Standardised Chemical Pump

CPKN
Bearings UP02 to UP06 and P08s

Installation/Operating
Manual
Legal information/Copyright
Installation/Operating Manual CPKN
Original operating manual

KSB Aktiengesellschaft Pegnitz

All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited
or processed for any other purpose, nor otherwise transmitted, published or made available to a third
party without KSB´s express written consent.

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft Frankenthal 21.07.2010

Contents

Contents

Glossary ................................................................................................ 5

1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Installation of partly completed machinery .................................................. 6
1.3 Target group ................................................................................................... 6
1.4 Other applicable documents .......................................................................... 6
1.5 Symbols ............................................................................................................ 6

2 Safety ................................................................................................... 8
2.1 Key to safety symbols/markings ..................................................................... 8
2.2 General ............................................................................................................ 8
2.3 Intended use .................................................................................................... 8
2.4 Personnel qualification and training ............................................................. 9
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 9
2.6 Safety awareness ............................................................................................. 9
2.7 Safety information for the operator/user .................................................... 10
2.8 Safety information for maintenance, inspection and installation work ... 10
2.9 Unauthorised modes of operation ............................................................... 10
2.10 Explosion protection ..................................................................................... 10

3 Transport/Temporary Storage/Disposal ........................................... 13

3.1 Transport ....................................................................................................... 13
3.2 Storage and preservation ............................................................................. 13
3.3 Return to supplier ......................................................................................... 14
3.4 Disposal .......................................................................................................... 14

4 Description of the Pump (Set) .......................................................... 15

4.1 General description ....................................................................................... 15
4.2 Designation ................................................................................................... 15
4.3 Name plate .................................................................................................... 15
4.4 Design details ................................................................................................ 15
4.5 Design and function ...................................................................................... 17
4.6 Noise characteristics ..................................................................................... 18
4.7 Scope of supply ............................................................................................. 19
4.8 Dimensions and weights ............................................................................... 19

5 Installation at Site ............................................................................. 20

5.1 Safety regulations ......................................................................................... 20
5.2 Checking the site before installation ........................................................... 20
5.3 Installing the pump set ................................................................................. 20
5.4 Piping ............................................................................................................. 22

CPKN 3 of 68
Contents

5.5 Protective equipment ................................................................................... 25

5.6 Checking the coupling alignment ................................................................ 26
5.7 Aligning the pump and motor ..................................................................... 26
5.8 Electrical connection ..................................................................................... 28
5.9 Checking the direction of rotation .............................................................. 29

6 Commissioning/Start-up/Shutdown ................................................. 31
6.1 Commissioning/start-up ................................................................................ 31
6.2 Operating limits ............................................................................................ 37
6.3 Shutdown/storage/preservation ................................................................... 39
6.4 Returning to service after storage ............................................................... 40

7 Servicing/Maintenance ...................................................................... 41
7.1 Safety regulations ......................................................................................... 41
7.2 Servicing/inspection ...................................................................................... 41
7.3 Drainage/disposal .......................................................................................... 47
7.4 Dismantling the pump set ............................................................................ 47
7.5 Reassembling the pump set .......................................................................... 50
7.6 Tightening torques ....................................................................................... 54
7.7 Spare parts stock ........................................................................................... 55

8 Trouble-shooting ............................................................................... 59

9 Related Documents ........................................................................... 61

9.1 General assembly drawing with list of components ................................... 61

10 EC Declaration of Conformity .......................................................... 64

11 Certificate of Decontamination ....................................................... 65

Index .................................................................................................. 66

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Glossary

Glossary

Back pull-out design Pool of pumps

The complete back pull-out unit can be pulled Pumps which are purchased and stored
out without having to remove the pump casing independently of their later use
from the piping.
Pump
Back pull-out unit Machine without drive, additional components
Pump without pump casing; partly completed or accessories
machinery
Pump set
Certificate of decontamination Complete pump set consisting of pump, drive,
A certificate of decontamination certifies that additional components and accessories
the pump (set) has been properly drained to
eliminate any environmental and health
Suction lift line/suction head line
hazards arising from components in contact
with the fluid handled. The line which is connected to the suction
nozzle

Discharge line
The line which is connected to the discharge
nozzle

Hydraulic system
The part of the pump in which the kinetic
energy is converted into pressure energy

CPKN 5 of 68
1 General

1 General

1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. It 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
clearly identify the pump (set) and serve as identification for all further business
processes.

In the event of damage, contact your nearest KSB service centre immediately 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. (⇨ Section 7.5.5 Page 54)

1.3 Target group

This 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/ Description of mating and installation dimensions
Outline drawing for the pump (set)
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
of accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components1) Description of all pump components

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 to be included in the scope of supply

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1 General

Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product

CPKN 7 of 68
2 Safety

2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER

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 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 responsible specialist
personnel/operators 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 which
are not taken into account in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits which are
described in the other applicable documents.
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate partially assembled pumps/pump sets.

8 of 68 CPKN
2 Safety

▪ Only use the pump to handle the fluids specified in the data sheet or product
literature of the respective design variant.
▪ Never operate the pump without the fluid to be handled.
▪ Observe the 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 discharge-side shut-off elements further than permitted.
– The maximum flow rate specified in the data sheet or product literature
would be exceeded.
– Risk of cavitation damage
▪ Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved in

installation, operation, maintenance and inspection must be clearly defined by the
operator.

Deficits in knowledge must be rectified by sufficiently trained specialist personnel

training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.

Training on the pump (set) must always be supervised by technical specialist

personnel.

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

instructions
▪ Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪ Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– 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

CPKN 9 of 68
2 Safety

▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold or moving parts and check that
the guards function properly.
▪ Do not remove any contact guards while the pump is running.
▪ Connect an earth conductor to the metal jacket if the fluid handled is
electrostatically charged.
▪ 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.)

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.
▪ Carry out work on the pump (set) during standstill only.
▪ 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 6.1.12 Page 37)
▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3
Page 47)
▪ As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning. (⇨ Section 6.1 Page 31)

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. (⇨
Section 2.3 Page 8)

2.10 Explosion protection

Always observe the information on explosion protection given in this section when
! DANGER 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 2.10.1 Page 11) to (⇨ Section 2.10.4 Page 12) (⇨

10 of 68 CPKN
2 Safety

Section 2.10.4 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.

2.10.1 Marking
Pump The marking on the pump refers to the pump part only.
Example of such marking: II 2 G c TX
Refer to the Temperature limits table for the temperatures permitted for the
individual pump variants. (⇨ Section 2.10.2 Page 11)

Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.

Motor The motor must be considered separately.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected on the
surface of the pump casing, at the shaft seal and in the bearing areas.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated in addition, the operator of the system is
responsible for observing the specified temperature classes and fluid temperature
(operating temperature).
The table below lists the temperature classes and the resulting theoretical
temperature limits of the fluid handled (a possible temperature rise in the shaft seal
area has already 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 as per EN 13463-1 Maximum permissible fluid
temperature
T1 Maximum 400 °C2)
T2 280 °C
T3 185 °C
T4 120 °C
T5 85 °C
T6 Only after consultation
with the manufacturer

Temperature class T5 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.

Temperature class T6 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, the data sheet is missing or if

the pump is part of a pool of pumps, contact KSB for the maximum permissible
operating temperature.

2) Depending on the material variant

CPKN 11 of 68
2 Safety

2.10.3 Monitoring equipment

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

2.10.4 Operating limits

The minimum flows indicated in (⇨ Section 6.2.3 Page 38) refer to water and water-
like fluids. Longer operating periods with these fluids and at the flow rates indicated
will not cause an additional increase in the temperatures at the pump surface.
However, if the physical properties of the fluids handled are different from water, 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 6.2.3 Page 38) can be used to check whether an additional heat build-up
may lead to a hazardous temperature increase at the pump surface.

12 of 68 CPKN
3 Transport/Temporary Storage/Disposal

3 Transport/Temporary Storage/Disposal

3.1 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in horizontal position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Refer to the weights given in the general arrangement drawing.
▷ Observe the local accident prevention regulations.
▷ Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.

To transport the pump/pump set suspend it from the lifting tackle as shown below.

Fig. 1: Transporting the pump

max. 90 °

Fig. 2: Transporting the complete pump set

max. 90 °

Fig. 3: Transporting the pump on the baseplate

3.2 Storage and 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.

CPKN 13 of 68
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, observe the instructions in
(⇨ Section 6.3.1 Page 39) .

3.3 Return to supplier

1. Drain the pump as described in the manual. (⇨ Section 7.3 Page 47)
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 fluids handled by the pump leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might
ignite when coming into contact with oxygen, the pump set must also be
neutralised, and anhydrous gas must be blown through the pump for drying
purposes.
4. The pump (set) must always be accompanied by a completed certificate of
decontamination. (⇨ Section 11 Page 65)
It is imperative to indicate any safety and decontamination measures taken.

NOTE
If required, a blank Certificate of Decontamination can be downloaded on the internet
under: www.ksb.com/certificate_of_decontamination

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

1. Dismantle the pump (set).

Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another controlled
manner.

14 of 68 CPKN
4 Description of the Pump (Set)

4 Description of the Pump (Set)

4.1 General description

▪ Standardised chemical pump with shaft seal

Pump for handling aggressive liquids in the chemical and petrochemical industries.

4.2 Designation
Example: CPKN - C1 F 40-160
Table 5: Key to the designation
Code Description
CPKN Type series
C1 Casing material, e.g. C1 = stainless steel
F Additional code, e.g. F = off-standard flange design
40 Nominal discharge nozzle diameter [mm]
160 Nominal impeller diameter [mm]

4.3 Name plate

KSB Aktiengesellschaft 6
1 67227 Frankenthal

CPKN-C1.V 080-160 2008

2
0520-5-P-10000-31 7
3
4 P-No. 997125086300550001
Q 115 m3/h H 25 m
5
n 2955 1/min

Mat-No. 01 109 223 ZN 3804 - D 52 x 74

Fig. 4: Name plate

1 Type series, pump size (⇨ Section 2 Customer-specific information

4.2 Page 15) (optional)
3 KSB order and order item number 4 Flow rate
5 Speed 6 Year of construction
7 Head

4.4 Design details

Design
▪ Volute casing pump
▪ Horizontal installation
▪ Back pull-out design
▪ Single-stage
▪ Meets technical requirements to ISO 5199
▪ Dimensions and ratings to EN 22 858/ISO 2858
complemented by pumps of nominal diameters DN 25, DN 200 and above

Pump casing
▪ Single or double volute, depending on the pump size
▪ Radially split volute casing
▪ Volute casing with integrally cast pump feet
▪ Volute casing (partly with casing wear ring) and casing cover

CPKN 15 of 68
4 Description of the Pump (Set)

Impeller type
▪ Closed radial impeller with multiply curved vanes
▪ Back vanes reduce axial thrust
Shaft seal
▪ Gland packing
▪ Commercial single and double acting mechanical seals
Preferable:
▪ Standardised mechanical seals to EN 12756 variant K

NOTE
Conversion from gland packing to mechanical seal and vice versa is possible without any
rework on the casing cover by using the relevant replacement parts.

Possible:
▪ Commercial cartridge seals
Alternative:
▪ Version without shaft protecting sleeve with "wet shaft"
Table 6: Seal chamber with different shaft seals (examples)
Type of seal Illustration
Conical seal chamber (A-type
cover)
Standardised mechanical seal

D00458

Cylindrical seal chamber

Standardised mechanical seal

D00459

Cartridge seal

D00460

Double-acting mechanical seal

(back-to-back)
both sides unbalanced

D01167

Bearings
Design specifications Motor-end bearing:
▪ Fixed bearing
▪ Paired angular contact ball bearing
▪ Axial movement of the rotor limited to maximum 0.5 mm
▪ Oil lubrication
▪ Optional: grease lubrication
Pump-end bearing:

16 of 68 CPKN
4 Description of the Pump (Set)

▪ Radial bearing
▪ Cylindrical roller bearing
▪ Absorbs radial loads only
▪ Oil lubrication
▪ Optional: grease lubrication

Bearing bracket Example: UP03

designation
Table 7: Bearing bracket designation
Code Description
UP Bearing bracket
03 Size code (based on dimensions of seal chamber and shaft
end)

Refer to the data sheet to find your bearing design.

Bearings used Table 8: Bearing design
KSB designation FAG designation SKF designation
B.G B-TVP-UA BECBP
B.G.8 B-TVP-UA 80 BEC86P

Table 9: Standard bearing assembly

Bearing bracket Rolling element bearing
Pump end Motor end
UP02 NU307 2 x 7307 B.G
UP03 NU311 2 x 7311 B.G.8
UP04 NU311 2 x 7311 B.G.8
UP05 NU313 2 x 7313 B.G.8
UP06 NU416 2 x 7319 B.G
P08s NU416 2 x 7319 B.G

4.5 Design and function

Fig. 5: Sectional drawing

CPKN 17 of 68
4 Description of the Pump (Set)

1 Clearance gap 2 Discharge nozzle

3 Casing cover 4 Drive shaft
5 Bearing bracket 6 Suction nozzle
7 Impeller 8 Shaft seal
9 Rolling element bearing, pump end 10 Rolling element bearing, motor
end

Design The pump is designed with an axial fluid inlet and a radial or tangential outlet. The
hydraulic system runs in its own bearings and is connected to the motor by a shaft
coupling.

Function The fluid enters the pump axially via the suction nozzle (6) and is accelerated
outward in a cylindrical flow by the rotating impeller (7). In the flow passage of the
pump casing the kinetic energy of the fluid is converted into pressure energy. The
fluid is pumped to the discharge nozzle (2), where it leaves the pump. The clearance
gap (1) prevents any fluid from flowing back from the casing into the inlet. At the
rear side of the impeller, the shaft (4) enters the casing via the casing cover (3). The
shaft passage through the cover is sealed towards the atmosphere by a shaft seal (8).
The shaft runs in rolling element bearings (9 and 10), which are supported by a
bearing bracket (5) linked with the pump casing and/or casing cover.

Sealing The pump is sealed by a shaft seal.

Standardised mechanical seal or gland packing

4.6 Noise characteristics

Table 10: Surface sound pressure level LpA3) 4)
Rated Pump Pump set
power 2900 rpm 1450 rpm 960 rpm 2900 rpm 1450 rpm 960 rpm
input 760 rpm 760 rpm
PN[kW] [dB] [dB] [dB] [dB]
[dB] [dB]
1 54 53 52 63 58 56
2 56 55 53 66 60 58
3 57 56 55 68 62 60
4 59 58 56 69 63 61
6 61 59 58 71 65 62
8 62 61 59 72 66 64
11 64 63 61 74 68 65
15 66 65 63 75 69 67
19 67 66 64 76 70 68
22 68 67 65 77 71 68
30 70 68 66 78 72 70
37 71 70 67 79 73 70
45 72 71 68 80 74 71
55 73 72 69 80 74 72
75 75 73 71 81 76 73
90 76 74 71 82 76 73
110 77 75 72 82 77 74
132 78 76 73 83 77 75
160 79 77 74 84 78 75
200 80 78 75 84 79 76
250 81 79 - 85 80 -

3) Spatial average; as per ISO 3744 and EN 12639; valid for operating range Q/Qopt = 0.8 - 1.1 and non-cavitating pump
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 68 CPKN
4 Description of the Pump (Set)

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:
▪ Pump
Drive ▪ Surface-cooled IEC three-phase current squirrel-cage motor
Shaft coupling ▪ Flexible coupling with or without spacer
Contact guard ▪ Coupling guard to EN 294
Baseplate ▪ Baseplate (to ISO 3661), cast or welded, for pump and motor, in torsion-resistant
design
▪ Channel section steel or folded steel plate
Special accessories ▪ As required

4.8 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump (set).

CPKN 19 of 68
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 Checking the site before installation

Place of installation

WARNING
Installation on foundations which are unsecured and cannot support the load
Personal injury and damage to property!
▷ Make sure the foundation concrete is of sufficient strength (min. X0 to
DIN 1045).
▷ Only place the pump set on a foundation whose concrete has set firmly.
▷ Only place the pump set on a horizontal and level surface.
▷ Refer to the weights given in the general arrangement drawing.

1. Check the structural requirements.

All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.

5.3 Installing the pump set

Always install the pump set in horizontal position.

DANGER
Excessive temperatures due to improper installation
Explosion hazard!
▷ Install the pump in horizontal position to ensure self-venting of the pump.

5.3.1 Installation on the foundation

2
1

3 4
Fig. 6: Fitting the shims

1 Bolt-to-bolt clearance 2 Shim

3 Shim for bolt-to-bolt clearance > 4 Foundation bolt
800 mm
✓ The foundation has the required strength and characteristics.

20 of 68 CPKN
5 Installation at Site

✓ The foundation has been prepared in accordance with the dimensions given in
the outline drawing/general arrangement drawing.
1. Position the pump set on the foundation and align it with the help of a spirit
level placed on the shaft and discharge nozzle.
Permissible deviation: 0.2 mm/m.
2. Use shims (2) for height compensation, if necessary.
Always fit shims between the baseplate/foundation frame and the foundation
itself; always insert them to the left and right of the foundation bolts (4) and in
close proximity to these bolts.
For a bolt-to-bolt clearance > 800 mm, fit additional shims (3) halfway between
the adjoining holes.
All shims must lie perfectly flush.
3. Insert the foundation bolts (4) into the holes provided.
4. Use concrete to set the foundation bolts (4) into the foundation.
5. Wait until the concrete has set firmly, then align the baseplate.
6. Tighten the foundation bolts (4) evenly and firmly.
7. Grout the baseplate using low-shrinkage concrete with a standard particle size
and a water/cement ratio of ≤ 0.5.
Produce flowability with the help of a solvent.
Perform secondary treatment of the concrete to DIN 1045.

NOTE
For low-noise operation contact KSB to check whether the pump set can be installed on
anti-vibration mounts.

NOTE
Expansion joints can be fitted between pump and suction/discharge line.

5.3.2 Installation without foundation

1

4
Fig. 7: Adjusting the levelling elements

1, 3 Locknut 2 Levelling nut

4 Levelling element
✓ The installation surface has the required strength and characteristics.
1. Position the pump set on the adjusting elements (4) and align it with the help of
a spirit level (on the shaft/discharge nozzle).
2. To adjust any differences in height, loosen the bolts and locknuts (1, 3) of the
adjusting elements (4).
3. Turn the levelling nut (2) until any differences in height have been compensated.
4. Re-tighten the locknuts (1, 3) at the adjusting elements (4).

CPKN 21 of 68
5 Installation at Site

5.4 Piping

5.4.1 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
5.4.2 Page 23)
▷ Take appropriate measures to compensate thermal expansion of the piping.

CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.

NOTE
It is recommended to install check and shut-off elements in the system, depending on the
type of plant. However, such elements must not obstruct proper drainage or hinder
disassembly of the unit.

✓ The suction lift line/suction head line has been laid with a rising/downward slope
towards the pump.
✓ The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
✓ To prevent excessive pressure losses, adapters to larger diameters have a diffuser
angle of approximately 8°.
✓ The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the suction
and discharge nozzles of the pump.

CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Free the piping from any impurities.
▷ If necessary, install a filter.
▷ Observe the instructions in (⇨ Section 7.2.2.3 Page 43).
3. If required, install a filter in the piping (see drawing: Filter in the piping).

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5 Installation at Site

2
Fig. 8: Filter in the piping

1 Differential pressure gauge 2 Filter

NOTE
Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of
corrosion-resistant material.
Use a filter three times the diameter of the piping.
Conical filters have proved suitable.
4. Connect the pump nozzles with the piping.

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

5.4.2 Permissible forces and moments at the pump nozzles

[+] Fy The resulting permissible forces have

Fy
been determined according to the
Fz Fz My following formulas:
Mz

Fx Fx Mx

Fy
Fz

Fx

Forces and moments at the pump nozzles

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!
The values are only applicable if the pump is installed on a completely grouted
baseplate and bolted to a rigid and level foundation.
The forces and moments were determined on the basis of API 610 (6th edition), table
2, values doubled.

CPKN 23 of 68
5 Installation at Site

Table 11: Forces and moments at the pump nozzles

Pump size Suction nozzle Discharge nozzle Suction nozzle Discharge nozzle
[N] [N] [Nm] [Nm]
Fx Fy Fz Fres Fx FyTens FyPress- Fz Fres Mx My Mz Mx My Mz
+
25-160 1050 700 850 1100 500 350 650 450 700 550 450 300 400 300 200
25-200
32-125 1350 900 1100 1400 700 450 850 550 900 700 550 350 450 350 250
32-160
32-200
32-250
40-160 1750 1150 1400 1800 850 550 1100 700 1100 1150 850 600 550 450 300
40-200
40-250
40-315
50-160 2150 1400 1700 2200 1100 700 1350 900 1400 1450 1100 750 700 550 350
50-200
50-250
50-315
65-160 2700 1750 2150 2750 1400 900 1750 1150 1800 2000 1500 1000 1150 850 600
65-200
65-250
65-315
80-160 3700 2400 2950 3800 1700 1100 2150 1400 2200 2750 2100 1400 1450 1100 750
80-200
80-250
80-315
80-400
100-200 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000
100-250
100-315
100-400
125-250 4700 3100 3750 4750 2950 1850 3700 2400 3800 3450 2650 1750 2750 2100 1400
125-315
125-400
150-250 7350 4700 5700 7400 3750 2350 4700 3100 4850 5300 3850 2650 3450 2650 1750
150-315
150-400
150-500
200-250 7350 4700 5700 7400 5700 3550 7350 4700 7400 5300 3850 2650 5300 3850 2650
200-315 10000 6700 8000 10450 5700 3550 7350 4700 7400 7500 5700 3650 5300 3850 2650
200-400
200-500
250-315 12000 8000 10000 12800 8000 5000 10000 6700 10450 9150 6900 4500 7500 5700 3650
250-400
250-500
300-400 13350 8700 10700 13800 10000 6150 12000 8000 12800 9550 7150 4700 9150 6900 4500
300-500
350-400 13350 8700 10700 13800 10700 6700 13350 8700 13800 9550 7150 4700 9550 7150 4700
350-500
Correction coefficients depending on material and temperature (see diagram below).

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5 Installation at Site

Correction coefficient
1.00

0.95

0.90

0.85

0.80

0.75
GP240GH+N
0.70 JS1025
JL1040
0.65

0.60
1.4408
0.55

0.50
120 150 200 250 300 350 400 °C

Fig. 9: Temperature correction coefficients

5.4.3 Auxiliary connections

CAUTION
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing liquid,
etc.)
Malfunction of the pump!
▷ Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the dimensions and locations of auxiliary connections.
▷ Use the auxiliary connections provided.

5.5 Protective equipment

DANGER
Risk of potentially explosive atmosphere due to insufficient venting
Explosion hazard!
▷ Make sure the space between the casing cover/discharge cover and the bearing
cover is sufficiently vented.
▷ Never close or cover the perforation of the bearing bracket guards (e.g. by
insulation).

WARNING
The volute casing and casing/discharge cover take on the same temperature as the fluid
handled
Risk of burns!
▷ Insulate the volute casing.
▷ Fit protective equipment.

CAUTION
Heat build-up in the bearing bracket
Damage to the bearing!
▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover.

CPKN 25 of 68
5 Installation at Site

5.6 Checking the coupling alignment

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

CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷ Always check the coupling after the pump has been installed and connected to
the piping.
▷ Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.

a) 1 b) 1

A B A B

A B A B

1 2 1 2
Fig. 10: a) Checking the coupling alignment and b) Aligning a spacer-type coupling

1 Straight-edge 2 Wedge gauge

✓ The coupling guard and step guard, if any, have been removed.
1. Loosen the support foot and re-tighten it without transmitting any stresses and
strains.
2. Place the straight-edge axially on both coupling halves.
3. Leave the straight-edge in this position and turn the coupling by hand.
The coupling is correctly aligned if the distances A) and B) to the respective shafts
are the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed 0.1 mm
during standstill as well as at operating temperature and under inlet pressure.
4. Check the distance between the two coupling halves around the circumference.
The coupling is correctly aligned if the distance between the two coupling halves
is the same at all points around the circumference.
The radial and axial deviation of both coupling halves must not exceed 0.1 mm
during standstill as well as at operating temperature and under inlet pressure.

5.7 Aligning the pump and motor

After having installed the pump set and connected the piping, check the coupling
alignment and, if required, re-align the pump set (at the motor).

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5.7.1 Motors with levelling screw

1
2
3

Fig. 11: Motor with levelling screw

1 Hexagon head bolt 2 Levelling screw

3 Locknut
✓ The coupling guard and step guard, if any, have been removed.
1. Check the coupling alignment.
2. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at the
baseplate.
3. Turn the levelling screws (2) by hand or by means of an open-jawed wrench until
the coupling alignment is correct.
4. Re-tighten the hexagon head bolts (1) at the motor and the locknuts (3) at the
baseplate.
5. Check that the coupling and shaft can easily be rotated by hand.

WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.

DANGER
Risk of ignition by frictional sparks
Explosion hazard!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
6. Re-install the coupling guard and step guard, if any.
7. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.

5.7.2 Motors without levelling screw

Any differences in the centre heights of the pump and motor shafts are compensated
by means of shims.

CPKN 27 of 68
5 Installation at Site

1
Fig. 12: Pump set with shim

1 Shim
✓ The coupling guard and step guard, if any, have been removed.
1. Check the coupling alignment.
2. Unscrew the hexagon head bolts at the motor.
3. Insert shims underneath the motor feet until the difference in shaft centre height
has been compensated.
4. Re-tighten the hexagon head bolts.
5. Check that the coupling and shaft can easily be rotated by hand.

WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.

DANGER
Risk of ignition by frictional sparks
Explosion hazard!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
6. Re-install the coupling guard and step guard, if any.
7. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.

5.8 Electrical connection

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

DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained electrician.
▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pump
sets, IEC 60079 (DIN VDE 0165).

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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
It is recommended to fit a motor protection device.

5.8.1 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 (see table:
Time relay settings for star-delta starting).

Table 12: Time relay settings for star-delta starting:

Motor rating Y time to be set
≤ 30 kW <3s
> 30 kW <5s

5.8.2 Connecting the motor

NOTE
In compliance with DIN VDE 0530 - Part 8, three-phase motors are always wired for
clockwise rotation (looking at the motor shaft stub).
The pump's direction of rotation is indicated by an arrow on the pump.

1. Change the motor's direction of rotation to match that of the pump.

2. Observe the manufacturer's product literature supplied with the motor.

5.9 Checking the direction of rotation

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

WARNING
Hands or objects inside the pump casing
Risk of injuries, damage to the pump!
▷ Never insert your hands or any other objects into the pump.
▷ Check that the inside of the pump is free from any foreign objects.

CPKN 29 of 68
5 Installation at Site

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
Motor 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, interchange any two phases to
correct the direction of rotation.
The correct direction of rotation of motor and pump is clockwise (seen from the
motor 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 the control system, if necessary.

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6 Commissioning/Start-up/Shutdown

6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

Before starting up the pump set make sure that the following requirements are met:
▪ The pump set has been properly connected to the electric power supply and is
equipped with all protection devices.
▪ The pump has been primed with the fluid to be handled. (⇨ Section 6.1.4 Page
32)
▪ The direction of rotation has been checked. (⇨ Section 5.9 Page 29)
▪ All auxiliary connections required are connected and operational.
▪ The lubricants have been checked.
▪ After prolonged shutdown of the pump (set), the activities described in (⇨
Section 6.4 Page 40) have been carried out.

6.1.2 Filling in lubricants

Grease-lubricated bearings Grease-lubricated bearings have been packed with grease at the factory.

Oil-lubricated bearings Fill the bearing bracket with lubricating oil.

Oil quality see (⇨ Section 7.2.3.1.2 Page 44)
Oil quantity see (⇨ Section 7.2.3.1.3 Page 44)

Filling the constant-level oiler with lubricating oil (oil-lubricated

bearings only)
✓ The constant-level oiler is screwed into the upper tapping hole of the bearing
bracket.

NOTE
If no constant-level oiler is provided on the bearing bracket, the oil level can be read in
the middle of the oil level sight glass arranged at the side of the bearing bracket.

CAUTION
Insufficient 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.

1 2

3 4 5
Fig. 13: Bearing bracket with constant-level oiler

CPKN 31 of 68
6 Commissioning/Start-up/Shutdown

1 Constant-level oiler 2 Vent plug

3 Connection elbow of the constant- 4 Screwed plug
level oiler
5 Bearing bracket
1. Pull out the vent plug (2).
2. Hinge down the reservoir of the constant-level oiler (1) from the bearing bracket
(5) and hold it in this position.
3. Fill in oil through the hole for the vent plug until the oil reaches the connection
elbow of the constant-level oiler (3).
4. Completely fill the reservoir of the constant-level oiler (1).
5. Snap the constant-level oiler (1) back into its operating position.
6. Fit the vent plug (2) again.
7. 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 an optimum oil
level. Repeat steps 1 - 6, if necessary.
8. To check the function of the constant-level oiler (1), slowly drain some oil via the
screwed plug (4) until air bubbles can be seen in the oil reservoir.

NOTE
An excessively high oil level can lead to a temperature rise and to leakage of the fluid
handled or oil.

6.1.3 Shaft seal

Shaft seals are fitted prior to delivery.

Observe the instructions on dismantling (⇨ Section 7.4.6 Page 48) or reassembly (⇨
Section 7.5.3 Page 51) .
Reservoir of non- If applicable, fill the reservoir of non-pressurised external fluid in accordance with
pressurised external fluid the general arrangement drawing.
Double-acting mechanical Prior to starting up the pump, apply barrier pressure as specified in the general
seal arrangement drawing.
External liquid feed Apply the quantities and pressures specified in the data sheet and the general
arrangement drawing.

6.1.4 Priming and venting the pump

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

DANGER
Shaft seal failure caused by dry running
Hot or toxic fluid could escape!
Damage to the pump!
▷ Before starting up the pump set, vent the pump and suction line and prime
both with the fluid to be handled.

1. Vent the pump and suction line and prime both with the fluid to be handled.

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2. Fully open the shut-off element in the suction line.

3. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc).

6.1.5 Final check

1. Remove the coupling guard and step guard, if any.
2. Check the coupling alignment; re-align the coupling, if required. (⇨ Section 5.6
Page 26)
3. Check that the coupling and shaft can easily be rotated by hand.
4. Re-install the coupling guard and step guard, if any.
5. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.

6.1.6 Water cooling

CAUTION
Deposit-forming, aggressive cooling water
Damage to the pump!
▷ Observe the cooling water quality.

Observe the following quality data of the cooling water:

▪ Not deposit forming
▪ Not aggressive
▪ Free from suspended solids
▪ Hardness on average 5 °dH (~1mmol/l)
▪ pH > 8
▪ Conditioned and neutral with regard to mechanical corrosion
▪ Inlet temperature tE= 10 to 30 °C
Outlet temperature tA= maximum 45 °C

6.1.7 Cooling of the shaft seal

CAUTION
Vaporisation pressure of fluid handled higher than atmospheric pressure
Damage to the shaft seal/pump!
▷ Cool the shaft seal.
▷ Provide sufficient quantities of cooling liquid (see table).

NOTE
The vaporisation pressure varies depending on the fluid handled, the system pressure
and the material of the shaft seal (e.g. hot water).

Table 13: Cooling of the shaft seal5)

Bearing bracket Cooling liquid quantity in l/min at a product temperature of
Standard design "K" design
up to 250 °C up to 400 °C up to 250 °C up to 400 °C
UP02 3 4 3 4
UP03 4 5 4 5
UP04 5 6 4 5
UP05 5 6 5 6

5) Not possible for conical seal chamber "A".

CPKN 33 of 68
6 Commissioning/Start-up/Shutdown

Bearing bracket Cooling liquid quantity in l/min at a product temperature of

Standard design "K" design
up to 250 °C up to 400 °C up to 250 °C up to 400 °C
UP06 6 7 5 6
P08s 7 8 6 7

6.1.8 Heating
The space between discharge cover and bearing bracket lantern can be used as a
heating chamber, if necessary. It can be fed with hot water, steam or thermal oil,
especially in combination with internal circulation.

DANGER
Excessive surface temperature
Explosion hazard!
Risk of burns!
▷ Observe the permissible temperature classes. (⇨ Section 2.10.2 Page 11)

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: Temperature limits for heating with hot water or thermal oil
Design Hot water / saturated Thermal oil
steam
t max [°C] pmax[bar] t max [°C] pmax[bar]
Standard design; 183 10 - -
lantern JL 1040 6) ,
O-ring EPDM
Lantern JS 1025 7) ; 250 20 300 6
profile joint PTFE/steel alloy
Welded casing cover 300 20 300 6

6) GJL-250 to EN 1561
7) GJS-400-18-LT to EN 1563

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6 Commissioning/Start-up/Shutdown

6.1.9 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.

Observe the following when heating up the pump (set) and keeping it warm:
▪ Make sure the temperature is increased continuously.
▪ Max. heating speed: 10 °C/min (10 K/min)

Fluid temperatures above If the pump is used for handling fluids with fluid temperatures exceeding 150 °C,
150 °C make sure that the pump has been sufficiently heated throughout before starting it
up.

Temperature difference 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.

6.1.10 Start-up

DANGER
The permissible pressure and temperature limits will be exceeded if the pump is
operated with the suction and discharge lines 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 gate valve slightly or fully
open.

DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid handled
Explosion hazard!
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▷ Prime the pump as specified. (⇨ Section 6.1.4 Page 32)
▷ 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.

✓ Pump, suction line and inlet tank, if any, have been vented and filled with the
fluid to be pumped.
✓ The filling and venting lines have been closed.

CAUTION
Start-up against open discharge line
Overloading of the motor!
▷ Use a soft starter.
▷ Use speed control.
▷ Make sure the power reserve of the motor is sufficient.

CPKN 35 of 68
6 Commissioning/Start-up/Shutdown

1. Fully open the shut-off element in the suction head/suction lift 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 comply with the duty
point.

DANGER
Seal leakage at operating temperature
Hot or toxic fluid could escape!
▷ After the operating temperature has been reached and/or in the event of
leakage, switch off the pump set and re-tighten the bolts between lantern and
casing.
▷ Check the coupling alignment. Re-align the coupling if required.
5. When the operating temperature has been reached and/or in the event of
leakage, switch off the pump set and re-tighten the bolts between lantern and
casing.
6. Check the coupling alignment and re-align the coupling, if required.

6.1.11 Checking the shaft seal

Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
Gland packing The packed gland must leak slightly during operation.

DANGER
Impermissibly high temperatures at packed glands
Explosion hazard!
▷ Always use suitable temperature monitoring for packed glands.
▷ Pack glands properly.

Pure graphite packing ring If a pure graphite packing ring is used, some leakage is essential.
Table 15: Leakage rate of the pure graphite packing ring
Quantity Values
Minimum 10 cm³/min
Maximum 20 cm³/min

Adjusting the leakage

Prior to commissioning 1. Only lightly tighten the nuts of the gland follower by hand.
2. Use a feeler gauge to verify that the gland follower is mounted centred and at a
right angle to the shaft.
⇨ The gland must leak after the pump has been primed.
After five minutes of The leakage can be reduced.
operation
1. Tighten the nuts of the gland follower by 1/6 turn.
2. Monitor the leakage for another five minutes.
Excessive leakage:
Repeat steps 1 and 2 until the minimum value has been reached.
Not enough leakage:
Slightly loosen the nuts at the gland follower.
No leakage:
Switch off the pump set immediately!
Loosen the gland follower and repeat start-up.

36 of 68 CPKN
6 Commissioning/Start-up/Shutdown

Checking the leakage

After the leakage has been adjusted, monitor the leakage for about two hours at
maximum fluid temperature.
Check that enough leakage occurs at the gland at minimum fluid pressure.

6.1.12 Shutdown
✓ The shut-off element in the suction line is and remains open.
✓ On pump sets with double-acting 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 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 non-return or check valve, the shut-off element
may remain open as long as there is some back pressure.

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.

6.2 Operating limits

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

CPKN 37 of 68
6 Commissioning/Start-up/Shutdown

6.2.1 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.

6.2.2 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 steady-
state operation and on the starting conditions (d.o.l., star-delta, moments of inertia,
etc). If the start-ups are evenly spaced over the period indicated, the following limits
can be used for orientation for start-up with the discharge-side gate valve slightly
open:
Table 17: Frequency of starts
Motor rating Maximum number of start-ups
[kW] [Start-ups/hour]
up to 12 15
up to 100 10
more than 100 5

CAUTION
Re-start 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.

6.2.3 Flow rate

Unless specified otherwise in the characteristic curves or in the data sheets, the
following applies:
▪ Short-time operation: Qmin8) =0.1xQopt 9)
▪ Continuous operation: Qmin8) =0.3xQopt 9)
▪ 2-pole operation: Qmax10) =1.1xQopt 9)
▪ 4-pole operation: Qmax10) =1.25xQopt9)
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

8) Minimum permissible flow rate

9) Best efficiency point
10) Maximum permissible flow rate

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6 Commissioning/Start-up/Shutdown

temperatures on the pump surface. However, if the physical properties of the fluids
handled are different from water, the calculation formula below must be used to
check if an additional heat build-up may lead to a dangerous temperature increase at
the pump surface. 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 head m
Tf Temperature of the fluid handled °C
To Temperature at the casing surface °C
Pump efficiency at duty point -
Temperature difference °C

6.2.4 Density of the fluid handled

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

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

6.2.5 Abrasive fluids

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

6.3 Shutdown/storage/preservation

6.3.1 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 (⇨ Section 7.3 Page 47) and the safety
instructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page
47)
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 and discharge nozzles.
It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).

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6 Commissioning/Start-up/Shutdown

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 3.2 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 after storage

For returning the pump to service observe the sections on commissioning/start-up (⇨
Section 6.1 Page 31) and the operating limits. (⇨ Section 6.2 Page 37)
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (⇨ Section 7 Page 41)

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 completed, 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.

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7 Servicing/Maintenance

7 Servicing/Maintenance

7.1 Safety regulations

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

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

WARNING
Fluids posing a health hazard or hot fluids
Risk of personal injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps handling fluids posing a health hazard.

A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump (set) with a minimum of maintenance
expenditure and work.

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

Never use force when dismantling and reassembling a pump set.

7.2 Servicing/inspection

7.2.1 Supervision of operation

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

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7 Servicing/Maintenance

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

CAUTION
Impermissibly high temperature of fluid handled
Damage to the pump!
▷ Prolonged operation against a closed shut-off element is not permitted (heating
up of the fluid).
▷ Observe the temperature limits in the data sheet and in the section on
operating limits. (⇨ Section 6.2 Page 37)

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

▪ The pump must run quietly and free from vibrations at all times.
▪ In case of oil lubrication, ensure the oil level is correct. (⇨ Section 6.1.2 Page 31)
▪ Check the shaft seal. (⇨ Section 6.1.11 Page 36)
▪ Check the static seals for leakages.
▪ Check the rolling element bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
▪ Monitor the correct functioning of any auxiliary connections.
▪ 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 on the outside of the
bearing bracket).

CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured
on the outside of the bearing bracket).

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 h depending on the conditions).

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7.2.2 Inspection work

DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
Damage to the pump set!
▷ Regularly check the coupling guard, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.

7.2.2.1 Checking the coupling

Check the flexible elements of the coupling. Replace these parts in due time if there
is any sign of wear.

7.2.2.2 Checking the clearance gaps

Remove the back pull-out unit to be able to check the clearance gaps. (⇨ Section
7.4.4 Page 48)
If the clearance gap is larger than permitted (see the following table), replace casing
wear ring 502.01 with a new one.
The clearances given refer to the diameter.
Table 19: Clearances between impeller and casing / between impeller and casing
wear ring
Nominal diameter of the CPKN-S1/-S2 CPKN-C1/-C1.V/-C3.1/-C3.2
discharge nozzle CPKN-E
up to DN 65 0.40 mm + 0.1 0.60 mm + 0.1
DN 80 to DN 200 0.5 mm + 0.1 0.60 mm + 0.1
DN 250 and above 0.65 mm + 0.1 0.75 mm + 0.1
These values are valid for temperatures up to 250 °C; for temperatures higher than
250 ° the clearance is increased by 0.1 to 0.2 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.

7.2.2.3 Cleaning filters

CAUTION
Insufficient inlet pressure due to clogged filter in the suction line
Damage to the pump!
▷ Monitor contamination of filter with suitable means (e.g. differential pressure
gauge).
▷ Clean filter in appropriate intervals.

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7 Servicing/Maintenance

7.2.3 Lubrication and lubricant change of rolling element bearings

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

7.2.3.1 Oil lubrication

The rolling element bearings are usually lubricated with mineral oil.

7.2.3.1.1 Intervals
Table 20: Oil change intervals
Temperature at the First oil change All subsequent oil
bearing changes11)
up to 70 ℃ After 300 operating hours After 8500 operating hours
70 °C - 80 °C After 300 operating hours After 4200 operating hours
80 °C - 90 °C After 300 operating hours After 2000 operating hours

7.2.3.1.2 Oil quality

Table 21: Oil quality
Designation Symbol to DIN Properties
51502
CLP46 lubricating oil □ Kinematic viscosity 46±4 mm²/s
to DIN 51517 at 40 °C
or Flash point (to +175 ℃
HD 20W/20 SAE Cleveland)
Solidification point -15 ℃
(pour point)
Application Higher than
temperature12) permissible bearing
temperature

7.2.3.1.3 Oil quantity

Table 22: Oil quantity
Bearing bracket Oil quantity [l]
UP02 0.3
UP03 0.5
UP04 0.5
UP05 1.5
UP06 1.4
P08s 4.5

11) At least once a year

12) For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.

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7.2.3.1.4 Changing the oil

WARNING
Lubricants posing a health hazard
Hazard to persons and the environment!
▷ When draining the lubricant take appropriate measures to protect persons and
the environment.
▷ Observe all legal regulations on the disposal of liquids posing a health hazard.

1 2 3
Fig. 14: Bearing bracket with constant-level oiler

1 Constant-level oiler 2 Screwed plug

3 Bearing bracket
✓ A suitable container for the used oil is on hand.
1. Place the container underneath the screwed plug.
2. Undo the screwed plug (2) at the bearing bracket (3) and drain the oil.
3. Once the bearing bracket (3) has been drained, re-insert and re-tighten the
screwed plug (2).
4. Re-fill with oil. (⇨ Section 6.1.2 Page 31)

7.2.3.2 Grease lubrication

The bearings are supplied packed with high-quality lithium-soap grease.

7.2.3.2.1 Intervals
The bearings are re-lubricated via the lubricating nipples, see the following drawing.
1 2

Fig. 15: Position of lubricating nipples

1 Lubricating nipple 2 Lubricating nipple

CPKN 45 of 68
7 Servicing/Maintenance

CAUTION
Contaminated lubricating nipples
The lubricating grease could become contaminated!
▷ Clean the grease lubricating nipples before using them for re-lubrication.
Re-lubrication ▪ After approx. 5,000 operating hours
▪ At least once a year
▪ Required grease quantity (⇨ Section 7.2.3.2.3 Page 46)
Grease change ▪ After 16,000 operating hours
▪ At least every 2 years
▪ Required grease quantity (⇨ Section 7.2.3.2.3 Page 46)
Under unfavourable operating conditions (e.g. high room temperature, high
atmospheric humidity, dust laden air, aggressive industrial atmosphere) check the
bearings earlier and clean and re-lubricate them, if required.

7.2.3.2.2 Grease quality

Table 23: Grease quality to DIN 51825

Soap basis NLGI grade Worked penetration Drop point Temperature range
at 25 °C in mm/10
Lithium 2 to 3 220-295 ≥ 175 °C -30 ℃ to 120 ℃

7.2.3.2.3 Grease quantities

Table 24: Grease quantities for re-lubrication and re-filling
Bearings Re-lubrication Re-fill
Pump-end bearing Drive-end bearing Bearing+cover, pump Bearing+cover, drive
end end
UP02 7.5 g / 8.5 cm³ 15 g / 17 cm³ approx. 10 g / 11 cm³ approx. 30 g / 33 cm³
UP03 12.5 g / 14 cm³ 25 g / 28 cm³ approx. 25 g / 28 cm³ approx. 60 g / 67 cm³
UP04 12.5 g / 14 cm³ 25 g / 28 cm³ approx. 25 g / 28 cm³ approx. 60 g / 67 cm³
UP05 17.5 g / 20 cm³ 35 g / 40 cm³ approx. 40 g / 45 cm³ approx. 80 g / 90 cm³
UP06 35 g / 40 cm³ 70 g / 80 cm³ approx. 80 g / 90 cm³ approx. 205 g / 225
cm³
P08 35 g / 40 cm³ 70 g / 80 cm³ approx. 80 g / 90 cm³ approx. 205 g / 225
cm³

7.2.3.2.4 Changing the grease

CAUTION
Mixing greases of differing soap bases
Changed lubricating qualities!
▷ Thoroughly clean the bearings.
▷ Adjust the re-lubrication intervals to the grease used.

✓ The pump has been dismantled for changing the grease. (⇨ Section 7.4 Page
47)
1. Only half-fill the bearing cavities with grease.
2. Fill the bearing cavities in the bearing cover until they are about 1/3 full.

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7 Servicing/Maintenance

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

If the fluids handled by the pump (set) leave residues which might lead to corrosion
when coming into contact with atmospheric humidity, or which might ignite when
coming into contact with oxygen, the pump (set) must be flushed through,
neutralised, and blown through with anhydrous inert gas for drying purposes.
Use connection 6B to drain the fluid handled (see auxiliary connections).

7.4 Dismantling the pump set

7.4.1 General notes/Safety regulations

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

WARNING
Hot surface
Risk of personal injury!
▷ Allow the pump set to cool down to ambient temperature.

Observe the general safety instructions and information. (⇨ Section 7 Page 41)
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 61)
In the event of damage you can always contact our service staff.

DANGER
Insufficient preparation of work on the pump (set)
Risk of personal injury!
▷ Properly shut down the pump set. (⇨ Section 6.1.12 Page 37)
▷ Close the shut-off elements in the suction and discharge line.
▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 47)
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.

7.4.2 Preparing the pump set

1. Disconnect the power supply (e.g. at the motor).
2. Disconnect and remove all auxiliary pipework.
3. Remove the coupling guard.
4. Remove the coupling spacer, if any.

CPKN 47 of 68
7 Servicing/Maintenance

5. Drain the oil fill of oil-lubricated bearings. (⇨ Section 7.2.3.1.4 Page 45)

7.4.3 Dismantling the motor

NOTE
For pump sets with spacer-type couplings, the back pull-out unit can be removed while
the motor remains bolted to the baseplate.

1. Disconnect the motor from the power supply.

2. Unbolt the motor from the baseplate.
3. Shift the motor to separate it from the pump.

WARNING
Motor tipping over
Risk of squashing hands and feet!
▷ Suspend or support the motor to prevent it from tipping over.

7.4.4 Removing the back pull-out unit

✓ Pumps without spacer-type coupling: the motor has been removed.

WARNING
Back pull-out unit tipping over
Risk of squashing hands and feet!
▷ Suspend or support the bearing bracket at the pump end.
1. If required, suspend or support bearing bracket 330 to prevent it from tipping
over.
2. Unbolt support foot 183 from the baseplate.
3. Undo hexagon nut 920.01 at the volute casing.
4. Pull the back pull-out unit out of the volute casing.
5. Remove and dispose of joint ring 411.10.
6. Place the back pull-out unit on a clean and level surface.

7.4.5 Removing the impeller

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 47) to (⇨ Section 7.4.4 Page
48) have been observed/carried out.
✓ The back pull-out unit is kept in a clean and level assembly area.
1. Undo impeller nut 922 (right-hand thread).
2. Remove impeller 230 with an impeller removal device.
3. Place impeller 230 on a clean and level surface.
4. Remove keys 940.1 from shaft 210.
5. Remove and dispose of joint rings 411.31/411.32.

7.4.6 Dismantling the shaft seal

7.4.6.1 Dismantling the mechanical seal - cylindrical casing cover

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 47) to (⇨ Section 7.4.5 Page
48) have been observed/carried out.
✓ The back pull-out unit is kept in a clean and level assembly area.

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1. Undo hexagon nuts 920.02 and push back seal cover 471.01 (if fitted) until it rests
against thrower 507.01.
2. Remove casing cover 161 with O-ring 412.01.
3. Remove and dispose of O-ring 412.01.
4. Pull complete mechanical seal 433 with shaft protecting sleeve 524.01, seal cover
471 and thrower 507.01 off shaft 210.

7.4.6.2 Dismantling the mechanical seal - conical casing cover

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 47) to (⇨ Section 7.4.5 Page
48) have been observed/carried out.
✓ The back pull-out unit is kept in a clean and level assembly area.
1. Pull shaft sleeve 524.01 with the rotating assembly of mechanical seal 433 off the
shaft.
2. Dismantle casing cover 161 with the stationary seat ring of mechanical seal 433.
3. Remove thrower 507.01.
4. Press the seat ring of mechanical seal 433 out of casing cover 161.

7.4.6.3 Dismantling the packed gland

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 47) to (⇨ Section 7.4.5 Page
48) have been observed/carried out.
✓ The back pull-out unit is kept in a clean and level assembly area.
1. Unscrew hexagon nuts 920.02 at gland follower 452 and remove the gland
follower.
2. Remove stuffing box ring 454.01 and drip plate 463.01.
3. Remove casing cover 161 with O-ring 412.01 and gland packing 461.01.
4. Remove packing rings 461.01 and lantern ring 458.01, if any, from the packing
chamber.
5. Pull off guard 680.
6. Pull shaft protecting sleeve 524.01 and thrower 507.01 off shaft 210.

7.4.7 Dismantling the bearings

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 47) to (⇨ Section 7.4.6 Page
48) have been observed/carried out.
✓ The bearing bracket is kept in a clean and level assembly area.
1. Unscrew hex. nuts 920.04 at the flange of bearing bracket lantern 344.
2. Remove bearing bracket lantern 344.
3. Unscrew the socket head cap screw in the coupling hub.
4. Pull the coupling half off the pump shaft with a puller.
5. Remove key 940.02.
6. Undo screws 914.02 and remove motor-end bearing cover 360.02 and joint ring
400.02.
7. Undo screws 914.01 and remove pump-end bearing cover 360.01 and joint ring
400.01.
8. Carefully drive shaft 210 together with angular contact ball bearing 320.02 and
the inner ring of cylindrical roller bearing 322.01 out of the bearing bracket
towards the drive end.
9. In case of grease lubrication, remove disc 550.25.
10. Remove support disc 550.23 of angular contact ball bearing 320.02 from bearing
bracket 330.
11. Remove cylindrical roller bearing 322.01 (roller cage) from bearing bracket 330.

CPKN 49 of 68
7 Servicing/Maintenance

12. In case of grease lubrication, remove disc 550.24.

13. Bend open lockwasher 931.01 behind keywayed nut 920.21 on shaft 210.
14. Unscrew keywayed nut 920.21 (right-hand thread) and remove lockwasher
931.01.
15. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical
roller bearing 322.01 to 80 °C, and pull them off shaft 210.
16. Dispose of joint rings 400.01/.02.

7.5 Reassembling the pump set

7.5.1 General notes/Safety regulations

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 Always reassemble the pump in accordance with the corresponding general assembly
drawing.
Seal elements ▪ 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.
▪ Assembly adhesives
– For gaskets, avoid the use of assembly adhesives, if possible.
– Should assembly adhesives be required after all, 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.

Tightening torques For reassembly, tighten all screws and bolts as specified in this manual. (⇨ Section 7.6
Page 54)

7.5.2 Installing the bearings

✓ The individual parts are kept in a clean and level assembly area.
✓ All dismantled components 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.

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7 Servicing/Maintenance

1. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical
rolling element bearing 322.01 to approx. 80 ℃ in an oil bath.
2. Push the angular contact ball bearing and the inner ring of cylindrical roller
bearing 322.01 onto shaft 210 until they will not go any further.

NOTE
Angular contact ball bearings must be installed in "O" arrangement. Angular contact ball
bearings installed in pairs must always be from the same manufacturer.

3. Use a spanner wrench to tighten keywayed nut 920.21 without lockwasher

931.01.
4. Let angular contact ball bearing 320.01 cool down to approximately 5 °C above
ambient temperature.
5. Re-tighten keywayed nut 920.21, then unscrew it again.
6. Apply a few spots of a suitable lubricant (e.g. Molykote) to the contact faces of
lockwasher 931.01 and keywayed nut 920.21.
7. Fit lockwasher 931.01.
8. Tighten keywayed nut 920.21.
9. Bend back lockwasher 931.01.
10. Insert circlip 932.01/932.02 into the bearing bracket.
11. In case of grease lubrication, insert disc 550.24.
12. Fit cylindrical roller bearing 322.01 (roller cage) in the bearing bracket.
13. Insert support disc 550.23 of the angular contact ball bearing 320.02 into bearing
bracket 330.
14. In case of grease lubrication, insert disc 550.25.
15. In case of grease lubrication, fill bearing and bearing cover with grease.
Grease lubrication (⇨ Section 7.2.3.2 Page 45)
16. Carefully push pre-assembled shaft 210 with angular contact ball bearing 320.02
and the inner ring of cylindrical roller bearing 322.01 from the drive end into
bearing bracket 330.
17. Fit pump-end bearing cover 360.01 with joint ring 400.01; take care not to
damage lip seal 421.01.
18. Fit motor-end bearing cover 360.02 with joint ring 400.02; take care not to
damage lip seal 421.02.
19. Fit bearing bracket lantern 344.
20. Tighten hex. nuts 920.04 at the flange of bearing bracket lantern 330.
21. Fit keys 940.02.
22. Pull the coupling hub onto the shaft end.
23. Secure the coupling hub with a set screw.
24. Fit thrower 507.01, if any.

7.5.3 Installing the shaft seal

7.5.3.1 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 seal faces immediately before
installation takes place.
▪ Prevent any damage to the sealing surfaces or O-rings.

CPKN 51 of 68
7 Servicing/Maintenance

▪ After inserting the seat ring, check that it is plane-parallel 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 unit onto the shaft protecting sleeve, take appropriate
steps to protect the surface of the shaft protecting sleeve from damage.

Re-installing the mechanical seal - cylindrical casing cover

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 50) to (⇨ Section 7.5.2 Page
50) have been observed/carried out.
✓ The assembled bearing and the individual parts of mechanical seal 433 are kept
in a clean and level assembly area.
✓ All dismantled components 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. Slip thrower 507.01 (if any) onto shaft 210 from the pump end.
2. Fasten seal cover 471 with inserted O-ring and the seat ring of the mechanical
seal to casing cover 161 with hexagon nut 920.02.
3. Insert casing cover 161 with O-ring 412.01 into lantern 344; watch joint ring
411.11.
4. Fit the rotating unit of mechanical seal 433 on shaft protecting sleeve 524.01
(observe distance B - see Supplementary Sheet of the mechanical seal).
5. Slip pre-assembled mechanical seal 433 and shaft protecting sleeve 524.01 onto
shaft 210.

Re-installing the mechanical seal - conical casing cover

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 50) to (⇨ Section 7.5.2 Page
50) have been observed/carried out.
✓ The bearing assembly and the individual parts of mechanical seal 433 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.
✓ The sealing surfaces have been cleaned.
1. Slip thrower 507.01 (if any) onto shaft 210 from the pump end.
2. Carefully press the stationary seat ring of mechanical seal 433 with O-ring into
casing cover 161.
3. Fit casing cover 161 with inserted seat ring into lantern 344.
4. Slide the rotating unit of mechanical seal 433 and spacer ring (if any) onto shaft
protecting sleeve 524.01 (observe distance B - see Supplementary Sheet of the
mechanical seal).
5. Slip pre-assembled mechanical seal 433 and shaft protecting sleeve 524.01 onto
shaft 210.

7.5.3.2 Packing the gland

a) b)
l l

da d1 da d1
Fig. 16: Gland packing chamber a) with lantern ring and b) without lantern ring

52 of 68 CPKN
7 Servicing/Maintenance

Table 25: Gland packing chamber

Bearing Gland packing chamber Packing cross- Packing rings
bracket Ø d1 Ø da l section
UP02 35 51 53 8x8 4 rings and
UP03 45 65 64 10 x 10 1 lantern ring
UP04 55 75 64 10 x 10
UP05 70 95 79 12.5 x 12.5 OR
UP06 80 105 79 12.5 x 12.5
6 rings
P08s 100 132 102 16 x 16
Pure graphite packings see supplementary operating instructions.
Always use pre-compressed packing rings.
✓ The notes and steps stated in (⇨ Section 7.5.1 Page 50) to (⇨ Section 7.5.2 Page
50) have been observed/carried out.
✓ The bearing assembly 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.
✓ The sealing surfaces have been cleaned.
1. Clamp casing cover 161 into a vice.
2. Push in neck bush 456.01.
3. Insert the first packing ring, ensuring that its cut edge is in horizontal position.
4. Hold the packing ring in place and slide shaft protecting sleeve 524 (chamfered
side first) into the gland packing chamber from the pump end.
5. Slightly expand the inside diameter of the packing ring by moving shaft
protecting sleeve 524 back and forth. Then pull out the shaft protecting sleeve.
Insert lantern ring 458, if any.
Insert each subsequent packing ring separately with its joint offset by approx. 90°
in relation to the previous one. Repeat the expansion procedure.
When the last packing ring has been inserted, shaft protecting sleeve 524
remains in the packing chamber.
6. Insert stuffing box ring 454.01 with the drilled hole down.
7. Fit gland follower 452 and lightly fasten it by hand with the two hexagon nuts
920.02; watch discs 550.01.
8. Fit guard 680.
9. Install complete discharge cover 161 with shaft protecting sleeve 524 in the
pump; take care not to damage joint ring 411.11.

7.5.4 Fitting the impeller

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 50) to (⇨ Section 7.5.3 Page
51) have been observed/carried out.
✓ The assembled bearing/mechanical seal as well as the individual parts are kept in
a clean and level assembly area.
✓ All dismantled components 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.
✓ Impeller bore, shaft and keyways are clean and free from burrs.
1. Insert keys 940.01 into the shaft keyway.
2. Insert joint ring 411.32.
3. Coat the impeller with a suitable lubricant.
4. Slip impeller 230 onto shaft 210.
5. Insert joint ring 411.31.

CPKN 53 of 68
7 Servicing/Maintenance

6. Screw impeller nut 922 to shaft 210. (⇨ Section 7.6.2 Page 55)

7.5.5 Fitting the back pull-out unit

WARNING
Back pull-out unit tipping over
Risk of squashing hands and feet!
▷ Suspend or support the bearing bracket at the pump end.

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 50) to (⇨ Section 7.5.4 Page
53) have been observed/carried out.
✓ Any damaged or worn parts have been replaced by original spare parts.
✓ The sealing surfaces have been cleaned.
✓ For back pull-out units without coupling, fit the coupling in accordance with the
manufacturer's instructions.
1. If required, suspend or support the back pull-out unit to prevent it from tipping
over. Then push it into volute casing 102 with a new gasket 411.10.
2. Tighten nut 920.01 at the volute casing.
3. Fasten support foot 183 to the baseplate with a foundation bolt.

7.5.6 Mounting the motor

NOTE
Steps 1 and 2 do not apply to versions with spacer-type coupling.

1. Shift the motor to connect it to the pump via the coupling.

2. Fasten the motor to the baseplate.
3. Align the pump. (⇨ Section 5.7 Page 26)
4. Connect the motor to the power supply (refer to manufacturer's product
literature).

7.6 Tightening torques

7.6.1 Tightening torques

Use torque wrench to tighten the screwed connections (902.02/920.01) between the
volute casing and the bearing bracket lantern.

54 of 68 CPKN
7 Servicing/Maintenance

Table 26: Tightening torques for screwed connections

Material C35E+Qt/C 35 A4-70/A4-70 1.7709+QT/1.7258+QT
stud/hex. nut 1.6772/1.6722
Stamp mark YK/Y A4-70/A4-70 GA/G
stud/hex. Tightening torques [Nm]
nut13)
Bearing A B A B A B
bracket
lantern14)
New -15 -20 New -15 -20 New -15 %16) -20 %16)
threads15) %16) %16) threads15) %16) %16) threads15)
M10 - - - 30 25.5 24 47 30 39.9 25,5 37.6 24
M12 40 34 32 55 46.7 44 80 55 68 46.7 64 44
M16 100 85 80 155 131.7 124 190 155 161.5 131.7 152 124
M20 - - - 200 170 160 330 200 280.5 170 264 160

7.6.2 Tightening torques for the impeller nut

Observe the following tightening torques for impeller nut (922):
Table 27: Tightening torques for the impeller nut
Bearing bracket Tightening torque Width across flats
[Nm] [mm]
UP02 80 22
UP03 125 27
UP04 200 32
UP05 300 41
UP06 520 55
P08s 1000 60

Re-tighten the impeller nut some 20 to 30 minutes after assembly.

7.7 Spare parts stock

7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:
▪ Type series
▪ Size
▪ KSB order number
▪ Material variant
▪ Year of construction

Refer to the name plate for all data.

Also supply the following data:

▪ Description
▪ Part No.
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)

13) Treat unstamped screwed connections like material pair C35/E+QT/C35.

14) A: made of toughened material - except for JL 1040; B: made of material JL 1040
15) These values are determined on the basis of a friction coefficient μ = 0.12.
16) After repeated tightening of the threads and in case of good lubrication, reduce the values by 15 to 20 %.

CPKN 55 of 68
7 Servicing/Maintenance

Refer to the general assembly drawing for part numbers and descriptions. (⇨ Section
9.1 Page 61)

Also see
• Name plate [⇨ 15]

7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 28: Quantity of spare parts for recommended spare parts stock
Part No. Description Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 10 and
more
210 Shaft 1 1 1 2 2 2 20 %
230 Impeller 1 1 1 2 2 2 20 %
320.02 Angular contact ball bearing 1 1 2 2 2 3 25 %
(set)
322.01 Cylindrical roller bearing 1 1 2 2 2 3 25 %
502.01 Casing wear ring 2 2 2 3 3 4 50 %
524.01 Shaft protecting sleeve 2 2 2 3 3 4 50 %
- Gaskets for pump casing (set) 4 6 8 8 9 12 150 %
- Torque-transmitting coupling 1 1 2 2 3 4 30 %
elements (set)
For variants with mechanical seal:
433 Mechanical seal complete 1 1 2 2 2 3 25 %
For variants with gland packing:
456.01 Neck bush 1 1 2 2 2 3 30 %
461.01 Gland packing (set) 4 4 6 6 6 8 100 %

7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

NOTE
Volute casing 102 and impeller 230 are not interchangeable between different pump
sizes.

Table 29: Interchangeability of pump components

Description
Angular contact ball bearing

Shaft protecting sleeve17)

Cylindrical roller bearing

Bearing bracket lantern

Stuffing box ring

Casing wear ring
Bearing bracket

Mechanical seal

Gland follower

Gland packing
Support foot
Casing cover

Lantern ring
Impeller nut

Neck bush
Seal cover
Thrower
Bearing bracket

Shaft
Pump size

Part No.
320.02

322.01

502.01

507.01

524.01

471.07

452.01

454.01

456.01

458.01

461.01
161

183

210

330

344

922

433

25-160 UP02 2 2 1 1 1 1 2 25 1 1 1 1 1 1 1 1 1 1
25-200 3 3 1 1 1 1 3 25 1 1 1 1 1 1 1 1 1 1
32-125 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

17) Depending on mechanical seal type

56 of 68 CPKN
7 Servicing/Maintenance

Description

Angular contact ball bearing

Shaft protecting sleeve17)

Cylindrical roller bearing

Bearing bracket lantern

Stuffing box ring

Casing wear ring
Bearing bracket

Mechanical seal

Gland follower

Gland packing
Support foot
Casing cover

Lantern ring
Impeller nut

Neck bush
Seal cover
Thrower
Bearing bracket

Shaft
Pump size

Part No.
320.02

322.01

502.01

507.01

524.01

471.07

452.01

454.01

456.01

458.01

461.01
161

183

210

330

344

922

433
32-160 2 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1
32-200 3 3 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1
40-160 2 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1
40-200 3 3 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1
50-160 2 3 1 1 1 1 2 3 1 1 1 1 1 1 1 1 1 1
50-200 3 3 1 1 1 1 3 3 1 1 1 1 1 1 1 1 1 1
32-250 UP03 6 5 2 2 2 2 6 6 2 2 2 2 2 2 2 2 2 2
40-250 6 5 2 2 2 2 6 5 2 2 2 2 2 2 2 2 2 2
40-315 7 6 2 2 2 2 7 5 2 2 2 2 2 2 2 2 2 2
50-250 6 5 2 2 2 2 6 4 2 2 2 2 2 2 2 2 2 2
50-315 7 7 2 2 2 2 7 7 2 2 2 2 2 2 2 2 2 2
65-160 4 4 2 2 2 2 4 7 2 2 2 2 2 2 2 2 2 2
65-200 5 5 2 2 2 2 5 8 2 2 2 2 2 2 2 2 2 2
65-250 6 6 2 2 2 2 6 8 2 2 2 2 2 2 2 2 2 2
80-160 4 5 2 2 2 2 4 9 2 2 2 2 2 2 2 2 2 2
80-200 5 5 2 2 2 2 5 10 2 2 2 2 2 2 2 2 2 2
80-250 6 7 2 2 2 2 6 11 2 2 2 2 2 2 2 2 2 2
100-200 5 6 2 2 2 2 5 12 2 2 2 2 2 2 2 2 2 2
65-315 UP04 9 8 3 2 2 2 7 9 3 3 3 3 3 3 3 3 3 3
80-315 9 9 3 2 2 2 7 12 3 3 3 3 3 3 3 3 3 3
80-400 10 10 3 2 2 2 8 27 3 3 3 3 3 3 3 3 3 3
100-250 8 8 3 2 2 2 6 13 3 3 3 3 3 3 3 3 3 3
100-315 9 9 3 2 2 2 7 14 3 3 3 3 3 3 3 3 3 3
100-400 10 10 3 2 2 2 8 14 3 3 3 3 3 3 3 3 3 3
125-250 8 9 3 2 2 2 6 15 3 3 3 3 3 3 3 3 3 3
125-315 9 10 3 2 2 2 7 16 3 3 3 3 3 3 3 3 3 3
125-400 10 11 3 2 2 2 8 15 3 3 3 3 3 3 3 3 3 3
150-250 8 10 3 2 2 2 6 16 3 3 3 3 3 3 3 3 3 3
150-315 UP05 12 12 4 3 3 3 10 18 4 4 4 4 4 4 4 4 4 4
150-400 13 12 4 3 3 3 11 18 4 4 4 4 4 4 4 4 4 4
150-500 14 14 4 3 3 3 12 18 4 4 4 4 4 4 4 4 4 4
200-250 11 13 4 3 3 3 9 17 4 4 4 4 4 4 4 4 4 4
200-315 12 13 4 3 3 3 10 19 4 4 4 4 4 4 4 4 4 4
200-400 13 13 4 3 3 3 11 20 4 4 4 4 4 4 4 4 4 4
200-500 14 17 4 3 3 3 12 28 4 4 4 4 4 4 4 4 4 4
250-315 12 16 5 3 3 3 10 21 4 4 4 4 4 4 4 4 4 4
250-400 UP06 15 17 6 4 4 4 11 22 5 5 5 5 5 5 5 5 5 5
250-500 16 15 6 4 4 4 12 23 5 5 5 5 5 5 5 5 5 5
300-400 P08s 17 15 7 4 4 5 13 22 6 6 6 6 6 6 6 6 6 6

17) Depending on mechanical seal type

CPKN 57 of 68
17)
350-500
350-400
300-500

58 of 68
Pump size

Bearing bracket

18
17
18
161 Casing cover

Part No.

18
18
18
183 Support foot
Description

7
8
7
210 Shaft

CPKN
Depending on mechanical seal type
4
4
4
320.02 Angular contact ball bearing

4
4
4
322.01 Cylindrical roller bearing

5
5
5
330 Bearing bracket
7 Servicing/Maintenance

14
13
14

344 Bearing bracket lantern

26
26
24

502.01 Casing wear ring

6
6
6

507.01 Thrower
6
6
6

524.01 Shaft protecting sleeve17)

6
6
6

922 Impeller nut

6
6
6

433 Mechanical seal

6
6
6

471.07 Seal cover

6
6
6

452.01 Gland follower

6
6
6

454.01 Stuffing box ring

6
6
6

456.01 Neck bush

6
6
6

458.01 Lantern ring

6
6
6

461.01 Gland packing

8 Trouble-shooting

8 Trouble-shooting
A Pump delivers insufficient flow rate

B Motor is overloaded

C Excessive pump discharge pressure

D Increased bearing temperature

E Leakage at the pump

F Excessive leakage at the shaft seal

G Vibrations during pump operation

H Impermissible rise of temperature inside the pump

Table 30: Trouble-shooting
A B C D E F G H Possible cause Remedy 18)
X Pump delivers against an excessively Re-adjust to duty point.
high discharge pressure. Check system for impurities.
Fit a larger impeller. 19)
Increase the speed (turbine, I.C. engine).
X X X Pump or piping are not completely Vent and/or prime.
vented or primed.
X Supply line or impeller clogged. Remove deposits in the pump and/or piping.
X Formation of air pockets in the piping. Alter the piping layout.
Fit a vent valve.
X X X Suction head is too high/NPSH available Check/alter fluid level.
(positive suction head) is too low. 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.
X Air intake at the shaft seal. Clean barrier fluid duct, supply external
barrier fluid, if necessary, or increase barrier
fluid pressure.
Fit new shaft seal.
X Wrong direction of rotation. Interchange two of the phases of the power
cable.
X Speed is too low. 19)
- Increase voltage/frequency at the FI within
- Operation with frequency inverter the permissible range.
- Operation without frequency inverter - Increase the voltage.
X X Impeller Replace worn parts by new ones.
X X Pump back pressure is lower than Re-adjust to duty point.
specified in the purchase order. In the case of persistent overloading, turn
down impeller. 19)
X Density or viscosity of the fluid Contact KSB.
pumped is higher than stated in the
purchase order.
X X Gland follower too tight or askew. Correct.
X X Speed is too high. Reduce speed. 19)
X Defective seal Fit new seal between volute casing and
discharge cover.
X Worn shaft seal. Fit new shaft seal.
Check flushing liquid / barrier fluid.

18) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
19) Contact KSB.

CPKN 59 of 68
8 Trouble-shooting

A B C D E F G H Possible cause Remedy 18)

X X Score marks or roughness on shaft Replace shaft protecting sleeve / shaft sleeve.
protecting sleeve / shaft sleeve Fit new shaft seal.
X Vibrations during pump operation. Correct suction conditions.
Re-align the pump.
Re-balance the impeller.
Increase pressure at the pump suction nozzle.
X X X The pump set is misaligned. Re-align.
X X X Pump is warped or sympathetic Check pipeline connections and secure fixing
vibrations in the piping. of pump; if required, reduce the distances
between the pipe clamps.
Fix the pipelines using anti-vibration material.
X X Insufficient or excessive quantity of Top up, reduce or change lubricant.
lubricant or unsuitable lubricant.
X Non-compliance with specified Correct distance according to the general
coupling distance. arrangement drawing.
X X Motor is running on two phases only. Replace the defective fuse.
Check the power cable connections.
X Rotor is out of balance. Clean the impeller.
Re-balance the impeller.
X Defective bearing(s) Fit new bearing(s).
X X Insufficient flow rate Increase the minimum flow rate.
X Incorrect inflow of circulation liquid. Increase the free cross-section.

18) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

60 of 68 CPKN
9 Related Documents

9 Related Documents

9.1 General assembly drawing with list of components

903.03 903.02 902.04
230 524.01 411.11 344 400.01 322.01 672 550.23 400.02
411.03 411.02 920.04
102 412.01 411.10 901.31 914.01 330 932.02 320.02

914.02
903.18
411.18 920.21

360.02
903.04
411.04
210
903.16/.17
411.16/.17

940.02

421.02

931.01
922 502.01
561.01
901.04
930.01
914.04

D00462 183
903.01 903.18 638
161
411.01 411.32 411.18 360.01 932.01 903.46
940.01 561.02 902.01 507.01 421.01 411.46
411.31
920.01
Fig. 17: General assembly drawing of standard variant (oil-lubricated)

CPKN 61 of 68
9 Related Documents

550.01
920.02
411.15 471.01
a) 463.01 902.02
b) c)
458.01 452.01 680
902.02
920.02

561.03

456.01 454.01
461.01 648 433.02 561.03 524.01 524.01 433.02
Fig. 18: Variant with gland packing (a), Mechanical seal with conical casing cover (b), Mechanical seal with
cylindrical casing cover (c)

636.02 360.01 400.01 932.02 550.23 400.02 360.02

322.01 932.01 320.02 636.03

507.01 421.01 550.24 550.25 931.01 421.02

914.01 914.02 920.21

Fig. 19: Grease-lubricated version

Table 31: List of components
Part No. Description Scope of supply
102 Volute casing with joint ring 411.01/.03, joint ring 411.1020) , casing wear ring
502.0121) , stud 902.01, screwed plug 903.01/.03, hexagon nut
920.01
161 Casing cover with joint ring 411.11/.16/.17, O-ring 412.0122) , stud23) 902.02,
screwed plug 903.16/.17, hexagon nut 920.02
183 Support foot with hexagon head bolt 901.0424) , spring washer 930.01

20) Joint ring 411.10 (and 411.15 for variants with mechanical seal) depending on the operating temperature. Order
separately in spare parts order.
21) For CPKN-S only.
22) Not fitted on pump version with conical seal chamber.
23) Not shown in drawing
24) On bearing bracket UP02: socket head cap screw 914.04.

62 of 68 CPKN
9 Related Documents

Part No. Description Scope of supply

210 Shaft with keywayed nut 920.21, lockwasher 931.01, key 940.01/.02
230 Impeller with joint ring 411.32 or O-ring 412.0620)
320.02 Angular contact ball bearing
322.01 Cylindrical roller bearing
330 Bearing bracket
330 Bearing bracket complete with bearing cover 360.01/.02, gasket 400.01/.02, joint ring 411.46,
lip seal 421.01/.02, support disc 550.23, constant level oiler25) 638,
vent plug 672, screwed plug 903.46, socket head cap screw
914.01/.02, circlip 932.01/.02, disc 550.24/.2526) , lubricating nipple
636.02/.0326)
344 Bearing bracket lantern with O-ring 412.0122) , grooved pin 561.02, screwed plug 903.18,
stud 902.04, hexagon head bolt 901.31, hexagon nut 920.04, joint
ring 411.18
360.01/02 Bearing cover with gasket 400.01/.02, socket head cap screw 914.01/.02
421.01/02 Lip seal
433.01 Mechanical seal complete23)
471.01 Seal cover23) with joint ring 411.1520) , grooved pin 561.03
452.01 Gland follower
454.01 Stuffing box ring
456.01 Neck bush
458.01 Lantern ring
461.01 Gland packing
463.01 Drip plate
502.0121) Casing wear ring with grooved pin 561.01
507.01 Thrower
524.01 Shaft protecting sleeve with joint ring 411.32
638 Constant-level oiler
922 Impeller nut with joint ring 411.31

25) Not applicable for grease-lubricated variants.

26) For grease lubricated variants only.

CPKN 63 of 68
10 EC Declaration of Conformity

10 EC Declaration of Conformity

Manufacturer: KSB Aktiengesellschaft

Johann-Klein-Straße 9
67227 Frankenthal (Germany)

The manufacturer herewith declares that the pump/pump set:

CPKN, CPKNO, CPKN-CHs

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

▪ is in conformity with the provisions of the following directives as amended from time to time:
– EC Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:
– ISO 12100-1/A1, ISO 12100-2/A1,
– ISO 14121-1,
– EN 809/A1

▪ Applied national technical standards and specifications, in particular:

– DIN EN ISO 5199

Pegnitz, 29 December 2009

...........................................................
Name
Function
Responsible for compiling the technical documentation
KSB Aktiengesellschaft
Bahnhofplatz 1
91257 Pegnitz (Germany)

64 of 68 CPKN
11 Certificate of Decontamination

11 Certificate of Decontamination

Type ................................................................................................................................
Order number/
Order item number27) ................................................................................................................................

Delivery date ................................................................................................................................

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

Fluid handled27) : ................................................................................................................................

Please tick where applicable27) :

⃞ ⃞ ⃞ ⃞
radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞
harmful bio-hazardous highly flammable safe

Reason for return27) : ................................................................................................................................

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

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

The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing
at your disposal.
On seal-less pumps, the rotor has been removed from the pump for cleaning.

⃞ No special safety precautions are required for further handling.

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

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

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

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

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

Place, date and signature Address Company stamp

27) Required fields

CPKN 65 of 68
Index

Index

A Installation
Installation on foundation 20
Abrasive fluids 39 Installation without foundation 21
Installation at site 20
B Intended use 8
Interchangeability of pump components 56
Bearing temperature 42
Bearings 16
K
C Keeping the pump warm 35

Certificate of decontamination 65
Clearance gaps 43 M
Commissioning/start-up 31 Maintenance/repair 41
Constant-level oiler 31 Mechanical seal 36
Coupling 43 Misuse 9
Coupling alignment 26 Monitoring equipment 12

D N
Design 15, 18 Name plate 15
Designation 15 Noise characteristics 18
Direction of rotation 30
Dismantling 47
Disposal 14 O
Oil lubrication
E Intervals 44
Oil quality 44
Explosion protection 10, 20, 25, 26, 27, 28, 29, 32, 34, Oil quantity 44
35, 36, 38, 41, 43, 44 Operating limits 8
Order number 6
F Ordering spare parts 55
Other applicable documents 6
Filter 22, 43
Final check 33
Flow rate 38 P
Frequency of starts 38 Partly completed machinery 6
Function 18 Permissible forces and moments at the pump nozzles
23
G Piping 22
Preservation 14, 40
General assembly drawing 61 Priming and venting 32
Gland packing 36 Product description 15
Grease lubrication Pure graphite packing ring 36
Grease quality 46
Intervals 45
R
H Return to supplier 14
Returning to service 40
Heating 34 Running noises 41, 42
Heating speed 35
Heating up 35

I
Impeller type 16

66 of 68 CPKN
Index

S T
Safety 8 Temperature difference 35
Safety awareness 9 Temperature limits 11
Scope of supply 19 Tightening torques 54, 55
Shaft seal 16 Transport 13
Shutdown 37, 40 Trouble-shooting 59
Spare parts stock 56
Start-up 35
Storage 14, 40 W
Water cooling 33

CPKN 67 of 68
2730.8/4-10

KSB Aktiengesellschaft
P.O. Box 1361 • 91253 Pegnitz • Bahnhofplatz 1, 91257 Pegnitz (Germany)
Tel. +49 9241 71-0 • Fax +49 9241 71-1793
www.ksb.com