documents

9.4 Assembly drawings/instructions

Fig. 70: UA3 37814 01 P1 - Assembly drawing

CHTR 137 of 168

 9 Related Documents

Fig. 71: UA3 37814 01 P2 Assembly instructions

138 of 168 CHTR

 9 Related Documents

Fig. 72: UA3 37814 01 P3 - Assembly drawing

CHTR 139 of 168

 9 Related Documents

Fig. 73: UA3 37815 01 P1 - Assembly instructions

140 of 168 CHTR

 9 Related Documents

Fig. 74: UA3 37815 01 P2 - Assembly instructions

CHTR 141 of 168

 9 Related Documents

Fig. 75: UA3 37815 01 P3 - Assembly instructions

142 of 168 CHTR

 9 Related Documents

Fig. 76: UA3 37816 01 - Assembly instructions

CHTR 143 of 168

 9 Related Documents

Fig. 77: UA3 37817 01 - Assembly instructions

144 of 168 CHTR

 9 Related Documents

Fig. 78: UA3 37818 01 P1

CHTR 145 of 168

 (* ) This view is applicable only in case of double entry suction

146 of 168
Record

Fig. 79: UA3 37818 01 P2

CHTR
CHECKED / VERIFIED DIMENSIONS SIZE
t1 = L1-L3 = Dimension with 2 gaskets and1 Spacer
NOMINAL DIM. CHTR2=8.6 mm±0.1 disc of 2 mm thickness
9 Related Documents

NOMINAL DIM. CHTR3-5=9 mm±0.1

t2 = L2-L4-L5+5 = Length of the compensator consisting of 4
NOMINAL DIMENSION = 19±0.1 mm gaskets & 3 spacer discs before assembly
t2 = L2-L4-L5+6.2 = Length of the compensator consisting of 5
NOMINAL DIMENSION = 24±0.1 mm gaskets & 4 spacer discs before assembly
t4 = L6-L7 = Length of the single gasket
NOMINAL DIMENSION = 3.2±0.1 mm
t7 = L15-L16-L12 Dimension with 2 gaskets and1 Spacer
NOMINAL DIM. CHTR4/1+=8.6 mm±0.1 disc of 2 mm thickness
NOMINAL DIM. CHTR5/1+=9 mm±0.1
A = L5+t2+L4 = Total length of barrel-cover resting face to
A ≅ L6-L7 = inlet ring-barrel resting face
 9 Related Documents

Fig. 80: UA3 37819 01 P1 - Assembly instructions

CHTR 147 of 168

 9 Related Documents

Fig. 81: UA3 37819 01 P2 - Assembly instructions

148 of 168 CHTR

 9 Related Documents

Fig. 82: UA3 37819 01 P3 - Assembly instructions

CHTR 149 of 168

 9 Related Documents

Fig. 83: UA3 37821 01 P1 - Tightening torques

150 of 168 CHTR

 9 Related Documents

Fig. 84: UA3 37821 01 P2 - Tightening torques

CHTR 151 of 168

 9 Related Documents

Work instruction for tightening torques

Note: (1) See separate table in chapter 9.1.

(2) See separate information on mechanical seals.
(3) Secure with Loctite 221.
(4) Secure with Loctite 2701.
(5) Heat prior to removal.

Fig. 85: UA3 37821 01 P3 - Tightening torques

152 of 168 CHTR

 9 Related Documents

1 2 3 4
NENNMASS ABMASS 1. WERK-NR.
NOMINAL SIZE TOLERANCE 1. WORK NUMBER
US

1:1
AS PER PART LIST
ALT. IND./ALT. No.
DATED/PRP. BY CHTR 2-5 100 bar ANG. CONT. B RG.

WORK INSTRUCTION
PROTO SCALE 1 : 2

312
F BRG. END COVER MACHINING
H&LP; KSBTECH
UA4 37827 01 1

2010 2

Fig. 86: UA4 37827 01

CHTR 153 of 168

 9 Related Documents

1 2 3 4
NENNMASS ABMASS 1. Works No.
NOMINAL SIZE TOLERANCE 1. WORK NUMBER
US

Note:

1) Maß A = Abstand zwischen Stirnseite Lagergehäuse und

B
Stirnseite Endlager messen
2) Maß B = Einstellen durch spanende Bearbeitung der Anlage-
fläche des Endlagerdeckels an der Stirnseite des
Endlagers.
3) Der 1 mm breite Spalt zwischen der Stirnseite des
Endlagerdeckels und der Stirnseite des Lagergehäu-
ses existiert nicht mehr.

1:1
AS PER PART LIST
Old
CHTR 2-5 100bar Antifrict.
IND./ALT. No.
DATED/PRP. BY CO NT. B RG.

WORK INSTRUCTION
PROTO SCALE 1 : 2

312
F BRG. END COVER MACHINING
H&LP; KSBTECH
UA4 37827 01 2

2010 2

Fig. 87: UA4 37827 01

154 of 168 CHTR

 9 Related Documents

1 2 3 4
NENNMASS ABMASS 1. WERK-NR.
NOMINAL SIZE TOLERANCE 1. WORK NUMBER
US

1:1
AS PER PART LIST
ALT. IND./ALT. No.
DATED/PRP. BY CHTR 2-5 100 bar TAPER ROLL BRG.

WORK INSTRUCTION
PROTO SCALE 1 : 2

312
F BRG. END COVER MACHINING
H&LP; KSBTECH
UA4 37828 01 1

2010 2

Fig. 88: UA4 37828 01

CHTR 155 of 168

 9 Related Documents

1 2 3 4
NENNMASS ABMASS 1. WERK-NR.
NOMINAL SIZE TOLERANCE 1. WORK NUMBER
US

Note:
B

1) DIM. A = Measure distance from brg. hsg. face to outboard

bearing face.
2) DIM. B = To be obtained by machining face of bearing end
cover abutting to outboard bearing face.

3) The gap of 1 mm between bearing end cover face &

bearing hsg. face no longer exists.
C

1:1
AS PER PART LIST
ALT. IND./ALT. No.
DATED/PRP. BY CHTR 2-5 100 bar TAPER ROLL BRG.

WORK INSTRUCTION
PROTO SCALE 1 : 2

312
F BRG. END COVER MACHINING
H&LP; KSBTECH
UA4 37828 01 2

2010 2

Fig. 89: UA4 37828 01

156 of 168 CHTR

 9 Related Documents

Fig. 90: UA1 37858 01

CHTR 157 of 168

 9 Related Documents

Fig. 91: UA1 37858 02

158 of 168 CHTR

 9 Related Documents

Fig. 92: UA4 28699 01 Work instruction

CHTR 159 of 168

 9 Related Documents

Fig. 93: UA4 28699 02 Work instruction

160 of 168 CHTR

 9 Related Documents

Fig. 94: UA4 28699 03 Work instruction

CHTR 161 of 168

 9 Related Documents

Fig. 95: UA4 28699 04 Work instruction

162 of 168 CHTR

 9 Related Documents

Fig. 96: UA4 28699 05 Work instruction

CHTR 163 of 168

 9 Related Documents

Fig. 97: UA4 28699 06 Work instruction

164 of 168 CHTR

 10 EC Declaration of Conformity

10 EC Declaration of Conformity

Manufacturer: KSB Pumps Ltd

Mumbai Pune Road, Pimpri
Pune - 411018 (India)
The manufacturer herewith declares that the product:

CHTR

KSB order number: ...................................................................................................

▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
Person authorised to compile the technical file:
Detlef Prokasky
Head of Product Development
High-pressure Ring-section Pumps from 64 bar
KSB Aktiengesellschaft
Johann-Klein-Straße 9
67227 Frankenthal
The EC Declaration of Conformity was issued in/on:
Place, date

..............................9).............................
Name
Function
Company
Address

9) A signed, legally binding declaration of conformity is supplied with the product.

CHTR 165 of 168

 11 Certificate of Decontamination

11 Certificate of Decontamination

Type: ................................................................................................................................
Order number/
Order item number10): ................................................................................................................................

Delivery date: ................................................................................................................................

Field of application: ................................................................................................................................

Fluid handled10): ................................................................................................................................

Please tick where applicable10):

⃞ ⃞ ⃞ ⃞
Radioactive Explosive Corrosive Toxic

⃞ ⃞ ⃞ ⃞
Harmful Bio-hazardous Highly flammable Safe

Reason for return10): ................................................................................................................................

Comments: ................................................................................................................................

................................................................................................................................

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.
On seal-less pumps, the rotor has been removed from the pump for cleaning.

⃞ No special safety precautions are required for further handling.

⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

...............................................................................................................................................................

...............................................................................................................................................................

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with
the relevant legal provisions.

.................................................................... ....................................................... .......................................................

Place, date and signature Address Company stamp

10) Required fields

166 of 168 CHTR

 Index

Index

A Monitoring equipment 13

Abrasive fluids 69
Aligning the coupling 36 O
Applications 9 Oil lubrication
Assembly drawing 137, 138, 139 Oil quantity 128
Assembly Instructions 141, 142, 143, 144 Oil pipes 42
Oil quality 128
C Oil ring lubrication 128
Operating limits 62, 67
Certificate of decontamination 166 Order number 7
Clearance 122, 123, 124 Ordering spare parts 115
Plain bearing 124
Tilting-pad thrust bearing 125
Total theoretical axial clearances 125 P
Concrete quality 127 Partly completed machinery 7
Pickling solution 42
D Preservation for standstill 73

Designation 23
Dismantling 81 R
Disposal 22 Reassembly 81
Return to supplier 21
E Returning to service 74
Running noises 77
Explosion protection 12, 27, 34, 35, 46, 47, 48, 55, 59,
60, 65, 66, 67, 75, 77
S
F Safety 9
Safety awareness 11
Fluid handled Spare parts stock 115
Density 69 strainer/filter 43
Frequency of starts 67

T
I Temperature limits 12
Installation at site 27 Thrust bearing 101
Intended use 9 Tightening torques 125, 150, 151, 152

M W
Maintenance 75 Weights 128
Mechanical seal 60 Work Instructions 147, 148, 149, 159, 160, 161, 162,
Misuse 10 163, 164

CHTR 167 of 168

 2701.811/03-EN

KSB Pumps Ltd

Mumbai - Pune Road, Pimpri • Pune 411018 • India
Tel. +91 020 2710 1000 • Fax +91 020 2742 6000
www.ksb.co.in
 Motors | Automation | Energy | Transmission & Distribution | Coatings

Manual Geral de Instalação, Operação e

Manutenção de Motores Elétricos para
Atmosferas Explosivas

Installation, Operation and Maintenance

Manual of Electric Motors for Use in
Explosive Atmospheres

Manual General de Instalación, Operación

y Mantenimiento de Motores Eléctricos
para Atmosferas Explosivas

--
www.weg.net

Português 2

English 58

Español 115

58 Motores Elétricos
 www.weg.net

Installation, Operation and Maintenance Manual

of Electric Motors for Use in Explosive Atmospheres
This manual provides information about WEG induction motors fitted with squirrel cage, permanent magnet or hybrid
rotors, low, medium and high voltage, in frame size IEC 56 to 630 and NEMA 42 to 9606/10 for use in explosive
atmospheres with the following types of protection:
JEquipment protection by increased safety – “Ex e”

JEquipment protection by type of protection “n” – “Ex n”

JEquipment protection by flameproof enclosures – “Ex d” and “Ex de”

JEquipment dust ignition protection by enclosure – “Ex t” and “Ex tD”

JEquipment protection for use in Class I, Division 1

JEquipment protection for use in Class I, Division 2

These motors meet the following standards, if applicable:

JNBR 17094-1 (2008): Máquinas Elétricas Girantes - Motores de Indução - Parte 1: Trifásicos
JNBR 17094-2 (2008): Máquinas Elétricas Girantes - Motores de Indução - Parte 2: Monofásicos

JIEC 60034-1 (2010): Rotating Electrical Machines - Part 1: Rating and Performance

JNEMA MG 1 (2009): Motors and Generators

JEN / IEC 60079-0 (2007): Explosive Atmospheres – Part 0: Equipment - General Requirements

JNBR IEC 60079-0 (2008): Atmosferas Explosivas - Equipamentos - Requisitos Gerais

JEN / IEC 60079-1 (2007): Explosive Atmospheres – Part 1: Equipment protection by flameproof enclosures “d”

JNBR IEC 60079-1 (2009): Proteção de Equipamento por Invólucro à Prova de Explosão “d”

JEN / IEC 60079-7 (2006): Explosive Atmospheres – Part 7: Equipment protection by increased safety “e”

JNBR IEC 60079-7 (2008): Proteção de Equipamentos por Segurança Aumentada “e”

JEN / IEC 60079-15 (2010): ): Explosive Atmospheres – Part 15: Equipment protection by type of protection “n”

JNBR IEC 60079-15 (2007): Construção, Ensaio e Marcação de Equipamentos Elétricos com Tipo de Proteção “n”

JEN / IEC 60079-31 (2008): Explosive Atmospheres – Part 31: Equipment dust ignition protection by enclosure “t”

JIEC 61241-0 (2004): Electrical apparatus for use in the presence of combustible dust - Part 0: General requirements

JNBR IEC 61241-0 (2006): Equipamentos Elétricos para Utilização em Presença de Poeira Combustível - Parte 0:

Requisitos Gerais
JNBR IEC 61241-1 (2007): Equipamentos Elétricos para Utilização em Presença de Poeira Combustível - Parte 1:

Proteção por Invólucros “tD”

JUL 674 (2010) – Electric Motors and Generators for Use in Division 1 Hazardous (Classified) Locations

JCSA C22.2 N°145 (1986) – Motors and Generators for Use in Hazardous Locations

JCSA C22.2 N°30 (1986) - Explosion-Proof Enclosures for Use in Class I Hazardous Locations

JCSA C22.2 N°213 (1987) - Non-Incendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations

Information about classification of areas and safety requirements to be considered during equipment repair, overhaul
and reclamation, when applicable, can be found in the following standards:
JEN / IEC 60079-10-1 (2008): Classification of areas - Explosive gas atmospheres

JABNT NBR IEC 60079-10-1 (2009): Classificação de áreas - Atmosferas explosivas de gás
JEN/ IEC 60079-10-2 (2009): Classification of areas - Combustible dust atmospheres

JEN / IEC 60079-14 (2007): Electrical installations design, selection and erection

JNBR IEC 60079-14 (2009): Projeto, Seleção e Montagem de Instalações Elétricas

JEN / IEC 60079-17 (2007): Electrical installations inspection and maintenance

JNBR IEC 60079-17 (2009): Inspeção e Manutenção de Instalações Elétricas

JEN / IEC 60079-19 (2006): Equipment repair, overhaul and reclamation

JNBR IEC 60079-19 (2008): Reparo, Revisão e Recuperação de Equipamentos

If you have any questions regarding this manual, please contact WEG branch.

Manual of Electric Motors 59

 www.weg.net

TABLE OF CONTENTS
1. TERMINOLOGY 62

2. INITIAL RECOMMENDATIONS 66

2.1. WARNING SYMBOL ............................................................................................................................ 66

2.2. RECEIVING INSPECTION................................................................................................................... 66
2.3. NAMEPLATES ..................................................................................................................................... 67

3. SAFETY INSTRUCTIONS 71

4. HANDLING AND TRANSPORT 72

4.1. LIFTING................................................................................................................................................. 72
4.1.1. Horizontal motors with one eyebolt ......................................................................................... 72
4.1.2. Horizontal motor with two eyebolts ........................................................................................ 73
4.1.3. Vertical Motors .......................................................................................................................... 74
4.1.3.1. Procedures to place W22 motors in the vertical position .................................................. 74
4.1.3.2. Procedures to place HGF motors in the vertical position ................................................. 75
4.2 PROCEDURES TO PLACE W22 VERTICAL MOUNT MOTORS IN HORIZONTAL POSITION ....... 76

5. STORAGE 78

5.1. EXPOSED MACHINED SURFACES .................................................................................................... 78

ENGLISH

5.2. STORAGE............................................................................................................................................. 78
5.3 BEARINGS ............................................................................................................................................ 79
5.3.1 Grease lubricated bearings ....................................................................................................... 79
5.3.2 Oil Lubricated bearings ............................................................................................................. 79
5.3.3 Oil Mist lubricated bearings ...................................................................................................... 80
5.3.4 Sleeve Bearing ............................................................................................................................ 80
5.4. INSULATION RESISTANCE ................................................................................................................ 80
5.4.1. Insulation resistance measurement ........................................................................................ 80

6. INSTALLATION 83

6.1. FOUNDATIONS .................................................................................................................................... 84

6.2. MOTOR MOUNTING ........................................................................................................................... 85
6.2.1. Foot mounted motors................................................................................................................ 86
6.2.2. Flange mounted motors ........................................................................................................... 86
6.2.3. Pad mounted motors ................................................................................................................ 87
6.3. BALANCING......................................................................................................................................... 87
6.4. COUPLINGS ......................................................................................................................................... 87
6.4.1. Direct coupling ........................................................................................................................... 87
6.4.2. Gearbox coupling ...................................................................................................................... 87
6.4.3. Pulley and belt coupling ........................................................................................................... 88
6.4.4. Coupling of sleeve bearing motors ......................................................................................... 88
6.5. LEVELING ............................................................................................................................................ 89
6.6. ALIGNMENT......................................................................................................................................... 89
6.7. CONNECTION OF OIL LUBRICATED OR OIL MIST LUBRICATED MOTORS ................................ 90
6.8. CONNECTION OF THE COOLING WATER SYSTEM........................................................................ 90
6.9. ELECTRICAL CONNECTION .............................................................................................................. 90
6.10. CONNECTION OF THE THERMAL PROTECTION DEVICES ......................................................... 94
6.11. RESISTANCE TEMPERATURE DETECTORS (PT-100) ................................................................... 96

60 Manual of Electric Motors

 www.weg.net

6.12. CONNECTION OF THE SPACE HEATERS ....................................................................................... 97

6.13. STARTING METHODS ....................................................................................................................... 98
6.14. MOTORS DRIVEN BY FREQUENCY INVERTER ............................................................................. 98
6.14.1. Use of dV/dt filter ...................................................................................................................... 99
6.14.1.1. Motor with enameled round wire......................................................................................... 99
6.14.1.2. Motor with prewound coils .................................................................................................. 99
6.14.2. Bearing insulation .................................................................................................................... 99
6.14.3. Switching Frequency ............................................................................................................. 100
6.14.4. Mechanical speed limitation ................................................................................................ 100

7. COMMISSIONING 101

7.1. INITIAL START-UP ............................................................................................................................ 101

7.2. OPERATING CONDITIONS .............................................................................................................. 102
7.2.1.Limits of vibration .................................................................................................................... 104

8. MAINTENANCE 105

8.1. GENERAL INSPECTION .................................................................................................................... 105

8.2. LUBRICATION ................................................................................................................................... 105
8.2.1. Grease lubricated rolling bearings ........................................................................................ 106
8.2.1.1. Motor without grease fitting ................................................................................................ 108
8.2.1.2. Motor with grease fitting ..................................................................................................... 108
8.2.1.3. Compatibility of the Mobil Polyrex EM grease with other greases ................................ 108

ENGLISH
8.2.2. Oil lubricated bearings ........................................................................................................... 109
8.2.3. Oil mist lubricated bearings................................................................................................... 109
8.2.4. Sleeve bearings ....................................................................................................................... 109
8.3. MOTOR ASSEMBLY AND DISASSEMBLY ...................................................................................... 110
8.3.1. Terminal box ..............................................................................................................................111
8.4. DRYING THE STATOR WINDING INSULATION .............................................................................. 112
8.5. SPARE PARTS ................................................................................................................................... 112

9. ENVIRONMENTAL INFORMATION 113

9.1. PACKAGING ....................................................................................................................................... 113
9.2. PRODUCT .......................................................................................................................................... 113

10. TROUBLESHOOTING CHART X SOLUTIONS 114

Manual of Electric Motors 61

 www.weg.net

1. TERMINOLOGY
Balancing: the procedure by which the mass distribution of a rotor is checked and, if necessary, adjusted to
ensure that the residual unbalance or the vibration of the journals and/or forces on the bearings at a frequency
corresponding to service speed are within specified limits in International Standards.

[ISO 1925:2001, definition 4.1]

Balance quality grade: indicates the peak velocity amplitude of vibration, given in mm/s, of a rotor running
free-in-space and it is the product of a specific unbalance and the angular velocity of the rotor at maximum
operating speed.

Hazardous area: area in which an explosive atmosphere is present, or may be expected to be present, in
quantities such as to require special precautions for the construction, installation and use of electrical
apparatus.

[IEC 60050 IEV number 426-03-01]

Non-hazardous area: area in which an explosive atmosphere is not expected to be present in quantities such
as to require special precautions for the construction, installation and use of electrical apparatus.

[IEC 60050 IEV number 426-03-02]

Explosive atmosphere: mixture with air, under atmospheric conditions, of flammable substances in the form
of gas, vapour, dust, fibres, or flyings which, after ignition, permits self-sustaining propagation.

[IEC 60050 IEV number 426-01-06]

ENGLISH

Temperature class: maximum surface temperature of the equipment. Following temperature classes are
defined:

Temperature Class
Maximum surface temperature (°C)
IEC NEC
T1 T1 450
T2 T2 300
- T2A 280
- T2B 260
- T2C 230
- T2D 215
T3 T3 200
- T3A 180
- T3B 165
- T3C 160
T4 T4 135
- T4A 120
- T5 100
- T6 85

[IEC 60050 IEV number 426-01-05]

Simple apparatus: electrical component or combination of components of simple construction with well-
defined electrical parameters which is compatible with the intrinsic safety of the circuit in which it is used.

[IEC 60050 IEV number 426-11-09]

Flameproof enclosure "d" (Ex d): type of protection in which the parts capable of igniting an explosive gas
atmosphere are provided with an enclosure which can withstand the pressure developed during an internal
explosion of an explosive mixture, and which prevents the transmission of the explosion to the explosive gas
atmosphere surrounding the enclosure

62 Manual of Electric Motors

 www.weg.net

[IEC 60050 IEV number 426-06-01]

Increased safety "e" (Ex e): type of protection applied to electrical apparatus in which additional measures
are applied so as to give increased security against the possibility of excessive temperatures and of the
occurrence of arcs and sparks in normal service or under specified abnormal conditions.

[IEC 60050 IEV number 426-08-01]

Type of protection "n" (Ex n): type of protection applied to electrical apparatus such that, in normal operation
and in certain specified abnormal conditions, it is not capable of igniting a surrounding explosive gas
atmosphere.

[IEC 60050 IEV number 426-13-01]

Dust ignition protection by enclosure “t” (Ex t): type of protection for explosive dust atmosphere where
electrical equipment is provided with an enclosure providing dust ingress protection and a means to limit
surface temperatures.

[IEC 60079-31 item 3.1]

Gas groups: are subdivided according to the nature of the explosive atmosphere for which they are intended:
JGroup I: coal mines susceptible to firedamp (methane).

JGroup II: areas not susceptible to firedamp. This group is subdivided into:

 JGroup IIA (IEC) / D (NEC): propane, acetone, butane, combustible gas, gasoline, ethyl alcohol, methyl

alcohol, benzene, etc.

 JGroup IIB (IEC) / C (NEC): ethylene, cyclopropane, butadiene 1-3, etc.

 JGroup IIC (IEC): hydrogen, acetylene, etc.

 JGroup B (NEC): hydrogen.

 JGroup A (NEC): acetylene.

ENGLISH
Dust groups: are subdivided into (excepting mines susceptible to firedamp (methane)):
JGroup IIIA (IEC): combustible fibers / combustible flyings – solid particles, including fibers larger than 500 μm
JGroup IIIB (IEC): electrically nonconductive dusts – solid particles smaller than 500 μm, with electrical

resistivity ≤ 10³ Ω.m

JGroup IIIC (IEC): electrically conductive dusts - solid particles smaller than 500 μm, with electrical resistivity >

10³ Ω.m
JGroup E (NEC): combustible metallic powders, for example: aluminum, magnesium and their commercial

alloys.
JGroup F (NEC): combustible carbonaceous dusts that have more than 8% total entrapped volatiles.

JGroup G (NEC):atmospheres containing dusts not included in Group E and F, including flour, grain wood ,

plastic, chemicals, etc.

Flameproof joint: place where the corresponding surfaces of two parts of an enclosure, or the conjunction of
enclosures, come together, and which prevents the transmission of an internal explosion to the explosive gas
atmosphere surrounding the enclosure.

[IEC 60050 IEV number 426-06-02]

Symbol “X”: symbol used to denote special conditions for safe use.

[IEC 60050 IEV number 426-04-32]

Equipment Protection Level - EPL: level of protection assigned to equipment based on its likelihood of
becoming a source of ignition and distinguishing the differences between explosive gas atmospheres, explosive
dust atmospheres, and the explosive atmospheres in mines susceptible to firedamp. These EPLs are classified
into:
JEPL Ga: equipment for explosive gas atmospheres, having a “very high” level of protection, which is not a

source of ignition in normal operation, during expected malfunctions ou during rare malfunctions.

EPL Gb: equipment for explosive gas atmospheres, having a “high” level of protection, which is not a source
J

of ignition in normal operation, during expected malfunctions.

EPL Gc: equipment for explosive gas atmosphere, having a “enhanced” level of protection, which is not a
J

source of ignition in normal operation and which may have some additional protection to ensure that it
remains inactive as an ignition source in case of regular expected occurrences (for example failure of a lamp).
Manual of Electric Motors 63
 www.weg.net

EPL Da: equipment for explosive dust atmospheres, having a “very high” level of protection, which is not a
J

source of ignition in normal operation, during expected malfunctions, or during rare malfunctions.

EPL Db: equipment for explosive dust atmospheres, having a “high” level of protection, which is not a source
J

of ignition in normal operation or during expected malfunctions

EPL Dc: equipment for explosive dust atmospheres, having a “enhanced” level of protection, which is not a
J

source of ignition in normal operation and which may have some additional protection to ensure that it
remains inactive as an ignition source in the case of regular expected occurrences ( for example failure of a
lamp).

EPL Ma: equipment for installation in a mine susceptible to firedamp, having a “very high” level of protection,
J

which has sufficient security that it is unlikely to become an ignition source in normal operation, during
expected malfunctions or during rare malfunctions, even when left energized in the presence of an outbreak
of gas.

EPL Mb: equipment for installation in a mine susceptible to firedamp, having a “high” level of protection, which
J

has sufficient security that it is unlikely to become an source of ignition in normal operation or during expected
malfunctions in the time span between there being an outbreak of gas and the equipment being de-
energized.

[IEC 60079-0 item 3.18]

Time “tE”: time taken for an a.c. rotor or stator winding, when carrying the initial starting current IA, to be heated
up to the limiting temperature from the temperature reached in rated service at the maximum ambient
temperature. See Figure 1-1.
ENGLISH

Symbols
T - temperature
A – maximum allowed ambient temperature
B – service temperature
C – limiting temperature
t - time
1 – temperature rise in rated service
2 – Temperature rise during locked rotor test

Figure 1.1: Time “tE”

64 Manual of Electric Motors

 www.weg.net

[IEC 60050 IEV number 426-08-03]

Type of protection: set of specific measures applied to electrical apparatus to avoid ignition of a surrounding
explosive atmosphere by such apparatus.

[IEC 60050 IEV number 426-01-02]

Zones: hazardous areas are classified in terms of zones on the basis of the frequency and duration of the
occurrence of an explosive atmosphere.

Zone 0 (IEC) / Class I Div 1 (NEC): area in which an explosive gas atmosphere is present continuously, or for
long periods or frequently.

[IEC 60050 IEV number 426-03-03]

Zone 1 (IEC) / Class, I Div 1 (NEC): area in which an explosive gas atmosphere is likely to occur in normal
operation occasionally.

[IEC 60050 IEV number 426-03-04]

Zone 2 (IEC) / Class I, Div 2 (NEC): area in which an explosive gas atmosphere is not likely to occur in normal
operation, but if it does occur, will persist for a short period only.

[IEC 60050 IEV number 426-03-05]

Zone 20 (IEC) / Class II, Div 1 (NEC): area in which an explosive atmosphere in the form of a cloud of
combustible dust in air is present continuously, or for long periods or frequently.

ENGLISH
[IEC 60050 IEV number 426-03-23]

Zone 21 (IEC) / Class II, Div 1 (NEC): area in which an explosive atmosphere in the form of a cloud of
combustible dust in air is likely to occur, occasionally, in normal operation.

[IEC 60050 IEV number 426-03-24]

Zone 22 (IEC) / Class II, Div 2 (NEC): area in which an explosive atmosphere in the form of a cloud of
combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for a short
period only.

[IEC 60050 IEV number 426-03-25]

Grounded Part: metallic part connected to the grounding system.

Live Part: Conductor or conductive part intended to be energized in normal operation, including a neutral
conductor.

Authorized personnel: employee who has formal approval of the company.

Qualified personnel: employee who meets the following conditions simultaneously:

Jreceives training under the guidance and responsibility of a qualified and authorized professional;
Jworks under the responsibility of a qualified and approved professional.

Note: The qualification is only valid for the company that trained the employee in the conditions set out by the authorized and qualified
professional responsible for training.

Manual of Electric Motors 65

 www.weg.net

2. INITIAL RECOMMENDATIONS
Motors for hazardous areas are specially designed to meet the government regulations regarding the
environment in which they are installed. Misapplication, incorrect connection or other changes although
small, may jeopardize product reliability.
Electric motors have energized circuits, exposed rotating parts and hot surfaces that may cause serious injury
to people during normal operation. Therefore, it is recommended that transportation, storage, installation,
operation and maintenance services are always performed by qualified personnel.
Also the applicable procedures and relevant standards of the country where the machine will be installed must
be considered.
Noncompliance with the recommended procedures in this manual may cause severe personal injuries and/or
substantial property damage and may void the product warranty.

For practical reasons, it is not possible to include in this Manual detailed information that covers all construction
variables nor covering all possible assembly, operation or maintenance alternatives.
This Manual contains only the required information that allows qualified and trained personnel to carry out their
services. The product images are shown for illustrative purpose only and the type of protection is not represented.

The type of protection and the Equipment Protection Level (EPL) indicated on the motor nameplate must be
respected considering the explosive atmosphere where the motor will be installed.

Components added to the motor by the user, such as cable-glands, threaded plugs, encoder, etc. must meet the
type of protection, the Equipment Protection Level (EPL) in accordance with the standards indicated on the
product certificate.

The symbol “X” added to the certificate number, informed on the motor nameplate, denotes that motor requires
special conditions for installation, use and/or maintenance, as described in the certificate.
ENGLISH

Failure to follow these requirements may affect the product and installation safety.
For Smoke Extraction Motors, please refer to the additional instruction manual 50026367 available on the website
www.weg.net.
For brake motors, please refer to the information contained in WEG 50006742 / 50021973 brake motor manual
available on the website www.weg.net.
For information about permissible radial and axial shaft loads, please check the product technical catalogue.

The user is responsible for the correct classification of the area for the motor installation, for the definition
of environment conditions and application characteristics.

During the warranty period, all repair, overhaul and reclamation services must be carried out by WEG
authorized Service Centers for explosive atmospheres to maintain validity of the warranty.

2.1. WARNING SYMBOL

Warning about safety and warranty.

2.2. RECEIVING INSPECTION

All motors are tested during the manufacturing process.
The motor must be checked when received for any damage that may have occurred during the transportation.
All damages must be reported in writing to the transportation company, to the insurance company and to
WEG. Failure to comply with such procedures will void the product warranty.
You must inspect the product:
J Check if nameplate data complies with the purchase order.

 Special attention should be given to the type of protection and/or to the Equipment Protection Level.
J Remove the shaft locking device (if any) and rotate the shaft by hand to ensure that it rotates freely.

J Check that the motor has not been exposed to excessive dust and moisture during the transportation.

Do not remove the protective grease from the shaft, or the plugs from the cable entries. These protections must
remain in place until the installation has been completed.

66 Manual of Electric Motors

 www.weg.net

2.3. NAMEPLATES
The nameplate contains information that describes the construction characteristics and the performance of the
motor. Figure 2-1, Figure 2-2, Figure 2-3 and Figure 2-4 show nameplate layout examples.

ENGLISH

Manual of Electric Motors 67

 www.weg.net

Figure 2.1 - IEC motor nameplate.

ENGLISH

Figure 2.2 – NEMA motor nameplate.

Figure 2.3 - Nameplate of fuel pump motor.

68 Manual of Electric Motors

 www.weg.net

Figure 2.4 - HGF motor nameplate.

Number Symbol Features

1 Motor code (SAP material )
2 ~ Number of phases
3 V Rated voltage (V)
4 REG. / DUTY Duty
5 REND. / NOM. EFF. / EFF. Efficiency (%)
6 CARC. / FRAME Frame
7 IP Degree of protection
8 ISOL. / INSL. / INS.CL. Insulation class
9 ΔT Temperature rise (K)
10 Hz Frequency (Hz)
11 kW (HP-cv) / kW / HP Output (kW / HP / cv)
12 RPM / min-1 Revolution per minute (RPM)
13 A Rated current (A)

ENGLISH
14 F.P / P.F Power factor
15 AMB. Ambient Temperature (°C)
16 F.S. / S.F. Service factor
17 ALT. Altitude (m.a.s.l.)
18 kg / lb / WEIGHT Weight (kg / lb)
19 DE bearing specification and amount of grease
20 NDE bearing specification and amount of grease
21 Grease type used for bearing lubrication
22 Lubrication interval (h)
23 Connection diagram
24 Hazardous areas / Type of protection / Certificate1)
25 I A / IN / IP / IN Starting current / rated current relationship
26 CAT. / DES. Design
27 I.F.S. / S.F.A. Service factor amps (A)
28 Serial number

The product certificates can be obtained from WEG. Please contact WEG nearest Office.
Motor marking intended for use in hazardous areas: the marking system is indicated according to the standards
applicable for each type of protection:

Marking according to IEC

Apparatus grouping Equipment Protection
Ex equipment Type of protection Temperature Class
for gas or dust Level EPL
nA II T3 Gc
e II T3
IIB
d
IIC Gb
T4
Ex IIB
de
IIC
tc IIIB Dc
T125 °C
tb IIIC Db
d I T4 Mb

Manual of Electric Motors 69

 www.weg.net

Marking according to NEC

Apparatus grouping
Class Division or Zone Temperature class
for gas or dust
Class I Div. 1 Gr. C and D T4
Class II Div. 1 Gr. E, F and G T4
Class I Zona 1 IIB T4
Class II Zona 21 IIIC T125 °C
Class II Zona 22 IIIB T125 °C
Class I Div. 2 Gr. A, B, C and D T3

* Other temperature classes are available upon request.

Marking according to ATEX

Apparatus Equipment
Apparatus Equipment Gas, dust or Type of Temperature
Ex equipment grouping for Protection
grouping category mine protection class
gas or dust Level (EPL)
3 nA II T3 Gc
e II T3
IIB
G d
2 IIC Gb
II T4
Ex IIB
de
IIC
3 tc IIIB Dc
D T125 °C
2 tb IIIC Db
I 2 M d I T4 Mb

* Other temperature classes are available upon request.

ENGLISH

70 Manual of Electric Motors

 www.weg.net

3. SAFETY INSTRUCTIONS
The motor must be disconnected from the power supply and be completely stopped before conducting
any installation or maintenance procedures. Additional measures should be taken to avoid accidental
motor starting.

Professionals working with electrical installations, either in the assembly, operation or maintenance,
should use proper tools and be instructed on the application of standards and safety requirements,
including the use of Personal Protective Equipment (PPE) that must be carefully observed in order to
reduce risk of personal injury during these services.

Electric motors have energized circuits, exposed rotating parts and hot surfaces that may cause serious
injury to people during normal operation. It is recommended that transportation, storage, installation,
operation and maintenance services are always performed by qualified personnel.

Always follow the safety, installation, maintenance and inspection instructions in accordance with the applicable
standards in each country.

ENGLISH

Manual of Electric Motors 71

 www.weg.net

4. HANDLING AND TRANSPORT

Individually packaged motors should never be lifted by the shaft or by the packaging. They must be lifted only by
means of the eyebolts, when supplied. Use always suitable lifting devices to lift the motor. Eyebolts on the frame
are designed for lifting the machine weight only as indicated on the motor nameplate. Motors supplied on pallets
must be lifted by the pallet base with lifting devices fully supporting the motor weight.
The package should never be dropped. Handle it carefully to avoid bearing damage.

Eyebolts provided on the frame are designed for lifting the machine only. Do not use these eyebolts for
lifting the motor with coupled equipment such as bases, pulleys, pumps, reducers, etc.

Never use damaged, bent or cracked eyebolts. Always check the eyebolt condition before lifting the motor.

Eyebolts mounted on components, such as on end shields, forced ventilation kits, etc. must be used for lifting
these components only. Do not use them for lifting the complete machine set.

Handle the motor carefully without sudden impacts to avoid bearing damage and prevent excessive mechanical
stresses on the eyebolts resulting in its rupture.

To move or transport motors with cylindrical roller bearings or angular contact ball bearings, use always
the shaft locking device provided with the motor.
All HGF motors, regardless of bearing type, must be transported with shaft locking device fitted.

4.1. LIFTING

Before lifting the motor ensure that all eyebolts are tightened properly and the eyebolt shoulders are in
contact with the base to be lifted, as shown in Figure 4.1. Figure 4.2 shows an incorrect tightening of the
eyebolt.
ENGLISH

Ensure that lifting machine has the required lifting capacity for the weight indicated on the motor nameplate.

Figure 4.1 – Correct tightening of the eyebolt Figure 4.2 – Incorrect tightening of
the eyebolt.

The center-of-gravity may change depending on motor design and accessories. During the lifting
procedures the maximum allowed angle of inclination should never be exceeded as specified below.

4.1.1. Horizontal motors with one eyebolt

For horizontal motors fitted with only one eyebolt, the maximum allowed angle-of-inclination during the lifting
process should not exceed 30º in relation to the vertical axis, as shown in Figure 4.3.
30° Max.

Figure 4.3 – Maximum allowed angle-of-inclination for motor with one eyebolt.

72 Manual of Electric Motors

 www.weg.net

4.1.2. Horizontal motor with two eyebolts

When motors are fitted with two or more eyebolts, all supplied eyebolts must be used simultaneously for the
lifting procedure.

There are two possible eyebolt arrangements (vertical and inclined), as shown below:

J For motors with vertical lifting eyebolts, as shown in Figure 4.4, the maximum allowed lifting angle should not
exceed 45° in relation to the vertical axis. We recommend to use a spreader beam for maintaining the lifting
elements (chain or rope) in vertical position and thus preventing damage to the motor surface.

45° Max.

Figure 4.4 – Maximum resulting angle for motors with two or more lifting eyebolts.

J For HGF motors, as shown in Figure 4.5, the maximum resulting angle should not exceed 30° in relation to the
vertical axis.

ENGLISH
30° Max.

Figure 4.5 – Maximum resulting angle for horizontal HGF motors

J For motors fitted with inclined eyebolts, as shown in Figure 4.6, the use of a spreader beam is required for
maintaining the lifting elements (chain or rope) in vertical position and thus preventing damage to the motor
surface.

Figure 4.6 – Use of a spreader beam for lifting.

Manual of Electric Motors 73

 www.weg.net

4.1.3. Vertical Motors

For vertical mounted motors, as shown in Figure 4.7, the use of a spreader beam is required for maintaining the
lifting element (chain or rope) in vertical position and thus preventing damage to the motor surface.

Figure 4.7 – Lifting of vertical mounted motors.

Always use the eyebolts mounted on the top side of the motor, diametrically opposite, considering the
mounting position. See Figure 4.8.
ENGLISH

Figure 4.8 – Lifting of HGF motors.

4.1.3.1. Procedures to place W22 motors in the vertical position

For safety reasons during the transport, vertical mounted Motors are usually packed and supplied in horizontal
position.
To place W22 motors fitted with eyebolts (see Figure 4.6), to the vertical position, proceed as follows:
1. Ensure that the eyebolts are tightened properly, as shown in Figure 4.1;
2. Remove the motor from the packaging, using the top mounted eyebolts, as shown in Figure 4.9;

Figure 4.9 – Removing the motor from the packaging.

74 Manual of Electric Motors

 www.weg.net

3. Install a second pair of eyebolts, as shown in Figure 4.10;

Figure 4.10 – Installation of the second pair of eyebolts.

4. Reduce the load on the first pair of eyebolts to start the motor rotation, as shown in Figure 4.11. This
procedure must be carried out slowly and carefully.

ENGLISH
Figure 4.11 – End result: motor placed in vertical position.

These procedures will help you to move motors designed for vertical mounting. These procedures are also
used to place the motor from the horizontal position into the vertical position and vertical to horizontal.

4.1.3.2. Procedures to place HGF motors in the vertical position

HGF motors are fitted with eight lifting points: four at drive end and four at non-drive end. The HGF motors are
usually transported in horizontal position, however for the installation they must be placed in the vertical
position.
To place an HGF motor in the vertical position, proceed as follows:
1. Lift the motor by using the four lateral eyebolts and two hoists, see Figure 4.12;

Figure 4.12 – Lifting HGF motor with two hoists.

Manual of Electric Motors 75

 www.weg.net

2. Lower the hoist fixed to motor drive end while lifting the hoist fixed to motor non-drive end until the motor
reaches its equilibrium, see Figure 4.13.

Figure 4.13 – Placing HGF motor in vertical position

3. Remove the hoist hooks from the drive end eyebolts and rotate the motor 180° to fix the removed hooks into
the two eyebolts at the motor non-drive end, see Figure 4.14.
ENGLISH

Figure 4.14 – Lifting HGF motors by the eyebolts at the non-drive end.

4. Fix the removed hoist hooks in the other two eyebolts at the non-drive end and lift the motor until the vertical
position is reached, see Figure 4.15.

Figure 4.15 – HGF motor in the vertical position

These procedures will help you to move motors designed for vertical mounting. These procedures are also
used to place the motor from the horizontal position into the vertical position and vertical to horizontal.

4.2 Procedures to place W22 vertical mount motors in horizontal position

To place W22 vertical mount motor in horizontal position, proceed as follows:

76 Manual of Electric Motors

 www.weg.net

1. Ensure that all eyebolts are tightened properly, as shown in Figure 4.1;

2. Install the first pair of eyebolts and lift the motor as shown in Figure 4.16;

Figure 4.16 – Install the first pair of eyebolts

3. Install the second pair of eyebolts, as shown in Figure 4.17;

ENGLISH
Figure 4.17 – Install the second pair of eyebolts

4. Reduce the load on the first pair of eyebolts for rotating the motor, as shown in Figure 4.18. This procedure
must be carried out slowly and carefully.

Figure 4.18 – Motor is being rotated to horizontal position

5. Remove the first pair of eyebolts, as shown in Figure 4.19.

Figure 4.19 – Final result: motor placed in horizontal position

Manual of Electric Motors 77

 www.weg.net

5. STORAGE
If the motor is not installed immediately, it must be stored in a dry and clean environment, with relative humidity
not exceeding 60%, with an ambient temperature between 5 ºC and 40 ºC, without sudden temperature
changes, free of dust, vibrations, gases or corrosive agents. The motor must be stored in horizontal position,
unless specifically designed for vertical operation, without placing objects on it. Do not remove the protection
grease from shaft end to prevent rust.

If the motor are fitted with space heaters, they must always be turned on during the storage period or when the
installed motor is out of operation. Space heaters will prevent water condensation inside the motor and keep
the winding insulation resistance within acceptable levels. Store the motor in such position that the condensed
water can be easily drained. If fitted, remove pulleys or couplings from the shaft end (more information are given
on item 6).

The space heaters should never be energized when the motor is in operation.
For the use of space heaters in motors that are stored in hazardous area, adopt the same cable inlet and
connection requirements described in item 6.

5.1. EXPOSED MACHINED SURFACES

All exposed machined surfaces (like shaft end and flange) are factory-protected with temporary rust inhibitor. A
protective film must be reapplied periodically (at least every six months), or when it has been removed and/or
damaged.
5.2. STORAGE
The stacking height of the motor packaging during the storage period should not exceed 5 m, always
considering the criteria indicated in Table 5.1:
ENGLISH

Table 5.1 – Max. recommended stacking height

Packaging Type Frame sizes Maximum stacking quantity

IEC 63 to 132 Indicated on the top side of
Cardboard box
NEMA 143 to 215 the cardboard box
IEC 63 to 315
06
NEMA 48 to 504/5
IEC 355
Wood crate 03
NEMA 586/7 and 588/9
HGF IEC 315 to 630
Indicated on the packaging
HGF NEMA 5000 to 9600

Notes:
1) Never stack larger packaging onto smaller packaging.
2) Align the packaging correctly (see Figure 5.1 and Figure 5.2).

Figure 5.1 – Correct stacking

X
Figure 5.2 – Incorrect stacking

78 Manual of Electric Motors

 www.weg.net

3) The feet of the crates above should always be supported by suitable wood battens (Figure 5.3) and never
stand on the steel tape or without support (Figure 5.4).

Figure 5.3 – Correct stacking

X XFigure 5.4 – Incorrect stacking

4) When stacking smaller crates onto longer crates, always ensure that suitable wooden supports are provided
to withstand the weight (see Figure 5.5). This condition usually occurs with motor packaging above IEC 225S/M
(NEMA 364/5T) frame sizes.

ENGLISH
Figure 5.5 – Use of additional battens for stacking

5.3 BEARINGS
5.3.1 Grease lubricated bearings
We recommend rotating the motor shaft at least once a month (by hand, at least five revolutions, stopping the
shaft at a different position from the original one). If the motor is fitted with shaft locking device, remove it before
rotating the shaft and install it again before performing any handling procedure. Vertical motors may be stored
in the vertical or in horizontal position. If motors with open bearings are stored longer than six months, the
bearings must be relubricated according to Item 8.2 before commissioning of the motor.
If the motor is stored for longer than 2 years, the bearings must be replaced or removed, washed, inspected
and relubricated according to Item 8.2.

5.3.2 Oil Lubricated bearings

The motor must be stored in its original operating position and with oil in the bearings. Correct oil level must be
ensured. It should be in the center of the sight glass.
During the storage period, remove the shaft locking device and rotate the shaft by hand every month, at least
five revolutions, thus achieving an even oil distribution inside the bearing and maintaining the bearing in good
operating conditions. Reinstall the shaft locking device every time the motor has to be moved.
If the motor is stored for a period of over six months, the bearings must be relubricated according to Item 8.2
before starting the operation. If the motor is stored for a period of over two years, the bearings must be
replaced or removed, washed according to manufacturer instructions, checked and relubricated according to
Item 8.2. The oil of vertical mounted motors that are transported in horizontal position is removed to prevent
oils leaks during the transport. These motors must be stored in vertical position after receiving and the bearing
must be lubricated.

Manual of Electric Motors 79

 www.weg.net

5.3.3 Oil Mist lubricated bearings

The motor must be stored in horizontal position. Lubricate the bearings with ISO VG 68 mineral oil in the
amount indicated in the Table 5.2 (this is also valid for bearings with equivalent dimensions). After filling with oil,
rotate the shaft by hand, at least five revolutions)
During the storage period, remove the shaft locking device (if any) and rotate the shaft by hand every week, at
least five revolutions, stopping it at a different position from the original one. Reinstall the shaft locking device
every time the motor has to be moved. If the motor is stored for a period of over two years, the bearings must
be replaced or removed, washed according to manufacturer instructions, checked and relubricated according
to item 8.2.
Table 5.2 – Amount of oil per bearing
Bearing Size Amount of Oil (ml) Bearing Size Amount of Oil (ml)
6201 15 6309 65
6202 15 6311 90
6203 15 6312 105
6204 25 6314 150
6205 25 6315 200
6206 35 6316 250
6207 35 6317 300
6208 40 6319 350
6209 40 6320 400
6211 45 6322 550
6212 50 6324 600
6307 45 6326 650
6308 55 6328 700
ENGLISH

The oil must always be removed when the motor has to be handled. If the oil mist system is not operating after
installation, fill the bearings with oil to prevent bearing rusting. During the storage period, rotate the shaft by
hand, at least five revolutions, stopping it at a different position from the original one. Before starting the motor,
all bearing protection oil must be drained from the bearing and the oil mist system must be switched ON.

5.3.4 Sleeve Bearing

The motor must be stored in its original operating position and with oil in the bearings. Correct oil level must be
ensured. It should be in the middle of the sight glass. During the storage period, remove the shaft locking
device and rotate the shaft by hand every month, at least five revolutions (and at 30 rpm), thus achieving an
even oil distribution inside the bearing and maintaining the bearing in good operating conditions. Reinstall the
shaft locking device every time the motor has to be moved.
If the motor is stored for a period of over six months, the bearings must be relubricated according to the Item
8.2 before starting the operation.
If the motor is stored for a period longer than the oil change interval, or if it is not possible to rotate the motor
shaft by hand, the oil must be drained and a corrosion protection and dehumidifiers must be applied.
5.4. INSULATION RESISTANCE
We recommend measuring the winding insulation resistance at regular intervals to follow-up and evaluate its
electrical operating conditions. If any reduction in the insulation resistance values are recorded, the storage
conditions should be evaluated and corrected, where necessary.

5.4.1. Insulation resistance measurement

We recommend measuring the winding insulation resistance at regular intervals to follow-up and evaluate its
electrical operating conditions. If any reduction in the insulation resistance values are recorded, the storage
conditions should be evaluated and corrected, where necessary.

The insulation resistance must be measured in a safe environment.

80 Manual of Electric Motors

 www.weg.net

The insulation resistance must be measured with a megohmmeter. The machine must be in cold state and
disconnected from the power supply.

To prevent the risk of an electrical shock, ground the terminals before and after each measurement.
Ground the capacitor (if any) to ensure that it is fully discharged before the measurement is taken.

It is recommended to insulate and test each phase separately. This procedure allows the comparison of the
insulation resistance between each phase. During the test of one phase, the other phases must be grounded.
The test of all phases simultaneously evaluates the insulation resistance to ground only but does not evaluate
the insulation resistance between the phases.
The power supply cables, switches, capacitors and other external devices connected to the motor may
considerably influence the insulation resistance measurement. Thus all external devices must be disconnected
and grounded during the insulation resistance measurement.
Measure the insulation resistance one minute after the voltage has been applied to the winding. The applied
voltage should be as shown in Table 5.3.
Table 5.3 – Voltage for the insulation resistance

Winding rated voltage (V) Testing voltage for measuring the insulation resistance (V)
< 1000V 500
1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001 - 12000 2500 - 5000
> 12000 5000 - 10000

The reading of the insulation resistance must be corrected to 40 °C as shown in the Table 5.4.

Table 5.4 – Correction Factor for the Insulation Resistance corrected to 40 °C

ENGLISH
Measuring temperature Correction factor of the Measuring temperature of Correction factor of the
of the insulation insulation resistance the insulation resistance insulation resistance
resistance (°C) corrected to 40 °C (°C) corrected to 40 °C
10 0.125 30 0.500
11 0.134 31 0.536
12 0.144 32 0.574
13 0.154 33 0.616
14 0.165 34 0.660
15 0.177 35 0.707
16 0.189 36 0.758
17 0.203 37 0.812
18 0.218 38 0.871
19 0.233 39 0.933
20 0.250 40 1.000
21 0.268 41 1.072
22 0.287 42 1.149
23 0.308 43 1.231
24 0.330 44 1.320
25 0.354 45 1.414
26 0.379 46 1.516
27 0.406 47 1.625
28 0.435 48 1.741
29 0.467 49 1.866
30 0.500 50 2.000

Manual of Electric Motors 81

 www.weg.net

The motor insulation condition must be evaluated by comparing the measured value with the values
indicated in Table 5.5 (corrected to 40 °C):
Table 5.5 – Evaluation of the insulation system
Limit value for rated voltage Limit value for rated voltage
Situation
up to 1.1 kV (MΩ) above 1.1 kV (MΩ)
Dangerous. The motor can not
Up to 5 Up to 100
be operated in this condition
5 to 100 100 to 500 Regular
100 to 500 Higher than 500 Good
Higher than 500 Higher than 1000 Excellent

The values indicated in the table should be considered only as reference values. It is advisable to log all
measured values to provide a quick and easy overview on the machine insulation resistance.
If the insulation resistance is low, moisture may be present in the stator windings. In this case the motor
should be removed and transported to a WEG authorized Service Center for proper evaluation and repair
(This service is not covered by the warranty). To improve the insulation resistance through the drying
process, see section 8.4.
ENGLISH

82 Manual of Electric Motors

 www.weg.net

6. INSTALLATION
The installation of electric motors in hazardous areas must be always performed by qualified personnel
with knowledge on relevant standards and safety rules.

Check some aspects before proceeding with the installation:

1. Insulation resistance: must be within the acceptable limits. See item 5.4.
2. Bearings:
If the electric motor is installed without running immediately, proceed as described in item 5.3.
3. Operating conditions of the start capacitors: If single-phase motors are stored for a period of over two years,
it is recommended to change the start capacitors before motor starting since they lose their operating
characteristics.
4. Terminal box:
a. the inside of the terminal box must be clean and dry.
b. the contacts must be correctly connected and corrosion free. See 6.9 and 6.10.
c. the cable entries must be correctly sealed and the terminal box cover properly mounted in order to ensure
the degree of protection indicated on the motor nameplate.
5. Cooling: the cooling fins, air inlet and outlet openings must be clean and unobstructed. The distance
between the air inlet openings and the wall should not be shorter than ¼ (one quarter) of the diameter of the
air inlet. Ensure sufficient space to perform the cleaning services. See item 7.
6. Coupling: remove the shaft locking device (where fitted) and the corrosion protection grease from the shaft
end and flange just before installing the motor. See item 6.4.
7. Drain hole: the motor must always be positioned so the drain hole is at the lowest position (If there is any
indication arrow on the drain, the drain must be so installed that the arrow points downwards).
Motors supplied with rubber drain plugs leave the factory in the closed position and must be opened
periodically to allow the exit of condensed water. For environments with high water condensation levels and

ENGLISH
motor with degree of protection IP55, the drain plugs can be mounted in open position (see Figure 6.1).
For motors with degree of protection IP56, IP65 or IP66, the drain plugs must remain at closed position (see
Figure 6.1), being opened only during the motor maintenance procedures.
The drain system of motors with Oil Mist lubrication system must be connected to a specific collection
system (see Figure 6.12).

Closed position Open position

Figure 6.1 – Detail of the rubber drain plug mounted in closed and open position.

Manual of Electric Motors 83

 www.weg.net

8.Additional recommendations:
a. Check the direction of motor rotation, starting the motor at no-load before coupling it to the load.
b. Vertical mounted motors with shaft end down must be fitted with drip cover to protect them from liquids
or solids that may drop onto the motors.
c. Vertical mounted motors with shaft end up should be fitted with water slinger ring to prevent water
ingress inside the motor.

Remove or fix the shaft key before starting the motor.

6.1. FOUNDATIONS
The foundation is the structure, structural element, natural or prepared base, designed to withstand the
stresses produced by the installed equipment, ensuring safe and stable performance during operation. The
foundation design should consider the adjacent structures to avoid the influences of other installed equipment
and no vibration is transferred through the structure.
The foundation must be flat and its selection and design must consider the following characteristics:
a) The features of the machine to be installed on the foundation, the driven loads, application, maximum
allowed deformations and vibration levels (for instance, motors with reduced vibration levels, foot flatness,
flange concentricity, axial and radial loads, etc. lower than the values specified for standard motors).
b) Adjacent buildings, conservation status, maximum applied load estimation, type of foundation and fixation
and vibrations transmitted by theses constructions.
If the motor is supplied with leveling/alignment bolts, this must be considered in the base design.

Please consider for the foundation dimensioning all stresses that are generated during the operation
ENGLISH

of the driven load.

The user is responsible for the foundation designing and construction.

The foundation stresses can be calculated by using the following equations (see Figure 6.2):

F1 = 0,5 * g * m – (4 * Tb / A)
F2 = 0,5 * g * m + (4 * Tb / A)

Where:

F1 and F2 = lateral stresses (N);

g = gravitational acceleration (9,8 m/s2);
m = motor weight (kg);
Tb = breakdown torque (Nm);
A = distance between centerlines of mounting holes in feet or base of the machine (end view) (m).

The motors may be mounted on:

J Concrete bases: are most used for large-size motors (see Figure 6.2);

J Metallic bases: are generally used for small-size motors (see Figure 6.3).

F1 F1
A
F2 F2

Figure 6.2 – Motor installed on concrete base Figure 6.3 – Motor installed on metallic base

84 Manual of Electric Motors

 www.weg.net

The metallic and concrete bases may be fitted with sliding system. These types of foundations are generally
used where the power transmission is achieved by belts and pulleys. This power transmission system is easier
to assemble/disassemble and allows the belt tension adjustment. Other important aspect of this foundation
type is the location of the base locking screws that must be diagonally opposite. The rail nearest the drive
pulley is placed in such a way that the positioning bolt is between the motor and the driven machine. The other
rail must be placed with the bolt on the opposite side (diagonally opposite), as shown in Figure 6.4 .

To facilitate assembly, the bases may have the following features:

J shoulders and/or recesses;

J anchor bolts with loose plates;

J bolts cast in the concrete;

J leveling screws;

J positioning screws;

J steel & cast iron blocks, plates with flat surfaces.

ENGLISH
Figure 6.4 – Motor installed on sliding base

After completing the installation, it is recommended that all exposed machined surfaces are coated with
suitable rust inhibitor.

6.2. MOTOR MOUNTING

Footless motors supplied with transportation devices, according to Figure 6.5, must have their devices
removed before starting the motor installation.

Figure 6.5 - Detail of the transportation devices for footless motors.

Manual of Electric Motors 85

 www.weg.net

6.2.1. Foot mounted motors

The drawings of the mounting hole dimensions for NEMA or IEC motors can be checked in the respective
technical catalogue.
The motor must be correctly aligned and leveled with the driven machine. Incorrect alignment and leveling may
result in bearing damage, generate excessive vibration and even shaft distortion/breakage.
For more details, see section 6.5 and 6.6. The thread engagement length of the mounting bolt should be at
least 1.5 times the bolt diameter. This thread engagement length should be evaluated in more severe
applications and increased accordingly.
Figure 6.6 shows the mounting system of a foot mounted motor indicating the minimum required thread
engagement length.

L = 1.5 x D

D
Figure 6.6 – Mounting system of a foot mounted motor

6.2.2. Flange mounted motors

ENGLISH

The drawings of the flange mounting dimensions, IEC and NEMA flanges, can be checked in the technical
catalogue.
The coupling of the driven equipment to the motor flange must be properly dimensioned to ensure the required
concentricity of the assembly.
Depending on the flange type, the mounting can be performed from the motor to the driven equipment flange
(flange FF (IEC) or D (NEMA)) or from the driven equipment flange to the motor (flange C (DIN or NEMA)).
For the mounting process from the driven equipment flange to the motor, you must consider the bolt length,
flange thickness and the thread depth of the motor flange.

If the motor flange has tapped through-holes, the length of the mounting bolts must not exceed the
tapped through-hole length of the motor flange, thus preventing damage to the winding head.

For flange mounting the thread engagement length of the mounting bolt should be at least 1.5 times the bolt
diameter. In severe applications, longer thread engagement length may be required.
In severe applications or if large motors are flange mounted, a foot or pad mounting may be required in addition
to the flange mounting (Figure 6.7). The motor must never be supported on its cooling fins.

Figure 6.7 - Mounting method of flange mounted motors with frame base support

Note:
When liquid (for example oil) is likely to come into contact with the shaft seal, please contact your local WEG representative.

86 Manual of Electric Motors

 www.weg.net

6.2.3. Pad mounted motors

Typically, this method of mounting is used in axial fans. The motor is fixed by tapped holes in the frame. The
dimensions of these tapped holes can be checked in the respective product catalogue. The selection of the
motor mounting rods/bolts must consider the dimensions of the fan case, the installation base and the thread
depth in the motor frame.
The mounting rods and the fan case wall must be sufficiently stiff to prevent the transmission of excessive
vibration to the machine set (motor & fan). Figure 6.8 shows the pad mounting system.

Figure 6.8 – Mounting of the motor inside the cooling duct

6.3. BALANCING
Unbalanced machines generate vibration which can result in damage to the motor. WEG motors are
dynamically balanced with “half key” and without load (uncoupled). Special balancing quality level must be
stated in the Purchase Order.

The transmission elements, such as pulleys, couplings, etc., must balanced with “half key” before they
are mounted on the motor shaft.

The balance quality grade meets the applicable standards for each product line.

ENGLISH
The maximum balancing deviation must be recorded in the installation report

6.4. COUPLINGS
Couplings are used to transmit the torque from the motor shaft to the shaft of the driven machine. The
following aspects must be considered when couplings are installed:
J Use proper tools for coupling assembly & disassembly to avoid damages to the motor and bearings.

J Whenever possible, use flexible couplings, since they can absorb eventual residual misalignments during the

machine operation.
J The maximum loads and speed limits informed in the coupling and motor manufacturer catalogues cannot

be exceeded.
J Level and align the motor as specified in sections 6.5 and 6.6, respectively.

Remove or fix the shaft key firmly when the motor is operated without coupling in order to prevent
accidents.

6.4.1. Direct coupling

Direct coupling is characterized when the Motor shaft is directly coupled to the shaft of the driven machine
without transmission elements. Whenever possible, use direct coupling due to lower cost, less space required
for installation and more safety against accidents.

Do not use roller bearings for direct coupling unless sufficient radial load is expected.

6.4.2. Gearbox coupling

Gearbox coupling is typically used where speed reduction is required.
Make sure that shafts are perfectly aligned and strictly parallel (in case of straight spur gears) and in the right
meshing angle (in case of bevel and helical gears).

Manual of Electric Motors 87

 www.weg.net

6.4.3. Pulley and belt coupling

Pulleys and belts are used when speed increase or reduction between motor shaft and driven load is required.

Excessive belt tension will damage the bearings and cause unexpected accidents such as breakage of
the motor shaft.

To prevent the buildup of static electricity in the belt drive system, use only properly grounded belts in
conductive construction.

6.4.4. Coupling of sleeve bearing motors

Motors designed with sleeve bearings must be operated with direct coupling to the driven machine or a
gearbox. Pulley and belts can not be applied for sleeve bearing motors.

Motors designed with sleeve bearings have 3 (three) marks on the shaft end. The center mark is the indication
of the magnetic center and the 2 (two) outside marks indicate the allowed limits of the rotor axial movement, as
shown in Figure 6.9.
The motor must be so coupled that during operation the arrow on the frame is placed over the central mark
indicating the rotor magnetic center. During start-up, or even during operation, the rotor may freely move
between the two outside marks when the driven machine exerts an axial load on the motor shaft. However,
under no circumstance, the motor can operate continuously with axial forces on the bearing.

Axial Clearance
ENGLISH

Figure 6.9 - Axial clearance of motor designed with sleeve bearing

For coupling evaluation consider the maximum axial bearing clearance as shown in Table 6.1.
The axial clearance of the driven machine and coupling influence the maximum bearing clearance.

Table 6.1 – Clearance used for sleeve bearings

Bearing size Total axial clearance (mm)

9* 3+3=6
11* 4+4=8
14* 5 + 5 =10
18 7,5 + 7,5 = 15

* For Motors in accordance with API 541, the total axial clearance is 12.7 mm

The sleeve bearings used by WEG were not designed to support axial load continuously.
Under no circumstance must the motor be operated continuously at its axial clearance limits.

88 Manual of Electric Motors

 www.weg.net

6.5. LEVELING
The motor must be leveled to correct any deviations in flatness arising from the manufacturing process and the
material structure rearrangement. The leveling can be carried out by a leveling screw fixed on the motor foot or
on the flange or by means of thin compensation shims. After the leveling process, the leveling height between
the motor mounting base and the motor cannot exceed 0.1 mm.
If a metallic base is used to level the height of the motor shaft end and the shaft end of the driven machine, level
only the metallic base relating to the concrete base.
Record the maximum leveling deviations in the installation report.

6.6. ALIGNMENT
The correct alignment between the motor and the driven machine is one of the most important variables that
extends the useful service life of the motor. Incorrect coupling alignment generates high loads and vibrations
reducing the useful life of the bearings and even resulting in shaft breakages. Figure 6.10 illustrates the
misalignment between the motor and the driven machine.
Motor shaft Driven machine shaft
Max.
misalignment

Driven machine
offset (mm)
Motor
offset (mm)

ENGLISH
Figure 6.10 – Typical misalignment condition

Alignment procedures must be carried out using suitable tools and devices, such as dial gauge, laser alignment
instruments, etc. The motor shaft must be aligned axially and radially with the driven machine shaft.
The maximum allowed eccentricity for a complete shaft turn should not exceed 0.03 mm, when alignment is
made with dial gauges, as shown in Figure 6.11. Ensure a gap between couplings to compensate the thermal
expansion between the shafts as specified by the coupling manufacturer.

Dial gauge

Reference
Line

GAP

Parallel alignment Angular alignment

Figure 6.11 – Alignment with dial gauge.

If alignment is made by a laser instrument, please consider the instructions and recommendations provided by
the laser instrument manufacturer.
The alignment should be checked at ambient temperature with machine at operating temperature.

The coupling alignment must be checked periodically

Manual of Electric Motors 89

 www.weg.net

Pulley and belt couplings must be so aligned that the driver pulley center lies in the same plane of the driven
pulley center and the motor shaft and the shaft of the driven machine are perfectly parallel.
After completing the alignment procedures, ensure that mounting devices do not change the motor and
machine alignment and leveling resulting into machine damage during operation.
It is recommended to record the maximum alignment deviation in the Installation Report.

6.7. CONNECTION OF OIL LUBRICATED OR OIL MIST LUBRICATED MOTORS

When oil lubricated or oil mist lubricated motors are installed, connect the existing lubricant tubes (oil inlet and
oil outlet tubes and motor drain tube), as shown in Figure 6.12. The lubrication system must ensure continuous
oil flow through the bearings as specified by the manufacturer of the installed lubrication system.

Inlet

Drain

Outlet

Figure 6.12 – Oil supply and drain system of oil lubricated or oil mist lubricated motors

6.8. CONNECTION OF THE COOLING WATER SYSTEM

When water cooled motors are installed, connect the water inlet and outlet tubes to ensure proper motor
ENGLISH

cooling. According to item 7.2, ensure correct cooling water flow rate and water temperature in the motor
cooling system.

6.9. ELECTRICAL CONNECTION

Consider the rated motor current, service factor, starting current, environmental and installation conditions,
maximum voltage drop, etc. to select appropriate power supply cables and switching and protection devices.
All motors must be installed with overload protection systems. Three-phase motors should be fitted with phase
fault protection systems.

Before connecting the motor, check if the power supply voltage and the frequency comply with the
motor nameplate data. All wiring must be made according to the connection diagram on the motor
nameplate. Please consider the connection diagrams in the Table 6.2 as reference value.
To prevent accidents, check if motor has been solidly grounded in accordance with the applicable standards.

90 Manual of Electric Motors

 www.weg.net

Table 6.2 - Typical connection diagram for three-phase motors.

Configuration Quantity of Leads Type of connection Connection diagram
1 2 3
3 -
L1 L2 L3

6 4 5 6 4 5

6 '-Y 1 2 3 1 2 3
L1 L2 L3 L1 L2 L3

4 5 6 4 5 6
7 8 9 7 8 9
YY - Y 1 2 3 1 2 3
L1 L2 L3 L1 L2 L3

9
4 5 6 4 5 6
7 8 9 7 8 9
Single Speed ''-' 1 2 3 1 2 3
L1 L2 L3 L1 L2 L3

11 12 10 11 12 10 11 12 10 11 12 10
5 6 4 5 6 4 5 6 4 5 6 4
8 9 7 8 9 7 8 9 7 8 9 7
'' - YY - ' - Y 2 3 1 2 3 1 2 3 1 2 3 1
L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1

12 PART-WINDING WYE-DELTA
START RUN START RUN
' - PWS 12 10 11 12 10 11 12 10 11 12 10 11
Part-winding start 7 8 9 7 8 9 6 4 5 6 4 5
6 4 5 6 4 5 7 8 9 7 8 9
1 2 3 1 2 3 1 2 3 1 2 3
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3

4 5 6 4 5 6

YY - Y 1 2 3 1 2 3

Variable Torque L1 L2 L3 L1 L2 L3

ENGLISH
LOW SPEED HIGH SPEED

4 5 6 4 5 6

' - YY 1 2 3 1 2 3
6
Constant Torque L1 L2 L3 L1 L2 L3
LOW SPEED HIGH SPEED
Double Speed
Dahlander 4 5 6 4 5 6

YY - ' 1 2 3 1 2 3

Constant Output L1 L2 L3 L1 L2 L3
LOW SPEED HIGH SPEED

7 8 9 7 8 9 7 8 9
1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6
9 ' - Y - YY
L1 L2 L3 L1 L2 L3 L1 L2 L3
ONLY FOR
LOW SPEED HIGH SPEED STARTING

1 2 3 6 4 5
Double Speed
6 -
Double Winding L1 L2 L3 L1 L2 L3
LOW SPEED HIGH SPEED

Equivalent table for lead identification

Lead identification on the wiring diagram 1 2 3 4 5 6 7 8 9 10 11 12
NEMA MG 1 Part 2 T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12
IEC 60034-8 U1 V1 W1 U2 V2 W2 U3 V3 W3 U4 V4 W4
Single Speed
JIS (JEC 2137) - up to 6 terminals U V W X Y Z
JIS (JEC 2137) - above 6 terminals U1 V1 W1 U2 V2 W2 U5 V5 W5 U6 V6 W6
Double Speed NEMA MG 1 Part 21) 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
(Dahlander / IEC 60034-8 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
Double Winding) JIS (JEC 2137) 1U 1V 1W 2U 2V 2W 3U 3V 3W 4U 4V 4W
1) NEMA MG 1 Part 2 defines T1 to T12 for two or more winding, however WEG adopts 1U to 4W.

Connect the motor properly to the power supply by means of safe and permanent contacts.

The grounding connectors are provided inside the terminal box and on the motor frame. Upon request,
grounding terminals may be also provided on the motor feet. According to IEC 60079-0, the grounding cable
must have a cross-section area of at least 4 mm².

Manual of Electric Motors 91

 www.weg.net

When connectors are used, all wires of the stranded cable must be properly inserted and fixed inside
the connector.

If motors are supplied without terminal blocks, insulate the cable terminals with suitable insulation material that
meets the power supply voltage and the insulation class indicated on the motor nameplate. The connection
must be made outside the hazardous area or protected by a standardized type of protection.

Ensure correct tightening torque for the power cable and grounding connections as specified in Table 8-8.

The clearance distance (see Figure 6.13) between non-insulated live parts with each other and between
grounded parts must be as indicated in Table 6.3.

Clearance distance

Clearance distance Clearance distance

Clearance distance
ENGLISH

Figure 6.13 - Clearance distance representation

Table 6.3 - Minimum clearance distance (mm) x supply voltage.

Minimum clearance distance (mm) x type of protection

Ex n
Voltage Ex e
Ex d
Ex de
Ex t
U ≤ 440 V 6 4
440 < U ≤ 690 V 10 5.5
690 < U ≤ 1000 V 14 8
1000 < U ≤ 6900 V 60 45
6900 < U ≤ 11000 V 100 70
11000<U ≤ 16500 V - 105

Even when the motor is off, dangerous voltages may be present inside the terminal box used for the
space heater supply or winding energization when the winding is used as heating element.
Motor capacitors will hold a charge even after the power has been cut off. Do not touch the capacitors
and/or motor terminals, before discharging the capacitors completely.

After the motor connection has been completed, ensure that no tool or foreign body has been left inside
the terminal box.

92 Manual of Electric Motors

 www.weg.net

The thread types and sizes for cable inlet are specified in Table 6.4 and Table 6.5.
Tabela 6.4 - Thread dimensions for inlet power cables.

Frame Threads for power cables

IEC NEMA Pg NPT/Rp/Gk Metric
- EX61G - 1/2" -
63
71 Pg11 1/4"
M20
80 143/5 Pg13.5 1/2"
M25
90 Pg16 3/4"
100
Pg11
1/2" M20
112 182/4 Pg13.5
3/4" M25
132 213/5 Pg16
1" M32
Pg21
Pg11
M20
Pg13.5 1/2"
160 254/6 M25
Pg16 3/4"
180 284/6 M32
Pg21 1"
200 324/6 M40
Pg29 1 1/2"
M50
Pg36
364/5
404/5
444/5
225 445/7
250 447/9
M32
280 L447/9 1"
M40
315 504/5 Pg29 1 1/2"
M50
355 5008 Pg36 2"
M63
400 586/7 Pg42 2 1/2"
M72
450 588/9 Pg48 3"
M75
500 5800 4"
M80

ENGLISH
560 6800
630 7000
8000
8800
9600

Note: explosion-proof motors are supplied with Metric or NPT threads only.

Tabela 6.5 - Thread dimensions for accessory cable inlet.

Frame Threads for accessory cables

IEC NEMA Pg NPT/Rp/Gk Metric
Pg11 1/4" M20
Pg13.5 1/2" M25
All All
Pg16 3/4" M32
Pg21 1" M40

Note: explosion-proof motors are supplied with Metric or NPT threads only.

Unused cable entry holes in the terminal box must be properly closed to ensure the type of protection,
the degree of protection and the Equipment Protection Level (EPL) indicated on the motor nameplate.
Cable entry holes used by the user for the motor and accessory connection must be fitted with
components (such as, cable glands and conduits) that meet the applicable standards and regulations in each
country. For “Ex d” motors, conduit entries are permitted only for electrical equipment of group II.
All terminal box holes must be properly closed/protected to ensure the degree of protection, the Equipment
Protection Level (EPL) and the type of protection of the enclosure indicated on the motor nameplate.

If the motor is fitted with accessories, such as brakes and forced cooling systems, these devices must
be connected to the power supply according to the information provided on their nameplates and with
special care as indicated above.

Manual of Electric Motors 93

 www.weg.net

All protection devices, including overcurrent protection, must be set according to the rated machine conditions.
These protection devices must protect the machine against short circuit, phase fault or locked rotor condition.

The motor protection devices intended for use in hazardous areas must be set according to the applicable
standards.

Delta connected motors must be protected against phase fault. To do that, connect the overload relay in series
to the winding phases and set it to 0.58 times the rated current.

Check the direction of rotation of the motor shaft. If there is no limitation for the use of unidirectional fans, the
shaft rotation direction can be changed by reversing any two of the phase connections. For single-phase motor,
check the connection diagram indicated on the motor nameplate.

6.10. CONNECTION OF THE THERMAL PROTECTION DEVICES

If the motor is supplied with temperature monitoring devices, such as, thermostat, thermistors, automatic
thermal protectors, Pt-100 (RTD), etc., they must be connected to the corresponding control devices as
specified on the accessory nameplates. The non-compliance with this procedure may void the product
warranty and cause serious material damages.

All thermal protections (RTDs, bimetal thermal protectors and thermistors for stator protection) used in the
motor protection circuit must be connected as a simple equipment in and intrinsically safe circuit.

Motors driven by frequency inverters must have their winding thermal protections connected.
For other starting methods, the use of the thermal protections is optional.

Do not apply test voltage above 2.5 V on thermistors and current above 1 mA on RTDs (Pt-100)
ENGLISH

according to IEC 60751 standard.

Figure 6.14 and Figure 6.15 show the connection diagram of the bimetal thermal protector (thermostats) and
thermistors, respectively.

Figure 6.14 - Connection of the bimetal thermal protectors (thermostats)

Figure 6.15 – Thermistor connection

In applications with protection by increased safety “Ex e”, the protection device, in case of overload or locked
rotor, must trip with time delay based on the current along with monitoring the three external leads. The time-
“tE” indicated on the motor nameplate should not be exceeded.

If motors with protection by increased safety “Ex e” are submitted to acceleration time > 1.7x time-“tE”, they
must be protected by protection devices against overcurrent.
94 Manual of Electric Motors
 www.weg.net

Table 6.6 - Maximum activation temperature of the thermal protections.

Marking for hazardous Hazardous area where Max. operating temperature (°C)
Component area on the motor the equipment will be
Alarm Tripping
nameplate installed
Ex d Ex d 130 150
Ex n Ex n 130 155
Ex t Ex t 120 140
Ex e Ex e - 110
Ex n 140 155
Ex n + Ex t
Winding Ex t - 140
Ex d 140 150
Ex d + Ex t
Ex t - 140
Class I Div. 1 Class I Div. 1 130 150
Class I Div. 2 Class I Div. 2 130 155
Class II Div. 1 Class II Div. 1 120 140
Bearing All All 110 120

Notes:
1) The number and type of the installed protection devices are stated on the accessory nameplate of the motor.
2) If the motor is supplied with calibrated resistance, (for example, Pt-100), the motor monitoring system must be set according to the
operating temperatures indicated in Table 6.6

The non-isolated part of the accessory cables should not exceed 1 mm up to the connector as shown in Figure
6.16.

ENGLISH

Figure 6.16 - Connection of the accessory cables to the connector.

Manual of Electric Motors 95

 www.weg.net

6.11. RESISTANCE TEMPERATURE DETECTORS (Pt-100)

The RTDs (Pt-100) are made of materials, whose resistance depends on the temperature variation, intrinsic
property of some materials (usually platinum, nickel or copper), calibrated resistance. Its operation is based on
the principle that the electric resistance of a metallic conductor varies linearly with the temperature, thus
allowing a continuous monitoring of the motor warm-up through the controller display ensuring a high level of
precision and answer stability. These devices are widely used for measuring temperatures in various industry
sectors.
In general these devices are used in installations where precise temperature control is required, for example, in
installation for irregular or intermittent duty.
The same detector may be used for alarm and tripping purposes.
Table 6.7 and Figure 6.17 show the equivalence between the Pt-100 resistance and the temperature.
Table 6.7 – Equivalence between the Pt-100 resistance and the temperature.

ºC Ω ºC Ω ºC Ω ºC Ω ºC Ω
-29 88.617 17 106.627 63 124.390 109 141.908 155 159.180
-28 89.011 18 107.016 64 124.774 110 142.286 156 159.553
-27 89.405 19 107.404 65 125.157 111 142.664 157 159.926
-26 89.799 20 107.793 66 125.540 112 143.042 158 160.298
-25 90.193 21 108.181 67 125.923 113 143.420 159 160.671
-24 90.587 22 108.570 68 126.306 114 143.797 160 161.043
-23 90.980 23 108.958 69 126.689 115 144.175 161 161.415
-22 91.374 24 109.346 70 127.072 116 144.552 162 161.787
-21 91.767 25 109.734 71 127.454 117 144.930 163 162.159
-20 92.160 26 110.122 72 127.837 118 145.307 164 162.531
-19 92.553 27 110.509 73 128.219 119 145.684 165 162.903
-18 92.946 28 110.897 74 128.602 120 146.061 166 163.274
-17 93.339 29 111.284 75 128.984 121 146.438 167 163.646
ENGLISH

-16 93.732 30 111.672 76 129.366 122 146.814 168 164.017

-15 94.125 31 112.059 77 129.748 123 147.191 169 164.388
-14 94.517 32 112.446 78 130.130 124 147.567 170 164.760
-13 94.910 33 112.833 79 130.511 125 147.944 171 165.131
-12 95.302 34 113.220 80 130.893 126 148.320 172 165.501
-11 95.694 35 113.607 81 131.274 127 148.696 173 165.872
-10 96.086 36 113.994 82 131.656 128 149.072 174 166.243
-9 96.478 37 114.380 83 132.037 129 149.448 175 166.613
-8 96.870 38 114.767 84 132.418 130 149.824 176 166.984
-7 97.262 39 115.153 85 132.799 131 150.199 177 167.354
-6 97.653 40 115.539 86 133.180 132 150.575 178 167.724
-5 98.045 41 115.925 87 133.561 133 150.950 179 168.095
-4 98.436 42 116.311 88 133.941 134 151.326 180 168.465
-3 98.827 43 116.697 89 134.322 135 151.701 181 168.834
-2 99.218 44 117.083 90 134.702 136 152.076 182 169.204
-1 99.609 45 117.469 91 135.083 137 152.451 183 169.574
0 100.000 46 117.854 92 135.463 138 152.826 184 169.943
1 100.391 47 118.240 93 135.843 139 153.200 185 170.313
2 100.781 48 118.625 94 136.223 140 153.575 186 170.682
3 101.172 49 119.010 95 136.603 141 153.950 187 171.051
4 101.562 50 119.395 96 136.982 142 154.324 188 171.420
5 101.953 51 119.780 97 137.362 143 154.698 189 171.789
6 102.343 52 120.165 98 137.741 144 155.072 190 172.158
7 102.733 53 120.550 99 138.121 145 155.446 191 172.527
8 103.123 54 120.934 100 138.500 146 155.820 192 172.895
9 103.513 55 121.319 101 138.879 147 156.194 193 173.264
10 103.902 56 121.703 102 139.258 148 156.568 194 173.632
11 104.292 57 122.087 103 139.637 149 156.941 195 174.000
12 104.681 58 122.471 104 140.016 150 157.315 196 174.368
13 105.071 59 122.855 105 140.395 151 157.688 197 174.736
14 105.460 60 123.239 106 140.773 152 158.061 198 175.104
15 105.849 61 123.623 107 141.152 153 158.435 199 175.472
16 106.238 62 124.007 108 141.530 154 158.808 200 175.840

96 Manual of Electric Motors

 www.weg.net

Figure 6.17 - Ohmic resistance of the Pt-100 x temperature

6.12. CONNECTION OF THE SPACE HEATERS

Before switching ON the space heaters, check if the space heaters connection have been made according to
the connection diagram shown on the space heater nameplate. For motors supplied with dual voltage space
heaters (110-127/220-240 V), see Figure 6.18.

ENGLISH
Figura 6.18 - Dual voltage space heater connection.

The space heaters should never be energized when the motor is in operation.

6.13. STARTING METHODS

Whenever possible, the motor starting must be Direct On Line (DOL) at rated voltage. This is the most simple
and feasible starting method. However, it must only be applied when the starting current does not affect the
power supply. Please consider the local electric utility regulations when installing a motor.
High inrush current may result in:
a) high voltage drop in the power supply line creating unacceptable line disturbance on the distribution system;
b) requiring oversized protection system (cables and contactor) increasing the installation costs.
If DOL starting is not allowed due to the reasons mentioned above, an indirect starting method compatible with
the load and motor voltage to reduce the starting current may be used.
If reduced voltage starters are used for starting, the motor starting torque will also be reduced.
Table 6.8 shows the possible indirect starting methods that can be used depending on the number of the
motor leads.

Manual of Electric Motors 97

 www.weg.net

Table 6.8 - Starting method x number of motor leads.

Number of leads Possible starting methods
Autotransformer
3 leads
Soft-starter
Star-Delta
6 leads Autotransformer
Soft-Starter
Star-Delta
Series/Parallel
9 leads Part Winding
Autotransformer
Soft-Starter
Star-Delta
Series/Parallel
12 leads Part Winding
Autotransformer
Soft-Starter

Table 6.9 shows examples of possible indirect starting methods to be used according to the voltage indicated
on the motor nameplate and the power supply voltage.
Table 6.9 – Starting methods x voltage
Starting by
Operating Autotransformer Part Winding Starting by
Nameplate voltage Star-delta series/parallel
voltage Starting Starting soft-starter
switch
220 V YES YES NO NO YES
220/380 V
380 V NO YES NO NO YES
220 V NO YES YES YES YES
220/440 V
440 V NO YES NO NO YES
230 V NO YES YES YES YES
230/460 V
460 V NO YES NO NO YES
380/660 V 380 V YES YES NO NO YES
220 V YES YES YES YES YES
ENGLISH

220/380/440 V 380 V NO YES YES YES YES

440 V YES YES NO NO YES

The W22 Quattro line motors must be started direct on-line (DOL) or driven by a frequency inverter in
scalar mode.

The starting by frequency inverter may be another starting method to avoid overloading the power supply line.
For more information about the motor control by frequency inverter, see item 6.14.

6.14. MOTORS DRIVEN BY FREQUENCY INVERTER

The operation with frequency inverter must be stated in the Purchase Order since this drive type may
require some changes of the motor design.

Motors driven by frequency inverters must have their winding thermal protections connected.

W22 Magnet Motors must only be driven by WEG frequency inverter.

The frequency inverter used to drive motors up to 690 V must be fitted with Pulse With Modulation (PWM) with
vector control.

Motors driven by frequency inverters have an additional nameplate fixed on the motor frame indicating the
Service Factor, inverter type, frame size, and/or load type (constant or variable torque) as function of the speed
range and motor torque.

When a motor is driven by a frequency inverter at lower frequencies than the rated frequency, you must reduce
the motor torque to prevent motor overheating. The torque reduction (derating torque) can be found in the item
6.4 of the “Technical Guidelines for Induction Motors driven by PWM Frequency inverters” available on the site
www.weg.net.

98 Manual of Electric Motors

 www.weg.net

If the motor is operated above the rated frequency, please note:

J That the motor must be operated at constant output;

J That the motor can supply max. 95% of its rated output;

J Do not exceed the maximum speed and please consider:

 J max. operating frequency informed on the additional nameplate;

 J mechanical speed limitation of the motor.

The “Ex n” motor line driven by frequency inverter (used in Zone 2 – presence of gas) can be operated up to the
limit of the Temperature Class T3 (200 °C).
The “Ex t” motor line driven by frequency inverter (used in Zone 22 and Zone 21 - in the presence of
combustible dust) can be operated up to the temperature limit of 125 °C.

Information on the selection of the power cables between the frequency inverter and the motor can be found in
the item 6.8 of the “Technical Guidelines for Induction Motors driven by PWM Frequency inverters” available at
www.weg.net.

6.14.1. Use of dV/dt filter

6.14.1.1. Motor with enameled round wire
Motors designed for rated voltages up to 690 V, when driven by frequency inverter, do not require the use of
dV/dT filters, provided that following criteria are considered.
Criteria for the selection of motors with round enameled wire when driven by frequency inverter 1
Inverter MTBP 3
Peak voltage at the dV/dt
Motor rated votage 2 Rise Time 3 Time between pulses
motor terminals (max) inverter output (max)
(min.) (min)
Vnom ≤ 460 V ≤ 1600 V ≤ 5200 V/μs
460 < Vnom ≤ 575 V ≤ 1800 V ≤ 6500 V/μs

ENGLISH
≥ 0,1 μs ≥ 6 μs
575 < Vnom ≤ 690 V 4 ≤ 1600 V ≤ 5200 V/μs
575 < Vnom ≤ 690 V 5 ≤ 2200 V ≤ 7800 V/μs

Notes:
1. For the application of motors with round enameled wires designed for 690 < Vnom ≤ 1100 V, please contact WEG.
2. For the application of dual voltage motors, example 380/660 V, consider the lower voltage (380 V).
3. Information supplied by the inverter manufacturer.
4. When not stated in the Purchase Order that the motor will be driven by frequency inverter.
5. When stated in the Purchase Order that the motor will be driven by frequency inverter.

6.14.1.2. Motor with prewound coils

Motors with prewound coils (medium and high voltage motors regardless of frame sizes, and low voltage
motors from IEC 500 / NEMA 800 frame on), designed for the use with frequency inverters, do not require the
use of filters, provided they comply with the criteria in Table 6.10.
Table 6.10 - Criteria to be considered when using motor with prewound coils to be drive by frequency inverters
Turn to turn insulation (phase-phase) Phase-ground insulation
Type of Peak voltage at Peak voltage at
Motor rated voltage dV/dt at the motor dV/dt at the motor
modulation the motor the motor
terminals terminals
terminals terminals
Sinusoidal ≤ 5900 V ≤ 500 V/μs ≤ 3400 V ≤ 500 V/μs
690 < Vnom ≤ 4160 V
PWM ≤ 9300 V ≤ 2700 V/μs ≤ 5400 V ≤ 2700 V/μs
Sinusoidal ≤ 9300 V ≤ 500 V/μs ≤ 5400 V ≤ 500 V/μs
4160 < Vnom ≤ 6600 V
PWM ≤ 14000 V ≤ 1500 V/μs ≤ 8000 V ≤ 1500 V/μs

6.14.2. Bearing insulation

Only the motors in IEC frame size 400 (NEMA 680) and larger are supplied, as standard, with insulated bearing.
If motor must be driven by frequency inverter, insulate the bearing according to Table 6.11.

Manual of Electric Motors 99

 www.weg.net

Table 6.11 – Recommendation on the bearing insulation for inverter driven motors
Frame size Recommendation
IEC 315 and 355
NEMA L447/9, 504/5, 5006/7/8, 5009/10/11, 586/7, 5807/8/9, One bearing is isolated
5810/11/12 and 588/9
IEC 400 and higher
NDE-bearing is isolated
NEMA 680 and higher

The shaft grounding system for explosion-proof motors can be used only inside the enclosure. For other
types of protection the shaft grounding system is not allowed.

6.14.3. Switching Frequency

The minimum inverter switching frequency must not be lower than 2.5 kHz and should not exceed 5 kHz.

The non-compliance with the criteria and recommendations indicated in this manual may void the
product warranty.

The use of sparking components, such as grounding brushes, is not allowed in explosive atmospheres.

6.14.4. Mechanical speed limitation

Table 6.12 shows the maximum speeds allowed for motors driven by frequency inverter.
ENGLISH

Table 6.12 – Maximum motor speed (in rpm).

Frame size Maximum speed for
DE-bearing
IEC NEMA standard motors
6201
6202
63-90 143/5 6203 10400
6204
6205
100 - 6206 8800
6207 7600
112 182/4
6307 6800
132 213/5 6308 6000
160 254/6 6309 5300
180 284/6 6311 4400
200 324/6 6312 4200
6314 3600
6315 3600
6316 3200
6319 3000
6220 3600
225-630 364/5-9610
6320 2200
6322 1900
6324 1800
6328 1800
6330 1800

Note:
To select the maximum allowed motor speed, consider the motor torque derating curve.

For more information on the application of frequency inverters, contact WEG or check the “Technical Guidelines
for Induction Motors driven by PWM Frequency inverters” available at www.weg.net.

100 Manual of Electric Motors

 www.weg.net

7. COMMISSIONING
7.1. INITIAL START-UP
After finishing the installation procedures and before starting the motor for the first time or after a long period
without operation, the following items must be checked:
J If the nameplate data (voltage, current, connection diagram, degree of protection, type of protection, cooling

system, service factor, etc.) meet the application requirements.

J If the machine set (motor + driven machine) has been mounted and aligned correctly.

J If the motor driving system ensures that the motor speed does not exceed the max. allowed speed indicated

in Table 6.12.
J Measure the winding insulation resistance, making sure it complies with the specified values in item 5.4.

J Check the motor rotation direction.

J Inspect the motor terminal box for damage and ensure that it is clean and dry and all contacts are rust-free,

the seals are in perfect operating conditions and all unused threaded holes are properly closed thus ensuring
the degree of protection and the type of protection of the motor indicated on the motor nameplate.
J Check if the motor wiring connections, including grounding and auxiliary equipment connection, have been

carried out properly and are in accordance with the recommendations in item 6.9.
J Check the operating conditions of the installed auxiliary devices (brake, encoder, thermal protection device,

forced cooling system, etc.).

J Check bearing operating conditions. If the motors are stored and/or installed for more than two years without

running, it is recommended to change the bearings, or to remove, wash, inspect and relubricate them before
the motor is started. If the motor is stored and/or installed according to the recommendations described in
item 5.3, lubricate the bearings as described in item 8.2. For the bearing condition evaluation, it is
recommended to use of the vibration analysis techniques: Envelope Analysis or Demodulation Analysis.
J When motors are fitted with sleeve bearings, ensure:

 J correct oil level for the sleeve bearing. The oil level should be in the center of the sight glass (see Figure 6.8);

 J that the motor is not started or operated with axial or radial loads;

ENGLISH
 J that if the motor is stored for a period equal or longer than the oil change interval, the oil must be changed

before starting the motor.

J Inspect the capacitor operating condition, if any. If motors are installed for more than two years, but were

never commissioned, it is recommended to change the start capacitors since they lose their operating
characteristics.
J Ensure that the air inlet and outlet opening are not blocked. The minimum clearance to the nearest wall (L)

should be at least ¼ of the fan cover diameter (D), see Figure 7.1. The intake air temperature must be at
ambient temperature.

Figure 7.1- Minimum clearance to the wall

Manual of Electric Motors 101

 www.weg.net

Please consider the minimum distances shown in the Table 7.1 as reference value
Table 7.1 – Minimum distance between the fan cover and wall
Frame size Distance between the fan cover and the wall (L)
IEC NEMA mm inches
63 - 25 0.96
71 - 26 1.02
80 - 30 1.18
90 143/5 33 1.30
100 - 36 1.43
112 182/4 41 1.61
132 213/5 50 1.98
160 254/6 65 2.56
180 284/6 68 2.66
200 324/6 78 3.08
225 364/5
85 3.35
250 404/5
444/5
280 445/7 108 4.23
447/9
L447/9
504/5
315 122 4.80
5006/7/8
5009/10/11
586/7
588/9
355 136 5.35
5807/8/9
5810/11/12
6806/7/8
400
6809/10/11
147 5.79
450 7006/10 159 6.26
ENGLISH

500 8006/10 171 6.73

560 8806/10 185 7.28
630 9606/10 200 7.87

J ensure correct water flow rate and water temperature when water cooled motors are used. See item 7.2.
J ensure that all rotating parts, such as pulleys, couplings, external fans, shaft, etc. are protected against
accidental contact.
Other tests and inspections not included in the manual may be required, depending on the specific installation,
application and/or motor characteristics.
After all previous inspections have been carried out, proceed as follows to start the motor:
J Start the motor on no-load (if possible) and check the motor direction of rotation. Check for the presence of

any abnormal noise, vibration or other abnormal operating conditions.

J Ensure the motor starts smoothly. If any abnormal operating condition is noticed, switch off the motor, check

the assembly system and connections before the motor is started again.
J If excessive vibrations are noticed, check if the motor mounting bolts are well tightened or if the vibrations are

not generated and transmitted from adjacent installed equipment. Check the motor vibration periodically and
ensure that the vibration limits are as specified in item 7.2.1.
J Start the motor at rated load during a short time and compare the operating current with the rated current

indicated on the nameplate.

J Continue to measure the following motor variables until thermal equilibrium is reached: current, voltage,

bearing and motor frame temperature, vibration and noise levels.

J Record the measured current and voltage values on the Installation Report for future comparisons.

As induction motors have high inrush currents during start-up, the acceleration of high inertia load requires an
extended starting time to reach full speed resulting in fast motor temperature rise. Successive starts within
short intervals will result in winding temperature increases and can lead to physical insulation damage reducing
the useful life of the insulation system. If the duty S1 is specified on the motor nameplate, this means that the
motor has been designed for:
J two successive starts: first start from cold condition, i. e., the motor windings are at room temperature and

the second start immediately after the motor stops.

J one start from hot condition, i. e., the motor windings are at rated temperature.

The Troubleshooting Chart in section 10 provides a basic list of unusual cases that may occur during motor
operation with the respective corrective actions

102 Manual of Electric Motors

 www.weg.net

7.2. OPERATING CONDITIONS

Unless otherwise stated in the Purchase Order, electric motors are designed and built to be operated at
altitudes up to 1000 meters above sea level and in a temperature range from -20 °C to +40 °C. Any deviation
from the normal condition of motor operation must be stated on the motor nameplate. Some components must
be changed if the ambient temperature is different from the specified one. Please contact WEG to check the
required special features.

For operating temperatures and altitudes differing from those above, the factors indicated in Table 7.2 must be
applied to the nominal motor power rating in order to determine the derated available output (Pmax = Pnom x
correction factor).
Table 7.2 - Correction factors for altitude and ambient temperature.
Altitude (m)
T (°C)
1000 1500 2000 2500 3000 3500 4000 4500 5000
10 0.97 0.92 0.88
15 0.98 0.94 0.90 0.86
20 1.00 0.95 0.91 0.87 0.83
25 1.00 0.95 0.93 0.89 0.85 0.81
30 1.00 0.96 0.92 0.90 0.86 0.82 0.78
35 1.00 0.95 0.93 0.90 0.88 0.84 0.80 0.75
40 1.00 0.97 0.94 0.90 0.86 0.82 0.80 0.76 0.71
45 0.95 0.92 0.90 0.88 0.85 0.81 0.78 0.74 0.69
50 0.92 0.90 0.87 0.85 0.82 0.80 0.77 0.72 0.67
55 0.88 0.85 0.83 0.81 0.78 0.76 0.73 0.70 0.65
60 0.83 0.82 0.80 0.77 0.75 0.73 0.70 0.67 0.62
65 0.79 0.76 0.74 0.72 0.70 0.68 0.66 0.62 0.58
70 0.74 0.71 0.69 0.67 0.66 0.64 0.62 0.58 0.53
75 0.70 0.68 0.66 0.64 0.62 0.60 0.58 0.53 0.49
80 0.65 0.64 0.62 0.60 0.58 0.56 0.55 0.48 0.44

Motors installed inside enclosures (cubicles) must be ensured an air renewal rate in the order of one cubic
meter per second for each 100 kW installed power or fraction of installed power. Totally Enclosed Air Over

ENGLISH
motors - TEAO (fan and exhaust / smoke extraction) are supplied without cooling fan and the manufacturer of
the driven machine is responsible for sufficient motor cooling. If no minimum required air speed between motor
fins is indicated on the motor nameplate, ensure the air speed indicated in the table 7.3 is provided. The values
shown in Table 7.3 are valid for 60 Hz motors. To obtain the minimum air speed for 50 Hz motors, multiply the
values in the table by 0.83.
Table 7.3 – Minimum required air speed between motor fins (metres/second).

Frame Poles
IEC NEMA 2 4 6 8
63 to 90 143/5 13 7 5 4
100 to 132 182/4 to 213/5 18 12 8 6
160 to 200 254/6 to 324/6 20 15 10 7
225 to 280 364/5 to 444/5 22 20 15 12
315 to 450 445/7 to 7008/9 25 25 20 15

The voltage and frequency variations may affect the performance characteristics and the electromagnetic
compatibility of the motor. The power supply variations should not exceed the values specified in the applicable
standards. Examples:
J ABNT NBR 17094 - Parts 1 and 2. The motor has been designed to supply the rated torque for a combined

variation in voltage and frequency:

 J Zone A: ±5% of the rated voltage and ±2% of the rated frequency.

 J Zone B: ±10% of the rated voltage and +3% -5% of the rated frequency.

When operated continuously in Zone A or B, the motor may show performance variations and the operating
temperature may increase considerably. These performance variations will be higher in Zone B. Thus it is not
recommended to operate the motor in Zone B during extended periods.
J IEC 60034-1. The motor has been designed to supply the rated torque for combined variation in voltage and
frequency:
J Zone A: ±5% of the rated voltage and ±2% of the rated frequency.

J Zone B: ±10% of the rated voltage and +3% -5% of the rated frequency.

When operated continuously in Zone A or B, the motor may show performance variations and the operating
temperature may increase considerably. These performance variations will be higher in Zone B. Thus it is not
recommended to operate the motor in Zone B during extended periods. For multivoltage motors (example 380-
415/660 V), a ±5% voltage variation from the rated voltage is allowed.
Manual of Electric Motors 103
 www.weg.net

J NEMA MG 1 Part 12. The motor has been designed to be operated in one of the following variations:
 J ±10% of the rated voltage, with rated frequency;

 J ±5% of the rated frequency, with rated voltage;

 J A combined variation in voltage and frequency of ±10%, provided the frequency variation does not exceed ±5%.

“Ex e“ motors are designed to be operated only in Zone A – voltage and frequency variation.
If the motor is cooled by ambient air, clean the air inlet and outlet openings and cooling fins at regular intervals to
ensure a free airflow over the frame surface. The hot air should never be returned to the motor. The cooling air must
be at room temperature limited to the temperature range indicated on the motor nameplate (if no room temperature
is specified, please consider a temperature range between -20 °C and +40 °C).
Table 7.4 shows the minimum required water flow for water cooled motors considering the different frame sizes and
the maximum allowed temperature rise of the cooling water after circulating through the motor. The inlet water
temperature should not exceed 40 °C.
Table 7.4 – Minimum required water flow and the maximum allowed
temperature rise of the cooling water after circulating through the motor
Frame size Flow rate Maximum allowed water
IEC NEMA (litres/minute) temperature rise (°C)
180 284/6 12 5
200 324/6 12 5
225 364/5 12 5
250 404/5 12 5
444/5
280 445/7 15 6
447/9
315 504/5 16 6
586/7
355 25 6
588/9

Motors fitted with oil mist lubrication systems can be operated continuously for a maximum of one hour after
ENGLISH

the failure of the oil pumping system.

Considering the sun’s heat increases the operating temperature, externally mounted motors should always be
protected from direct sunlight exposure.
Each and every deviation from the normal operating condition (tripping of the thermal protection, noise and
vibration level increase, temperature and current rise) should be investigated and corrected by WEG Authorized
Service Centers for explosive atmospheres.

Motors fitted with cylindrical roller bearings require a minimum radial load to ensure a normal operation.
For information regarding the radial preload, please contact WEG.

7.2.1.Limits of vibration
The vibration severity is the maximum vibration value measured at all positions and in all directions as
recommended in the standard IEC 60034-14. Table 7.5 specifies the limits of the maximum vibrations
magnitudes according to standard IEC 60034-14 for shaft heights IEC 56 to 400, for vibrations grades A and B.
The vibration severity limits in Table 7.5 are given as RMS values (Root Mean Square values or effective values)
of the vibration speed in mm/s measured in free suspension condition.
Table 7.5 - Limits of maximum vibration magnitude according to standard IEC 60034-14
Shaft height [mm] 56 < H < 132 132 < H < 280 H > 280
Vibration Grade Vibration severity on elastic base [mm/s RMS]
A 1.6 2.2 2.8
B 0.7 1.1 1.8

Notes:
1 – The values in Table 7.5 are valid for measurements carried out with decoupled machines (without load) operated at rated voltage and
frequency.
2 - The values in Table 7.5 are valid regardless of the direction of rotation of the machine.
3 – The values in Table 7.5 are not applicable to single-phase motors, three-phase motors powered by a single-phase system or to
machines mounted in situ or coupled with inertia flywheels or to loads.

According to NEMA MG 1, the allowed vibration limit for standard motors is 0.15 in/s (peak vibration in in/s).
Note:
For the load operation condition, the use of the standard ISO 10816-3 is recommended for evaluating the motor vibration limits. In the
load condition the motor vibration will be influenced by several factors, such as, type of the coupled load, condition of the motor fixation,
alignment condition under load, structure or base vibration due to other equipments, etc.

104 Manual of Electric Motors

 www.weg.net

8. MAINTENANCE
The purpose of the maintenance is to extend the useful life of the equipment. The non-compliance with one of
these previous items can cause unexpected machine failures.

If motors with cylindrical roller or angular contact bearings are to be transported during the maintenance
procedures, the shaft locking device must always be fitted. All HGF motors, regardless of the bearing type,
must always be transported with the shaft locking device fitted.

All repairs, disassembly and assembly related services must be carried out only by qualified and well-trained
personnel by using proper tools and techniques. Make sure that the machine has stopped and it is
disconnected from the power supply, including the accessory devices (space heater, brake, etc.), before any
servicing is undertaken.
The company does not assume any responsibility or liability for repair services or maintenance operations to
motor for use in hazardous areas executed by non-authorized Service Centers or by non qualified service
personnel. The company shall have no obligation or liability whatsoever to the buyer for any indirect, special,
consequential or incidental loss or damage caused or arising from the company’s proven negligence.

Repairs to motor for use in hazardous areas must be executed in accordance with the applicable standards.

8.1. GENERAL INSPECTION

The inspection intervals depend on the motor type, application and installation conditions. Proceed as follows
during inspection:
J Visually inspect the motor and coupling. Check if abnormal noises, vibrations, excessive heating, wear signs,
misalignment or damaged parts are noticed. Replace the damaged parts as required.
J Measure the insulation resistance according to the item 5.4.

ENGLISH
Clean the motor enclosure. Remove oil spills and dust accumulation from the motor frame surface to
ensure a better heat transfer to the surrounding ambient. Motors with potential risk for electrostatic charge
accumulation, duly identified, must be cleaned carefully by using a damp cloth to prevent electrostatic
discharge during maintenance interventions.
J Check cooling fan condition and clean the air inlet & outlet openings to ensure a free air flow over the motor.
J Investigate the actual condition of the seals and replace them, if required.
J Drain the condensed water from inside the motor. After draining, reinstall the drain plugs to ensure the degree
of protection as indicated on the motor nameplate. The motor must always be positioned so the drain hole is
at the lowest position (see item 6).
J Check the connections of the power supply cables, ensuring the correct clearance distance between live and
grounded parts, as specified in Table 6-2.
J Check if the tightening torque of the bolted connections and mounting bolts meets the tightening torque
specified in Table 8 8.
J Check the status of the cable passages, the cable gland seals and the seals inside the terminal box and
replace them, if required.
J Check the bearing operating conditions. Check for the presence of any abnormal noise, vibration or other
abnormal operating conditions, like motor temperature rise. Check the oil level, the lube oil condition and
compare the workings hours with the informed life time.
J For explosion-proof motors check if the gap between the components is according to the Table 8-7. The
tolerance class of the metric threads for the cable inlet must be 6H or better.
J Record and file all changes performed on the motor.

Do not reuse damaged or worn parts. Damaged or worn parts must be replaced by parts supplied by
the manufacturer and must be installed as if they were the original parts.

8.2. LUBRICATION
Proper lubrication plays a vital role in the motor performance. Only use the grease or oil types, amounts and
lubrication intervals recommended for the bearings. This information is available on the motor nameplate and
the lubrication procedures must be carried out according to the type of lubricant (oil or grease).
When the motor is fitted with thermal protection devices for bearing temperature control, consider the operating
temperature limits shown in Table 6.3.
The maximum operating temperature of motors used in special applications may differ from those shown in
Table 6.3. The grease and oil disposal should be made in compliance with applicable laws in each country
Manual of Electric Motors 105
 www.weg.net

Please contact WEG when motors are to be installed in special environments or used for special
applications.

8.2.1. Grease lubricated rolling bearings

Excess grease causes bearing overheating, resulting in bearing failure.

The lubrication intervals specified in Table 8.1, Table 8.2, Table 8.3 and Table 8.4 consider an absolute
temperature on the bearing of 70 °C (up to frame size IEC 200 / NEMA 324/6) and 85 °C (for frame size IEC 225
/ NEMA 364/5 and above) the motor running at rated speed, a motor mounted in horizontal position, greased
with Mobil Polyrex EM grease. Any variation of the parameters listed above must be evaluated.
Table 8.1 - Lubrication intervals for deep groove ball bearings.
Lubrication intervals (hours)
W21 TEFC W22 TEFC
Frame Bearing Amount of
Poles (Totally Enclosed Fan (Totally Enclosed Fan
designation grease (g)
Cooled) Cooled)
IEC NEMA 50 Hz 60 Hz 50 Hz 60 Hz
2
4
90 143/5 6205 4 20000 20000 25000 25000
6
8
2
4
100 - 6206 5 20000 20000 25000 25000
6
8
2
4 6207/
112 182/4 9 20000 20000 25000 25000
6 6307
ENGLISH

8
2 20000 18400 25000 23200
4
132 213/5 6308 11
6 20000 20000 25000 25000
8
2 18100 15700 22000 20000
4
160 254/6 6309 13
6 20000 20000 25000 25000
8
2 13700 11500 17000 14000
4
180 284/6 6311 18
6 20000 20000 25000 25000
8
2 11900 9800 15000 12000
4
200 324/6 6312 21
6 20000 20000 25000 25000
8
2 4500 3600 5000 4000
4 11600 9700 14000 12000
6314 27
6 16400 14200 20000 17000
364/5 8 19700 17300 24000 20000
404/5 *Upon *Upon
2 3500 4000
444/5 request request
225 445/7 4 6316 34 10400 8500 13000 10000
250 447/9 6 14900 12800 18000 16000
280 L447/9 8 18700 15900 20000 20000
315 504/5 *Upon *Upon
2 2400 3000
355 5008 request request
5010/11 4 6319 45 9000 7000 11000 8000
586/7 6 13000 11000 16000 13000
588/9 8 17400 14000 20000 17000
4 7200 5100 9000 6000
6 6322 60 10800 9200 13000 11000
8 15100 11800 19000 14000

106 Manual of Electric Motors

 www.weg.net

Table 8.2 - Lubrication intervals for cylindrical roller bearings

Lubrication intervals (hours)
Frame W21 TEFC W22 TEFC
Bearing Amount of
Poles (Totally Enclosed Fan (Totally Enclosed Fan
designation grease (g)
Cooled) Cooled)
IEC NEMA 50 Hz 60 Hz 50 Hz 60 Hz
2 13300 9800 16000 12000
4
160 254/6 NU309 13
6 20000 20000 25000 25000
8
2 9200 6400 11000 8000
4 19100
180 284/6 NU311 18
6 20000 25000 25000
20000
8
2 7600 5100 9000 6000
4 17200 21000
200 324/6 NU312 21
6 20000 25000
20000 25000
8
4 8900 7100 11000 9000
364/5 6 NU314 27 13100 11000 16000 13000
404/5 8 16900 15100 20000 19000
444/5 4 7600 6000 9000 7000
225 445/7 6 NU316 34 11600 9500 14000 12000
250 447/9 8 15500 13800 19000 17000
280 L447/9
315 504/5 4 6000 4700 7000 5000
355 5008 6 NU319 45 9800 7600 12000 9000
5010/11 8 13700 12200 17000 15000
586/7 4 4400 3300 5000 4000
588/9 6 NU322 60 7800 5900 9000 7000
8 11500 10700 14000 13000

ENGLISH
Table 8.3 – Lubrication intervals for deep groove ball bearings – HGF line.
Frame Bearing Amount of Lubrication intervals (hours)
Poles
IEC NEMA designation grease (g) 50 Hz 60 Hz
2 6314 27 3100 2100
315L/A/B and 5006/7/8T and
6320 50 4500 4500
315C/D/E 5009/10/11T 4–8
6316 34 4500 4500
2 6314 27 3100 2100
355L/A/B and 5807/8/9T and
6322 60 4500 4500
355C/D/E 5810/11/12T 4–8
6319 45 4500 4500
2 6315 30 2700 1800
400L/A/B and 6806/7/8T and
6324 72 4500 4500
400 C/D/E 6809/10/11T 4–8
6319 45 4500 4500
2 6220 31 2500 1400
6328 93 4500 3300
4
450 7006/10 6322 60 4500 4500
6328 93 4500 4500
6–8
6322 60 4500 4500
6330 104 4200 2800
4
6324 72 4500 4500
500 8006/10
6330 104 4500 4500
6–8
6324 72 4500 4500
6330 104 4200 2800
4
6324 72 4500 4500
500 8006/10
6330 104 4500 4500
6–8
6324 72 4500 4500
560 8806/10 4-8
*Upon request
630 9606/10 4-8

Manual of Electric Motors 107

 www.weg.net

Table 8.4 - Lubrication intervals for cylindrical roller bearings – HGF line
Frame Bearing Amount of Lubrication intervals (hours)
Poles
IEC NEMA designation grease (g) 50 Hz 60 Hz
315L/A/B and 5006/7/8 and 4 4300 2900
NU320 50
315C/D/E 5009/10/11 6-8 4500 4500
355L/A/B and 5807/8/9 and 4 3500 2200
NU322 60
355C/D/E 5810/11/12 6-8 4500 4500
400L/A/B and 6806/7/8 and 4 2900 1800
NU324 72
400C/D/E 6809/10/11 6-8 4500 4500
4 2000 1400
450 7006/10 6 NU328 93 4500 3200
8 4500 4500
4 1700 1000
500 8006/10 6 NU330 104 4100 2900
8 4500 4500
4 75 2600 1600
560 8806/10 NU228 + 6228
6-8 106 4500 4500
4 92 1800 1000
630 9606/10 6 NU232 + 6232 120 4300 3100
8 140 4500 4500

For each increment of 15 ºC above the room temperature, the relubrication intervals given in the Table must be
halved. The relubrication interval of motors designed by the manufacturer for mounting in horizontal position,
but installed in vertical position (with WEG authorization), must be halved.
For special applications, such as: high and low temperatures, aggressive environments, driven by frequency
inverter (VFD – frequency inverter), etc., please contact WEG about the required amount of grease and the
relubrication intervals.

8.2.1.1. Motor without grease fitting

ENGLISH

Motors without grease fittings must be lubricated in accordance with the existing Maintenance Plan. Motor
disassembly must be carried out as specified in Item 8.3. If motors are fitted with shielded bearings (for
example, ZZ, DDU, 2RS, VV), these bearings must be replaced at the end of the grease service life.
8.2.1.2. Motor with grease fitting
To lubricate the bearings with the motor stopped, proceed as follows:
Motors with grease fittings must be stopped to be lubricated. Proceed as follows:
J Before lubricating, clean the grease nipple and immediate vicinity thoroughly;

J Lift grease inlet protection;

J Remove the grease outlet plug;

J Pump in approximately half of the total grease indicated on the motor nameplate and run the motor for about

1 (one) minute at rated speed;

J Switch-off the motor and pump in the remaining grease;

J Lower again the grease inlet protection and reinstall the grease outlet protection.

To grease the motor while running, proceed as follows:

J Before lubricating, clean the grease nipple and immediate vicinity thoroughly;
J Pump the total grease indicated on the motor nameplate;

J Lower again the grease inlet protection.

For lubrication, use only manual grease gun.

If Motors are provided with a spring device for grease removal, the grease excess must be removed by pulling
the rod and cleaning the spring until the spring does not remove more grease.
8.2.1.3. Compatibility of the Mobil Polyrex EM grease with other greases
The Mobil Polyrex EM grease has a polyurea thickener and a mineral oil thus being compatible with greases
that contain:
J Lithium based thickener, lithium-based complex thickener, polyurea thickener and refined mineral oil;

J The used grease must have in its formulation corrosion and oxidation inhibitors.

In general terms, greases with the same type of soap are compatible to each other. However, depending on the
proportion of the mixture there may be incompatibility. In such a case, it is not recommended to mix different
types of greases without contacting the supplier or WEG beforehand.
108 Manual of Electric Motors
 www.weg.net

8.2.2. Oil lubricated bearings

To change the oil of oil lubricated motor proceed as follows:
J switch-off the motor;

J remove threaded oil drain plug;

J open the valve and drain the oil;

J close the drain vale again;

J reinstall the threaded oil drain plug;

J fill-up with the type and amount of oil as specified on the nameplate;

J check oil level. The oil level is OK when the lubricant can be viewed approximately in the center of the sight

glass;
J reinstall oil inlet plug;

J check for oil leaks and ensure that all not used threaded plugs are closed with plugs.

The bearing lubricating oil must be replaced as specified on the nameplate or whenever changes in the oil
properties are noticed. The oil viscosity and pH must be checked periodically. The oil level must be checked
every day and must be kept in the center of the sight glass.
Please contact WEG, when oils with different viscosities should be used.
Note:
The HGF vertical mounted motors with high axial thrust are supplied with grease lubricated DE-bearings and with oil lubricated NDE-
bearings. The DE-bearings must be lubricated according to recommendations in item 8.2.1. Table 8.5 specifies the oil type and the
amount of oil required for this motor lubrication.

Table 8.5 – Oil properties for HGF vertical mounted motors with high axial thrust

Frame Bearing Lubricant

Mounting - High axial thrust

Poles Oil (liters) Interval (h) Lubricant

IEC NEMA designation specification
315L/A/B e 5006/7/8T e
4-8 29320 20
315C/D/E 5009/10/11T
355L/A/B e 5807/8/9T e ISO VG150

ENGLISH
4-8 29320 26 mineral oil
355C/D/E 5810/11/12T Renolin
with antifoam
400L/A/B e 6806/7/8T e 8000 DTA 40 /
4-8 29320 37 and
400C/D/E 6809/10/11T SHC 629
antioxidant
additives
450 7006/10 4-8 29320 45

8.2.3. Oil mist lubricated bearings

Check the service conditions of the seals and if replacement is required use only original components. Clean
the seal components before assembly (bearing caps, end shields, etc.).
Apply joint sealant between the bearing caps and end shields. The joint sealant must be compatible with the
used lubricating oil. Connect the oil lubricant tubes (oil inlet and oil outlet tubes and motor drain tube), as
shown in Figure 6.12.
8.2.4. Sleeve bearings
The lubricating oil of sleeve bearings must be changed at the intervals specified in Table 8.6. To replace the oil,
proceed as follows:
J NDE-bearing: remove the protection plate from the fan cover;

J Drain the oil through the drain hole located at the bottom of the bearing (see Figure 8.1);

J Close the oil drain hole;

J Remove the oil inlet plug;

J Fill the sleeve bearing with the specified oil and with the amount of oil specified in;

J Check the oil level and ensure it is kept close to the center of the sight glass;

J Install the oil inlet plug;

J Check for oil leaks. Oil inlet

Oil sight glass

Oil outlet

Figure 8.1 – Sleeve bearing

Manual of Electric Motors 109
 www.weg.net

Table 8.6 – Oil properties for sleeve bearings.

Frame Bearing Oil Lubricant

Poles Interval (h) Lubricant
IEC NEMA designation (liters) Specification
315L/A/B and 5006/7/8T and
315C/D/E 5009/10/11T ISO VG32
355L/A/B and 5807/8/9T and mineral oil with
355C/D/E 5810/11/12T Renolin
2 9-80 2.8 8000 antifoam and
DTA 10
400L/A/B and 6806/7/8 and antioxidant
400C/D/E 6809/10/11T additives
450 7006/10
315L/A/B and 5006/7/8T and
9-90
315C/D/E 5009/10/11T
2.8 ISO VG46
355L/A/B and 5807/8/9T and
9-100 mineral oil with
355C/D/E 5810/11/12T
4-8 8000 Renolin DTA 15 antifoam and
400L/A/B and 6806/7/8 and
11-110 antioxidant
400C/D/E 6809/10/11T
4.7 additives
450 7006/10
11-125
500 8006/10

The lubricating oil must be replaced as specified on the nameplate or whenever changes on the oil properties
are noticed. The oil viscosity and pH must be checked periodically. The oil level must be checked every day
and kept in the center of the sight glass.
Please contact WEG, when oils with different viscosities are to be used.

8.3. MOTOR ASSEMBLY AND DISASSEMBLY

All repair services on motors for use in hazardous areas should be always performed by qualified
personnel and in accordance with the applicable laws and regulations in each country. Always use
proper tools and devices for motor disassembly and assembly.
ENGLISH

Disassembly and assembly services can be carried out only after the motor has been disconnected
from the power supply and is completely stopped.
Dangerous voltages may be present at the motor terminals inside the terminal box since capacitors can
retain electrical charge for long periods of time even when they are not connected directly to a power source or
when space heaters are connected to the motor or when the motor windings are used as space heaters.
Dangerous voltages may be present at the motor terminals when they are driven by frequency inverter even
when they are completely stopped.

For explosion-proof motors and protection by enclosure motors, open the terminal box and/or
disassemble the motor only after the enclosure surface temperature has cooled down up to ambient
temperature.

Record the installation conditions such as terminal connection diagram, alignment / leveling conditions before
starting the disassembly procedures. These records should be considered for later assembly.

Disassemble the motor carefully without causing scratches on machined surfaces or damaging the threads.

Assemble the motor on a flat surface ensuring a good support base. Footless motors must be fixed/locked on
the base to prevent accidents.

Handle the motor carefully to not damage the insulated components such as windings, insulated rolling
bearings, power cables etc.

Seal elements, such as joint seals and bearing seals should always be replaced when wear or damage is
noticed.

Motors with degree of protection higher than IP55, the machined joints are protected at factory by a suitable
rust inhibitor. Thus all machined surfaces (for example, covers of the terminal boxes of explosion-proof motors)
must be carefully cleaned before assembly and provided again by a thin coat of rust inhibitor as shown in
Figure 8.2.

110 Manual of Electric Motors

 www.weg.net

For explosion-proof motors, the joints can be coated only with the following products:
J
Lumomoly PT/4 (Lumobras);
J
Molykote DC 33 (Dow Corning).
For other types of protection, apply Loctite 5923 (Henkel) on the joints.

Apply rust inhibitor on all

machined surfaces of the motors
with degree of protection higher
than IP55.

Figure 8.2 - Machined surface of the terminal box of explosion-proof Motors.

For explosion-proof motors special care should be taken with the machined surfaces of the flame path. These
surfaces must be free of burrs, scratches, etc. that reduce the flame path length and increase the gap.
The gaps between terminal boxes and the respective terminal box covers should not exceed the values
specified in Table 8.7.
Table 8.7 - Maximum gap between terminal box and terminal box cover for explosion-proof enclosures.
Flat joint Cylindrical joint
Frame size
W21 W22X W22X
IEC 71 to 355
0.05 mm 0.076 mm 0.158 mm
NEMA 143 to 586/7

ENGLISH
8.3.1. Terminal box
Proceed as follows to remove the terminal box cover and to disconnect/connect the power supply cables and
the cables of the accessory devices:
J Ensure that during the screw removal the terminal box cover does not damage the components installed

inside the terminal box.

J If the terminal box cover is fitted with lifting eyebolt, lift the terminal box cover always by its lift eyebolt.

J If motors are supplied with terminal blocks, ensure the correct tightening torque on the motor terminals as

specified in Table 8.7.

J Ensure that the cables do not contact sharp edges.

J Ensure that the original IP degree of protection is not changed and is maintained as indicate on the motor

nameplate. The power supply cables and the control cables must always be fitted with components (cable
glands, conduits) that meet the applicable standards and regulations of each country.
J Ensure that the pressure relief device is in perfect operating condition, if provided. The seals in the terminal

box must be in perfect condition for reuse and must be reinstalled correctly to ensure the specified degree of
protection.
J Ensure the correct tightening torque for the securing bolts of the terminal box cover as specified in Table 8.8.

Table 8.8 – Tightening torque for the securing bolts [Nm]

Screw type and seal M4 M5 M6 M8 M10 M12 M16 M20
Hex bolt/hex socket bolt
- 4 to 7 7 to 12 16 to 30 30 to 50 55 to 85 120 to 180 230 to 360
(without seal)
Combined slotted screw
- 3 to 5 5 to 10 10 to 18 - - - -
(without seal)
Hex bolt/hex socket bolt
(with seal with metallic - - - 13 to 20 25 to 37 40 to 55 50 to 65 -
stop/cord)
Combined slotted screw
(with flat seal and/or - 3 to 5 4 to 8 8 to 15 - - - -
mettallic stop/cord)
Hex bolt/hex socket bolt
- - - 8 to 15 18 to 30 25 to 40 35 to 50 -
(with flat seal)
Terminal blocks 1 to 1,5 1,5 to 4 3 to 6,5 6 to 9 10 to 18 15,5 to 30 30 to 50 -
Grounding terminals - 3 to 5 5 to 10 10 to 18 30 to 50 55 to 85 120 to 180 -
Explosio-proof
Terminal - - - 35 to 41 69 to 83 120 to 145 295 to 355 580 to 690
motors
box cover
Other types of
- 3 to 5 4 to 8 8 to 15 25 to 37 40 to 55 50 to 65 -
protection

Manual of Electric Motors 111

 www.weg.net

8.4. DRYING THE STATOR WINDING INSULATION

Dismantle the motor completely. Remove the end shields, the rotor with the shaft, the fan cover, the fan and the
terminal box before the wound stator with the frame is transferred to the oven for the drying process. Place the
wound stator in the oven heated to max. 120 °C for two hours. For larger motors a longer drying time may be
required. After the drying process has been concluded, allow the stator to cool to room temperature. Measure
the insulation resistance again as described in item 5.4. Repeat the stator drying process if the required
insulation resistance does not meet the values specified in Table 5.3. If the insulation resistance does not
improve despite several drying processes, evaluate the causes of the insulation resistance drop carefully and an
eventual replacement of the motor winding may be required. If in doubt contact WEG.

To prevent electrical shock, discharge the motor terminals immediately before, and after each
measurement. If the motor is equipped with capacitors, these must be discharged before beginning any
repair.

8.5. SPARE PARTS

When ordering spare parts, always provide complete motor designation, indicating the motor type, the code
number and the serial number, which are stated on the motor nameplate.
Spare parts must always be purchased from WEG authorized Service Centers. The use of non-original spare
parts can cause motor failure, performance drop and void the product warranty.
The spare parts must be stored in a clean, dry and properly ventilated room, with relative air humidity not
exceeding 60%, with ambient temperature between 5 °C and 40 °C, free of dust, vibrations, gases, corrosive
smokes and at constant temperature. The spare parts must be stored in their normal mounting position without
placing other components onto them.
ENGLISH

Figure 8.3 - Exploded view of the components of a motor with type of protection “n”.

112 Manual of Electric Motors

 www.weg.net

9. ENVIRONMENTAL INFORMATION

9.1. PACKAGING
WEG electric motors are supplied in cardboard, plastic or wooden packaging. These materials can be recycled
and must be disposed according to the applicable laws and regulations in each country. All wood used in the
packaging of WEG motors come from the company reforestation program and is not submitted to any chemical
conservation treatment.
9.2. PRODUCT
Electric motors consist mainly of ferrous metals (steel plates and cast iron), non ferrous metals (copper and
aluminum) and plastic materials.
In general, electric motors have relatively long service live. However when they must be discarded, WEG
recommends to dismantle the motor, sort the different materials and send them for recycling.
No-recyclable materials should be disposed of at industrial landfills according to the applicable environmental
laws and regulations in each country, or co-processed in cement kilns or incinerated.
The recycling service providers, the disposal in industrial landfills, the waste co-processing or the incineration
process must be properly authorized by the state environment agency to carry out these activities.

ENGLISH

Manual of Electric Motors 113

 www.weg.net

10. TROUBLESHOOTING CHART X SOLUTIONS

This troubleshooting chart provides a basic list of problems that may occur during motor operation, possible
causes and recommended corrective actions. In case of doubts, please contact WEG Service Center.
Problem Possible cause Corrective action
Check the control panel and the motor
Power cables are interrupted.
power supply cables.
Blown fuses. Replace blown fuses.
Motor does not start, neither coupled nor
decoupled Correct the motor connection according to
Wrong motor connection.
connection diagram.
Check motor shaft to ensure that it rotates
Locked rotor.
freely.
Load toque is too high during start-up. Do not start the motor on load.
The motor starts at no-load, but fails when
load is applied. It starts very slowly and Check the installation dimensioning
does not reach the rated speed. Too high voltage drop in the power cables (transformer, cable cross section, relays,
circuit breakers, etc.)
Defective transmission component or Check the transmission force, the coupling
defective driven machine. and the alignment.
Align / level the motor with the driven
Misaligned / unleveled base.
machine
Unbalanced components or unbalanced
Balance the machine set again
driven machine
Abnormal / excessive noise Different balancing methods used for motor
Balance the motor again
and coupling balancing (halve key, full key)
Wrong motor direction of rotation Reverse the direction of rotation
Loose bolts Retighten the bolts
ENGLISH

Foundation resonance Check the foundation design

Damaged bearings Replace the bearings
Clean air inlet and outlet and cooling fins
Check the minimum required distance
Insufficient cooling between the fan cover and nearest walls.
See item 7
Check air temperature at inlet
Measure motor current, evaluate motor
Overload
application and if required, reduce the load
Number of starts per hour is too high or the
Reduce the number of starts per hour
load inertia moment is too high
Check the motor power supply voltage.
Motor overheating Power supply voltage too high Power supply voltage must not exceed the
tolerance specified in item 7.2
Check the motor power supply voltage and
the voltage drop. Power supply voltage
Power supply voltage too low
must not exceed the tolerance specified in
item 7.2
Interrupted power supply Check the connection of the power cables
Check for blown fuses, wrong commands,
Voltage unbalance at the motor terminals voltage unbalance in the power line, phase
fault or interrupted power cables
Direction of rotation is not compatible with Check if the direction of rotation matches
the unidirectional fan the rotation arrow indicated on end shield
Excessive grease / oil
Clean the bearing and lubricate it
Grease / oil aging
according to the provided
The used grease / oil does not matches the recommendations
specified one
Bearing overheating
Lubricate the bearing according to the
Lack of grease / oil provided recommendations
Excessive axial or radial forces due to Reduce the belt tension
the belt tension Reduce the load applied to the motor

114 Manual of Electric Motors

ARGENTINA DENMARK JAPAN SWITZERLAND
WEG EQUIPAMIENTOS WEG SCANDINAVIA DENMARK* WEG ELECTRIC MOTORS BIBUS AG*
ELECTRICOS S.A. Sales Office of WEG Scandinavia AB JAPAN CO., LTD. Allmendstrasse 26
Sgo. Pampiglione 4849 Verkstadgatan 9 - 434 22 Yokohama Sky Building 20F, 2-19-12 8320 – Fehraltorf
Parque Industrial San Francisco, Kumgsbacka, Sweden Takashima, Nishi-ku, Yokohama City, Phone: + 41 44 877 58 11
2400 - San Francisco Phone: +46 300 73400 Kanagawa, Japan 220-0011 www.bibus-holding.ch
Phone: +54 (3564) 421484 www.weg.net/se Phone: + 81 45 5503030
www.weg.net/ar www.weg.net/jp UNITED ARAB EMIRATES
FRANCE The Galleries, Block No. 3, 8th Floor,
AUSTRALIA WEG FRANCE SAS * MEXICO Office No. 801 - Downtown Jebel Ali
WEG AUSTRALIA PTY. LTD. ZI de Chenes - Le Loup13 / 38297 WEG MEXICO, S.A. DE C.V. 262508, Dubai
14 Lakeview Drive, Scoresby 3179, Saint Quentin Fallavier, Rue du Morel- Carretera Jorobas-Tula Phone: +971 (4) 8130800
Victoria lon - BP 738 / Rhône Alpes, 38 > Isère Km. 3.5, Manzana 5, Lote 1 www.weg.net/ae
Phone: +03 9765 4600 Phone: + 33 47499 1135 Fraccionamiento Parque
www.weg.net/au www.weg.net/fr Industrial - Huehuetoca, UNITED KINGDOM
Estado de México - C.P. 54680 WEG (UK) Limited*
AUSTRIA GREECE Phone: +52 55 53214275 Broad Ground Road - Lakeside
WATT DRIVE ANTRIEBSTECHNIK MANGRINOX* www.weg.net/mx Redditch, Worcestershire B98 8YP
GMBH* 14, Grevenon ST. Phone: + 44 1527 513800
Wöllersdorfer Straße 68 GR 11855 - Athens, Greece NETHERLANDS www.weg.net/uk
2753, Markt Piesting Phone: + 30 210 3423201-3 WEG NETHERLANDS *
Phone: + 43 2633 4040 Sales Office of WEG Benelux S.A. ERIKS *
www.wattdrive.com GERMANY Hanzepoort 23C, 7575 DB Oldenzaal Amber Way, B62 8WG
WEG GERMANY GmbH* Phone: +31 541 571090 Halesowen, West Midlands
LENZE ANTRIEBSTECHNIK Industriegebiet Türnich 3 www.weg.net/nl Phone: + 44 (0)121 508 6000
GES.M.B.H* Geigerstraße 7
Ipf - Landesstrasse 1 50169 Kerpen-Türnich PORTUGAL BRAMMER GROUP *
A-4481 Asten Phone: + 49 2237 92910 WEG EURO - INDÚSTRIA PLC43-45 Broad St, Teddington
Phone: +43 (0) 7224 / 210-0 www.weg.net/de ELÉCTRICA, S.A.* TW11 8QZ
www.lenze.at Rua Eng. Frederico Ulrich, Phone: + 44 20 8614 1040
GHANA Sector V, 4470-605 Maia, Apartado
BELGIUM ZEST ELECTRIC MOTORS (PTY) LTD. 6074, 4471-908 Maia, Porto USA
WEG BENELUX S.A.* 15, Third Close Street Airport Phone: +351 229 477 705 WEG ELECTRIC CORP.
Rue de l’Industrie 30 D, 1400 Nivelles Residential Area, Accra www.weg.net/pt 6655 Sugarloaf Parkway,
Phone: +32 67 888420 Phone: +233 3027 66490 Duluth, GA 30097
www.weg.net/be www.zestghana.com.gh RUSSIA Phone: +1 678 2492000
WEG ELECTRIC CIS LTD* www.weg.net/us
BRAZIL HUNGARY Russia, 194292, St. Petersburg, Pro-
WEG EQUIPAMENTOS AGISYS AGITATORS & spekt Kultury 44, Office 419 VENEZUELA
ELÉTRICOS S.A. TRANSMISSIONS LTD.* Phone: +7 812 3632172 WEG INDUSTRIAS VENEZUELA C.A.
Av. Pref. Waldemar Grubba, 3000, Tó str. 2. Torokbalint, H-2045 www.weg.net/ru Centro corporativo La Viña
CEP 89256-900 Phone: + 36 (23) 501 150 Plaza, Cruce de la Avenida
Jaraguá do Sul - SC www.agisys.hu SOUTH AFRICA Carabobo con la calle Uzlar de la
Phone: +55 47 3276-4000 ZEST ELECTRIC MOTORS (PTY) LTD. Urbanización La Viña /
www.weg.net/br INDIA 47 Galaxy Avenue, Linbro Business Jurisdicción de la Parroquia
WEG ELECTRIC (INDIA) PVT. LTD. Park - Gauteng Private Bag X10011 San José - Valencia
CHILE #38, Ground Floor, 1st Main Road, Sandton, 2146, Johannesburg Oficinas 06-16 y 6-17, de la planta
WEG CHILE S.A. Lower Palace, Orchards, Phone: +27 11 7236000 tipo 2, Nivel 5, Carabobo
Los Canteros 8600, Bangalore, 560 003 www.zest.co.za Phone: (58) 241 8210582
La Reina - Santiago Phone: +91 804128 2007 www.weg.net/ve
Phone: +56 2 2784 8900 www.weg.net/in SPAIN
www.weg.net/cl WEG IBERIA INDUSTRIAL S.L.*
ITALY C/ Tierra de Barros, 5-7
CHINA WEG ITALIA S.R.L.* 28823 Coslada, Madrid
WEG (NANTONG) ELECTRIC MOTOR Via Viganò de Vizzi, 93/95 Phone: +34 91 6553008
MANUFACTURING CO. LTD. 20092 Cinisello Balsamo, Milano www.weg.net/es
No. 128# - Xinkai South Road, Phone: + 39 2 6129 3535
Nantong Economic & www.weg.net/it SINGAPORE
Technical Development Zone, WEG SINGAPORE PTE LTD
Nantong, Jiangsu Province FERRARI S.R.L.* 159, Kampong Ampat, #06-02A KA
Phone: +86 513 8598 9333 Via Cremona 25 26015 PLACE. 368328
www.weg.net/cn Soresina (CR), Cremona Phone: +65 68581081
Phone: + 39 (374) 340-404 www.weg.net/sg
COLOMBIA www.ferrarisrl.it
The values shown are subject to change without prior notice.

WEG COLOMBIA LTDA SWEDEN

Calle 46A N82 - 54 STIAVELLI IRIO S.P.A.* WEG SCANDINAVIA AB*
Portería II - Bodega 6 y 7 Via Pantano - Blocco 16 - Capalle Box 27, 435 21 Mölnlycke
San Cayetano II - Bogotá 50010 , Campi Bisenzio (FI) Visit: Designvägen 5, 435 33
Phone: +57 1 416 0166 Phone: + 39 (55) 898.448 Mölnlycke, Göteborg
Cod: 50034162 | Rev: 08 | Date (m/y): 04/2016

www.weg.net/co www.stiavelli.com Phone: +46 31 888000

www.weg.net/se

* European Union Importers

 EC DECLARATION OF CONFORMITY
WEG Equipamentos Elétricos S/A
Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaraguá do Sul – SC – Brazil,

and its authorised representative established in the European Community,

WEGeuro – Industria Electrica SA
Contact person: Luís Filipe Oliveira Silva Castro Araújo
Rua Eng Frederico Ulrich, Apartado 6074
4476-908 – Maia – Porto – Portugal

hereby declare that the products:

WEG induction motors and components for using in these motors:

Three-phase
IEC frames 63 to 630
Nema frames 42, 48, 56 and 143 to 9610
……………
Single-phase
IEC frames 63 to 132
Nema frames 42, 48, 56 and 143 to 215
……………

when installed, maintained and used in applications for which they were designed, and in compliance with the relevant
installation standards and manufacturer’s instructions, comply with the requirements of the following European Directives
and standards where applicable:

Directives:
Low Voltage Directive 2006/95/EC*
ENGLISH

Regulation (EC) No 640/2009*

Directive 2009/125/EC*
Machinery Directive 2006/42/EC**
EMC Directive 2004/108/EC (inductions motors are considered inherently benign in terms of electromagnetic
compatibility)

Standards:
EN 60034-1:2010/ EN 60034-2-1:2007/EN 60034-5:2001/A1:2007/ EN 60034-6:1993/ EN 60034-7:1993/A1:2001/
EN 60034-8:2007/ EN 60034-9:2005/A1:2007/ EN 60034-11:2004/ EN 60034-12:2002/A1:2007/
EN 60034-14:2004/A1:2007/ EN 60034-30:2009, EN 60204-1:2006/AC:2010 and EN 60204-11:2000/AC:2010

CE marking in: 1996

* Electric motors designed for use with a voltage rating higher than 1,000 V are not considered under the scope.
** Low voltage electric motors are not considered under the scope and electric motors designed for use with a voltage
rating higher than 1,000 V are considered partly completed machinery and are supplied with a

Declaration of Incorporation:

The products above cannot be put into service until the machinery into which they have been incorporated has been
declared in conformity with the Machinery Directive.

A Technical Documentation for the products above is compiled in accordance with part B of annex VII of Machinery
Directive 2006/42/EC.

We undertake to transmit, in response to a reasoned request by the national authorities, relevant information on the partly
completed machinery identified above through WEG authorised representative established in the European Community.
The method of transmission shall be electronic or physical method and shall be without prejudice to the intellectual
property rights of the manufacturer.

Milton Oscar Castella

Engineering Director
Jaraguá do Sul, April 8th, 2013
Operating Manual

These instructions are intended for the assembly, operating and supervising
personnel and should be kept at hand on site.

EagleBurgmann Mechanical Seal (M.S.)

H75VA4-051-S7P0-DE001(2)A2

EagleBurgmann Germany GmbH & Co. KG

Äussere Sauerlacher Straße 6-10 . D-82515 . Wolfratshausen . Tel.: +49 (0)8171 23 0 . Fax: +49 (0)8171 23 12 14
[email protected] . www.eagleburgmann.com
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 2 / 28

Table of contents
1 KEYWORDS..................................................................................................................................................... 4

2 GENERAL SAFETY NOTES ............................................................................................................................ 5

2.1 Instructions for worker's protection ........................................................................................................... 5

2.2 Notes on explosion protection .................................................................................................................. 6

3 TRANSPORT / STORAGE............................................................................................................................... 7

3.1 Transport .................................................................................................................................................. 7

3.2 Storage, "mothballing" (long term storage)............................................................................................... 8

3.3 M.S. in the stock ....................................................................................................................................... 9

3.4 M.S. installed into the machine................................................................................................................. 9

4 INFORMATION ABOUT THE PRODUCT ...................................................................................................... 10

4.1 Manufacturer and country of origin ......................................................................................................... 10

4.2 Required space, connecting dimensions ................................................................................................ 10

4.3 Materials ................................................................................................................................................. 10

4.4 Designated use....................................................................................................................................... 11

4.5 Operating conditions............................................................................................................................... 11

4.6 Drawings, diagrams ................................................................................................................................ 11

5 DESCRIPTION ............................................................................................................................................... 12

6 Operation of the M.S. ..................................................................................................................................... 13

7 SUPPLY OF M.S. ........................................................................................................................................... 14

7.1 Pressure ratios........................................................................................................................................ 14

7.2 Piping and connecting threads ............................................................................................................... 14

7.3 Suitable quench fluid .............................................................................................................................. 16

7.4 Viscosities for the medium to be sealed ................................................................................................. 17

8 INSTALLATION .............................................................................................................................................. 18

8.1 General notes dealing with assembly utilities ......................................................................................... 18

8.2 Preparation for assembly........................................................................................................................ 19

8.3 Assembly / installation ............................................................................................................................ 21

8.4 Possible installation order....................................................................................................................... 22

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 3 / 28

9 OPERATION .................................................................................................................................................. 23

9.1 Safe operation ........................................................................................................................................ 23

9.2 Start-up ................................................................................................................................................... 23

10 SERVICING.................................................................................................................................................... 24

10.1 Maintenance ........................................................................................................................................... 24

10.2 Directives in case of failure..................................................................................................................... 24

10.3 After-sales service by EagleBurgmann................................................................................................... 24

10.4 Reconditioning ........................................................................................................................................ 25

10.5 Removal.................................................................................................................................................. 26

10.6 Required details for enquiries and orders of spare seals / parts ............................................................ 27

10.7 Disposal of the mechanical seal ............................................................................................................. 27

10.8 Copyright ................................................................................................................................................ 27

11 TROUBLESHOOTING ................................................................................................................................... 28

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 4 / 28

1 KEYWORDS
Please pay special attention to the following keywords:

Death or serious injuries of persons

DANGER
Dangerous situations. If they are not avoided they lead to death or serious injury
of persons.

Possibility of serious injuries or death to persons

WARNING
Dangerous situations. If they are not avoided they can lead to death or serious in-
jury of persons.

Slight injuries, serious damage of the machine/plant or the environment

CAUTION
Dangerous situations. If they are not avoided they can lead to slight injuries or
serious damage of the machine/plant.

Identifies tips for use and other particularly useful information.

NOTICE

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 5 / 28

2 GENERAL SAFETY NOTES

Operating with hazardous substances
WARNING
Injuries of persons and environment have to be prevented by observing of:

regulations for hazardous substances according to directive 91/155/EWG

country-specific regulations
safety data sheets
general operating notes
directives concerning the personal protective equipment

Any person being involved in assembly, disassembly, start-up, operation and

maintenance of an EagleBurgmann product must have read and understood this
operating manual and in particular the safety notes. We recommend the user hav-
ing this confirmed.
EagleBurgmann products are manufactured to a high quality level and they have
a high working reliability. Yet, if the products are not operated within their inten-
ded purpose or handled inexpertly they may create risks.
Any operating mode which affects the operational safety is not permitted.
Unauthorised modifications or alterations are not permitted.
EagleBurgmann products must be installed, operated, maintained and removed
by authorised, trained and supervised qualified personnel only. In case the per-
sonnel has inadequate experience in handling with and operating of mechanical
seals, magnetic couplings and supply systems, for this purpose EagleBurgmann
offers corresponding seminars for achieving of the required knowledge.
The responsibilities for the respective jobs to be done have to be determined
clearly and observed in order to prevent ambiguous competencies from the point
of security.
Work is only permitted when the machine is at a standstill, depressurised and
cooled. The machine/plant must be protected against accidental start-up.
Apart from the notes given in this manual the general regulations for worker's pro-
tection and those for prevention of accidents have to be observed.

2.1 Instructions for worker's protection

Medium to be sealed and/or supply medium may escape if the seal fails. Injury
of persons and environment must be prevented by the user. Care has to be
taken by the user for proper disposal of the leakage. The user has to control
these measures. Examples for providing measures are the installation of splash
protection, seal versions with outboard throttle and drainage bore, wearing of
safety goggles etc.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 6 / 28

Seal failure
WARNING
Hot medium to be sealed and/or supply medium may escape.
ü Preventive measures to protect persons and environment
a) Providing for splash protection and collecting device
b) Wearing of personal protective equipment
c) Care has to be taken by the user for disposal of the leakage, and he has to
control this measure

The user has to check what effects a failure of the mechanical seal might have
and what safety measures have to be taken to prevent personal injury or damage
to the environment.

2.2 Notes on explosion protection

Mechanical seals are mechanical parts, which are put in circulation for general
technical purposes. They are no components within the meaning of Directive
94/9/EC
The respective probation as to explosion protection for the provided temperat-
ure class must be carried out during the conformity assessment of the machine,
into which the mechanical seal is installed, by the machine manufacturer.
In case the assessment is carried out by the end user, the respective additional
operating manual has to be requested from EagleBurgmann.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 7 / 28

3 TRANSPORT / STORAGE

3.1 Transport
If not specified differently by contract the EagleBurgmann standard packaging is
used which is suitable for dry transport by truck, train or plane.
In addition seaworthy packaging may become necessary.
The following points have to be considered:
▪ graphical symbols for use on equipment
▪ weight specifications
▪ handling instructions
Notes for income inspection:
▪ Check packaging for visible damage.
▪ Open packaging carefully. Do not damage or lose parts supplied separately.
▪ Check if consignment is complete (delivery note). Inform the supplier imme-
diately in writing if parts are damaged or missing.
The seal has to be protected from damage during transport and storage. The
transport case in which the seal is supplied is well suited for this purpose.
Please keep it for a possible return transport.
If the machine as well as the seal installed into the machine are transported to-
gether, the shaft must be protected from deflection at all times, shocks and axial
displacement by means of a suitable machine support. Damage at the mechan-
ical seal resp. magnetic coupling caused by insufficient protection during trans-
port is excluded from the warranty.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 8 / 28

3.2 Storage, "mothballing" (long term storage)

The following recommendations apply to all mechanical seals which have been
supplied and stored in their undamaged original packaging, as well as to seals
which have been installed in a machine (e.g. pump, compressor, agitator, etc.)
but have not yet been put into operation.
Sliding materials and secondary sealing elements are subject to material-spe-
cific and time-based alterations (distortion, ageing) which might reduce the full
efficiency of the mechanical seals. Hence, this may be avoided by observing the
storage instructions.
For the stock keeping of elastomers and all rubber-elastic secondary sealing
elements special conditions are required.

Optimum conditions for storing of mechanical seals:

▪ dust free
▪ moderately ventilated
▪ constant temperature
– relative air humidity below 65 %,
– temperature between 15 °C and 25 °C.

In order to avoid embrittlement of the secondary sealing elements,

the M.S. has to be protected from:
▪ direct exposure to heat (sun, heating)
▪ ultraviolet light (halogen or fluorescent lamps, arc welding, sunlight)
▪ presence or development of ozone (arc welding, mercury vapour lamps,
high-voltage devices, electric motors)

It must be recognised that a difference exists between:

▪ M.S. stored in the stock room
▪ M.S. installed in the machine, but not yet in operation.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 9 / 28

3.3 M.S. in the stock

Store the seal in the original packaging lying on a flat surface.
▪ The packaging should be periodically checked for damage.
▪ Sealings packed in plastic-foil with humidity indicators have to be checked
every 8 weeks. The check has to be recorded.
All steam-tight films inside the package are supplied with humidity indicators.
These show the relative air humidity inside the packaging. On a scale the colour
changes from blue (= dry) to pink (= humid).
Check of the mechanical seal at EagleBurgmann:
▪ after a damage of the packaging
▪ after a shock on the seal (e.g. by dropping the packed seal)
▪ at a relative air humidity >50 %.
Unused stored mechanical seal under optimum conditions:
▪ For reasons of safety reasons, after 3 years from delivery of the mechanical
seal the M.S. should be returned to EagleBurgmann resp. nearest Eagle-
Burgmann Service centre for
– exchange of all secondary seals and springs
– verification of the flatness of the faces
– perhaps static pressure test.

3.4 M.S. installed into the machine

Material damage due to wrong "mothballing" (long term storage)
CAUTION
Deposition and possibly chemical attack of the secondary sealing elements,
which both can lead to a seal failure.
ü Do not use corrosion protection agents.
a) In case of a "mothballing" (long term storage) of complete machines with
mechanical seals installed EagleBurgmann has to be contacted.

Due to longer erecting times of newly designed plant the period between delivery
of the mechanical seal and its installation and start-up in the machine may exceed
a period of 2-3 years.
After 3 years at the latest and in good time before the planned start-up of the
plant the seal has to be dismantled sent to the manufacturer or the nearest Eagle-
Burgmann service centre where it can be checked and reconditioned, if neces-
sary.
EagleBurgmann do not accept any warranty for damage caused by improper stor-
age.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 10 / 28

4 INFORMATION ABOUT THE

PRODUCT
A mechanical seal (M.S.) is a machine part for sealing of the point of passage of
a rotating part (e.g. shaft) through a wall (e.g. machine housing).
The M.S. is characterised by two faces, that are normally positioned rectangu-
larly to the rotation axis, sliding on each other, and that are pressed against
each other by axial forces. Between the sealing faces a liquid or gaseous lubric-
ating film is generated by the surrounding medium depending on the aggregate
state.
A mechanical seal cannot be free of leakage due to physical and technical reas-
ons. Seal design, manufacture tolerances, operating conditions, running quality
of the machine, etc. mainly define the leakage value.
During the running-in phase of the M.S. an increased leakage may occur. If the
leakage amount does not decrease or if there are other malfunctions the mech-
anical seal has to be shut down, removed and checked for reasons of safety.

4.1 Manufacturer and country of origin

EagleBurgmann Germany GmbH & Co. KG
Äußere Sauerlacher Str. 6-10
D – 82515 Wolfratshausen
Federal Republic of Germany

4.2 Required space, connecting dimensions

The required installation space for the mechanical seal is decisive for the design
of the housing parts by the machine manufacturer. The connecting dimensions
have to be checked by the machine manufacturer by means of the Eagle-
Burgmann drawing before mounting the mechanical seal.

4.3 Materials
The materials of the mechanical seal depend on the application and are bound
to the customer order. They can be found on the drawing, and/or in the parts
lists attached to the documentation.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 11 / 28

4.4 Designated use

This mechanical seal is exclusively designed for the use in the specified applic-
ation. A different utilisation or usage going beyond the specification is con-
sidered contrary to its designated use and excludes a liability by the manufac-
turer.
Operation under conditions lying outside the limits stated on the drawing is con-
sidered contrary to its designated use.
Should the mechanical seal be operated under different conditions or in a differ-
ent application EagleBurgmann must confirm that such a change is safe in ad-
vance of subsequent operation.
▪ Changes to operating conditions have to be documented.

4.5 Operating conditions

Information about the operating conditions can be found on the EagleBurgmann
assembly drawing or in the specification sheets of the machine manufacturer.
The selection of the mechanical seal (type, suitability, materials) should be done
by EagleBurgmann staff or other authorised persons. A wrong selection by un-
authorised persons is not covered by EagleBurgmann's warranty.

4.6 Drawings, diagrams

H75VA4-051-S7P0-DE001A2 - Rev. 2 - 09.03.16
H75VA4-051-S7P0-DE002A2 - Rev. 2 - 09.03.16
The original assembly drawing in its latest edition (latest revision) only is decis-
ive for both the design of M.S. as well as the utilisation of this manual.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 12 / 28

5 DESCRIPTION
The horizontally arranged single M.S. has an integrated pumping device. At any
rate, the direction of rotation has to be taken from the drawing.
Together with the housing parts supplied the mechanical seal forms a premoun-
ted unit (seal cartridge), assembled at works, ready to be installed without any
adjustment.
Assembly fixtures are provided for holding the cartridge in one piece during
transport, storage, assembly and removal.
The seal face, preloaded by multiple springs, rotates with the shaft.
The seat is arranged stationary in the respective housing part.
A throttle ring at outboard prevents gushes of leakage.
The permitted axial displacement between shaft and housing is 1.5 mm in each
direction.
Torque transmission to the shaft by means of set screws with cup point.
Static pressure test before shipment.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 13 / 28

6 Operation of the M.S.

Description API, plan 23:
Recirculation from a circulation device in the seal chamber through a cooler and
back into the seal chamber.

Description API, plan 61:

Tapped and plugged atmospheric-side connections for purchaser’s use.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 14 / 28

7 SUPPLY OF M.S.

7.1 Pressure ratios

For a single mechanical seal the pressure in the seal chamber (stuffing box
pressure) has to be higher than the ambient pressure at the machine at any
time. Otherwise the machine will suck in air via the sliding faces, which will res-
ult in dry-running and consequent failure of the mechanical seal.
If in case of API, plan 61, the M.S. is operated by the customer with API,
plan 62, care must be taken that a pressure increase in the M.S. is excluded.
Operating with product-side flushing: ps > p1
At product side (inboard) a steady flow of flushing medium has to be fed in. A
flow direction towards the product side has to be ensured by a positive pressure
difference: flushing pressure > product pressure.

If on the valid M.S. drawing differential pressures are stated, these must be ob-
NOTICE served at any rate.

A clarification with EagleBurgmann is recommended.

7.2 Piping and connecting threads

The supply system must be installed in such a way that operating, monitoring
and maintenance are well practicable.
supply piping for liquids: min. 18 x 1.5 mm
supply piping for gases: min. 12 x 1.5 mm
impulse piping: min. 12 x 1.5 mm

▪ Use pipes of stainless steel or resistant material with a sufficient cross-sec-

tion.
▪ Clean the piping thoroughly, e.g. by air-cleaning.
▪ Use suitable pipe connections only.
▪ Fasten all pipe connections pressure-sealed.
▪ Install the pipes continuously rising, as short and as convenient as possible
for the flow to ensure self-venting.
▪ Avoid air inclusions and provide for venting connections at the highest point,
if necessary.
▪ For turns use pipe bends.
▪ Fasten the pipes with appropriate pipe clips.
If shutoffs in the piping to the seal are required, ball valves with torsion lock
have to be used.
As to details concerning installation, assembly and operation please observe
the operating manual of the corresponding supply system.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 15 / 28

The assignment of the connections is shown on the EagleBurgmann assembly

NOTICE drawing.
The supply connections are marked on the mechanical seal and must not be in-
terchanged during installation.
If several connections for one operating mode are provided at the seal cartridge,
the unused connection must be closed always pressure-tight (e.g. quench IN ex-
ists twice at the seal cartridge).

Sealing agents for threads (PTFE-tape, etc.) endanger the safe function of the
mechanical seal if they enter the seal chamber. When screwed connections are
opened take care by all means that sealing agents cannot enter the mechanical
seal.
Use DIN ISO 228 connecting threads only with encased gaskets or with self-seal-
ing pipe unions. Sealing agents for threads (e.g. PTFE-tape etc.) are not permit-
ted, because they may endanger the safe function of the seal if they enter the
sealing chamber.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 16 / 28

7.3 Suitable quench fluid

The end user has to be select the quench fluid of the M.S. in accordance with
the operating requirements.
The main functions of a quench fluid are:
Liquid quench
▪ Recording and/ or removal of leakage
▪ Dry run protection
▪ Exclusion of air for media which react with atmospheric oxygen in a undesir-
able manner
Vapour quench
▪ disposal of leakage
▪ Exclusion of air for media which react with atmospheric oxygen in a undesir-
able manner
Gas quench
▪ disposal of leakage
▪ Exclusion of air for media which react with atmospheric oxygen in a undesir-
able manner

Quench medium to be selected by the user in accordance with the following cri-
NOTICE teria:
a) product compatibility
b) environmental compatibility
c) compatible with the used materials
d) no tendency to build deposits

Swelling and decomposition of secondary sealing elements

WARNING
Failure of the mechanical seal
a) Never use supply fluids on the base of mineral oil for sealing elements made
of EP-rubber.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 17 / 28

7.4 Viscosities for the medium to be sealed

Information on suitable operating viscosities for supply liquids:

The viscosity of liquids depends on the temperature.

NOTICE
By default, single seals can be used up to an operating viscosity of 800 mPas. In
case of higher viscosities (max. 2500 mPas) operating parameters such as the
sliding speed and the boiling characteristics of the medium have to be con-
sidered. Coordination with EagleBurgmann is here absolutely necessary.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 18 / 28

8 INSTALLATION

8.1 General notes dealing with assembly utilities

Secondary sealing elements made of EP-rubber must never come into contact
NOTICE with mineral oil-based lubricants (swelling, possibly decomposition).
For applications free from silicone:
Lubricants must be free of silicones, fluorinated compounds which are able to mi-
grate, and tensides.
A wrong selection is not covered by EagleBurgmann's warranty.

For cleaning:
▪ ethyl alcohol
▪ cellulose-tissue (no rag, no cloth!)
For applications free from silicone:
▪ cotton-tissue (no rag, no cloth!)
▪ clean cotton gloves
For lubricating:
▪ suitable lubricants
▪ Lubricants must be compatible with all media (e.g. medium to be sealed, sup-
ply, flushing and/or cooling medium etc.), with those they get into contact with,
and they must not corrode the secondary sealing elements.
▪ Suitable synthetic lubricant for dynamic elastomeric secondary sealing ele-
ments, e.g. type "TURMOPOL GREASE SH 2 D" Fa. Lubricant Consult (LUB-
CON).
▪ Geeignetes Gleit-/Schmiermittel (FDA-Konform) z. B. Typ
"TURMSILON LMI 5000" make Lubricant Consult (LUBCON).
▪ Chloride-free surfactants (e.g. sodium dodecyl sulphate (SDS)) or low-tension
water for elastomeric bellows seals and static elastomeric secondary sealing
elements of seats
For installation:
▪ set of hexagon keys
▪ torque wrench
Additional for single seals:
▪ o-ring lifter
▪ cardboard discs to cover the sliding faces during installation
▪ hand screw press (compulsory for shaft diameter ≥80 mm)
▪ press-in tool (as usual for radial rotary shaft seals)

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 19 / 28

For sealing:
®
▪ sealing agents for threads for pipe connections, e.g. type "LOCTITE Nr. 266"
make: LOCTITE Corporation
For securing:
®
▪ for bolts, set screws etc. use liquid screw retention, e.g. type "LOCTITE
Nr. 243" make: LOCTITE Corporation

8.2 Preparation for assembly

To prevent damage to the seal, do not remove it from its packaging until all the
work described below has been completed.
Check the machine parts:
▪ Connection dimensions, if avail-
able tolerances of position and
shape for the connecting parts
(see drawing)
▪ Chamfered edges
(chamfers 2 mm / 30° or acc. to
EN 12756).
▪ Rounded transitions.
▪ Mating fits and surfaces for static
sealing elements:
fine finished, surface roughness
Rz = 10 µm
▪ shaft surface in the area of the
mechanical seal: Ra = 0.8 µm
▪ surface in the area of the dynamic-
ally loaded o-ring roughness:
Rmax 5 µm (e.g. component seal)
▪ sufaces for:
– static secondary sealing ele-
ments fine fiished: Rz = 10 µm
– PTFE secondary sealing ele-
ments fine finished Rz = 5 µm
Check on the machine:
▪ damage of connecting surfaces to the M.S.
▪ mating dimensions, rectangularity and concentricity to the shaft axis.
In case of an uni-directional M.S. the direction of rotation has to comply with the
drawing by all means, otherwise contact EagleBurgmann!
Fix the machine shaft in centric and axial position.
▪ Prepare the assembly place, take away any un-required tool, cuttings, dirty
cleaning wool etc.
▪ Cover the work bench with a piece of clean, non-fibrous cardboard.
Type and quality of the shaft bearing have a major influence on the well-func-
tioning and the service life of the M.S.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 20 / 28

Before the M.S. is installed the following has to be checked:

▪ the concentricity accuracy of the shaft
▪ the run-out accuracy between shaft and machine housing
The maximum permitted axial displacements have to be considered, and the in-
structions of the manufacturer have to be observed.
Concentricity accuracy of the shaft (acc. to DIN ISO 5199):
▪ Shaft diameters up to 50 mm: max. 0.05 mm
▪ Shaft diameters 50 mm - 100 mm: max. 0.08 mm
▪ Shaft diameters exceeding 100 mm: max. 0.10 mm
Eccentricity and run-out as specified by EagleBurgmann!
Eccentricity of the inner surface of the seal chamber to the shaft:
▪ max. 0.1 mm for seals with pumping screw
▪ max. 0.2 mm for seals without pumping screw
Run-out accuracy of the vertical contacting surface between seal chamber and
shaft axis (acc. to DIN ISO 5199):
▪ Shaft speed ≤ 750 rpm: max. 0.2 mm
▪ Shaft speed 1000 rpm: max. 0.15 mm
▪ Shaft speed 1500 rpm: max. 0.08 mm
▪ Shaft speed 3000 rpm: max. 0.025 mm
In case of installation into other machines the given values apply as directive.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 21 / 28

8.3 Assembly / installation

The regulations for the prevention of accidents have to be followed.

NOTICE The mechanical seal has to be installed under the cleanest conditions and very
carefully.
Avoid unnecessary rotation of the shaft (damage of the sliding faces is possible).
Never use force during installation.
Avoid knocking! Damage to mechanical seals has an adverse effect on their safe
operation.
When fitting the PTFE-sealing elements in no case widen or compress them. Oth-
erwise, their sealing function cannot be ensured.
Sealing elements made of PTFE or pure graphite have to be used only once.
Take care not to damage the sensitive rings made of pure graphite during as-
sembly!
Notes concerning the lubricants can be taken from the chapter "General notes
dealing with assembly utilities".
Observe the notes on the current drawing if necessary please contact Eagle-
Burgmann.

For installation the assembly drawing must be on hand and observed.

The order of assembly to install the mechanical seal into the machine depends on
the design of the machine and has to be determined by the machine manufac-
turer.
If the machine manufacturer specified auxiliaries (jigs and fixtures) they have to
be used in accordance with the specifications of the manufacturer.
When using double-PTFE-wrapped o-
rings care has to be taken that the
joint on the outer wrapping faces
against the assembly direction. Other-
wise there is a risk of the wrapping
opening and being pulled off, possibly
resulting in seal leakage.

For the assembly of o-rings made of solid PTFE considerable assembly forces
are required to compress them. Yet, these forces may result in permanent de-
formations of seal components, in particular of the assembly fixtures. To com-
press o-rings made of PTFE little force over an extended period of time has to be
applied (force x time = constant). If necessary, the fastening screws have to be
retightened several times.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 22 / 28

8.4 Possible installation order

▪ Unpack the seal.
– If necessary, use suitable auxiliaries (e.g. crane, elevating machinery,
lifting device, eye bolts etc.).
▪ If not described otherwise, the following parts have to be moistened slightly
with suitable lubricant during installation:
– o-rings in sliding contact with other parts when mounting the mechanical
seal,
– shafts in the area of the mechanical seal,
– centring seats (centring diameters) for housing parts.
▪ Make sure that all sealing elements have been installed which contact the
surrounding machine parts.
▪ Feed the complete seal cartridge onto the shaft.
▪ Bolt the M.S. cartridge to the machine housing.
▪ Arrangement of the connections according to the drawing.
▪ Make sure that all required machine components (e.g. distance ring, retain-
ing ring etc.) have been installed.
▪ Further assembly work and adjustments on the machine (e.g. bearing clear-
ance etc.) in accordance with the operating manual of the machine manu-
facturer.
▪ Degrease all the set screws and screw them with 1 drop each of liquid
®
screw retention, e.g. Loctite  243, by hand until they contact the shaft. After-
wards tighten them crosswise, evenly and gradually.
▪ Check the specified tightening torque (defined on the seal drawing) with a
torque wrench.

Set screws with cup point must be used only once. Repeated fastening en-
NOTICE dangers the safety of force transmission.

▪ Torque transmission to the M.S. duly installed.

Remove the assembly fixtures and keep them for a later removal of the seal by all
means. In case of shipment of the machine with installed mechanical seal, the as-
sembly fixtures must be included in the delivery to the end user by all means.
▪ Any further assembly of the machine must be in accordance with the instruc-
tions of the machine manufacturer.
▪ Close unused supply connections pressure-tight with threaded plugs.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 23 / 28

9 OPERATION

9.1 Safe operation

If during an interruption of operation values deviating from the operating condi-
tions / operating limits the mechanical seal must be removed and checked
either at the manufacturer's or at the nearest service centre.
For a single mechanical seal the pressure in the seal chamber has to be higher
than the ambient pressure at the machine at any time. Otherwise the machine
will suck in air via the sliding faces, which will result in dry-running and con-
sequent failure of the mechanical seal.
During every state of operation the mechanical seal has to be constantly wetted
by the medium to be sealed in its liquid form, in particular when the machine is
started or stopped. The machine design has to be such to take this necessity
into consideration.
Damage due to dry-running is excluded from the warranty.
For reasons of safety the temperature of circulation liquid should not exceed 60
°C, measured at the outlet line of the mechanical seal. Regulation of the tem-
perature by cooling the liquid.
Circulation of the liquid is only ensured when the shaft rotates. At standstill the
seal cannot be cooled because the liquid does not circulate. This can result in
damage caused by excessive heating!
Safe operation can be expected if the following temperatures are observed in
the sealing circuit, measured at the outlet of the mechanical seal:
warning temperature 80 °C
shut-off temperature 90 °C
standstill temperature <150 °C
If the operation limit values and the instructions given in this manual are fol-
lowed a trouble-free operation of the mechanical seal can be expected.

9.2 Start-up
Safety checks before start-up
▪ Seal assembly fixtures removed.
▪ Pipe connections tightened and pressure-sealed.
▪ Disposal connections installed environmentally safe.
▪ Direction of rotation has to comply with the drawing by all means, otherwise
contact EagleBurgmann!
▪ The machine must be earthed.
▪ Fill and vent the machine by all means in accordance with the instructions of
the machine manufacturer.
Now the seal is ready for operation.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 24 / 28

10 SERVICING

10.1 Maintenance
A correctly operated mechanical seal needs low maintenance. Wear parts, how-
ever, have to be replaced, if necessary.
A duly operation includes the regular check of the following parameters:
▪ Temperature
▪ Leakage (drainage) of the mechanical seal

An inspection of the mechanical seal should be carried out along with a revision
of the complete plant. We recommend having this inspection performed by
EagleBurgmann.
If the mechanical seal is removed during a revision of the plant the sliding parts
must be checked and the sliding faces be refinished or, if necessary, the sliding
parts must be replaced and all secondary sealing elements and springs must be
replaced.
The check should be carried out by EagleBurgmann personnel or qualified staff.

10.2 Directives in case of failure

Try to define the kind of failure and document it.
▪ In the event of excessive leakage, note changes in the leakage amount and
shut the machine down if necessary.
– A damage of the mechanical seal is indicated by a flowing leakage.
▪ In case of an inadmissible temperature rise (medium / supply medum) the
machine has to be shut down for reasons of safety.
BIf there is a malfunction which you cannot correct on your own, or if the cause
of malfunction is not clearly recognisable please immediately contact the
nearest EagleBurgmann agency, a EagleBurgmann service centre or the Eagle-
Burgmann headquarters.
During the warranty period the mechanical seal must only be disassembled with
approval of the manufacturer or when a representative is present.
Notes regarding the topic malfunctions you will find in chapter "Troubleshoot-
ing".

10.3 After-sales service by EagleBurgmann

EagleBurgmann's customer service department offers a comprehensive service
package covering consultancy, engineering, standardisation, installation, com-
missioning as well as damage analysis right through to seminars on sealing
technology.
Addresses are listed in various EagleBurgmann brochures as well as under

www.eagleburgmann.com.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 25 / 28

10.4 Reconditioning
If reconditioning is necessary, the complete seal should be sent to the manufac-
turer, as this is the best way to find out which components can be reconditioned
or which parts must be replaced in order to ensure an optimum tightness.
If, for compelling reasons, a reconditioning has to be carried out on site (e.g. no.
spare seal on stock, long transport, problems with customs) the seal may be re-
paired in a clean room by trained personnel of the user under the direction of
EagleBurgmann mechanics.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 26 / 28

10.5 Removal

a) Stop the machine as instructed, allow to cool, depressurise it and ensure that
WARNING pressure cannot build up again!
b) Work on the M.S. is only permitted when the machine is at a standstill and de-
pressurised.
c) Depressurise and shut off (or drain) the supply of the M.S.
d) There must be no product in the M.S. -> if necessary drain the machine and
rinse it out!
e) Isolate the machine to prevent it starting up unexpectedly!
f) Observe the safety notes (safety data sheets)!

If the medium to be sealed builds deposits or tends to solidify during cooling down
or standstill of the machine the stuffing box has to be flushed with suitable clean
liquid. The flow rate and the liquid should be determined by the user considering
the chemical resistance of the seal materials.
When removing, please observe by all means:
▪ current accident prevention regulations
▪ regulations for handling hazardous substances
Seals that have been used with hazardous substances must be properly cleaned
so that there is no possible danger to people or to the environment.
The packaging used to transport the seal must
▪ be identified with the relevant hazard symbol and
▪ include the safety data sheet for the product and/or supply medium.
The order of disassembly to remove the mechanical seal out of the machine de-
pends on the design of the machine and should be determined by the machine
manufacturer.
If the machine manufacturer specified auxiliaries (jigs and fixtures) they have to
be used in accordance with the specifications of the manufacturer.
▪ Remove the supply piping to the mechanical seal. Collect drained liquid and
dispose of properly.
▪ Drain the mechanical seal. Collect the drained liquid and dispose of properly.
▪ Install the assembly fixtures resp. assembly rings.
▪ Unscrew the set screws with cup point and dispose of.

Set screws with cup point must be used only once. Repeated fastening en-
NOTICE dangers the safety of force transmission.

▪ Loosen all screw connections between seal and the respective machine parts.
▪ Remove the mechanical seal in the reverse sequence as described for as-
sembly (set up).
– For an easier removal the mechanical seal is equipped with forcing
threads or any other disassembly devices (if available).
– In case of using sealing elements made of pure graphite (Statotherm)
and / or PTFE, these have to be used only once.

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 27 / 28

10.6 Required details for enquiries and orders of

spare seals / parts
Only EagleBurgmann original spare parts must be used, otherwise the guaran-
tee lapses.
For enquiries and orders the following details are required:
EagleBurgmann commission no.
M.S. drawing no.
Part item no., designation, material, parts list or number of pieces acc. to the
drawing.

Address of headquarters:
EagleBurgmann Germany GmbH & Co. KG
Postfach 1240
D - 82502 Wolfratshausen Germany
☎ +49 (0) 81 71-23 0
Fax +49 (0) 81 71-23 12 14
www.eagleburgmann.com

10.7 Disposal of the mechanical seal

Mechanical seals may be contaminated depending on the case of application.
At any rate they have to be disposed of by the personnel of the end user follow-
ing the respective instructions.

10.8 Copyright
EagleBurgmann Germany GmbH & Co. KG (Germany) holds the copyright to
this document. Customers and operators of mechanical seals are free to use
this document in the preparation of their own documentation. No claims of any
type or form can be derived in such instance.

Department Technical Documentation

Rev. 0 01/04/2016
Operating Manual / en
H75VA4-051-S7P0-DE001(2)A2 Page 28 / 28

11 TROUBLESHOOTING
Abnormal temperature distri- Open the valves and protect them against
bution at the circulation line. operating error.
Shut down the pump, if necessary, and
check the cooling water line for clogging.
Check the orifice for clogging.
Check the strainer for clogging.
In case of vertical pumps, eliminate gas ac-
cumulations in the seal chamber by thor-
oughly venting.
Clean the strainer.
Check the cyclone separator for clogging.
Remove obstacles (e.g. orifices) from the
lines.
Observe the specification of the cyclone
separator (solids content etc.).
Abnormal temperature in- Check the cooling water lines for clogging
crease in the cooling water. and clean the lines.

Abnormal temperature increase at Shut down the pump, if necessary,

the seal. and check the feed line and/or the
orifice for clogging.
Large quantities of the pumped me- Shut down the pump and cause an
dium leak out at the atmosphere side inspection of the mechanical seal.
of the seal.
Large quantities of the quench me- Shut down the pump and replace the
dium leak out at the atmosphere side seal ring.
of the seal.

Rev. 0 01/04/2016
 Metastream™ TSKS coupling I-TSKS ENG 0310
(PN 78257)
Fitting, & Maintenance Instructions. Page 1 of 10

1
2B
2 2A
6 8 7 5

3
A A

REFERENCE DESCRIPTION REFERENCE DESCRIPTION

1 Transmission Unit 5 Guard Ring
2 Standard Hub -external 7 Membrane Pack
location [sizes 0013-0230]
2A Standard Hub -internal 8 Drive Bolt Assembly
location [sizes 0350-1400]
2B Large-bore Hub 6 Spacer
[option on sizes 0013-0230]
3 Hub Bolt

Foreword
These instructions are provided to familiarise the user with the coupling and its designated use. These
instructions must be read and applied whenever work is carried out on the coupling and must be kept
available for future reference.

ATTENTION These instructions are for the fitting, operation and maintenance of the coupling as used in
rotating equipment and will help to avoid danger and increase reliability. The information
required may change with other types of equipment or installation arrangements. These
instructions must be read in conjunction with the instruction manuals for both the driver and
driven machinery.

If the coupling is to be used for an application other than that originally intended or outside the
recommended performance limits, John Crane must be contacted before its installation and use.

Any warranty may be affected by improper handling, installation, or use of this coupling. Contact the
company for information as to exclusive product warranty and limitations of liability

If questions or problems arise, contact your local John Crane sales/service engineer or the original
equipment manufacturer as appropriate.

ATTENTION John Crane couplings are precision products and must be handled appropriately. Take
particular care to avoid damage to spigots, mating faces, hub bores, keyways and
membranes. Do not excessively compress the coupling membranes during assembly. Refer
to Table 1 for compression limits. (X)

These instructions are written for standard catalogue products, generally designed in accordance with the
drawing shown.

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
(PN 78257)
Fitting, & Maintenance Instructions. Page 2 of 10

Safety Instructions
The following designations are used in the installation instructions to highlight instructions of particular
importance.

IMPORTANT is used for items of particular concern when using the coupling.

ATTENTION where there is an obligation or prohibition concerning the avoidance of risk.

where there is an obligation or prohibition concerning harm to people or damage to the

! equipment.

The usual extent of supply comprises

A factory assembled transmission unit, comprising 2-off guard rings (5), 1 –off spacer (6), 2-off membrane
packs (7) plus fasteners and fixings(8)
Driver hub
Driven hub
2 sets of bolts (3) to assemble the transmission unit to the two hub flanges

IMPORTANT If a general arrangement drawing is supplied with the coupling then all data indicated
on that drawing takes precedence over information included in these instructions.

Storage

If the coupling is not to be used immediately, it should be stored away from direct heat in its original
packing.

All documentation supplied with the coupling should be retained for future reference.

Spares

When requesting spares always quote the full designation of the coupling

The following spares can be purchased from John Crane.

Set of hub bolts (4) (please specify standard or/and large hubs)
Hubs, bored to your requirement or unbored (2, 3)
Complete transmission unit, balanced or unbalanced(l)
Membrane pack including drive bolts and guard ring assemblies (5, 7, 8)

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
(PN 78257)
Fitting, & Maintenance Instructions. Page 3 of 10

INSTALLATION
Remove coupling from packaging and carefully inspect for signs of damage. Pay particular attention to the
hub bores and the spigot/recess location features, which should be free from burrs and other damage.

INSTALLATION OF HUBS

! Prior to installing the coupling, ensure that the machinery is made safe. Hubs must be
adequately supported during installation to avoid accidental damage should they slip.

Ensure the hub bore and mating shaft are clean.

Parallel Bore with Keyed Drive

The hub is usually installed with the hub face and shaft end flush.
Measure the shaft diameter and hub bore to confirm the correct fit.
For clearance fits, install the key(s) into the shaft keyway and with a little lubrication on the shaft, slide the
hub onto the shaft. The key should be a tight sliding fit in the keyway with a small clearance at the top of the
key. Secure the hub to the shaft in the correct axial position with one or more grub screws.
John Crane recommend a light interference fit for most applications and it may be necessary to apply heat
to assist fitting of such hubs. A warm oil bath will usually be adequate. DO NOT use spot heat or exceed
175 degrees centigrade as this may cause distortion. A thermal heat stick can be used to estimate the
temperature before quickly sliding the hub onto the shaft. A suitable stop will ensure the correct axial
position is located.
Ensure the hub bore and mating shaft are clean.

Taper Bore with Keyed Drive

1. Fit the hub onto the shaft without the key(s). Lightly hammer FIGURE 2
the hub with a soft faced mallet to ensure metal to metal
contact takes place.
2. Measure the distance from the end of the shaft to the face of
the hub using a depth micrometer.
3. Securely mount a dial gauge onto the inboard hub flange and
set to zero.
4. If necessary remove the hub and fit the key(s) which should
be a tight sliding fit in the keyway with a small clearance at the
top of the key.
5. Refit the hub and draw up the shaft to the correct axial
position indicated by the dial gauge. The hub may have to be
heated to achieve the required interference. See Figure 2.
Note that the hub face may not be flush with the shaft end
when taper bores are used.

Taper Hubs Mounted by Oil Injection

1. Ensure that fillets and corner radii of mating surfaces, oil distribution and drainage grooves are well
rounded and free from burrs.
2. Thoroughly clean all contact surfaces and smear the tapered surfaces with oil.
3. Fit the hub onto the shaft.
4. Fit the oil injection equipment, axial stop and mounting tools. Consult the arrangement drawing and
the oil injection system suppliers' instructions.

Fit and secure the axial ram or hydraulic nut BEFORE injecting oil between the
components.

5. Inject oil between the components until the required mounting pressure is reached, or it leaks out at the
ends of the mating surfaces.
6. By means of the mounting tools, position the hub in the correct axial position, injecting oil during this
operation.

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
(PN 78257)
Fitting, & Maintenance Instructions. Page 4 of 10

7. Release the oil pressure.

8. Remove the mounting tool and oil injection equipment.
9. Assemble the locking washer and lock-nut to shaft end if applicable.

Unbored Hubs
John Crane recommend a light interference fit for keyed
hubs and shafts [e.g. a K7/m6 fit]. The finished bore size
can be calculated from the measured shaft diameter.
FIGURE 3
When setting up the hub to machine the bore use the
hub location recess and face as datum surfaces, as RECESS
shown in Figure 3. TIR

The hub face should be set such that the maximum

run-out does not exceed 0.00008mm per mm of hub FACE
flange diameter or 0.025 mm TIR, whichever is greater. TIR

The hub location recess should be set so the maximum run-out does not exceed 0.00008mm per mm of
recess diameter or 0.012 mm TIR, whichever is greater.

Adapters
For machines having an integral flanged shaft, the flange may be machined to suit the bolting configuration
of the coupling transmission unit. Alternatively, the coupling may be supplied with a customised flange
adapter. Refer to the specific general arrangement drawing for location and mounting details.

Shaft Alignment Figure 4.

Align the centre lines of the DRIVING and DRIVEN machine shafts
as follows:
1. Move the equipment into position
2. Check for any soft foot and correct before commencing
alignment.
3. With one machine firmly bolted down, set the distance between
shaft ends (DBSE) according to the drawing or catalogue
dimension.

IMPORTANT DBSE should be measured between the inner face of the hubs and should not be
taken as the length of the transmission unit at its outer periphery. DBSE may not be equal to
the precise distance between shaft ends. In particularly, the faces of taper bored hubs may
not be flush with the shaft end. Refer to Figure 4.

4. Align the shaft centre lines both horizontally and vertically by aligning the hub flanges. JOHN CRANE
recommends the reverse periphery method for accurate alignment. This can be done using dial gauges
or with the John Crane "Lase-A-Lign" shaft alignment kit. Further details are available from John Crane
on request.
5. Recheck the DBSE after the shafts have been aligned.
6. Axial shims (together with a shim carrier in some cases) may be supplied on applications where it is
difficult to accurately set a predetermined shaft end separation [DBSE]. This is often the case where
one or both of the hubs are taper bored. Where this feature is supplied, the thickness of shims [plus
carrier if applicable] are added to the free length of the transmission unit so that the combined length is
equal to the measured distance between the hub flange faces, making any allowance for known shaft
movements. Note - it is best to measure the transmission unit when it is in a gagged condition.

IMPORTANT The misalignment tolerances quoted in literature and on drawings, allow for
dynamic conditions and variations. For the best service from the coupling, John Crane
recommend that installed misalignment is no more than 10% of the maximum allowable
misalignment, allowance being made for any anticipated movements which will occur
during operation (eg. Thermal movements on hot pumps).

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
(PN 78257)
Fitting, & Maintenance Instructions. Page 5 of 10

INSTALLATION OF THE TRANSMISSION UNIT

1. Check spigot and recess locations on the hubs and transmission unit for damage

The transmission unit must be adequately supported during installation to avoid

accidental damage should it slip.
5

2. It may be necessary to compress the transmission unit whilst sliding it

between the hubs. Lever slots are provided in the hub flanges to make
this easier. Also the spacer flanges are drilled to allow hub bolts (ref. 3)
to be threaded into the guard ring. Tightening evenly will compress the 6
transmission unit until clearance between the hub spigots and length of
the transmission unit is achieved, allowing installation. (see Figure 5).
Minimum gap of X should not be less than the values shown in Table
1, unless indicated otherwise on the general arrangement drawing.
FIG.5 X 3
IMPORTANT Always remove the compression bolts as soon as the
transmission unit is in position, before fully tightening the hub bolts.

3. Align the hub/transmission unit flanges if they have been match marked
4. Fit the hub bolts and tighten these evenly to locate the transmission unit, ensuring the spigots enter
their recesses squarely. Bolt-threads should be lubricated with oil and tightened in a "diametrically
opposite" sequence to the torque values shown in Table 1.

5. Measure dimension 'A (see Figure 1) on the transmission unit. Check against the minimum and
maximum value in Table 1.
6. Rotate the machinery two or three times slowly to ensure it moves freely.

Hub tightening torque values apply to oil lubricated threads

TABLE 1
Coupling Hub bolt Hub bolt Min gap Coupling Dim’n Dim’n
Size Size Tightening X Max Axial 'A' (Min) 'A' (Max)
Torque mm Deflection mm mm
Nm +/- mm
0013 M6 13 7.1 1.0 7.7 7.8
0033 M8 25 7.2 1.25 8.2 8.4
0075 M8 25 7.6 1.5 8.8 9.0
0135 M8 25 8.1 2.0 9.6 9.9
0230 M10 50 8.3 2.5 10.2 10.4
0350 M8 25 11.6 2.75 13.6 13.9
0500 M10 50 11.8 3.25 14.4 14.7
0740 M10 50 12.3 3.75 15.2 15.5
0930 M12 86 12.5 4.25 15.9 16.2
1400 M12 86 13.4 5.0 17.4 17.8
Maximum angular misalignment = 0.5 degrees up to 3600rpm; 0.33 degrees up
to 7500rpm; 0.25 degrees above 7500rpm.

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
(PN 78257)
Fitting, & Maintenance Instructions. Page 6 of 10

OPERATION, INSPECTION AND MAINTENANCE

Before starting the machinery, ensure that all necessary safety procedures are being
observed and coupling guards are fitted.

Routine examination should include a periodic check on the tightness of fasteners and visual inspection of
transmission components for signs of fatigue or wear.

If the coupled machinery is disturbed at any time, shaft alignment should be re checked. Alignment
checking is recommended if a deterioration of installation alignment during service is suspected.

Maintenance work must only be carried out by suitably qualified personnel when the
equipment is stationary and has been made safe.

Failures are rare and can generally be attributed to excessive misalignment or / and severe torsional
overload. In all cases of coupling failure, the cause should be identified and corrected before replacing the
coupling.
It is possible to repair the coupling by fitting replacement Membrane unit assemblies or replacing the entire
transmission unit.

To replace the transmission unit, remove the hub bolts and then withdraw the transmission unit using the
compression bolts feature in the spacer as appropriate.

Transmission unit must be adequately supported during removal to avoid accidental damage
should it slip.

ATTENTION When repairing John Crane MetastreamTM flexible membrane couplings, only John
Crane approved parts should be used.

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling
I-TSKS ENG 0310
Fitting, & Maintenance Instructions – Refurbishment supplement Page 7 of 10

TRANSMISSION UNIT REFURBISHMENT

Metastream flexible power transmission couplings are designed and selected to give an unlimited service if
used within the conditions for which they were specified. Failures are rare and can generally be attributed to
excessive misalignment, severe overload, or a combination of both. In all cases of coupling failure it is
advisable that the cause of failure is first identified and corrected.
Failure of the coupling will generally be failure of a membrane assembly. Except for some special and large
couplings, these cannot be reconditioned and should be replaced.

NOTE: For balanced TSK spacer couplings, the transmission unit is usually supplied as a factory
assembled unit which should not be dismantled. However, when used at low or medium speeds, the
transmission unit can be reconditioned but will require rebalancing.
Membrane assemblies should be replaced in pairs, failure of one will usually result in damage to the other.

To replace the transmission unit, first remove the hub bolts (3) then
withdraw the transmission unit, using the lever slots in the hubs or
jacking holes in the spacer flanges. 8B 8S 8N

MEMBRANE UNIT REPLACEMENT

Remove the drive bolts (8B) and nuts (8N), and remove the
membrane assemblies from the spacer piece (6), Do not attempt to
dismantle the membrane assembly any further. Push washers (8S)
from the holes in the spacer piece.

Identify the fasteners on the new membrane assembly which attach Spacer
to the spacer flanges. Remove the loosely assembled nuts (8N).

With the bolts (8B) in position, carefully press on the bolt heads to
push the new sleeves (8S) into the holes in the spacer flange. Take
care not to over-strain the flexible discs.
Place a small amount of threadlocking compound (e.g. Loctite 242)
on the protruding bolt threads and then assemble the nuts (8N).
Holding the bolts firmly, turn the spacer nuts evenly to the correct
tightening torque value given in Table 2.

Complete the refurbishment of the transmission unit by replacing the

second membrane assembly.

TABLE 2 - STANDARD TIGHTENING TORQUES

TIGHTENING TORQUE
TSKS SPACER NUTS (8N)
COUPLING SIZE N-m
0011, 0013 11
0027, 0033 23
0060, 0075 47
0110, 0135 75
0180, 0230 130
0260, 0350 150
0400, 0500 205
0560, 0740 285
0750, 0930 380
1120, 1400 490

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
EEC Directives – Page 8 of 10
94/9/EC (ATEX95/100a) & 2006/42/EC (Machinery Directive)

This section refers to couplings which bear the CE and ATEX* required markings:

CE / ATEX marking
All couplings which comply with CE and ATEX legislation will be marked as shown. This will
be etched on the spacer element of the transmission unit.

εx IM2 εx II 2GD T6 M17 1SS, UK. 07

Note 07 is the year of manufacture and will change.

• Operation in aggressive atmospheres

The following components contain non-metallic materials. Confirm compatibility or provide
suitable protection if the coupling is to operate in an aggressive atmosphere.

- The hub electrical insulation. (if supplied option) - reinforced thermosetting plastic.
- Limited end float bearings. (if supplied option) – PTFE based plastic.
- Composite spacer tube. (if supplied option) – reinforced thermosetting plastic.

Temperature classification of Metastream couplings

Metastream metal membrane couplings from John Crane supplied in conformance with
Directive 94/9/EC have to the following classification when used in accordance with
instructions and information supplied. For Standard ambient temperature –20 to 40oC

Metastream T series and L series couplings, using the disk type flexible elements, are
covered by type certificate Sira 02ATEX9403

Metastream M series couplings, using the diaphragm type flexible elements, are covered by
type certificate Sira 02ATEX9404

Where Metastream metal membrane couplings from John Crane are required for use in
higher ambient temperatures, John Crane Ltd certifies that the equipment complies with the
temperature classification range listed in table 1 and in all other respects complies with the
type certificates.

I M2 II 2GD T# (amb. *C)

Table 1.
Max T Max. Surface
ambient Class temperature
o o
C # C
150 T3 200
90 T4 135
55 T5 100
40 T6 85

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
EEC Directives – Page 9 of 10
94/9/EC (ATEX95/100a) & 2006/42/EC (Machinery Directive)

John Crane
31, Nash Road
Trafford Park
Manchester
M17 1SS
United Kingdom
T: +44 (0) 161 872 2484
F: +44 (0) 161 872 1654
www.johncrane.com

Declaration of Conformity

EEC Directive 94/9/EC of 23

03.1994 and resultant legislation
and standards
We, the manufacturers – John Crane UK Ltd, – confirm that the explosion-prevention
requirements have been implemented for

Metastream® metal-membrane couplings

Equipment complies with the requirements of directive 94/9/EC. It is in accordance with
article 1 3. (a) of the directive and the fundamental Health and Safety requirements of Annex
II, are fulfilled.

The current Type-Examination certificates for the couplings are:-

‘T’ & ‘L’ series - Sira 02ATEX9403

‘M’ series - Sira 02ATEX9404

The technical Documentation is deposited with the designated Notified body in accordance
with article 8 1. (b) (ii) the Directive 94/9/EC:

SIRA Test & Certification Ltd

Hazardous Area Centre, Rake Lane
Eccleston, Chester, CH4 9JN
England

Signed: Date: 1st January 2010

P.D. Carlisle (Product Line Director - Couplings)

Metastream is a registered trademark of John Crane

 Metastream™ TSKS coupling I-TSKS ENG 0310
EEC Directives – Page 10 of 10
94/9/EC (ATEX95/100a) & 2006/42/EC (Machinery Directive)

John Crane
31, Nash Road
Trafford Park
Manchester
M17 1SS
United Kingdom
T: +44 (0) 161 872 2484
F: +44 (0) 161 872 1654
www.johncrane.com

Declaration of Incorporation

E.C. Machinery Directive (2006/42/EC)

Section 1.0 - Machinery Description:

Flexible Power Transmission Ring and Diaphragm Form Membrane Couplings
Types:

M, H, T, L Series

Section 2.0 - Applicable Harmonised Standards

ISO13709 (API 610) for centrifugal pumps
ISO14691 couplings for - General-purpose applications
ISO10441 (API 671) (opt) couplings for - Special-purpose applications

Section 3.0 - Declaration:

We, John Crane declare that under our sole responsibility for the supply of the
machinery defined in Section 1.0 above, the said machinery parts are intended to be
incorporated into other machinery or assembled with other machinery to constitute
machinery as covered by this Directive.

The machinery parts, covered by this declaration must not be put into
service until the machinery into which it is to be incorporated has been
declared in conformity with the provisions of the Directive.

Signed: Date: 3rd Sept 2009

P. D. Carlisle (Product Line Director – Couplings)

Metastream is a registered trademark of John Crane

 Operating manual

Heat exchanger (WEF)

WEF6100A4A001-D5

 These instructions are intended for the assembly, operating and monitoring personnel.
 This manual must be kept available on site.
 Read this manual diligently and follow all instructions.
 We definitely recommend you contact EagleBurgmann should anything be unclear.
 The product named on the title page will be called system in the following.
 The designation non-EagleBurgmann equipment refers to all non-EagleBurgmann com-
ponents, see equipment list and drawing
 Use this documentation only in conjunction with the documents stated in "System Infor-
mation" in order to avoid mistakes.

EBG_12.01.2016
EagleBurgmann Germany GmbH & Co. KG
Äußere Sauerlacher Straße 6-10 | D-82515 Wolfratshausen | Tel.: +49 (0)8171 23 0 | Fax: +49 (0)8171 23 12 14
[email protected] | www.eagleburgmann.com
Manufacturer and address
EagleBurgmann Germany GmbH & Co. KG
Stammhaus - Fachbereich Versorgungssysteme
Äußere Sauerlacher Straße 6-10
D - 82515 Wolfratshausen
Tel.: +49 (0) 81 71 - 23 0
Fax: +49 (0) 81 71 - 23 19 29

Dealer
http://www.eagleburgmann.com/en
 EagleBurgmann International
 Country (distribution locations and Service Center)

Service-Center
http://www.eagleburgmann.com/en
 EagleBurgmann International
 Country (distribution locations and Service Center)

Creation
Date: 12.04.2016
Supply Systems Department: F. Rößle
Documentation & Standardization Department: T. Eberl

Country of origin of the system

Germany

Version and date of document

Revision 0 on 12.04.2016

2
 Table of Contents
1. Safety ....................................................................................... 5
1.1. General safety notes ................................................................ 5
1.1.1. Operator-specific safety instructions and hazard analysis
results................................................................................ 5
1.1.2. Product-specific safety instructions .................................... 6
1.1.3. Operating-specific safety instructions ................................ 6
1.2. Personal, material, environmental damage and notes .............. 8
1.3. Standards and directives .......................................................... 9
1.4. Warranty and liability ................................................................ 9
2. System information..................................................................10
2.1. Intended use ...........................................................................10
2.2. Operating data and limits on use .............................................10
2.3. Materials .................................................................................10
2.4. Notes on explosion protection .................................................10
2.5. Findings from the general risk assessment..............................11
2.6. Other applicable documents and drawings ..............................12
3. Transportation .........................................................................13
3.1. Packaging ...............................................................................13
3.2. Delivery ...................................................................................13
4. Storage ...................................................................................14
5. Description and function ..........................................................15
5.1. Description of system ..............................................................15
5.2. Emission .................................................................................15
6. Assembly, and disassembly ....................................................16
6.1. Space required ........................................................................16
6.2. Accessories .............................................................................16
6.3. Assembly.................................................................................17
6.4. Disassembly ............................................................................18
7. Start up and shut down............................................................20
7.1. Requirements ..........................................................................20
7.2. Start-up ...................................................................................20
7.3. Shutdown ................................................................................20

12.04.2016 3
 8. Operation ................................................................................21
8.1. Notes for the operator .............................................................21
9. Servicing .................................................................................23
9.1. Cleaning ..................................................................................23
9.2. Maintenance............................................................................23
9.3. Repair .....................................................................................24
10. Faults ......................................................................................25
11. Disposal ..................................................................................26
12. Customer service ....................................................................27
12.1. Spare parts..............................................................................27
12.2. Accessories .............................................................................27
12.3. Queries and orders..................................................................27
13. Copyright .................................................................................28

12.04.2016 4
 WEF6100A4A001-D5 Safety

1. Safety
1.1. General safety notes
1.1.1. Operator-specific safety instructions and hazard analysis results
 EagleBurgmann systems are manufactured to a high quality and
have high operational reliability. However, the system is a poten-
tial source of risk if it is not operated correctly or is used
improperly.
 The regulations applicable at the location as well as the accident
prevention requirements must be complied with at all times.
 Unauthorized modifications and changes that adversely affect the
safety of the system are not permitted.
 The operator holds the responsibility for accident-free operation.
 Within the scope of his safety concept the operator is requested
to check what effects failure or damage to the system would have
on the environment, and which additional prevention measures
are necessary to protect people or the environment.
 The operator must prevent the system from being misused or op-
erated improperly.
 To avoid the risk of burns and personal injuries due to contact
with hot surfaces, the operator must affix appropriate insulation
and/or warning signs to the system.
 Safety and warning signs may not be removed and must be kept
in a legible condition.
 The maximum permissible operating pressure of the system and
other components in a closed supply circuit must not be exceed-
ed, regardless if caused by incorrect handling or through
procedures. Appropriate measures must be taken which comply
with the regulations applicable at the location.
 Work on the system is principally only permitted on a depressur-
ized machine during standstill and with disconnected supply
voltage. Secure the device to prevent unauthorized reactivation.
 For the sake of clarity, the operator is recommended to incorpo-
rate this document into his generally applicable company
regulations.
 The operating instructions of the operator must be observed and
complied with.
 The system can be lifted by the points shown in the drawing.
 The operator must ensure that the system is installed in the pre-
disposed installation point of the plant.

12.04.2016 5
 WEF6100A4A001-D5 Safety

1.1.2. Product-specific safety instructions

 Any person within the operator's company involved in the installa-
tion, removal, operation, start-up, and maintenance of the system
must have read and understood this operating manual, and the
safety notes in particular. We recommend that the operator con-
firm that this is the case.
 How the system is incorporated into the higher level system will
determine whether it is safe to operate. The technician with re-
sponsibility for the overall system is also responsible for matching
the system to the higher level system.
 Only competent, authorized, trained and instructed personnel
may install, commission, maintain or remove EagleBurgmann
systems. EagleBurgmann offers the corresponding seminars to
obtain the required skills.
 Responsibilities for the applicable tasks should be clearly as-
signed and obeyed to prevent confusing competencies regarding
safety.
 The personnel must wear safety clothing, safety gloves and safe-
ty glasses and respiratory protection, if necessary, that is
appropriate to the work to be done.
 This documentation must be accessible to the personnel at all
times.
 The system’s switching logic must be matched to the individual
seal and must be implemented and tested by the operator.
 The operator must interpret the test results and select the result-
ing status values for the seal (function, fault, danger) so that the
seal is guaranteed to work at all times and to minimize the re-
sponse time in the event of a fault.

1.1.3. Operating-specific safety instructions

 Systems that are operated with hazardous substances must be
free of hazardous substances during maintenance work to elimi-
nate risks to people or the environment.
 Depending on the medium and/or sealing gas (e.g. separating
gas) to be sealed, you must comply with the hazardous sub-
stance ordinance, the relevant regulations on handling hazardous
substances (e.g. safety data sheets as defined in directive
91/155/EEC, national regulations, etc.) and the accident preven-
tion regulations. If the utilized medium to be sealed is subject to a

12.04.2016 6
 WEF6100A4A001-D5 Safety

hazardous substance ordinance, then all regulations for handling

hazardous substances must be observed.
 The gas concentration in the atmosphere should be measured at
regular intervals, as required, while working on the system.
 When installing the units, check the local grounding and potential
requirements and power system conditions before connecting
any cables. The operator must take suitable measures if critical
potential differences are identified. Any ground connections used
must be regularly tested for effectiveness (resistance to ground).
 When nitrogen is used in enclosed spaces and pits, the nitrogen
concentration can rise very quickly. Danger of suffocation.
 Comply with the third-party manufacturer’s regulations and doc-
umentation for non-EagleBurgmann devices.
 Any mode of operation that adversely affects the operational
safety of the system is not permitted.
 All valves must be secured against unauthorized operation.

12.04.2016 7
 WEF6100A4A001-D5 Safety

1.2. Personal, material, environmental damage and notes

A list of notes used in the document along with an explanation is sup-
plied in the following:

Situation resulting in
death or severe injuries Type and source of danger
if not avoided.
Possible consequences

DANGER - Action
- Action

Situation which can

result in death or severe Type and source of danger
injuries if not avoided.
Possible consequences

WARNING - Action
- Action

Situation which can

result in light injuries if Type and source of danger
not avoided.
Possible consequences

CAUTION - Action
- Action

Situation which can

cause material or envi- Material or environmental damage
ronmental damage if
not avoided.

Additional note or in-

formation. Note

12.04.2016 8
 WEF6100A4A001-D5 Safety

1.3. Standards and directives

The system has been built according to currently valid technical stand-
ards and is safe to operate. The basic health and safety requirements of
the applicable laws, standards and directives were applied during the
development and execution of the system. All information pertaining to
safety in this documentation refers to the valid national laws and ordi-
nances of the European Union. The generally applicable regulations on
accident prevention and on environmental protection must be observed
in addition to the safety instructions given in this manual.

1.4. Warranty and liability

The General Terms and Conditions apply to all systems of EagleBurg-
mann Germany GmbH&Co. KG at: www.eagleburgmann.com

Warranty and liability claims for personal or material damage is excluded

if ascribable to one or several of the following causes:

 Improper use of the system.

 Improper transport, storage, assembly, disassembly, start-up,
shut down, operation, and maintenance of the system.
 Constructive changes to the system without written approval from
the manufacturer.
 Disregarding the General Safety Instructions, Notes on Personal
and Material Damage, and the supplemental notes and infor-
mation.
 Improper repair.
 Using spare and wearing parts as well as operating materials and
cleaning agents other than approved by the manufacturer.

EagleBurgmann Germany GmbH & Co. KG shall only assume warranty

and liability for material and manufacturing defects.

12.04.2016 9
 WEF6100A4A001-D5 System information

2. System information
2.1. Intended use
The system is intended solely for use in the specified application. Any
other or more extensive usage will be regarded as incorrect usage and
the manufacturer shall not be liable for any damage caused. Any usage
not conforming to the conditions stipulated under “Operating limits and
Limits on use” below will be regarded as incorrect usage. The risk asso-
ciated with such improper usage shall be borne solely by the operator.
Operation under other conditions or in another location must be agreed
with EagleBurgmann and documented.

2.2. Operating data and limits on use

System:
Process medium: Process Condensate
Tubeside: 250°C /
Maximum operating temperature:
Shellside: 150°C
Tubeside: 68,11 kg/cm^2(g) /
Maximum operating pressure:
Shellside: 16,32 kg/cm^2(g)
Additional information:
Shell (content / pressure) 2,6 l / ---
Tube (content / pressure) 2,2 l / ---
Cooling medium: Water

See drawing for further information

2.3. Materials
The materials used to construct the system are varied to suit the applica-
tion and are specific to the order. They can be referred to from the
drawing and the documentation.

2.4. Notes on explosion protection

The system is suitable for use in potentially explosive areas. There are
potential sources of ignition in the vicinity of the instruments. An appro-
priate risk assessment has been carried out. Interaction between the
individual components does not cause any additional potential sources

12.04.2016 10
 WEF6100A4A001-D5 System information

of ignition. This means that identification and certification in accordance

with ATEX 94/9/EG are only necessary for individual electrical or me-
chanical components. This situation may be certified with a handwritten
certificate.

 The system must be grounded by the end user to avoid electro-

Findings from the risk static sources of ignition.
assessment
 Brush discharge is possible due to paint coating thicknesses (>
0.2 mm). For this reason, use only category IIA and IIB sub-
stances to avoid electrostatic sources of ignition.
 To recognize hazards and take any appropriate measures, the
customer must comply with the minimum requirements for safety
and the health protection of employees as well as with the opera-
tor responsibilities.
A manufacturer's declaration will be issued as needed if the system will
be operated in a potentially explosive atmosphere. The customer can
use to this as reference for his higher level review.

2.5. Findings from the general risk assessment

The end user must ensure that the listed risks

are known and that appropriate measures have
been taken to prevent them.

Although an individual risk assessment was carried out during develop-

ment and construction, not all dangers can be eliminated because they
occur in the various product life cycles and cannot be prevented by the
manufacturer.

When handling this system the customer must take the following into
account:

 Transportation and set-up: The muscular and skeletal system

can be overstrained due to the forced postures from working and
the lifting and carrying of heavy loads.
 Sharp edges and crushing: Joining the system to the higher
level system or connections can be a source of risk to people due
to positioning and swinging movements and/or lack of freedom of
movement. Hands or other extremities could becrushed as a re-
sult.
 Electric shock: Faulty assembly, incorrect connections, defec-
tive parts, etc. can expose the personnel to the risk of electric
shock during the test run and during operation. Risk to people

12.04.2016 11
 WEF6100A4A001-D5 System information

and components due to live parts of the housing and/or electro-

static discharge.
 Hot surfaces: Hot/cold surfaces, e.g. pipelines, containers or
electrical components, could become a danger to people during
operation.
 Allergic reactions/poisoning: Components of the utilized media
can damage the human immune system or trigger allergic reac-
tions.
 Combination of hazards: Misjudgements during faults, mainte-
nance work or system operation can lead to hazardous situations
that are not foreseeable.

2.6. Other applicable documents and drawings

 Assembly drawing: WEF6100A4A001-D5

Not available for all  P&ID: FA-SPX01-306

systems  Equipment list / data sheets:
 Terminal diagram:
 Operating instructions for individual devices:
 Test run report:
 Certifications:

Use this documentation only in conjunction with

the other applicable documents stated above in
order to avoid mistakes.

The latest version of the assembly drawing, in

the original scale, is definitive for construction,
and for use in conjunction with this document.

If required, request drawings of the components

from EagleBurgmann.

12.04.2016 12
 WEF6100A4A001-D5 Transportation

3. Transportation

If the system is equipped with measuring devic-

es, vibration and impact during transportation
must be avoided.

Always lift the transport crates at the indicated

points.

3.1. Packaging
Unless otherwise contractually agreed, the packaging used conforms to
the "HPE" packaging guidelines issued by the "Bundesverband Holzmit-
tel, Paletten, Exportverpackung e.V." and "VDMA".

The pictograms and handling instructions on the

packaging should be followed.

3.2. Delivery
EagleBurgmann supplies the system and all components
(e.g. measuring devices, if available) fully assembled, purged, unpres-
surized and tested for leaks and function.

Before installation, check the system for visible

signs of damage to assemblies or devices. Obvi-
ous defects should be documented with
photographs to simplify subsequent clarification.

12.04.2016 13
 WEF6100A4A001-D5 Storage

4. Storage
If the unit will be stored for a few weeks or even months, it must be kept
indoors in a dry place protected against dust and from the weather. Even
when stored indoors, the system should be covered with a tarpaulin to
protect against dust. Long-term storage of the system is not permissible.

 The storage location must be suitable for the weight of the sys-
tem.
 There must be sufficient space available for maintenance and/or
repairs.
 The storage location must be free of vibrations and other im-
pacts.
 All equipment components must be stored upright on a flat sur-
face.
 Electrical equipment should also be prepared for storage in ac-
cordance with the manufacturer’s instructions where applicable.
 The system must be protected against freezing.
 Adequate ventilation should be provided.
 The temperature must be kept constant:
 Relative humidity: < 65 %
 Temperature: +25 °C to +45 °C
 Protection must be provided against direct heat sources (sun and
heaters) and UV radiation (sun, halogen and fluorescent lamps
and arc welding).
 The presence or creation of ozone (arc welding, mercury vapor
lamps, high voltage devices and electric motors) must be pre-
vented to avoid the risk of elastomer embrittlement.

EagleBurgmann will not accept liability for dam-

age caused by improper storage.

12.04.2016 14
 WEF6100A4A001-D5 Description and function

5. Description and function

EagleBurgmann supply systems are complete supply units for mechani-
cal seals. A seal can only be guaranteed to function correctly if a
sufficient volume of medium, and with the necessary pressure, is availa-
ble at any given time.
EagleBurgmann systems with available buffer medium are required to
supply (pressure, lubrication, cooling) to multiple mechanical seals in
back-to-back, face-to-face, or tandem arrangement. A double mechani-
cal seal with barrier can only work reliably if the barrier pressure is higher
at any given time than the pressure in the chamber to be sealed.

5.1. Description of system

The EagleBurgmann heat exchanger is a pressure vessel consisting of
two separate pressure chambers (jacket side and pipe side) for the
cooling of buffer media in sealing supply circuits. The pipe insert (bundle
or coil) increases the heat transfer surface and enables the exchange of
heat between the various media. The heat of the buffer medium is dis-
charged over the surface of the inserts (bundle or coil) to the cooling
medium and is removed to the outside with its fluid flow.

5.2. Emission
A seal is a dynamic system which cannot be leak-free for physical and
technical reasons. The leakage rate is influenced, among other things,
by the seal design, the production tolerances, the operating conditions,
and the running quality of the machine.
If the buffer pressure drops below the pressure in
the sealing chamber, the medium to be sealed
can access the sealing gap and contaminate the
flushing and buffer medium.

Components which can come into contact with

the leakage must be corrosion resistant or pro-
tected accordingly.

Risk of suffocation in closed rooms due to

increased nitrogen concentration.

Unconsciousness and suffocation followed by

death.

- Ensure the ventilation of rooms.

- Regularly check the nitrogen concentra-
tion.
- Wear personal protective equipment.

12.04.2016 15
 WEF6100A4A001-D5 Assembly, and disassembly

6. Assembly, and disassembly

The General Safety Instructions must be ob-

served.

Assembly drawing and flow chart must be to

hand during the assembly and disassembly.

It is absolutely mandatory to not apply force

during the assembly and disassembly.

All work on the system must be executed ex-

tremely carefully and under the cleanest possible
conditions.

The operator is responsible for the proper as-

sembly and disassembly.

6.1. Space required

You will find the main dimensions and connection dimensions in the
assembly drawing (size when completed for filter inserts and other com-
ponents, for example, must be taken into consideration by the operator).

6.2. Accessories
The following tools and accessories must be prepared for the assembly
and disassembly:

 Allen key
 Open-end or ring wrench
 Torque wrench
 Loctite (LOCTITE Corporation) or SWAK (Swagelok Company)
for thread locking
 Cellulose cloths for cleaning

 Collection tanks for pipelines and components to be drained

12.04.2016 16
 WEF6100A4A001-D5 Assembly, and disassembly

6.3. Assembly

The system must be installed so as to allow easy

access for operation, monitoring and servicing.

The installation site must be clean, level and

easy to access, if possible.
The installation site must be suitable for the
weight of the system. Given the size of the sys-
tem, it may be necessary for the end user to
check the stress analysis relating to wind and
working loads.
All further pipelines must be earthed at regular
intervals in accordance with end user specifica-
tions.

The system must be aligned analogous to the

drawing.

Transfer points must be tightened and main-

tained in accordance with manufacturer's
specifications.
 The system must be assembled so that the inlet of the system is
1 – 2 m above the supply outlet of the seal to permit natural circu-
lation of the liquid. The distance may be shorter if also using a
pump.
 The system must be firmly attached to the ground.
 Pipelines in the system should be made of stainless steel with
minimum dimensions of Ø 18 x 1.5 mm. Refer to the drawing and
the flow diagram for the exact connection sizes. The individual
pipe sections are normally connected through screwed joints.
Thoroughly clean the pipe sections entirely with compressed air
before assembly.
 Install venting devices at the highest points in the pipe system if
the layout of the pipes does not preclude the possibility of air
pockets.
 Drain connections must be installed at the lowest points of the
piping system.
 Install the cooling water pipes to the system so that the maximum
operating pressure of the cooling coil is not exceeded. Always fol-

12.04.2016 17
 WEF6100A4A001-D5 Assembly, and disassembly

low the regulations applicable at the installation site. It must be

possible to regulate the cooling water flow rate.
 Pipe sections should be as short as possible and create optimum
flow conditions. Run pipes so that they rise steadily and thus
avoid air pockets. Only use pipe bends for turns and ball valves
for shut-offs.
 Pipes should be fixed at regular intervals (no more than 2 m) us-
ing sound-proofed pipe clamps so that screwed joints and valves
are free of vibration and other mechanical forces.
 Relative movement between the system and mechanical seal
(linear expansion / vibration) should be taken into account when
laying the pipes.
 If available: Connect electrical components to suitable facilities
with due regard to the applicable connected loads of the third-
party manufacturer (e.g. control room). The function, fault and
alarm logic must be determined and defined by the end user.

6.4. Disassembly

 Switch off the complete system.

 Disconnect the electrical connection of the system.
 Allow the medium to cool off.

The medium must be collected and disposed of

properly. The medium should never reach the
drainage system and seep into the ground.

 Depressurize the system and drain the medium. For that pur-
pose, install a connecting pipe at the "DRAIN" (if available) outlet
to the collection tank. As soon as the system is depressurized
and the line is connected to the container the drain ball valve (if
available) can be opened. Next, the ball valve of the "VENT" ven-
tilation (if available) can be opened cautiously until the medium
has drained completely.

Risk of suffocation in closed rooms due to

increased nitrogen concentration.

Unconsciousness and suffocation followed by

12.04.2016 18
 WEF6100A4A001-D5 Assembly, and disassembly

WARNING death.
- Ensure the ventilation of rooms.
- Regularly check the nitrogen concentration.
- Wear personal protective equipment.

 Purge and clean the system with a suitable medium.

 Close all valves to prevent residual leakage of the medium during
movement and the invasion of dirt.
 Dismantle pipelines.
 Dismantle the system from the plant.

12.04.2016 19
 WEF6100A4A001-D5 Start up and shut down

7. Start up and shut down

The manufacturer’s instructions apply for all non-

EagleBurgmann devices.

7.1. Requirements
Do not start up until:

 The entire pipeline system has been installed and checked.

 The electrical installation work has been carried out correctly and
checked.

7.2. Start-up

The prescribed viscosity is product-dependent

and must be coordinated with EagleBurgmann.

The system is ready for operation after it has been properly assembled
and connected.

7.3. Shutdown
After shutting down the plant for reasons of maintenance or operation
the pressure must be relieved, using the devices or fittings provided.

12.04.2016 20
 WEF6100A4A001-D5 Operation

8. Operation

The manufacturer’s instructions apply for all non-

EagleBurgmann devices.

8.1. Notes for the operator

The valves between the system and seal must

always be open.

For operation at low temperatures, we advise

preheating the oil in the storage tank to at least
+10°C to avoid overloading the pump motor. It is
also sensible to provide trace heating for the
buffer fluid lines.

The heat exchanger may only be operated if all

of the safety equipment is available.

Depending on the operating requirement, the

end user must provide the safety equipment,
such as safety valves, heat protection covers,
temperature probes, etc.
The functionality of the safety equipment must be
inspected regularly. Any occurring defects must
be remedied immediately.
The heat exchanger must be secured with a
mechanical protection against unauthorized
contact and unauthorized access.

The heat exchanger may not be subjected to

overtemperature and overpressure.

12.04.2016 21
 WEF6100A4A001-D5 Operation

The system must be shut down immediately if

changes to the heat exchanger have been de-
termined during operation, for example in the
event of too high operating pressure.
The cooling water temperature must be kept
constant for the entire operating duration. Refer
to the drawing and the equipment list (if availa-
ble) for the temperature.
The end user must consider and implement the
health safety requirements applicable at the site
of installation as well as the product-specific
safety and inspection measures, including the
recurring tests.
 Regular functional checks of the monitoring devices.
 Compliance with EagleBurgmann's maintenance instructions.
 Compliance with the maintenance instructions of third-party man-
ufacturers.
 Documentation of all work.

12.04.2016 22
 WEF6100A4A001-D5 Servicing

9. Servicing

The manufacturer’s instructions apply for all

non-EagleBurgmann devices.

9.1. Cleaning
The cleaning intervals depend on the degree of contamination. After
maintenance and cleaning, we recommend purging the system to clean
the pipelines. In our experience, a large part of the impurities will have
drained out of the pipelines by this time.

9.2. Maintenance
If operated properly, the system is maintenance free. Wearing parts must
be replaced as necessary.

Carry out semi-annual inspections of the overall

system following the General Safety Instructions.

Defects (e.g. leaks and loosened pipe fasten-

ings) must be rectified immediately.

An Inspection should include checks of the system and all individual

components.

 Leakage checking of the system

 If barrier medium available: Check of pressure and temperature
of barrier medium. Change entire medium; for the first time after
50 operating hours, then every 3,000 operating hours (it will be
necessary to fully vent the system). For deviating operator re-
quirements the intervals can be considered for as long as they do
not exceed >3,000 operating hours.
 If heat exchanger/cooling coil available: Check flow rate of the
cooling medium.
 If pipe filters are available and cleanable: Clean the filter car-
tridge and filter casing after the first 50 operating hours, then
monthly to quarterly, depending on the degree of contamination.

12.04.2016 23
 WEF6100A4A001-D5 Servicing

The operator can extend the intervals if the degree of contamina-

tion.
 If storage tank available: Check the fill level and top up, if nec-
essary, initially during start-up, then every day or every week
(depending on the losses).
 If accumulator is available: Check the priming pressure. Pres-
sure as described under As-delivered State. Always use a
suitable filling and testing device (as specified by the manufac-
turer) to fill and test the accumulator.

9.3. Repair

If there are compelling reasons to repair the

system on site, repairs must be carried out by
the operator's own trained personnel or by the
EagleBurgmann service staff following the Gen-
eral Safety Instructions.

Only complete system components should be

replaced.

12.04.2016 24
 WEF6100A4A001-D5 Faults

10. Faults

The manufacturer’s instructions apply for all non-

EagleBurgmann devices.

Uninterrupted operation is to be expected if used correctly as intended, if

the limiting values are observed, if the wearing parts are checked regu-
larly and if the specified notes are observed.

In the event of a fault, proceed as follows:

 Identify the type of fault (if possible).

 Document the fault (if possible).
 Shut off the system as for the shutdown.
 Rectify fault.

Only start up the system after all causes of fault

have been rectified and the system is in a fault-
less condition.

For faults that cannot be rectified or unclear

identification of the cause of fault, immediately
contact either your local EagleBurgmann dealer,
an EagleBurgmann Service Center, or the Ea-
gleBurgmann Head Office..

12.04.2016 25
 WEF6100A4A001-D5 Disposal

11. Disposal

The correct disposal of the system, leakage,

waste and hazardous waste is the task of the
operator. Contaminated systems must be dis-
posed of under compliance with the local
regulations.

The manufacturer’s instructions apply for all non-

EagleBurgmann devices.

12.04.2016 26
 WEF6100A4A001-D5 Customer service

12. Customer service

The EagleBurgmann Customer Service offers an extensive service
package: From advice, engineering, standardization, assembly, starting
up, damage analysis to seal-related seminars. You will find more infor-
mation in diverse EagleBurgmann publications and at:
www.eagleburgmann.com

12.1. Spare parts

Use only EagleBurgmann spare parts or ap-

proved non-EagleBurgmann parts, otherwise
there is a risk that the system will not operate
correctly, representing a hazard to people and
the environment.

Use only EagleBurgmann spare parts or ap-

proved non-EagleBurgmann parts otherwise the
EagleBurgmann warranty will expire.

12.2. Accessories
Accessories can be obtained from the EagleBurgmann dealers, the
EagleBurgmann Service Center, or the EagleBurgmann Head Office.

12.3. Queries and orders

For all queries and orders, contact the EagleBurgmann Head Office and
provide the following information:

 Manufacturer-Commission number
 Drawing no.
 Diagram number
 Equipment list / data sheets
 Individual part-Item number
 Material
 Number of parts as per drawing

12.04.2016 27
 WEF6100A4A001-D5 Copyright

13. Copyright
EagleBurgmann Germany GmbH & Co. KG has the copyright in this
manual and reserves the right to make technical modifications to im-
prove the system, even if such modifications are not included in this
manual.

It may, however, be used by purchasers, planners and operators of the

system for the purposes of creating their own documentation. No claims
of any nature may be derived from such usage

12.04.2016 28
 IWS-Monjé Ltd.
Heat Exchangers
Tel.: +49 (0)2932 890 188 -0
Fax: +49 (0)2932 890 188 -5
[email protected]
www.iws-monje.com

Installations-
Betriebs- &
Wartungsanleitung

Druckbehälter SDB 245 /159 -1R-1W-100T-30P -SS-IW

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 1 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers

Inhaltsverzeichnis

1. Transport und Lagerung

2. Montage
3.1. Aufstellungsbedingungen
3.2. Anschließen des Druckgerätes
3.3. Ausrüstung des Druckgerätes mit Begrenzungseinrichtungen

3. Inbetriebnahme

4. Benutzung
5.1. Allgemeine Hinweise
5.2. Anfahrbetrieb
5.3 Normalbetrieb
5.4. Außerbetriebnahme
5.5 Unsachgemäße Verwendung

5. Wartung und Instandhaltung

6.1 Allgemeine Angaben
6.2 Schließen und Öffnen des Druckgerätes
6.3 Wartung und Inspektion
6.3.1 Wiederkehrende Prüfung durch zugelassene Überwachungsstellen
6.4 Instandsetzung

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 2 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers

1. Transport und Lagerung

Der Transport darf nur durch fachkundiges Personal erfolgen.

Das Druckgerät darf nur im drucklosen Zustand transportiert werden.

Durch geeignete Anschlagmittel ist sicherzustellen, dass hierdurch keine
Verformungen oder sonstige Beeinträchtigungen der
Oberflächen/Dichtflächen entstehen. Das Anschlagen des Druckgerätes
an Stutzen, Flanschen usw. ist nicht gestattet. Der Transport darf nur
am liegenden Druckgerät an den dafür vorgesehenen und markierten
Anschlagpunkten vorgenommen werden. Punktförmige Belastung der
Behälterwand kann zu unzulässigen Deformierungen führen.
Transport und Lagerung ist unterhalb der Frostgrenze (0°C) nicht
gestattet (Frostgefahr von möglichem Restwasser im Behälter).

Alle Öffnungen wie Stutzen, Flansche usw. sind mit geeigneten Mitteln zu
verschließen und dürfen nur durch fachkundiges Personal entfernt werden
(Achtung: Dichtflächen nicht beschädigen!)
Für Schäden an dem Druckgerät, die durch unsachgemässen Transport
entstehen, übernimmt der Hersteller keine Haftung.

2. Montage
2.1 Aufstellungsbedingungen
Die Montage darf nur durch fachkundiges Personal gemäss der jeweils
gültigen nationalen Rechtsvorschriften erfolgen. Druckgeräte sind so
aufzustellen, dass Beschäftigte oder Dritte nicht gefährdet werden.
Erforderliche Schutzabstände sind entsprechend den anwendbaren
nationalen gesetzlichen Bestimmungen des Aufstellungslandes
einzuhalten.

Die Druckgeräte sind so aufzustellen bzw. zu montieren, dass sie für

ggf. notwendige Besichtigungen und Inspektionen zugänglich sind und
allseits besichtigt werden können.
 das Fabrikschild gut erkennbar ist
 die Bedienung des Druckgerätes und seiner Ausrüstung von einem
sicheren Stand aus möglich ist.

Die Druckgeräte sind so zu gründen, dass

 durch die Gründung selbst
 durch das Eigengewicht des Druckgerätes einschließlich des
Beschickungsgutes oder des Druckprüfmittels (bei einer späteren
Druckprüfung) und
 durch äußere Kräfte keine unzulässigen Verlagerungen oder
Neigungen eintreten können.
 Geeignete Maßnahmen gegen elektrostatische Aufladung sind
vorzusehen.

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 3 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers

Das Druckgerät muss gegen mechanische Einwirkung von außen, z.B.

durch Fahrzeuge, soweit geschützt sein, dass Beschädigungen an das
Druckgerät nicht zu erwarten sind. Das Druckgerät und seine Ausrüstung
sind vor Eingriffen Unbefugter zu schützen. Wenn ein Brandlast besteht,
die im Brandfall das Versagen drucktragender Wandungsteile,
sicherheitstechnischer relevanter Ausrüstungsteile oder tragender
Bauteile (Stahlstützen, Standzargen, Tragplatzen) vom Druckgerät durch
unzulässige Erwärmung bewirken kann, sind entsprechende
Schutzmaßnahmen (Brandverhütung, Brandschutz oder
Brandbekämpfungsmaßnahmen) vorzusehen.

2.2 Anschließen des Druckgerätes

Auf die Einbaulage des Druckgerätes ist unbedingt zu achten
insbesondere bei verdampfenden und kondensierenden Medien
kann eine falsche Einbaulage zu Schäden führen. Es ist darauf zu
achten, dass eine korrekte Entlüftung und Entleerung des
Drückgerätes möglich ist.
Das Druckgerät ist an den vorgesehenen Stutzen und Anschlüssen
anzuschließen. Zusätzliche Einleitung von Kräften,
Biegemomenten oder Schwingungen an Anschlussstutzen durch
Rohrleitungsanschlüsse sind zu vermeiden.
Schweißtechnisch herzustellende Verbindungsnähte an Stutzen sind
nach gültigen oder anerkannten Schweißverfahren herzustellen und zu
prüfen.

2.3 Ausrüstung des Druckgerätes mit Begrenzungseinrichtungen

Um zu verhindern, dass die zulässigen Betriebsgrenzwerte wie
Druck, Temperatur, Füllstand überschritten werden, muss das
Druckgerät mit folgenden Begrenzungseinrichtungen ausgerüstet
werden:

-Regeleinrichtungen
Geeignete, von Hand bediente oder automatisch arbeitende Regel-
und Steuereinrichtungen für die Einhaltung der Betriebsparameter, wie
z.B. Mess-, Steuer- und Regeleinrichtungen (MSR), Druck-,
Temperatur-, Standschalter, um die Betriebsbedingungen, während
des bestimmungsgemäßen Betriebes innerhalb der zulässigen
Minimal-/Maximalgrenzwerte zu halten.

- Überwachungseinrichtungen
Angemessene Überwachungseinrichtungen zur Überwachung der
Betriebsparameter, wie z.B. Mess-, Steuer- und Regeleinrichtungen
(MSR), Messwertanzeigen, Alarmeinrichtungen, Druck-, Temperatur- und
Standschalter, die angemessenes manuelles oder automatisches
Eingreifen ermöglichen. Korrekturmaßnahmen auslösen und/oder
Abfahren und Verriegeln sorgen, um das Druckgerät innerhalb der
Betriebsgrenzwerte zu halten.

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 4 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers

- Sicherheitseinrichtungen
Angemessene Sicherheitseinrichtungen wie Sicherheitsventile,
Berstscheibensicherungen, Knickstabeinrichtungen usw. oder
sicherheitsrelevante MSR-Einrichtungen, die als letzte
Gefahrenabwehrmaßnahme sicherstellen, dass die zulässigen
Betriebsgrenzwerte nicht überschritten werden.

3. Inbetriebnahme
Die Prüfung vor Inbetriebnahme erfolgt durch die zugelassene
Überwachungsstelle.

Die Inbetriebnahme darf erst erfolgen, wenn das Druckgerät

 ordnungsgemäß in eine Anlage montiert und entsprechende
Begrenzungseinrichtungen vorgesehen und eingestellt sind, die
Aufstellungsbedingungen berücksichtigt wurden und
 auf ihren ordnungsgemäßen Zustand hinsichtlich der Montage,
den Aufstellungsbedingungen und der sicheren Funktion geprüft
wurden.
 Nach der Befüllung und der vollständigen Entlüftung des
Druckgerätes sind die eingebauten Regel- und
Sicherheitskomponenten auf ihre Funktionstüchtigkeit zu
überprüfen.
 Ebenfalls ist eine Dichtigkeitsprüfung aller Anschlussteile
vorzunehmen und die Durchflussrichtung der Medien zu
überprüfen.
 Nach der ersten Inbetriebnahme und dem Hochfahren der Anlage
auf Betriebstemperatur sind alle Schrauben und Flanschver-
bindungen in erkaltetem Zustand nachzuziehen

Die Prüfung vor Inbetriebnahme ist nur durch fachkundiges Personal des
Betreibers der Anlage zu veranlassen und in Deutschland in
Übereinstimmung mit § 14 der Betriebssicherheitsverordnung
durchzuführen. In anderen Aufstellungsländern sind die entsprechenden
nationalen Vorschriften für die Prüfung vor Inbetriebnahme zu beachten.
Eine Überschreitung des maximal zulässigen Drucks und/oder maximal
zulässiger Temperatur ist durch geeignete Maßnahmen zu verhindern.
Für die Einhaltung der technischen Daten gemäß Abnahmeprotokoll und
Typenschild muss der Betreiber sorgen. Der Betreiber hat die
Lastwechsel zu dokumentieren, maximal 1’000 Lastwechsel.

4. Benutzung

4.1 Allgemeine Hinweise

Der Betreiber hat das Druckgerät mit seinen Ausrüstungsteilen durch
fachkundiges und unterwiesenes Personal zu betreiben, zu überwachen,
dass Beschäftigte oder Dritte nicht gefährdet werden. Schutzzonen sind
einzuhalten.

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 5 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers

Der Betreiber muss entsprechende Betriebsanweisung erstellen, damit

das Bedien- und Wartungspersonal über den Betrieb des Druckgerätes
bzw. der Anlage die notwendigen Anweisungen erhält.
Entsprechende nationale Bestimmungen des Aufstellungslandes über
den Betrieb des Druckgerätes sind zu beachten.
Das Druckgerät darf ausschließlich innerhalb der im Abnahmeproto-
koll sowie auf dem Behälterschild angegebenen Grenzen betrieben
werden. Druckschwankungsbreite gemäß AD-S1 zulässige
Lastspielzahl gemäß Abschnitt 1.4. Die Auslegung, Fertigung und
Werkstoffbelegung erfolgte nach den technischen Regeln/Normen für
ASME VIII Div.1. Die Fluidverträglichkeit der Werkstoffe muss der
Betreiber sicherstellen. Das Druckgerät darf ausschließlich mit den
bei der Auslegung vorgesehenen Medien betrieben werden.

4.2 Anfahrbetrieb
Das Druckgerät ist so anzufahren, dass sich aus dem Temperaturanstieg
bzw. Druckanstieg keine unzulässigen Spannungserhöhungen ergeben.
Im Anfahrbetrieb ist das Druckgerät ständig zu beobachten und auf
mögliche Leckagen hin zu überprüfen.

4.3. Normalbetrieb
Druckgeräte dürfen nur betrieben werden, wenn die sicherheitstechnisch
erforderlichen Ausrüstungsteile auf Dauer wirksam sind und während des
Betriebes nicht außer Funktion gesetzt werden oder in ihrer
bestimmungsgemäßen Wirkung geändert werden.

4.4. Außerbetriebnahme
Das Druckgerät ist so abzufahren, dass sich aus dem Temperaturabfall
bzw. Druckabfall keine unzulässigen Spannungserhöhungen ergeben.
Bei längeren Betriebspausen und/oder bei Frostgefahr muss die Anlage
entleert werden. Um Stillstandschäden zu vermeiden ist gegebenenfalls
eine Konservierung (z.B. Stickstoffbefüllung) vorzunehmen.

4.5 Unsachgemäße Verwendung

Ergibt sich während des Betriebes des Druckgerätes ein unmittelbarer
Gefahrenzustand z.B. durch einen unvorhergesehenen Reaktionsablauf
oder durch eine gefährliche Einwirkung von außen, so sind die
erforderlichen Gegenmaßnahmen zu ergreifen und ggf. das Druckgerät
außer Betrieb zu nehmen.

Eine besondere Prüfung des Druckgerätes ist erforderlich, wenn bei der
Betriebsstörung der zulässige Druck um mehr als 10 % überschritten
wurde oder die zulässige Betriebstemperatur erheblich überschritten bzw.
unterschritten wurde oder das Druckgerät bzw. seine Ausrüstungsteile
beschädigt worden sind.

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 6 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers

5. Wartung und Instandhaltung

5.1. Allgemeine Angaben
Alle erforderlichen Maßnahmen für Inspektion, Wartung und
Instandsetzung sind in Übereinstimmung mit den nationalen
Bestimmungen des Aufstellungslandes durchzuführen.

5.2 Schließen und Öffnen des Druckgerätes

Druckgeräte müssen so verschlossen werden, dass alle konstruktiv
vorgesehenen Verschlüsse bestimmungsgemäß verwendet werden.
Dichtflächen müssen sauber und unbeschädigt sein.
Verschlussschrauben dürfen nur vorsichtig und gleichmäßig so weit
angezogen werden, wie es zum Abdichten erforderlich ist. Angegebene
Anzugsmomente sind einzuhalten. An unter Druck stehenden
Druckgeräten dürfen Verschlussschrauben nur von hierfür
unterwiesenem Personal unter Beachtung besonderer Vorsichts-
maßnahmen nachgezogen werden.
An dem unter Druck stehenden Druckgerät dürfen die Verschluss-
schrauben nicht gelöst werden.
Verschlüsse und Besichtigungsöffnungen am Druckgerät dürfen erst
geöffnet werden, wenn der Druckausgleich mit der Atmosphäre
hergestellt ist. Der Druckausgleich mit der Atmosphäre ist nach dem
Schließen der Druckzuleitung und durch Entspannen bzw. Belüften unter
Beobachtung des Druckmeßgerätes herzustellen.
Danach sind die Verschlussschrauben derart zu lockern, dass er nicht
mehr auf seinem Sitz haftet. Ist beim Öffnen von Verschlüssen mit einer
Gefährdung durch austretendes Fluid zu rechnen, sind besondere
Schutzmaßnahmen, z.B. persönliche Schutzausrüstung, erforderlich.

5.3 Wartung und Inspektion

Das Druckgerät ist regelmäßig durch fachkundiges Personal so zu warten,
dass sie bei den aufgrund der vorgesehenen Betriebsweise zu
erwartenden mechanischen, chemischen und thermischen
Beanspruchungen auf Dauer dicht bleiben.
Entsprechend den Betriebsbedingungen und Erfahrungen sind vom
Betreiber durch Betriebsanweisungen die notwendigen Maßnahmen
für die Wartung und Inspektion festzusetzen.
Zu den Inspektion- und Wartungsarbeiten gehören insbesondere die
Überwachung und Sicherstellung der
 Dichtheit
 Aufstellungsbedingungen und Schutzzonen
 Kennzeichnung
 ordnungsgemäßen Funktionsweise der Sicherheits- und
Warneinrichtungen
 Wanddicke bei Korrosionsbeanspruchung
 Reinigung der Wärmeübertragungsflächen

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 7 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers

5.3.1 Wiederkehrende Prüfung durch zugelassene Überwachungsstellen

Der Betreiber hat das Druckgerät bei Aufstellung in Deutschland nach
§ 15 der BetrSichV wiederkehrend einer Prüfung auf ihren ordnungs-
gemäßen Zustand überprüfen zu lassen. In anderen Aufstellungsländern
sind andere anwendbare nationale Bestimmungen zu beachten.

5.4 Instandsetzung
Alle schadhaften Verschlusselemente z.B. abgenutzte, rissige und
verbogene Schrauben, ausgebrochene oder sonst beschädigte Muttern,
verbogene Klammern oder Bügel, beschädigte Dichtungen dürfen nicht
mehr verwendet werden und sind durch gleichartige zu ersetzen.

Instandsetzungsarbeiten, die die Sicherheit des Druckgerätes

beeinträchtigen können, wie Maßnahmen, die die Werkstoffeigenschaften
z.B. durch Schweißen, Kalt- und Warmverformungen verändern, dürfen
nur in Übereinstimmung mit den nationalen Bestimmungen des
Aufstellungslandes durchgeführt werden.

ACHTUNG: Bei allen Arbeiten an der elektrischen Steuerung

oder am gesamten Gerät ist die Stromzufuhr zu
unterbrechen.

VORSICHT: Niemals Flanschverbindungen lösen, solange das

Gerät unter Druck steht. Dies gilt auch für die
Entlüftungs- und Entleerungsöffnungen.

Alle Arbeiten sind nur durch anerkanntes

Fachpersonal durchzuführen.

Die Firma IWS-Monjé Ltd. Arnsberg haftet nicht für Fehler die aus einem bestimmungswidrigen
Gebrauch des Produktes resultieren.
Wir behalten uns jederzeit das Recht vor ohne Ankündigung diese Bedienungsanleitung neueren
Erkenntnissen anzupassen.

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_DE ASME.doc Seite 8 von 8

Rev.0/15.02.2006
 IWS-Monjé Ltd.
Heat Exchangers
Tel.: +49 (0)2932 890 188 -0
Fax: +49 (0)2932 890 188 -5
[email protected]
www.iws-monje.com

Installation-
Operation- &
Maintenance Instruction

Pressure-Vessel SDB 245/159 -1R-1W-100T-30P -SS-IW

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 1 of 8

Rev.0/28.03.2007
 IWS-Monjé Ltd.
Heat Exchangers

Contents

1. Transport und Storage

2. Assembly
3.1. Conditions of installation
3.2. Connection of the pressure device
3.3. Equipment of the pressure unit with limitation units

3. Putting into Operation

4. Use
5.1. General indication
5.2. Starting operation
5.3 Regular operation
5.4. Putting out of operation
5.5 Inappropriate use

5. Maintenance and Servicing

6.1 General data
6.2 Closing and opening of pressure device
6.3 Maintenance and inspection
6.3.1 Recurring examination by certified observation places
6.4 Repair

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 2 of 8

Rev.0/28.03.2007
 IWS-Monjé Ltd.
Heat Exchangers

1. Transport and Storage

The transport is only to be carried out by instructed personnel.
The pressure device is only to be transported in pressureless condition.
By suitable stop medium it is to be made sure that through this no
disortions or other interferences of the surfaces/sealing areas are being
caused. The stop of the pressure device at nozzles, flanges etc. is not
permitted. The transport may only be carried out at lying pressure
device at the provided and remarked stop points. Point formed weight of
the shell wall can lead to improper deformings.
Transport and storage is not permitted below the frost border zone of
0°C (danger by possible rest water in container).
All openings like nozzles, flanges etc. are to be locked by suitable
mediums and may only be removed by instructed personnnel (caution:
do not damage sealing areas!).
For damages at the pressure device, caused by improper transport, the
manufacturer does not accept any responsibility!

2. Assembly
2.1 Conditions of Installation
The installation may only be handled by instructed personnel according
to the valid national conditions of law. Pressure devices are to be
installed the way that employed persons or third persons will not be
endangered. Requested security distances are to be obeyed according to
the usable national conditions of law of the country of installation.

The pressure devices are to be installed resp. assembled that way that
they are accessible for necessary viewings and inspections and can be
viewed at all sides,
 the factory sign is visible well
 the operation of the pressure device and its equipment is possible
from a secure position.

The pressure devices are to be based that way that

 by the base itself,
 by the net weight of the pressure device including the loading
goods or the pressure checking medium (at a later pressure check)
and
 by external power no improper movements or inclines may
occur.
 Suitable steps against electrostatic loading are to be provided.

The pressure device has to be protected so far against mechanical effect

from outside, e.g. by vehicles, that damages to the pressure device are
not to be expected. The pressure device and its equipment are to be

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 3 of 8

Rev.0/28.03.2007
 IWS-Monjé Ltd.
Heat Exchangers

protected against attacks by unauthorized persons. In case of a fire

burden which may cause the breakdown of pressure bearing wall pieces,
safety technological relevant equipment pieces or bearing building pieces
(steel supports, standing frames, bearing spaces), corresponding
protecting steps (fire prevention, fire protection or fire controlling) are to
be provided.

2.2 Connecting of the Pressure Device

It is to be payed attention to the installation position of the
pressure device; especially with vaporizing and condensating
mediums a wrong position can lead to damages.
The pressure device is to be connected to the provided nozzles and
connections. Additional introduction of powers, bending moments
or vibrations at connecting nozzles by tube connecting lines are to
be avoided.
Welding technologically manufactured connecting seams at nozzles are
to be produced and examined according to valid or recognized welding
processes.

2.3 Equipment of the Pressure Device with Limitation Fittings

In order to avoid that the permitted operation limits like pressure,
temperature, filling level are being exceeded, the pressure device
has to be equipped with the following limitation fittings:

- Regulating Equipments
Suitable, manually operated or automatically working regulating- and
steering devices for the keeping of the operating parameter like e.g.
measuring-, steering- and regulating equipments (MSR), pressure-,
temperature-, standing position switch in order to hold the operating
conditions during the standardized operation within the permitted
minimal/maximum limits.

- Observation Equipments
Appropriate observation equipment for the observation of operating
parameter like measuring-, steering- and regulating equipments (MSR),
measurement indicators, alarm equipments, pressure-, temperature-
and standing position switches which facilitate an adequate manual or
automatical intervention. Release correcting measures and/or taking
care of depart and bolting in order to hold the pressure device within the
operating limits.

- Security Equipments
Appropriate security equipments like safety valves, burst disc protections,
kink stick equipments etc. or security relevant MSR-equipments which at
least make sure the danger measure, so that the permitted operating

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 4 of 8

Rev.0/28.03.2007
 IWS-Monjé Ltd.
Heat Exchangers

limits are not being exceeded.

3. Start of Operation
The check before putting into operation is being carried out by the
permitted place of observation. The putting into operation may only take
place when the pressure device

 has accordingly been installed into an equipment and according

limitation installations have been provided and adjusted, the
conditions of installation have been considered and
 the according condition regarding the assembly, the conditions of
installation and the secure function have been examinated.
 after the filling and the complete exhaust of the space of
pressure vessel the installed rule- and safety components are to
be examined for their efficiency.
 likewise a leakage test of all connecting units flow direction of the
media is to be made.
 after first start-up and the starting of the equipment up to
operating temperature all screws and flange connections are to
be pulled tight in cooled-off condition.

The examination before start of operation is to be arranged only by expert

personnel of the operator of the equipment and be accomplished in
Germany in accordance with § 14 of the working reliability regulation.

In other countries of installation the appropriate national regulations for

the examination before start of operatioon are to be considered. An
excess of the maximally permitted pressure and/or maximally permitted
temperature is to be prevented by suitable measures. The adherence of
the technical data in accordance with test report and name plate has to be
provided by the operator. The operator has to document the load
changes; maximally 1000 load changes.

4. Use

4.1 General Indication

The operator has to operate the pressure device with its items of
equipment by expert and instructed personnel to supervise that
employed persons or third persons are not endangered. Protected zones
are to be kept.
The operator must provide appropriate operating instruction, so that the
serving and maintenance staff receive the necessary instructions about
the enterprise of the pressure device and/or the equipment.
Appropriate national regulations of the country of installation about the
enterprise of the pressure device are to be considered.
The pressure device may be operated exclusively within the indicated
borders of the test report as well as the container sign.
Pressure fluctuation width according to AD-S1 permitted number of

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 5 of 8

Rev.0/28.03.2007
 IWS-Monjé Ltd.
Heat Exchangers

cycles in accordance with section 1.4. The interpretation,

manufacturing and material allocation took place according to the
technical rules/standards for pressure containers ASME VIII Div.1.
The fluid compatibility of the materials must be guaranteed by the
operator. The pressure device may be operated exclusively with the
media planned during the interpretation.

4.2 Starting operation

The pressure device is to be started in such a way that from the
temperature rise and/or increase of pressure no inadmissiable voltage
increases result. In the starting operation the pressure device is to be
observed constantly and be examined for possible leakages.

4.3. Regular Operation

Pressure devices may only be operated if the safety relevant necessary
items of equipment are effective in the long term and are not out of
function during the operation resp. are being changed in its intended
effect.

4.4. Putting out of Operation

The pressure device is to be driven off in such a way that from the drop
of temperature and/or decrease of pressure no inadmissible voltage
increases result. With longer operation breaks and/or when there is
danger of frost the installation must be emptied. In order to avoid stop
damage a preservation (e.g. nitrogen filling) if necessary is to be
made.

4.5 Inappropriate Use

If a direct danger condition arises from the outside, e.g. from an
unexpected expiration of reaction or as a result of a dangerous effect
during the operation of the pressure device, the neceassary counter
measures are to be made and, if necessary, the pressure device is to be
set out of operation.

A special examination of the pressure device is necessary if during the

operational disturbance the permitted pressure was exceeded by more
than 10% or the permitted operating temperature was substantially
exceeded and/or fallen below or the pressure device and/or its items of
equipment were damaged.

5. Maintenance and Servicing

5.1. General Data
All necessary measures for inspection, maintenance and repair are to be
accomplished in agreement with the national regulations of the country
of installation.

5.2 Closing and Opening of the Pressure Device

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 6 of 8

Rev.0/28.03.2007
 IWS-Monjé Ltd.
Heat Exchangers

Pressure devices must be locked in such a way that all

constructionally planned locking devices are being used. Sealing
surfaces must be clean and intact.
Plugs may only be tightened carefully and evenly that way as it is
necessary for sealing. Indicated locked rotor torques are to be kept.
At pressure devices standing under pressure locking plugs may be
pulled tight only by instructed personnel considering special
precautionary measures.
At the pressure device which is at pressure, the locking plugs may not
be loosened.
Catches and inspection openings at the pressure device may only be
opened if the pressure balance with the atmosphere is manufactured.
The pressure balance with the atmosphere is to be manufactured after
closing the pressure inlet and be easing and/or ventilating under
observation of the gauge. Afterwards the plugs are to be loosened in
such a manner that it does not any more adheres on its seat.
If it is to be counted that when opening of lockings cause endangerment
by withdrawing fluid, special preventive measures, e.g. personal
protection equipment, are necessary.

5.3 Maintenance and Inspection

The pressure device is to be waited regularly by expert personnel in such
a way that it remains tight with due to the intended mode of operation to
expected mechanical, chemical and thermal stresses in the long term.
According to the operating conditions and experiences the necessary
measures are to be determined for maintenance and inspection by
the operator by operating instructions.
The observation and securing of the
 tightness
 installation conditions and protected zones
 marking
 correct function mode of the security and warning devices
 wall thickness during subjection to corrosion
 cleaning of the heat transfer surfaces

5.3.1 Recurring Examination by Certified Observation Places

The operator has to initiate the recurring examination of the pressure
device according to § 15 BetrSichV in order to proof ist correct condition.
In other countries of installation other applicable national regulations are
to be considered.

5.4 Repair
All defective locking elements e.g. worn out, cracked and bent screws,
broken out or otherwise damaged screw nuts, bent clips or handles,
damaged seals may not be used any more and have to be replaced by

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 7 of 8

Rev.0/28.03.2007
 IWS-Monjé Ltd.
Heat Exchangers

homogeneous ones.

Repairs which can impair the security of the pressure device like
measures which change the material properties e.g. by welding, cold- and
hot-formings, may be accomplished only in agreement with the national
regulations of the country of installation.

NOTE: With all works on the electrical control or on the

entire equipment the current supply is to be
interrupted.

CAUTION: Never loosen flange connections as long as the

equipment is at pressure. This applies also to the
exhaust and openings.

All works are to be accomplished only by

recognized technical personnel.

The company IWS Monj’e Ltd. Arnsberg is not responsible for errors, caused by use against the rules
of the product results.
We keep ourselves the right to adapt this operating instructions to newer findings without
announcement at any time.

C:\Users\Steffen\Desktop\Temp-Dokus\Burgmann\431\Manual DG-SDB_EN ASME.doc page 8 of 8

Rev.0/28.03.2007