Vertical Shaft Submersible Pump for the Chemical Industry CTN / CTN-H. Installation/Operating Manual

Transcription

1 Vertical Shaft Submersible Pump for the Chemical Industry CTN / CTN-H Installation/Operating Manual

2 Legal information/copyright Installation/Operating Manual CTN / CTN-H 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 Service GmbH, Frankenthal

3 Contents Contents Glossary General Principles Installation of partly completed machinery Target group Other applicable documents Symbols Safety Key to safety symbols/markings General Intended use Personnel qualification and training Consequences and risks caused by non-compliance with this manual Safety awareness Safety information for the operator/user Safety information for maintenance, inspection and installation work Unauthorised modes of operation Explosion protection Transport/Temporary Storage/Disposal Checking the condition upon delivery Transport Storage/preservation Return to supplier Disposal Description of the Pump (Set) General description Designation Name plate Design details Configuration and function Noise characteristics Scope of supply Dimensions and weights Installation at Site Safety regulations Checks to be carried out prior to installation Installing the pump set Piping CTN / CTN-H 3 of 70

4 Contents 5.5 Enclosure/insulation Aligning the pump and motor Electrical connection Checking the direction of rotation Commissioning/Start-up/Shutdown Commissioning/start-up Operating limits Shutdown/storage/preservation Returning to service Servicing/Maintenance Safety regulations Servicing/inspection Drainage/cleaning Dismantling the pump set Reassembling the pump set Tightening torques Spare parts stock Trouble-shooting Related Documents General assembly drawing with list of components EC Declaration of Conformity Certificate of Decontamination...68 Index of 70 CTN / CTN-H

5 Glossary Glossary Certificate of decontamination A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled. Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Pump Pump set Machine without drive, additional components or accessories Complete pump set consisting of pump, drive, additional components and accessories Pool of pumps Pumps which are purchased and stored independently of their later use CTN / CTN-H 5 of 70

6 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. In the event of damage, immediately contact your nearest KSB service centre to maintain the right to claim under warranty. Noise characteristics ( Section 4.6 Page 18) 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 9) 1.4 Other applicable documents Table 1: Overview of other applicable documents Document Contents Data sheet Description of the technical data of the pump (set) General arrangement drawing/ outline drawing Description of mating and installation dimensions for the pump (set), weights Drawing of auxiliary connections Description of auxiliary connections Hydraulic characteristic curve Characteristic curves showing head, NPSH required, efficiency and power input General assembly drawing 1) Sectional drawing of the pump Sub-supplier product literature 1) Operating manuals and other product literature describing accessories and integrated machinery components Spare parts lists 1) Description of spare parts Piping layout 1) Description of auxiliary piping List of components 1) Description of all pump components Drawing for assembly 1) Sectional drawing of the installed shaft seal For accessories and/or integrated machinery components observe the relevant manufacturer's product literature. 1.5 Symbols Table 2: 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) If agreed upon in scope of supply 6 of 70 CTN / CTN-H

7 1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product CTN / CTN-H 7 of 70

8 2 Safety! DANGER 2 Safety All the information contained in this section refers to hazardous situations. 2.1 Key to safety symbols/markings Table 3: 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. ( Section 1.4 Page 6) 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. 8 of 70 CTN / CTN-H

9 2 Safety 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 Never open the discharge-side control valve further than permitted. The maximum flow rates specified in the product literature or data sheet would be exceeded. Risk of cavitation damage. Never exceed the permissible operating limits specified in the data sheet or product literature regarding pressure, temperature, rotational speed, flow rate, head, NPSH value etc. Observe all safety information and instructions in this manual. 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 this manual Non-compliance with this operating manual will lead to forfeiture of warranty cover and of any and all rights to claims for damages. Non-compliance can, for example, have the following consequences: Hazards to persons due to electrical, thermal, mechanical and chemical effects and explosions Failure of important product functions Failure of prescribed maintenance and servicing practices Hazard to the environment due to leakage of hazardous substances 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, directives and laws CTN / CTN-H 9 of 70

10 2 Safety 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.) If shutting down the pump does not increase potential risk, fit an emergencystop control device in the immediate vicinity of the pump (set) during pump set installation. 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. 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. ( Section Page 31) ( Section 6.3 Page 34) Decontaminate pumps which handle fluids posing a health hazard. ( Section 7.3 Page 39) As soon as the work has been completed, re-install and/or re-activate any safetyrelevant 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.! DANGER 2.10 Explosion protection Always observe the information on explosion protection given in this section when operating the pump in potentially explosive atmospheres. Only pumps/pump sets marked as explosion-proof and identified as such in the data sheet may be used in potentially explosive atmospheres. Special conditions apply to the operation of explosion-proof pump sets to EC Directive 94/9/EC (ATEX). Especially adhere to the sections in this manual marked with the Ex symbol and the following sections ( Section Page 11) to ( Section Page 12). 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. 10 of 70 CTN / CTN-H

11 2 Safety Pump Shaft coupling Motor Marking 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. ( Section Page 11) An EC manufacturer's declaration is required for the shaft coupling; the shaft coupling must be marked accordingly. The motor must be considered separately Temperature limits In normal pump operation, the highest temperatures are to be expected at the surface of the pump casing, the pipe assembly, the flanged bend, the shaft seal and in the bearing areas. The surface temperature at the pump casing, the pipe assembly and the flanged bend 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 potential temperature rise in the shaft seal area has been taken into account). The temperature class specifies the maximum permissible temperature at the surface of the pump set during operation. For the permissible operating temperature of the pump in question refer to the data sheet. Table 4: Temperature limits Temperature class T5 Temperature class T6 Temperature class to EN Maximum permissible fluid temperature T1 Maximum 400 C 2) T2 280 C T3 185 C T4 120 C T5 85 C T6 Only after consultation with the manufacturer Based on an ambient temperature of 40 C and proper maintenance and operation, compliance with temperature class T5 is warranted in the area of the rolling element bearings. If the ambient temperature exceeds 40 C, contact the manufacturer. A special design is required to comply with the requirements of temperature class 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, if there is no data sheet or if the pump is part of a "pool of pumps", contact KSB for the maximum permissible operating temperature 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) Depending on the material variant CTN / CTN-H 11 of 70

12 2 Safety Operating limits The minimum flows indicated in ( Section Page 33) refer to water and waterlike 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 are different from water, it is essential to check whether an additional heat build-up may occur and if the minimum flow rate must therefore be increased. The calculation formula in ( Section Page 33) can be used to check whether additional heat build-up may lead to a dangerous temperature increase at the pump surface. 12 of 70 CTN / CTN-H

13 3 Transport/Temporary Storage/Disposal 3 Transport/Temporary Storage/Disposal 3.1 Checking the condition upon delivery 1. On transfer of goods, check each packaging unit for damage. 2. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) and the insurer about the damage in writing immediately. 3.2 Transport DANGER The pump (set) could slip out of the suspension arrangement Danger to life from falling parts! Pay attention to the weight data and the centre of gravity. Observe the applicable local accident prevention regulations. Use suitable, permitted lifting accessories. CAUTION Improper pump transport Damage to the pump! When transporting and lifting the pump in horizontal position, make sure that the pipe assembly is supported evenly at the bearings. NOTE The pipes of the pipe assembly must be positioned one above the other. Avoid bending stress or sagging. Vertical pumps with an overall length of up to approx. four metres are supplied fully assembled. Pumps with a greater overall length are supplied in sub-assemblies and must be assembled on site by a KSB service engineer. To transport the pump/pump set suspend it from the lifting tackle as shown. Fig. 1: Pump set with supported bearing locations 3.3 Storage/preservation If commissioning is to take place some time after delivery, we recommend that the following measures be taken for pump (set) 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. CTN / CTN-H 13 of 70

14 3 Transport/Temporary Storage/Disposal 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. Store the pump (set) in a dry, protected room where the atmospheric humidity is as constant as possible. Rotate the shaft by hand once a month, e.g. via the motor fan. If properly stored indoors, the pump set is protected for a maximum of 12 months. New pumps/pump sets are supplied by our factory duly prepared for storage. For storing a pump (set) which has already been operated, the shutdown measures must be adhered to. ( Section Page 34) 3.4 Return to supplier 1. Drain the pump as per operating instructions. ( Section 7.3 Page 39) 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 68) NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: Disposal WARNING Fluids, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! Collect and properly dispose of flushing fluid and any 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. 14 of 70 CTN / CTN-H

15 4 Description of the Pump (Set) 4 Description of the Pump (Set) CTN CTN-H 4.1 General description Vertical shaft submersible pump for the chemical industry Vertical pump for handling chemically aggressive fluids with a low solids content. Vertical pump for handling fluids which must not be allowed to cool down during processing. 4.2 Designation Example: CTN - C H / 2 Table 5: Key to the designation Code Description CTN Type series C Material of wetted components For materials, see data sheet H Additional code, e.g. H = heatable version 40 Nominal discharge nozzle diameter [mm] 250 Nominal impeller diameter [mm] 2 Identification of 2-stage pumps 4.3 Name plate Aktiengesellschaft D Frankenthal CTN-C H / / 01 Q 12 m 3 /h H 32 m n /min Id-No ZN A 52 x 74R Fig. 2: CTN/CTN-H name plate (example) 1 Type series, size and version 2 KSB order number (ten digits) ( Section 4.2 Page 15) 3 Flow rate 4 Speed 5 Order item number (six digits) 6 Consecutive number (two digits) 7 Head 8 Year of construction CTN-H 4.4 Design details Design Radially split vertical shaft submersible pump Vertical installation Wet or dry installation One or two stages Heatable Pump casing Volute casing (with casing wear ring, if applicable) and casing cover CTN / CTN-H 15 of 70

16 4 Description of the Pump (Set) Impeller type Closed radial impeller with multiply curved vanes Sealing clearance on both sides and balancing holes balance axial thrust Gland packing Shaft seal Gland packing Commercial single and double mechanical seals Commercial cartridge seals Table 6: Seal chamber with different shaft seals (examples) Mechanical seal Basic design Cooled Single Double Design specifications Bearings used Bearings Paired angular contact ball bearings for axial fixing of the shaft assembly Product-lubricated carbon plain bearing Grease lubrication Optional: oil lubrication Table 7: Thrust bearing design KSB designation FAG designation SKF designation B.G B.TVP.UA BECBP Table 8: Standard bearings: grease-lubricated thrust bearings (rolling element bearing) Sizes Bearing size 25/40/50 2 x 7206 B.G 80/100 2 x 7309 B.G 125/150 2 x 7309 B.G 200/250 2 x 7313 B.G Table 9: Optional: oil-lubricated thrust bearings (rolling element bearing) Sizes Bearing size 25/40/50 1 x 6312 DIN /100 2 x 7312 BUA DIN /150 2 x 7315 BUA DIN /250 2 x 7318 BUA DIN 628 Refer to the data sheet for the relevant bearing bracket design. 16 of 70 CTN / CTN-H

17 4 Description of the Pump (Set) 4.5 Configuration and function Fig. 3: Sectional drawing Design Function Sealing Shaft seal Clearance gap Thrust bearing (rolling element bearing) Sole plate Shaft assembly Impeller Plain bearing Suction nozzle Flanged bend Pipe assembly Volute casing Suction cover Vertical submersible pump with one or two stages. Shaft seal is not in contact with the fluid handled; pump is not self-priming. The fluid enters the pump vertically via the suction nozzle (4) and is accelerated outward by the rotating impeller (11). In the flow passage of the volute casing (10) the kinetic energy of the fluid is converted into pressure energy. The fluid is pumped through the pipe assembly (8) to the flanged bend (6), where it leaves the pump. The clearance gap (3) prevents any fluid from flowing back from the casing to the suction cover (12). At the rear side of the impeller, the shaft assembly (9) enters the volute casing (10) which provides the boundary for the hydraulic system. The shaft passage through the sole plate (7) is sealed to atmosphere with a shaft seal (1). Depending on the installation depth, the shaft assembly (9) can either consist of a single shaft or several shaft sections. Above the sole plate, the shaft assembly is supported radially and axially by thrust bearings (rolling element bearings) (5); below the sole plate, it is only supported radially by plain bearings (2). The pump is sealed with a shaft seal (either a standardised single or double mechanical seal or a gland packing). CTN / CTN-H 17 of 70

18 4 Description of the Pump (Set) 4.6 Noise characteristics Table 10: Surface sound pressure level L pa 3)4) Rated power input P N [kw] 2900 rpm [db] Pump 1450 rpm [db] 960 rpm 760 rpm 2900 rpm [db] Pump set 1450 rpm [db] 960 rpm 760 rpm [db] [db] , Drive Shaft coupling Sole plate Special accessories 4.7 Scope of supply Depending on the model, the following items are included in the scope of supply: Pump Surface-cooled IEC frame three-phase squirrel-cage motor Flexible coupling Cast or plate material, flange dimensions to EN 1092 or ASME B 16.3 As required 4.8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump/pump set. 3) Spatial average; as per ISO 3744 and EN Valid for pump operation in the Q/Qopt = range and for noncavitating operation. If noise levels are to be guaranteed: Add +3 db for measuring and constructional tolerance. 4) Increase for 60 Hz operation: 3500 rpm+3 db; 1750 rpm +1 db; 1160 rpm:±0 db 18 of 70 CTN / CTN-H

19 5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set! Comply with the applicable local explosion protection regulations. Observe the information in the data sheet and on the name plates of pump and motor. 5.2 Checks to be carried out prior to installation 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. 5.3 Installing the pump set The foundation for the pump is a dome with horizontal flange and corresponding flange connection. Check the flange with a spirit level and adjust if required. Permitted deviation 0.2 mm/m. Mounting the drive After mounting and bolting, the drive is centred in the flange of the drive lantern. Checking the coupling After mounting the drive on the pump, check the clearance between the two coupling halves on the basis of the general arrangement drawing. If the clearance is too large, reduce the distance between the coupling halves. Check the radial alignment. 1 Fig. 4: Checking the coupling alignment 1 Wedge gauge CTN / CTN-H 19 of 70

20 5 Installation at Site 5.4 Piping 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. Anchor the pipelines in close proximity to the pump and connect them without transmitting any stresses or strains. Observe the permissible forces and moments at the pump nozzles. ( Section Page 21) Take appropriate measures to compensate for thermal expansion of the piping. CAUTION Incorrect earthing during welding work at the piping Destruction of rolling element bearings (pitting effect)! NOTE Never earth the electric welding equipment on the pump or baseplate. Prevent current flowing through the rolling element bearings. 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. The nominal diameters of the pipelines are equal to or greater than the nominal diameters of the pump nozzles. Adapters to larger nominal diameters are designed with a diffuser angle of approx. 8 to avoid excessive pressure losses. The pipelines have been anchored in close proximity to the pump and connected without transmitting any stresses or strains. CAUTION Weld beads, scale and other impurities in the piping/tank Damage to the pump! Free the piping from any impurities. If necessary, install a filter. Observe the instructions in ( Section Page 37). 1. Thoroughly clean, flush and blow through all vessels, pipelines and connections (especially of new installations). 2. Remove the flange covers on the suction nozzles and flanged bends of the pump before installing the pump in the piping. 3. Check that the inside of the pump is free from any foreign objects. Remove any foreign objects. 4. Connect the pump nozzles to 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. 20 of 70 CTN / CTN-H

21 5 Installation at Site Permissible forces and moments at the pump nozzles The resulting permissible forces have been determined according to: D00203 Forces and moments acting on the flanged bend The data on forces and moments apply to static pipelines only. If the limits are exceeded, they must be checked and verified. If a computerised strength analysis is required, please contact KSB. Table 11: Permissible forces and moments acting on the flanged bend Size Materials Forces (in N) Moments (in Nm) F x F y F z F res M x M y M z 25 JL GP240GH+N For temperatures of more than 120 C, the values specified must be reduced in line with the drop in yield strength of the relevant material (see diagram below). Correction coefficients depending on material and temperature (see diagram below). CTN / CTN-H 21 of 70

22 5 Installation at Site Fig. 5: Temperature correction coefficients Auxiliary connections DANGER Risk of potentially explosive atmosphere by mixing of incompatible fluids in the auxiliary piping Risk of burns! Explosion hazard! Make sure that the barrier fluid and quench liquid are compatible with the fluid pumped. WARNING Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing fluid, etc.) Risk of injuries by escaping fluid! Risk of burns! Malfunction of the pump! Refer to the general arrangement drawing, the piping layout and pump markings (if any) for the number, dimensions and locations of auxiliary connections. Use the auxiliary connections provided. 5.5 Enclosure/insulation DANGER Risk of potentially explosive atmosphere due to insufficient venting Explosion hazard! Ensure adequate venting of the space in the bearing bracket lantern/drive lantern. Never close or cover the perforations of the contact guard on the drive lantern (e.g. with insulation). WARNING The volute casing, pipe assembly, flanged bend and areas of the sole plate take on the temperature of the fluid handled Risk of burns! Insulate the sole plate and flanged bend. Fit protective equipment. 22 of 70 CTN / CTN-H

23 5 Installation at Site CAUTION Heat build-up in the bearing bracket Damage to the bearing! The bearing bracket lantern and drive lantern must not be insulated. 5.6 Aligning the pump and motor WARNING Unprotected rotating coupling Risk of injury by rotating shafts! Always operate the pump set with a contact guard (coupling guard). 5.7 Electrical connection DANGER Incorrect electrical installation Explosion hazard! For electrical installation, also observe the requirements of IEC Always use a motor protection switch for explosion-proof motors. DANGER Electrical connection work by unqualified personnel Danger of death from electric shock! Always have the electrical connections installed by a trained and qualified electrician. Observe regulations IEC and, for explosion-proof models, EN 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 Setting the time relay CAUTION Switchover between star and delta on three-phase motors with star-delta starting takes too long. Damage to the pump (set)! Keep switch-over intervals between star and delta as short as possible. CTN / CTN-H 23 of 70

24 5 Installation at Site Table 12: Time relay settings for star-delta starting: Motor rating Y time to be set 30 kw < 3 s > 30 kw < 5 s Connecting the motor NOTE In compliance with IEC , 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. 5.8 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. Decouple the motor to check the direction of rotation. WARNING Hands inside the pump casing Risk of injuries, damage to the pump! Always disconnect the pump set from the power supply and secure it against unintentional start-up before inserting your hands or other objects into the pump. CAUTION Incorrect direction of rotation with non-reversible mechanical seal Damage to the mechanical seal and leakage! Separate the pump from the motor to check the direction of rotation. CAUTION Drive and pump running in the wrong direction of rotation Damage to the pump! Refer to the arrow indicating the direction of rotation on the pump. Check the direction of rotation. If required, check the electrical connection and correct the direction of rotation. The correct direction of rotation of motor and pump is clockwise (seen from the drive end). 1. Start the motor and stop it again immediately to determine the motor's direction of rotation. 2. Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. 3. If the motor is running in the wrong direction of rotation, check the electrical connection of the motor and switchgear, if any. 24 of 70 CTN / CTN-H

25 6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/start-up Prerequisites for commissioning/start-up Before commissioning/starting up the pump set, make sure that the following conditions are met: The pump set has been mechanically connected as specified. The pump set has been properly connected to the electric power supply and is equipped with all protection devices. The pump (volute casing) has been primed with the fluid to be handled and has been vented. The minimum fluid level as per general arrangement drawing is observed. ( Section Page 27) The direction of rotation has been checked. All auxiliary connections required are connected and operational. The lubricants have been checked. After prolonged shutdown of the pump (set), the activities required for returning the pump (set) to service have been carried out. ( Section 6.4 Page 34) The pump (volute casing) has been primed with the fluid to be handled and has been vented. The minimum fluid level as per general arrangement drawing is observed Filling in lubricants NOTE The rolling element bearings are usually lubricated with grease. Any deviation (e.g. oil lubrication) is indicated in the general arrangement drawing. Grease-lubricated bearings Oil-lubricated bearings Grease-lubricated bearings have been packed with grease. Fill the bearing bracket with lubricating oil. Oil quality see ( Section Page 39) Oil quantity see ( Section Page 39) The constant level oiler is screwed into the upper tapping hole of the bearing bracket. CAUTION Insufficient quantity of lubricating oil in the reservoir of the constant level oiler Damage to the bearings! Regularly check the oil level. Always fill the oil reservoir completely. Keep the oil reservoir properly filled at all times. CTN / CTN-H 25 of 70

26 6 Commissioning/Start-up/Shutdown 1 Fig. 6: Constant level oiler 2 1 Constant level oiler 2 Connection elbow of the constant level oiler 1. Hinge down the reservoir of the constant level oiler (1). 2. Fill oil through the open connection elbow. 3. Completely fill the reservoir of the constant level oiler (1). 4. Snap the constant level oiler (1) back into its operating position. 5. After approximately 5 minutes, check the oil level in the glass reservoir of the constant level oiler (1). The oil reservoir must be properly filled at all times to provide a constant oil level. Repeat steps 1-4, if necessary. 6. To check the function of the constant level oiler (1), slowly drain oil via the screw plug until air bubbles develop in the reservoir. NOTE An excessively high oil level can lead to a temperature rise and to leakage of the fluid handled or oil. Reservoir of nonpressurised external fluid Double mechanical seal External liquid feed Shaft seal Shaft seals are fitted prior to delivery. Observe the instructions on dismantling ( Section Page 42) or assembly ( Section Page 48). If applicable, fill the reservoir of non-pressurised external fluid in accordance with the general arrangement drawing. Prior to starting up the pump, apply barrier pressure as specified in the general arrangement drawing. Apply the quantities and pressures specified in the data sheet and the general arrangement drawing. 26 of 70 CTN / CTN-H

27 6 Commissioning/Start-up/Shutdown Priming and venting the pump DANGER Formation of a potentially explosive atmosphere inside the pump Explosion hazard! Damage to the pump! Make sure that the fluid level does not fall below the minimum level when starting the pump. The pump's interior (volute casing) in contact with the fluid handled and the auxiliary systems must be filled with the fluid handled at all times. Provide sufficient inlet pressure. Provide an appropriate monitoring system. DANGER Plain bearing failure caused by insufficient lubrication Explosion hazard! Damage to the pump! Make sure that the fluid level does not fall below the minimum level. DANGER Shaft seal failure caused by insufficient lubrication Leakage of hot or toxic fluid handled/vapours! Damage to the pump! Health hazard! Monitor the barrier fluid pressure of the mechanical seal. Tighten the gland packing gently and evenly. Monitor the barrier fluid/flushing fluid. Wet installation Dry installation 1. Make sure that the fluid level does not fall below the minimum level. The volute casing must be fully submerged. 2. Fully open all auxiliary connections (barrier fluid, flushing fluid, etc.). 1. The pump casing and suction line must be filled with the fluid handled. 2. Fully open the shut-off element in the suction line. 3. Fully open all auxiliary connections (barrier fluid, flushing fluid, etc.) Final check 1. Remove the contact guard. 2. Check the coupling alignment; re-align the coupling if required. ( Section 5.3 Page 19) 3. Check that the coupling and shaft can easily be rotated by hand. 4. Re-mount the contact guard. 5. Check the distance between coupling and contact guard. The coupling and contact guard must not come into contact Water cooling CAUTION Deposit-forming, aggressive cooling water Damage to the pump! Observe the cooling water quality. CTN / CTN-H 27 of 70

28 6 Commissioning/Start-up/Shutdown Observe the following quality data of the cooling water: Not deposit-forming Not aggressive Free from suspended solids Hardness on average 5 dh (~1 mmol/l) ph > 8 Conditioned and neutral with regard to mechanical corrosion Inlet temperature t E =10 to 30 C Outlet temperature t A = 45 C max Cooling/heating the shaft seal The shaft seal chamber, if any, can be cooled. To dissipate the generated heat, a fan impeller can be fitted by KSB above the shaft seal. If necessary, the shaft seal chamber can also be heated. WARNING Rotating fan impeller Risk of injury! Only remove the cover plate when the pump has been stopped. DANGER Excessive surface temperature Explosion hazard! Risk of burns! Observe the permissible temperature classes. ( Section Page 11) Table 13: Permissible pressure and temperature limits for the shaft seal chamber Sizes Cooling liquid Inlet temperature Quantity Max. pressure Heating (saturated vapour) Max. pressure Max. temperature [l/min] [bar] [ C] [bar] [ C] 25/40/ Approx. 20 7, / / /250 5 Pipe assemblies Heating CTN-H If pumping fluids which can only be pumped in warm or hot condition, the pipe assemblies must be heated. DANGER Excessive surface temperature Explosion hazard! Risk of burns! Observe the permissible temperature classes. ( Section Page 11) 28 of 70 CTN / CTN-H

29 6 Commissioning/Start-up/Shutdown CAUTION Lack of heating medium Damage to the pump! Provide sufficient quantities of a suitable heating medium. CAUTION Time for warming up the pump too short Damage to the pump! Check that the pump is sufficiently warmed up throughout. CAUTION Impermissibly high temperature of the heating medium Fluid or heating medium could escape! Observe the application limits of the heating media. Table 14: Permissible pressure and temperature limits when using saturated vapour Sizes Heating with saturated vapour, pipe assemblies made of: St Pressure Temperature Pressure Temperature [bar] [ C] [bar] [ C] 25/40/ / / /250 Table 15: Permissible pressure and temperature limits when using superheated vapour Flanged bend Sizes Heating with superheated vapour, pipe assemblies made of: St Pressure Temperature Pressure Temperature [bar] [ C] [bar] [ C] 25/40/ / / / The flanged bend can also be heated as part of a special design Heating up/keeping warm the pump (set) CAUTION Pump blockage Damage to the pump! Prior to pump start-up, heat up the pump as described in the manual. Fluid temperatures above 150 C Temperature difference Observe the following when heating up the pump (set) and keeping it warm: Make sure that the temperature is increased continuously. Max. heating speed: 10 C/min (10 K/min) When the pump is used for handling fluids at temperatures above 150 C make sure that the pump has been heated throughout before starting it up. The temperature difference between the pump's surface and the fluid handled must not exceed 100 C (100 K) when the pump is started up. CTN / CTN-H 29 of 70

30 6 Commissioning/Start-up/Shutdown Start-up 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. DANGER Excessive temperatures due to insufficient lubrication 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/tank as specified. Always operate the pump within the permissible operating range. 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. The system piping has been cleaned. In a dry installation configuration, the pump and suction line have been vented and primed with the fluid to be handled. CAUTION Start-up against open discharge line Motor overload! Make sure the motor has sufficient power reserves. Use a soft starter. Use speed control. 1. In a dry installation configuration, fully open the shut-off element in the inlet/ suction line. 2. Close or slightly open the shut-off element in the discharge line. 3. Start up the motor. 4. Immediately after the pump has reached full rotational speed, slowly open the shut-off element in the discharge line and adjust it to the duty point. DANGER Seal leakages at operating temperature Hot or toxic fluid could escape! For dry installation only: Once the operating temperature has been reached and/or in the event of leakage, switch off the pump set and re-tighten the bolts between pipe assembly/suction cover/volute casing. Check the coupling alignment. Re-align the coupling if required. 30 of 70 CTN / CTN-H

31 6 Commissioning/Start-up/Shutdown 5. For dry installation only: Once the operating temperature has been reached and/or in the event of leakage, switch off the pump set and re-tighten the bolts between pipe assembly/suction cover/volute casing. 6. Check the coupling alignment. Re-align the coupling if required. ( Section 5.3 Page 19) Mechanical seal Gland packing Checking the shaft seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation. Mechanical seals are maintenance-free. The gland packing must drip slightly (on models with barrier/flushing fluid supply). (Approximately 20 drops per minute) DANGER The temperatures at the gland packing have risen above the permissible limits Explosion hazard! Always use suitable temperature monitoring for gland packings. Gland packings must only be tightened slightly Shutdown The shut-off element in the suction line is and remains open. On pump sets with double mechanical seal, apply the required pressure specified in the general arrangement drawing to the mechanical seal chamber also during standstill. Also ensure quench liquid supply is ON during pump standstill. 1. Close the shut-off element in the discharge line. 2. Switch off the motor and make sure the pump set runs down smoothly to a standstill. NOTE If the discharge line is equipped with a check valve, the shut-off element in the discharge line may remain open, provided the site's requirements and regulations are taken into account and observed. NOTE If shut-off is not possible, the pump will run in reverse direction. The reverse runaway speed must be lower than the rated speed. For prolonged shutdown periods: 1. Close the shut-off element in the suction line. 2. Close the auxiliary connections. If the fluid to be handled is fed in under vacuum, also supply the shaft seal with barrier fluid during standstill. Only turn off the cooling liquid supply after the pump has cooled down. CAUTION Risk of freezing during prolonged pump shutdown periods Damage to the pump! Drain the pump and the cooling/heating chambers (if any) or otherwise protect them against freezing. CTN / CTN-H 31 of 70

32 6 Commissioning/Start-up/Shutdown 6.2 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 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 16: Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 C Minimum See data sheet 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. 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 steadystate operation and on the starting conditions (DOL, star-delta, moments of inertia, etc). If the start-ups are evenly spaced over the period indicated, the following limits serve as orientation for start-up with the discharge-side gate valve slightly open: Table 17: Frequency of starts CAUTION Motor rating Maximum number of start-ups [kw] [start-ups/hour] > 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. 32 of 70 CTN / CTN-H

33 6 Commissioning/Start-up/Shutdown Fluid handled Flow rate Unless specified otherwise in the characteristic curves or in the data sheets, the following applies: Short-time operation: Q min 5) = 0.1 Q opt 6) Continuous operation: Q min 5) = 0.3 Q opt 6) 2-pole operation: Q max 7) = 1.1 Q opt 6) 4-pole operation: Q max 7) = 1.25 Q opt 6) 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 on the pump surface. However, if the physical properties of the fluids handled differ from those of water, the calculation formula below must be used to check if an additional heat build-up may lead to a dangerous temperature increase at the pump surface. If necessary, the minimum flow must be increased. Table 18: Key Symbol Description Unit c Specific heat capacity J/kg K g Gravitational constant m/s² H Pump discharge head m T f Fluid temperature C T O Temperature at the casing surface C Pump efficiency at duty point - Temperature difference K Density of the fluid handled The pump input power changes in proportion to the density of the fluid handled. CAUTION Impermissibly high temperature of fluid handled. Motor overload! Observe the information on fluid density in the data sheet. Make sure the motor has sufficient power reserves 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, plain bearing and shaft seal are to be expected. In this case, reduce the intervals commonly recommended for servicing and maintenance. 5) Minimum permissible flow rate 6) Flow rate at best efficiency point 7) Maximum permissible flow rate CTN / CTN-H 33 of 70

34 6 Commissioning/Start-up/Shutdown 6.3 Shutdown/storage/preservation Measures to be taken for shutdown The pump (set) remains installed Sufficient fluid is supplied for the operation check run of the pump. 1. Start up the pump (set) regularly between once a month and once every three months for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pump intake area. The pump (set) is removed from the pipe and stored The pump has been properly drained and the safety instructions for dismantling the pump have been observed. ( Section Page 40) 1. Spray-coat the inside wall of the pump casing, and in particular the impeller clearance areas, with a preservative. 2. Spray the preservative through the suction nozzle and flanged bend. It is advisable to then close the pump nozzles (e.g. with plastic caps or similar). 3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil and grease, food-approved if required) to protect them against corrosion. Observe the additional instructions. ( Section 3.3 Page 13) If the pump set is to be stored temporarily, only preserve the wetted components made of low alloy materials. Commercially available preservatives can be used for this purpose. Observe the manufacturer's instructions for application/removal. Observe any additional instructions and information provided. ( Section 3 Page 13) 6.4 Returning to service For returning the pump to service observe the sections on commissioning/start-up and the operating limits. In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. ( Section 7 Page 35) WARNING Failure to re-install or re-activate protective devices Risk of personal injury from moving parts or escaping fluid! As soon as the work is complete, re-install and/or re-activate any safety-relevant and protective devices. NOTE If the pump has been out of service for more than one year, replace all elastomer seals. 34 of 70 CTN / CTN-H

35 7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations DANGER Sparks produced during servicing work Explosion hazard! Observe the safety regulations in force at the place of installation! Always perform maintenance work at an explosion-proof pump (set) outside of potentially explosive atmospheres. DANGER Improperly serviced pump set Explosion hazard! Damage to the pump set! Service the pump set regularly. 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, consumables and supplies which are hot and/or pose a health hazard Risk of injury! Observe all relevant laws. When draining the fluid take appropriate measures to protect persons and the environment. Decontaminate pumps which handle fluids posing a health hazard. WARNING Insufficient stability Risk of crushing hands and feet! During assembly/dismantling, secure the pump (set)/pump parts to prevent tipping or falling over. A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pump, pump set and pump parts with a minimum of servicing/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 " Never use force when dismantling and reassembling the pump set. CTN / CTN-H 35 of 70

36 7 Servicing/Maintenance 7.2 Servicing/inspection Supervision of operation DANGER Excessive temperatures as a result of thrust bearings (rolling element 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. While the pump is in operation, observe and check the following: The pump must run quietly and free from vibrations at all times. When lubricating with oil ensure the oil level is correct. ( Section Page 25) Check the shaft seal. Check the static seals for any leakage. 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. Cooling system Take the pump out of service at least once a year to thoroughly clean the cooling system. 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. The bearing temperature must not exceed 90 C (measured at the bearing). CAUTION Operation outside the permissible bearing temperature Damage to the pump! The bearing temperature of the pump (set) must never exceed 90 C (measured at the bearing). 36 of 70 CTN / CTN-H

37 7 Servicing/Maintenance NOTE After commissioning, increased temperatures may occur at grease-lubricated rolling element bearings due to the running-in process. The final bearing temperature is only reached after a certain period of operation (up to 48 hours depending on the conditions) Inspection work DANGER Excessive temperatures caused by friction, impact or frictional sparks Explosion hazard! Fire hazard! Damage to the pump set! Regularly check the contact guard, synthetic material parts and other guards of rotating parts for deformation and sufficient distance from the rotating parts Checking the coupling Check the flexible elements of the coupling. Replace the relevant parts in due time if there is any sign of wear and check the alignment Checking the clearances To check the clearance gaps, the impeller or the two impellers (of two-stage pumps) must be removed. ( Section Page 42) If the clearance gap is larger than permitted (see the following table), fit new casing wear rings The clearance gaps given refer to the diameter. Table 19: Clearances between impeller and casing / between impeller and casing wear ring Nominal diameter of the CTN-G/-C CTN-GH/-CH discharge nozzle up to and including DN mm mm DN 125 and above 0.70 mm mm NOTE If the clearances given are exceeded by more than 1 mm (referring to the diameter) replace the affected components or restore the original clearance by means of a casing wear ring. Contact KSB Cleaning filters CAUTION Insufficient inlet pressure due to clogged filter in the suction line Damage to the pump! Take appropriate measures to monitor contamination of filter. Clean filter in appropriate intervals. CTN / CTN-H 37 of 70

38 7 Servicing/Maintenance Lubrication and lubricant change of thrust bearings (rolling element bearings) DANGER Excessive temperatures as a result of thrust bearings (rolling element bearings) running hot or defective bearing seals Explosion hazard! Fire hazard! Damage to the pump set! Regularly check the condition of the lubricant Grease lubrication The bearings are supplied packed with high-quality lithium-soap grease Grease quality Table 20: Grease quality to DIN Soap basis NLGI grade Worked penetration Drop point Temperature range at 25 C in mm/10 Lithium 2 to C -30 C to 120 C Grease quantities and intervals Table 21: Grease change Size Bearing size Grease refill after hours/required quantity in cm³ at a speed of rpm /40/50 2 x 7206BUA 8000/ / / /70 80/100 2 x 7309BUA 6000/ / / /150 2 x 7309BUA 6000/ / / /250 2 x 7313BUA ) / / Oil lubrication The thrust bearings (rolling element bearings) can be also be lubricated with oil Intervals Table 22: Oil change intervals Temperature at the bearing First oil change All subsequent oil changes 9) 50 C After 300 operating hours Every 3000 operating hours > 50 C After 300 operating hours Every 2100 operating hours 8) 5200 hours if n = 960 rpm 9) At least once a year 38 of 70 CTN / CTN-H

39 7 Servicing/Maintenance Oil quality Table 23: Oil quality Designation CLP46 lubricating oil to DIN or HD 20W/20 SAE Symbol to DIN Kinematic viscosity at 40 C Flash point (to Cleveland) Solidification point (pour point) Application temperature 10) Properties 46±4 mm²/s Higher than permissible bearing temperature Oil quantity Table 24: Oil quantity Size Bearing size Oil quantity 11) [l] 25/40/50 1 x 6312 DIN /100 2 x 7312 BUA DIN /150 2 x 7315 BUA DIN /250 2 x 7318 BUA DIN Radial bearings In the volute casing and the pipe assemblies the shaft is guided in plain bearings lubricated by the fluid handled. If the fluid handled is contaminated, the bearings can be lubricated by an external liquid supplied via a lubrication line (special design). Table 25: External lubrication Sizes Quantity per bearing Fluid Bearings lubricated by Pressure for external lubrication Quantity per bearing Grease Max. permissible speed for grease lubrication 25/40/ l/min 1.5 bar above 4 g/h 1750 rpm 80/ l/min tank pressure 1450 rpm 125/ l/min 1450 rpm 200/ l/min 960 rpm 7.3 Drainage/cleaning WARNING Fluids, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! Collect and properly dispose of flushing fluid and any 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. 10) For ambient temperatures below -10 C use a different suitable type of lubricating oil. Contact KSB. 11) Including constant-level oiler CTN / CTN-H 39 of 70

40 7 Servicing/Maintenance 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 be neutralised, and anhydrous inert gas must be blown through the pump to ensure drying. 7.4 Dismantling the pump set General information/safety regulations 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 Hot surface Risk of injury! Allow the pump set to cool down to ambient temperature. 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. 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 refer to the general assembly drawing. ( Section 9.1 Page 58) In the event of damage you can always contact our service staff. DANGER Insufficient preparation of work on the pump (set) Risk of injury! Properly shut down the pump set. ( Section Page 31) 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. Wet installation Dry installation Preparing the pump set 1. De-energise the pump set and secure it against unintentional start-up. 2. Disconnect and remove all auxiliary pipework. 3. Undo the bolts and nuts between flanged bend 72-1 and discharge line. 4. Undo the bolts/screws and nuts between sole plate and the tank. Watch the sealing elements. 5. Lift the pump out of the tank and allow it to drain. 1. De-energise the pump set and secure it against unintentional start-up. 40 of 70 CTN / CTN-H

41 7 Servicing/Maintenance 2. Disconnect and remove all auxiliary pipework. Remove the return line between pump and tank. 3. Undo the bolts and nuts between flanged bend 72-1 and discharge line. 4. Undo the screws and nuts between sole plate and the foundation. 5. Undo hexagon head bolts and nuts Watch the sealing elements. 6. Lift the pump and allow it to drain Dismantling the motor 1. Disconnect the motor from the power supply. 2. Unscrew hexagon nuts Remove the motor with the coupling half. Grease-lubricated thrust bearings Oil-lubricated thrust bearings Dismantling the thrust bearings Work cleanly and accurately. The notes and steps stated in ( Section Page 40) bis ( Section Page 41) have been observed/carried out. 1. Bend open lockwasher and unscrew slotted round nuts (righthand thread). Remove both parts from shaft 210. Remove angular contact ball bearing and spacer discs with bearing bracket lantern Check lip seal Remove flanged bend 72-1 from the sole plate. Work cleanly and accurately. Do not damage the oil tube. Pump size 25/40/50 The notes and steps stated in ( Section Page 40) bis ( Section Page 41) have been observed/carried out. 1. Remove centring sleeve including rolling element bearing from the shaft by rotating it (right-hand thread). 2. Unlock and undo slotted round nuts Push rolling element bearing off the centring sleeve. 4. Remove constant-evel oiler Remove bearing bracket lantern 344 from the sole plate. Pump size 80/100/125/150/200/250 The notes and steps stated in ( Section Page 40) bis ( Section Page 41) have been observed/carried out. 1. Undo socket head cap screw and unscrew bearing nut 923 from the shaft (right-hand thread). Remove constant-level oiler Pull centring sleeve and angular contact ball bearing together with bearing bracket lantern 344 off the shaft. 3. Remove centring sleeve and angular contact ball bearing from the bearing bracket lantern Unlock and undo slotted round nuts Push rolling element bearing off the centring sleeve. 6. Remove flanged bend 72-1 from the sole plate. CTN / CTN-H 41 of 70

42 7 Servicing/Maintenance Removing the shaft seal Removing the mechanical seal The notes and steps stated in ( Section Page 40) bis ( Section Page 41) have been observed/carried out. 1. Remove ring with grub screw from shaft protecting sleeve Undo hexagon nuts Remove seal cover Pull complete mechanical seal 433 with shaft protecting sleeve off drive shaft Dismantle stuffing box housing Dismantling the gland packing The notes and steps stated in ( Section Page 40) bis ( Section Page 41) have been observed/carried out. 1. Unscrew hexagon nuts Remove gland follower Remove stuffing box ring , packing ring and lantern ring (if any) from stuffing box housing Dismantle stuffing box housing Single-stage pumps Two-stage pumps Dismantling the hydraulic system The notes and steps stated in ( Section Page 40) bis ( Section Page 42) have been observed/carried out. 1. Undo bolts and nuts (and additional studs and hexagon nuts , if applicable). Remove suction cover 162 with joint ring Remove casing wear ring (if required). 2. Bend open lockwasher and unscrew cap nut Pull impeller off the shaft. Remove key Undo bolts and nuts Remove volute casing 102 with gasket Remove casing wear ring (if required). The notes and steps stated in ( Section Page 40) bis ( Section Page 42) have been observed/carried out. 1. Undo bolts and nuts (and additional studs and hexagon nuts , if applicable). Remove suction cover 162 with joint ring Remove casing wear ring (if required). 2. Bend open lockwasher and unscrew cap nut Pull impeller off the shaft. Remove key Undo bolts and nuts (and additional studs and hexagon nuts , if applicable). Remove stage casing 108 with joint ring Remove casing wear rings /.04 (if required). 4. Remove bearing bush (if applicable and required). Pull spacer sleeve 525 (or bearing sleeve , if applicable) and impeller off the shaft. Remove key Undo bolts and nuts Remove volute casing 102 with gasket Remove casing wear ring (if required). 42 of 70 CTN / CTN-H

43 7 Servicing/Maintenance Removing the pipe assembly and shaft assembly The notes and steps stated in ( Section Page 40) bis ( Section Page 42) have been observed/carried out. On heatable designs (CTN-H), the pipes /.24/.25/.26 with pipe unions /.37/.38/.39/.40/.41 have been dismantled. 1. Undo bolts and nuts Remove pipe assembly with gasket Remove bearing housing with bearing bush , grooved pin and O-ring (if applicable) from the recess in the pipe assembly (not for CTN-H). 3. If pipe assembly is fitted, repeat steps 1 to If pipe assembly is fitted, repeat steps 1 to 2. CAUTION Bending of the shaft Damage to the shaft! Support the shaft assembly if the shaft is long. For large installation depths with several shafts 211, 212, 213, these have been dismantled once the threaded coupling is accessible, before dismantling the next piping assembly. 1. Dismantle shaft If applicable, unscrew threaded couplings Inject Caramba, Ferex etc. into the small drilled hole. Hold the threaded coupling and shaft with a wrench and turn them against each other (right-hand thread). If the threaded coupling cannot be unscrewed, heat the coupling to 180 C and repeat the process. Standard design CTN special design CTN-H special design Dismantling the bearing sleeves Shrink-fitted bearing sleeve /03 The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Carefully heat the bearing sleeve using a burner flame and remove with a pulloff device. If this proves difficult, turn off the bearing sleeve using a lathe or split it open along its length using an abrasive cutting machine. Bearing sleeve /03 fastened with parallel pin and grub screw The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Undo and remove grub screws / Remove parallel pins /.19. Bearing sleeve /03 fastened with screws (for brittle materials) The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Unscrew screws /.19 from the shaft. Pull off the bearing sleeve. Bearing sleeve /03 fastened with parallel pin (with special materials and single piece SiC sleeve) The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Carefully bore open parallel pins /.19 and remove. If the bearing sleeve shows signs of wear and needs to be replaced, it can be smashed and the parallel pin can be removed. Bearing sleeve /03 fastened with key and grub screw CTN / CTN-H 43 of 70

44 7 Servicing/Maintenance The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Undo and remove grub screws / Remove keys /.07. Bearing sleeve /03 fastened with screws (for brittle materials) The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Unscrew screws /.19 from the shaft. Pull off the bearing sleeve. Bearing sleeve /03 fastened with parallel pin (for hard metal) The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Carefully bore open parallel pins /.19 and remove. If the bearing sleeve shows signs of wear and needs to be replaced, it can be smashed and the parallel in can be removed. CTN CTN-H Dismantling the bearing bush In the volute casing The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Undo hexagon nut and grub screw Press out bearing bush In the stage casing (for two-stage pumps) The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Press out bearing bush from below. In the intermediate bearing (for large installation depths, the shaft assembly is supported by an intermediate bearing) The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Remove grub screw and bearing bush The notes and steps stated in ( Section Page 40) bis ( Section Page 43) have been observed/carried out. 1. Use an appropriate jig to press bearing bush out of pipe assembly Smash the bearing bush if it is made of carbon. 7.5 Reassembling the pump set General information/safety 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. 44 of 70 CTN / CTN-H

45 7 Servicing/Maintenance 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. Sequence Sealing elements Always reassemble the pump in accordance with the corresponding general assembly drawing. Gaskets Always use new gaskets, making sure that they have the same thickness as the old ones. Always fit gaskets of asbestos-free materials or graphite without using lubricants (e.g. copper grease, graphite paste). O-rings Never use O-rings that have been glued together from material sold by the metre. CAUTION Contact of O-ring with graphite or similar material Fluid could escape! Do not coat O-ring with graphite or similar material. Use animal fats or lubricants based on silicone or PTFE. Tightening torques Assembly adhesives For gaskets, avoid the use of assembly adhesives, if possible. If assembly adhesives are required, use a commercially available contact adhesive (e.g. "Pattex"). Only apply adhesive at selected points and in thin layers. Never use quick-setting adhesives (cyanoacrylate adhesives). Coat the locating surfaces of the individual components and screwed connections with graphite or similar before reassembly. For reassembly, tighten all screws and bolts as specified in this manual HB500 and Fitting the bearing sleeve Fitting the bearing sleeves Bearing sleeve made of HB500 and (standard design) The individual parts have been placed in a clean and level assembly area. All dismantled parts have been cleaned and checked for wear. Any damaged or worn parts have been corrected or replaced with original spare parts. The sealing surfaces have been cleaned. 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. SiC 1. Heat the bearing sleeve to approx. 150 to 200 C and slide quickly onto the shaft. Bearing sleeve made of SiC (standard design) The individual parts have been placed in a clean and level assembly area. CTN / CTN-H 45 of 70

46 7 Servicing/Maintenance All dismantled parts have been cleaned and checked for wear. Any damaged or worn parts have been corrected or replaced with original spare parts. The sealing surfaces have been cleaned. 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. 1. Heat the bearing sleeve to approx. 200 C and slide quickly onto the shaft. CAUTION Improper reassembly Damage to the plain bearing Always slide the guide ring with the marking (groove) onto the shaft first C30EH, solid SiC Fig. 7: Sliding the bearing sleeve onto the shaft 1 Guide ring without marking 2 Press fit 3 Guide ring with marking 4 Clearance fit Bearing sleeve made from brittle and wear-resistant materials, e.g. C30EH, solid SiC (special design) The individual parts have been placed in a clean and level assembly area. All dismantled parts have been cleaned and checked for wear. Any damaged or worn parts have been corrected or replaced with original spare parts. The sealing surfaces have been cleaned. 1. Slide the bearing sleeve onto the shaft and secure with grooved pin or hexagon head bolt CTN: The grooved pins /.22 must engage in the recess of the pipe assembly when installing bearing housing CTN-H: The grooved pins /.22 must engage in the recess of the pipe assembly when installing centring ring Assembling the pipe assembly and shaft assembly The notes and steps stated in ( Section Page 44) bis ( Section Page 45) have been observed/carried out. All disassembled parts have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. 1. Fasten pipe assembly with gasket to sole plate using bolts and nuts Fit stuffing box housing with joint ring on sole plate using bolts and nuts Fit shaft For large installation depths with several shafts 211, 212, 213, these must be connected with threaded coupling before assembling the next piping assembly. 46 of 70 CTN / CTN-H

47 7 Servicing/Maintenance 5. If threaded coupling is installed, the shaft and the threaded coupling must be held in place with the wrench and tightened against each other (righthand thread). 6. Insert bearing housing with bearing bush , grooved pin and O-Ring (if applicable) into the recess in the pipe assembly (not for CTN-H). 7. If pipe assembly is fitted, repeat steps 1 to If pipe assembly is fitted, repeat steps 1 to 6. CAUTION Bending of the shaft Damage to the shaft! Support the shaft assembly if the shaft is long. 9. CTN-H: after assembling the pump, fit the pipes /.24/.25/.26 with pipe unions /.37/.38/.39/.40/.41. Single-stage pumps Two-stage pumps Reassembly of hydraulic system The notes and steps stated in ( Section Page 44) bis ( Section Page 46) have been observed/carried out. All disassembled parts have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. The sealing surfaces have been cleaned. 1. Fit volute casing 102 with bearing bush , casing wear ring (if applicable) and gasket to the pipe assembly with bolts and nuts Insert key into the shaft. Fit impeller with a jig. 3. Insert lockwasher Tighten cap nut Bend down lockwasher Fasten suction cover 162, casing wear ring (if applicable) with joint ring to the volute casing 102 using bolts and nuts (and additional studs and hexagon nuts , if applicable). The notes and steps stated in ( Section Page 44) bis ( Section Page 46) have been observed/carried out. All disassembled parts have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. The sealing surfaces have been cleaned. 1. Fit volute casing 102 with bearing bush , casing wear ring (if applicable) and gasket to the pipe assembly with bolts and nuts Insert key into the shaft. Fit impeller with a jig. 3. Slip spacer sleeve 525 (or bearing sleeve , if applicable) onto the shaft. 4. Fit stage casing 108, casing wear rings /.04, bearing bush (if applicable) and joint ring using bolts and nuts (and additional studs and hexagon nuts , if applicable). 5. Insert key into the shaft. 6. Fit impeller with a jig. Insert lockwasher Tighten cap nut Bend lockwasher CTN / CTN-H 47 of 70

48 7 Servicing/Maintenance 8. Fasten suction cover 162, casing wear ring (if applicable) with joint ring to the stage casing 108 using bolts and nuts / (and additional studs and hexagon nuts , if applicable) Fitting the shaft seal Installing the mechanical seal The following rules must be observed when installing the mechanical seal: For installing the mechanical seal, proceed as shown in the seal installation drawing. Work cleanly and accurately. Only remove the protective wrapping of the contact faces immediately before installation takes place. Prevent any damage to the sealing surfaces or O-rings. After inserting the stationary ring of the mechanical seal, check that it is planeparallel in relation to the casing part. The surface of the shaft protecting sleeve must be absolutely clean and smooth, and the sleeve's mounting edge must be chamfered. When sliding the rotating assembly onto the shaft protecting sleeve, take appropriate steps to protect the surface of the shaft protecting sleeve from damage. The notes and steps stated in ( Section Page 44) to ( Section Page 47) have been observed/carried out. All dismantled parts have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. The sealing surfaces have been cleaned. 1. Fit the rotating assembly of the mechanical seal onto the shaft protecting sleeve. 2. Slide the shaft protecting sleeve with O-ring (if applicable) and preassembled mechanical seal unit onto the shaft. Make sure that anti-rotational device is assembled in the shaft. 3. Carefully press the stationary mating ring of mechanical seal 433 with O-ring into seal cover Screw seal cover with the pre-assembled mechanical seal unit to stuffing box housing using bolts and nuts Attach adjusting ring to the shaft protecting sleeve with grub screw CAUTION Fastening the adjusting ring to the shaft Damage to the mechanical seal! Secure the adjusting ring to the shaft with grub screw after setting the axial impeller clearance. ( Section Page 50) and ( Section Page 52) Fitting the gland packing Always use pre-compressed packing rings. The notes and steps stated in ( Section Page 44) to ( Section Page 47) have been observed/carried out. The assembled bearing as well as the individual parts are kept in a clean and level assembly area. All disassembled parts have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. 48 of 70 CTN / CTN-H

49 7 Servicing/Maintenance The sealing surfaces have been cleaned. 1. Fasten stuffing box housing with joint ring on sole plate If applicable, fasten shaft protecting sleeve to the shaft with grub screw If applicable, check the O-ring. 4. Insert the first packing ring in the stuffing box housing so that the cut edge is horizontal. 5. Insert the second packing ring with the cut edge displaced by Insert lantern ring The joint face must be offset from the cut edge of the packing ring. Insert other packing rings in the same way. 7. Insert stuffing box ring Fit gland follower 452 and lightly fasten it by hand with the two hexagon nuts ; watch discs CAUTION Over-tightened gland packing Damage to the gland packing NOTE Gently tighten the gland packing. The gland packing has no contact with the fluid handled and only seals against splashes and low gas pressure. 1 2 Table 26: Gland packing chamber Sizes No. of rings Gland packing chamber without shaft protecting sleeve Fig. 8: Dimensions of the packing chamber/number of packing rings; 1 = Design without shaft protecting sleeve, 2 = Design with shaft protecting sleeve Packing crosssection Gland packing chamber with shaft protecting sleeve Ø d i Ø d a l Ø d i Ø d a l Packing crosssection 25 / 40 / 50 4 packing rings and x x / lantern ring x x / 150 or x x / x x packing rings Barrier fluid for gland packing The gland packing seals against splashes and vapours. Gland packings with self-lubricating properties are used. This means no extra barrier fluid or grease is required. CTN / CTN-H 49 of 70

50 7 Servicing/Maintenance If necessary, clean fluid handled or a fluid compatible with the fluid handled can be used. If no barrier fluid is available, grease can be used in combination with a Conrad lubricator Fig. 9: Conrad lubricator 1 Counternut 2 Upper section 3 Plunger 4 Lower section (grease cup) The notes and steps stated in ( Section Page 44) bis ( Section Page 47) have been observed/carried out. The lubricator has been cleaned and checked. The grease container and threads are clean. 1. Screw lower section (4) into the connection for sealing grease. Fill grease cup (4) to the brim with grease. 2. Remove plunger (3) from the upper section. Apply a layer of grease to the inner lining of the upper section. 3. Tighten the bottom screw. 4. Insert plunger (3). The bottom screw must face outwards. 5. Turn the upper section (2) four turns into the lower section (4). 6. Tighten counter nut (1) on the edge of the lower section. Adjusting the lubricator NOTE Refill the lubricator approx. every 8 days when working in eight-hour operating periods. 1. Turn the counter nut (1) back by four turns. 2. Screw the upper section (2) in by four turns. 3. Tighten the counternut again (1). NOTE When the upper section is screwed into the lower section completely, the lubricator is emptied Assembling thrust bearings The notes and steps stated in ( Section Page 44) to ( Section Page 48) have been observed/carried out. All dismantled parts have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. 50 of 70 CTN / CTN-H

51 7 Servicing/Maintenance CTN with oil-lubricated thrust bearings CTN, CTN-H The sealing surfaces have been cleaned. 1. Heat bearings in the oil tank to approx. 80 C. 2. Slide bearings onto the cleaned shaft and into bearing bracket lantern 344 until they abut against the spacer discs The oil tube has been checked for unimpeded throughflow. 1. Slide the bearings onto cleaned centring sleeve Attach lockwasher Screw on slotted round nut , tighten and lock. The cast notches in bearing bracket lantern 344 and in bearing cover 360 must be located on top of each other. Ensure the position of the recess in the gasket is such that the oil return grooves can perform their function. Adjusting the axial impeller clearance The impeller is centred in the volute casing, i.e. the axial distance between the impeller and the suction cover or the impeller and the volute casing (for a singlestage pump) or the stage casing (for a two-stage pump) is the same. To achieve this, assemble the complete pump without angular contact ball bearing and drive lantern 341. Push the shaft down until it will not go any further and measure dimension A 1. Determine the difference B = A 1 - C. Push the shaft upwards until it will not go any further and measure dimension A 2. Determine the difference D = A 1 - A 2. The required thickness S of the spacer discs is calculated as follows: S = B - D/2 Sizes Dimension C 25 / 40 / 50 37,5 80 / 100 / 125 / ,0 200 / ,0 1. Slide the set of spacer discs onto the shaft as far as they can go in order to ensure dimension S. 2. Mount angular contact ball bearings with slotted round nut and lock washer NOTE Install angular contact ball bearings in face-to-face arrangement. Angular contact ball bearings installed must always be from the same manufacturer. Fig. 10: Determining spacer disc thickness S CTN / CTN-H 51 of 70

52 7 Servicing/Maintenance CTN with oil-lubricated thrust bearings Fig. 11: Assembled thrust bearings with set of spacer discs 3. Carefully slide on bearing cover with lip seal and fasten. Check that the rotor can easily be rotated by hand, without causing any grinding noises. 4. Align the coupling. ( Section 5.3 Page 19) NOTE The overall axial clearance of the pump rotor is determined by lowering and pulling the rotor up using the centring sleeve. Adjusting pump sizes 25/40/50 1. Turn the centring sleeve to the left. Move the rotor to the lower stop. 2. Measure the dimension of the upper edge of the centring sleeve/shaft end. 3. Turn the centring sleeve to the left. Move the rotor to the upper stop. 4. Measure the dimension of the upper edge of the centring sleeve/shaft end. 5. Lower the rotor from the upper stop by 0.5x the overall clearance. One full turn of the centring sleeve will cause the rotor to move upwards or downwards by 1.5 mm. 6. Secure the centring sleeve with key to prevent rotation. If the key cannot be pushed into the recess, turn the centring sleeve so that the nearest recess aligns with the keyway. Adjusting pump sizes 80/100/125/150/200/ Turn bearing nut 923 to the left. Move the rotor to the lower stop. 2. Measure the dimension of the upper edge of the bearing nut/shaft end. 3. Turn bearing nut 923 to the right. Move the rotor to the upper stop. 4. Measure the dimension of the upper edge of the bearing nut/shaft end. 5. Lower the rotor from the upper stop by 0.5x the overall clearance. One full turn of the bearing nut will cause the rotor to move upwards or downwards by 1.5 mm. 6. Screw the centring sleeve to the bearing nut with hexagon socket head cap screws and secure against rotation. The throughholes in the bearing nut align with the tapped holes in the centring sleeve Preloading the mechanical seal Move the setting ring and shaft protecting sleeve in the direction of the motor to the setting dimension of 5 mm (distance to the seal cover) and secure on shaft 210 with grub screw of 70 CTN / CTN-H

53 7 Servicing/Maintenance 7.6 Tightening torques Table 27: Tightening torques for screwed connections Material Stud/ hexagon nut Stamp on stud/ hexagon nut 12) Bearing bracket lantern 13) Use a torque wrench to tighten the screwed connections (902.01/920.01) between the volute casing and the bearing bracket lantern. C35E+Qt/C 35 A4-70/A QT/ QT YK/Y A4-70/A4-70 GA/G Tightening torques [Nm] A B A B A B New threads 14) -15 % 15) -20 % 15) New threads 14) -15 % 15) -20 % 15) New threads 14) -15 % 15) -20 % 15) M M M M Spare parts stock Ordering spare parts Always quote the following data when ordering replacement or spare parts: Order number Order item number Consecutive number Type series Size Material variant Seal code Year of construction Refer to the name plate for all data. Also specify the following data: Part No. and description ( Section 9.1 Page 58) Quantity of spare parts Shipping address Mode of dispatch (freight, mail, express freight, air freight) 12) Treat unstamped screwed connections like material pair C35/E+QT/C ) A: made of ductile material except JL 1040; B: made of material JL ) These values are determined on the basis of a friction coefficient of μ = ) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %. CTN / CTN-H 53 of 70

54 7 Servicing/Maintenance Recommended spare parts stock for 2 years' operation to DIN Table 28: Quantity of spare parts for recommended spare parts stock for CTN, CTN-H Part No. Description Number of pumps (including stand-by pumps) and 7 8 and 9 10 and more 210, 211, 212, 213 Shaft % /.02 16) Impeller % Angular contact ball bearing (set) % Radial ball bearing 17) % /.02/.03/.04 16) Casing wear ring % /.03 16) Bearing sleeve % 18) /.03 16) Bearing bush % 18) 852 Threaded coupling (set) % - Gaskets for pump casing (set) % - Other seal elements (set) % Variants with mechanical seal: 433 Mechanical seal, complete % Variants with gland packing: ) Gland packing (set) % Shaft protecting sleeve % 16) If fitted 17) Oil-lubricated thrust bearings (rolling element bearings) only 18) Per number of bearing points 54 of 70 CTN / CTN-H

55 7 Servicing/Maintenance Table 29: Interchangeability of pump components Interchangeability of pump components Components featuring the same number in a column are interchangeable. Size Description Volute casing Stage casing Suction cover Shaft Pump shaft Intermediate shaft Drive shaft Impeller Angular contact ball bearing Radial ball bearing (for oil-lubricated thrust bearings) Drive lantern Bearing bracket lantern Bearing housing Gland follower Stuffing box ring Lantern ring Gland packing Casing wear ring Casing wear ring Shaft protecting sleeve (gland packing) Bearing bush Bearing bush Pipe assembly Flanged bend Threaded coupling Sole plate Part No ) ) ) ) /.02 20) ) / / / / / / / ) ) ) ) /.02 20) /.04 20) / /.02 20) ) 19) For identical lengths 20) If fitted 21) For identical motors 22) Only for identical seal types 23) For identical nominal diameters CTN / CTN-H 55 of 70

56 8 Trouble-shooting 8 Trouble-shooting WARNING Improper work to remedy faults Risk of injury! For any work to remedy faults observe the relevant information in this manual or in the relevant accessory manufacturer's documentation. A B C D E F G Table 30: Trouble-shooting If problems occur that are not described in the following table, consultation with KSB s customer service is required. Pump delivers insufficient flow rate Motor is overloaded Excessive discharge pressure Increased bearing temperature Leakage at the pump Vibrations during pump operation Impermissible temperature increase in the pump A B C D E F G Possible cause Remedy 24) Pump delivers against an excessively high pressure. Re-adjust to duty point. Check system for impurities. Fit a larger impeller. 25) Increase the speed (turbine, I.C. engine). Vent and/or prime Pump or piping are not completely vented or primed Supply line or impeller clogged Remove deposits in the pump and/or piping Formation of air pockets in the piping Alter piping layout. Fit vent valve Suction lift is too high/npsh available (positive suction head) is too low. Check/alter fluid level. Install pump at a lower level. Fully open the shut-off element in the suction line. Change suction line, if the friction losses in the suction line are too high. Check any strainers installed/suction opening. Observe permissible speed of pressure fall Wrong direction of rotation Interchange two of the phases of the power cable Speed is too low. - Operation with frequency inverter - Operation without frequency inverter - Increase voltage/frequency at the frequency inverter in the permissible range. - Check voltage Impeller Replace worn components by new ones Pump back pressure is lower than specified in the purchase order. Re-adjust to duty point. In the case of persistent overloading, turn down impeller. 25) Density or viscosity of fluid handled higher Contact KSB. than stated in purchase order Gland follower over-tightened or cocked Adjust Speed is too high. Reduce speed. 25)26) Worn shaft seal Fit new shaft seal. Check flushing liquid/barrier fluid. 24) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. 25) Contact KSB. 26) The fault can be remedied by changing the impeller diameter 56 of 70 CTN / CTN-H

57 8 Trouble-shooting A B C D E F G Possible cause Remedy 24) Vibrations during pump operation Correct suction conditions. Re-align the pump. Re-balance the impeller. Increase pressure at the pump suction nozzle Pump is warped or sympathetic vibrations in the piping. Check the piping connections and secure fixing of pump; if required, reduce distances between the pipe clamps. Fix the pipelines using anti-vibration material Insufficient or excessive quantity of lubricant Top up, reduce or change lubricant. or unsuitable lubricant Motor is running on two phases only. Replace the defective fuse. Check the electric cable connections Connection bolts have worked loose. Re-tighten bolts. Fit new sealing elements Rotor out of balance Clean the impeller. Re-balance the impeller Defective bearing(s) Replace Flow rate is too low. Increase the minimum flow rate Air intake at pump inlet Increase the minimum fluid level System-induced vibrations 25) 24) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. CTN / CTN-H 57 of 70

58 9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components CTN Fig. 12: CTN general assembly drawing 58 of 70 CTN / CTN-H

59 9 Related Documents K/H Standard design, without shaft protecting sleeve Design with shaft protecting sleeve and lantern ring in the gland packing; can be cooled/heated (902.28) (902.27) / / Table 31: List of components Detail of two-stage pump Sizes: /2 and /2 Additional lock for PTFE bearings Detail of two-stage pump Sizes: /2, /2, /2, /2, /2 Part No. Description Scope of supply 102 Volute casing with gasket , casing wear ring ), grooved pin ), grub screw )27) /.10, hexagon head bolt ), stud ), hexagon nut / Stage casing 29) with joint ring , casing wear ring /.04, grub screw )28) /.08 27)28), bearing bush ), grooved pin ), hexagon head bolt ), stud ), hexagon nut Suction nozzle 27) with gasket , hexagon head bolt , hexagon nut Suction cover with joint ring , casing wear ring ), grooved pin )28), grub screw )28) 210 Shaft 30)28) with set of spacer discs , keywayed nut , cap nut , parallel pin ), lockwasher /.02, key /.02/.03 29) 211 Pump shaft with cap nut , lockwasher , key /.03 29) 212 Intermediate shaft 28) 213 Drive shaft with set of spacer discs , parallel pin ), with keywayed nut , lockwasher , key /.02 Impeller For two-stage pumps, specify whether for 1st or 2nd stage 27) If fitted 28) Not shown 29) Only for two-stage pumps 30) If only one shaft is fitted: For large installation depths, the shaft assembly consists of a pump shaft and drive shaft or pump shaft, intermediate shaft(s) and drive shaft CTN / CTN-H 59 of 70

60 9 Related Documents Part No. Description Scope of supply Angular contact ball bearing 341 Drive lantern with disc , guard , hexagon head bolt , stud , hexagon nut Bearing bracket lantern with bearing cover , lip seal /.04, hexagon head bolt ), studs , socket head cap screw , hexagon nut Bearing housing with O-ring )28), bearing bush , grooved pin , grub screw /.04 Lip seal Stuffing box housing with joint ring )28) /.34 27)28) /.47, disc , stud , screwed plug )28) /.34 27)28), hexagon nut Gland follower Stuffing box ring Lantern ring Gland packing /.02 Casing wear ring 27) with grooved pin )28) /.06 27)28), grub screw )28) /.04 27)28) /.04 Casing wear ring 27)29) with grooved pin )28) /.08 27)28), grub screw )28) /.35 27)28) Shaft protecting with O-ring , grub screw sleeve 27) 525 Spacer sleeve 29) /.03 27) Bearing sleeve with grooved pin /.19 27) or screw /.19 27) Bearing sleeve Bearing bush /.03 Bearing bush 27) Set of spacer discs Pipe assembly 31) with gasket , hexagon head bolt , hexagon nut Pipe assembly 31) with gasket , hexagon head bolt , hexagon nut Flanged bend with gasket Threaded coupling Sole plate with joint ring , disc , eyebolt , studs /.12/.30/.31, hexagon nuts /.12/.30/.31 31) /.02/.03 etc. for several pipe assemblies, counted from the pump 60 of 70 CTN / CTN-H

61 9 Related Documents CTN-H Fig. 13: CTN-H general assembly drawing CTN / CTN-H 61 of 70

62 9 Related Documents K/H (902.28) (902.27) / / Design with shaft protecting sleeve and lantern ring in the gland packing; can be cooled/heated Table 32: List of components Detail of two-stage pump Sizes: /2 and /2 Additional lock for PTFE bearings Detail of two-stage pump Sizes: /2, /2, /2, /2, /2 Part No. Description Scope of supply 102 Volute casing with gasket , casing wear ring ), grooved pin )28), grub screw )28) /.10/.15 27), hexagon head bolt ), stud ), hexagon nut /.28 27) 108 Stage casing 29) with joint ring , casing wear ring ) /.04, 27) grub screw ) /.08 27), bearing bush ), grooved pin )28), hexagon head bolt ), stud ), hexagon nut Suction nozzle 27) with gasket , hexagon head bolt , hexagon nut Suction cover with joint ring , casing wear ring ), grooved pin )28), grub screw )28) 210 Shaft 30)28) with set of spacer discs , keywayed nut , cap nut , lockwasher /.02, key /.02/.03 29) /.06 27)28) /.07 27)28) 211 Pump shaft with cap nut , lockwasher , key /.03 29) /.06 27)28) 212 Intermediate shaft 28) 213 Drive shaft with set of spacer discs , parallel pin ), with keywayed nut , lockwasher , key )28) /.02 29) Impeller For two-stage pumps, specify whether for 1st or 2nd stage Angular contact ball bearing 341 Drive lantern with coupling guard ), screw ), stud , hexagon nut Bearing bracket lantern with bearing cover , lip seal /.03, cover plate ), screw ), studs , socket head cap screw , hexagon nut /.03 Lip seal Stuffing box housing with joint ring )28) /.34 27)28) /.47, disc , stud , screwed plug )28) /.34 27)28), hexagon nut Gland follower Stuffing box ring Lantern ring Gland packing /.02 Casing wear ring 27) with grooved pin )28) /.02 27)28), grub screw )28) /.04 27)28) /.04 Casing wear ring 27)29) with grooved pin )28) /.08 27)28), grub screw )28) /.35 27)28) 511 Centring ring with grooved pin Shaft protecting with O-ring , grub screw , key )28) sleeve 27) 525 Spacer sleeve 29) /.03 27) Bearing sleeve with grooved pin /.19 27)28) or screw /.19 27)28) or grub screw /.12 27)28) ) Bearing sleeve 62 of 70 CTN / CTN-H

63 9 Related Documents Part No. Description Scope of supply Bearing bush )29) /.03 27) Bearing bush with grooved pin (for ) Set of spacer discs Pipe assembly 31) with gasket , hexagon head bolt , hexagon nut Pipe assembly 31) with gasket , hexagon head bolt , hexagon nut )28) -.26 Pipe with pipe union /.37 27)28) /.38 27)28) /.39/.40/ Flanged bend with gasket Threaded coupling Sole plate with disc , eyebolt , studs /.12/.30/.31, hexagon nuts /.12/.30/.31 CTN / CTN-H 63 of 70

64 9 Related Documents CTN with oil-lubricated thrust bearings Fig. 14: General assembly drawing for CTN with oil-lubricated thrust bearings 64 of 70 CTN / CTN-H

65 9 Related Documents K/H (902.28) / / (902.27) Design with shaft protecting sleeve and lantern ring in the gland packing; can be cooled/heated Detail of two-stage pump Sizes: /2 and /2 Additional lock for PTFE bearings Detail of two-stage pump Sizes: /2, /2, /2, /2, / Table 33: List of components Fig. 15: Bearings for pump sizes 80/100/125/150/200/250 Part No. Description Scope of supply 102 Volute casing with gasket , casing wear ring )28), grooved pin )28), grub screw )28) /.10/.15 27), hexagon head bolt ), stud ), hexagon nut /.28 27) 108 Stage casing 29) with joint ring ), casing wear ring /.04 27)28), grub screw /.08 27)28), bearing bush )28), grooved pin )28), hexagon head bolt )29)28), stud )29)28), hexagon nut )29)28) 153 Suction nozzle with gasket , hexagon head bolt , hexagon nut Suction cover with joint ring , casing wear ring ), grooved pin )28), grub screw )28) 210 Shaft 30)28) with cap nut , lockwasher , key /.02/.03 29) /.11 27) 211 Pump shaft with cap nut , lockwasher , key /.03 29) 212 Intermediate shaft 28) 213 Drive shaft with key /.11 27) /.02 Impeller For two-stage pumps, specify whether for 1st or 2nd stage CTN / CTN-H 65 of 70