Instruction Manual

Instruction Manual
DESCON - ENGRO
Boiler Feed Water Pump Driven By Electric Motor / Turbine
Works serial No. 9973105255 000100/1 & 9973105255 000300/1

Pump HGM 2/9
P.O. No. P/O-LMW-DEL PK No.: 4500040694
Position No. HP BFW Pump
All Maintenance, service and installation work can be carried out by KSB-
Service.
Service-adresses
Local service-adress
 Pakistan
 KSB Pumps Co. Limited
162, Sir Aga Khan Road
LAHORE – 54000
Tel.+92 42 6304173
+92 42 7311661
Fax+9242 6366192
E-mailksbpak@ms.net.pk
Service adress Germany
 KSB Service GmbH Michael Matthes

67227 Frankenthal
Nachtweideweg 1-7
67227 Frankenthal
Tel. +49 6233 86 3100

Fax +49 6233 86 3933
Round-the-clock phone number in case of necessity:
Tel. +49 6233 86-0
Internet:
www.ksb.com/contact
Contents
Legal information / Copyright
Installation/Operating Manual HGM

Original operating manual
KSB Aktiengesellschaft
All rights reserved. Contents provided herein must neither be distributed, copied,
reproduced, processed for any other purpose, nor otherwise transmitted to a third party
without KSB’s express written consent.
Subject to technical modification without prior notice.
E KSB Aktiengesellschaft Frankenthal 21.10.2009
Standard--Betriebshandbuch
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Ausführung_ungek. Revisionsdatum_21.10.2009
Contents
Chapter 1 General
1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Information on the Instruction Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Relevant Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2 Safety
2.1.1 Key to Safety Symbols/Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2. General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.2 Prevention of Foreseeable Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.3 Personnel Qualification and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.4 Non--compliance with Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.5 Safety Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.6 Safety Instructions for the Operator/User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.7 Safety Instructions for Work on the Pump (Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2.8 Unauthorised Modification and Manufacture of Spare Parts . . . . . . . . . . . . . . . . 6
2.3 Pump Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3.1 Temperature >80_C/176_F: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.2 Instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3.3 Name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 3 Transport / Temporary Storage / Disposal

3.1.1 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1.2 Lifting Accessories (e.g. eyebolt, ropes, lifting gear) . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1.3 Signals During Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1.4 Transport Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Transport of the Packaged Components of the Pump Set . . . . . . . . . . . . . . . . . . . . 4
3.3 Transport of the Partly--packaged or Unpackaged Components of the Pump Set . 5
3.3.1 Transport of the Pump Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3.2 Transport of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.3 Transport of the Other Pump Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.4 Transport of the Pump Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.5 Transport of Pump Set Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Temporary Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4.2 Place of Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4.3 Period of Storage up to 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.4 Period of Storage over 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Return to Supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.1 Oil and Oil--containing Waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.2 Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.3 Disposal of Electrotechnical and Electronic Components . . . . . . . . . . . . . . . . . . . 14
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Chapter 4 Description
4.1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.2 Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.3 Name Plate (to TRD401/402) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.4 Design Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4.5 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 5 Installation at Site

Checklist: Assembly
5.1.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2.1 Requisite Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2.2 Measures to be Taken after Long--term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5.2.2.1 Internal preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.2.2.2 External preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.2.3 Additional Work to be Carried out Prior to Returning to Service after
Standstill of more than 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5.2.4 Transporting the Pump Set Components to the Place of Installation . . . . . . . . . . 5
5.2.5 Unpackaging the Pump Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2.6 Dismantling the Coupling Guard and Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2.6.1 Coupling Guard (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2.6.2 Coupling Guard (explosion protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.6.3 Dismantling the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.6.4 Mounting the coupling hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2.6.5 Preparing the levelling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Installation of the Pump Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3.1 Fastening with Foundation Bolts (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3.2 Fastening with Bonded Anchors (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3.3 Fastening with Special Foundation Bolts (if applicable) . . . . . . . . . . . . . . . . . . . . . 11
5.4 Connecting Coupling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.4.1 Run--out Check of Pump Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4.1.1 For coupling hubs with outside step: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4.1.2 For coupling hubs without outside step: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4.2 Alignment of the Coupling Hubs Relative to Each Other . . . . . . . . . . . . . . . . . . . . 15
5.4.2.1 Examples of alignment using dial gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.4.2.2 Alignment of Connecting Coupling Using a Laser Device (alternative) . . . . . . . . 16
5.4.3 Considering Height and Lateral Displacements of the Pump Set Caused
by Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4.3.1 Determination of the Displacement in Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4.3.2 Example of Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4.3.3 Permissible Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4.4 Alignment Corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.4.1 Height correction on the electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.4.2 Lateral correction of the electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.4.4.3 Height correction on the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4.4.4 Alignment corrections on the other pump set components . . . . . . . . . . . . . . . . . . 22
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5.5 Drilling the Holes for Fastening the Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.6 Fastening the Baseplate on the Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6.1 With Foundation Bolts (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6.2 With Bonded Anchors (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.6.3 With Special Foundation Bolts (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.7 Mounting the Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.7.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.7.2 Cleaning the Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.7.3 Installation of Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.7.4 Connecting the Pipes to the Pump Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7.4.1 Flange end variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.7.4.2 Weld end nozzle variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.7.4.3 Minimum flow and balancing liquid pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.8 Final Installation of the Pump Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.8.1 Fastening the pump feet: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.8.2 Pinning the Pump Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.9 Mounting the Instruments (if applicable, and not fitted at the factory) . . . . . . . . . . . 36
5.9.1 Pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.9.2 Differential Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.10 Preservation for Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 6 Commissioning, Start--up / Operation / Shutdown

Checklist: Commissioning
6.2 Work to Be Carried out Prior to Commissioning, Start--up . . . . . . . . . . . . . . . . . . . . . 3
6.2.1 Requisite Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.2.2 Removal of Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.2.2.1 Internal preservation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.2.2.2 External preservation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standstill of more than 12 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
6.2.4 Checking the Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.2.4.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.2.4.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6.2.4.3 Checking the Direction of Rotation with a Phase--sequence Indicator . . . . . . . . 4
6.2.4.4 Checking the Direction of Rotation without Phase--sequence Indicator . . . . . . . 5
6.2.5 Rotatability of the Pump Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2.6 Mounting the Connecting Coupling and Guard Preventing Accidental Contact . 8
6.2.6.1 Mounting the Connecting Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2.6.2 Mounting the Guard Preventing Accidental Contact . . . . . . . . . . . . . . . . . . . . . . . . 8
6.2.7 Functional Test and Adjustment of the Instruments . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2.8 Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2.9 Priming the Pump and Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Commissioning, Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.3.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.3.2 Checks Prior to Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.3.3 Starting and Trial Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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6.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.1 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4.1.1 Frequency of starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4.1.2 Ambient temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.4.2 Safety Instructions for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.5.1 Shutdown -- Pump Set Remains Ready for Operation . . . . . . . . . . . . . . . . . . . . . . 17
6.5.2 Shutdown For Maintenance of the Pump Set or Prolonged Standstill . . . . . . . . . 17
6.6 Work after Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.6.1 Work after Shutdown during Readiness for Instant Start--up . . . . . . . . . . . . . . . . . 18
6.6.2 Work after Shutdown for Maintenance of the Pump Set . . . . . . . . . . . . . . . . . . . . . 18
6.6.3 Work after Shutdown for Standstill -- Pump not Ready for Operation . . . . . . . . . 20
6.6.3.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.7 Detailed Description of Preservation for Standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.8 Returning to Service after Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 7 Supervision / Servicing / Maintenance

7.1 Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.1.1 Pump Supervision Plan, HGM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2.1.1 Requisite Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.2.1.2 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.2.1.3 Servicing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.2.2 Dismantling the Guards Preventing Accidental Contact . . . . . . . . . . . . . . . . . . . . . 4
7.2.3 Pump Servicing Plan, HGM after Commissioning/Start--up and Stand--by . . . . . 5
7.2.4 Servicing Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.2.4.1 Servicing Work on the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.3.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.3.1.1 Requisite Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.3.2 Prerequisites for Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.3.3 Dismantling the Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.3.1 Sound Insulating Hood (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.3.2 Coupling Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.3.4 Dismantling the Connecting Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.3.4.1 Dismantling the Connecting Coupling Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.3.4.2 Checking the Thrust Bearing Clearance
(only necessary for checking the clearance increase) . . . . . . . . . . . . . . . . . . . . . . 11
7.3.4.3 Removing the Coupling Hubs (keyed connection) . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.3.4.4 Run--out Check of the Shaft Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.3.5 Removing the Pump from the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3.5.1 Dismantling the Piping and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3.5.2 Removing the Pump from the Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3.5.3 Transporting the Pump to the Place of Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Revisionsstand_00
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Contents
7.3.6 Dismantling the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

7.3.6.1 Dismantling the Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3.6.2 Dismantling the Thrust Bearing, Discharge--side Radial Bearing
and Balancing Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.3.7 Reassembling the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.3.7.1 General Information on Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.3.7.2 Reassembling the Discharge--side Radial Bearing and Thrust Bearing . . . . . . . 20
7.3.7.2.1 Not Using New Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.3.7.2.2 Using a New Balance Drum (603) and/or New Thrust Bearing Ring (386.01) . . 22
7.3.7.3 Mounting the Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.3.8 Installing the Pump in the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3.8.1 Transporting the Pump to the Place of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.3.8.2 Aligning the Pump Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3.8.3 Mounting the Pipes and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3.9 Mounting the Connecting Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.3.9.1 Run--out Check of the Shaft Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3.9.2 Fitting the Coupling Hubs (keyed connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3.9.3 Mounting the Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3.10 Mounting the Guards Preventing Accidental Contact . . . . . . . . . . . . . . . . . . . . . . . 34
7.3.10.1 Coupling Guard (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3.10.2 Coupling Guard (explosion protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3.11 Maintenance of the Other Pump Set Components . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.12 Maintenance of the Connecting Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.13 Maintenance of the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.14 Maintenance of the Minimum Flow System and the Minimum Flow Valve . . . . . 36
7.3.15 Maintenance of the Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.16 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.16.1 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3.16.2 Spare Parts Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.3.16.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 8 Trouble--shooting
Failure Report
Chapter 9 Relevant Documentation
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Chapter 1 General
Non--compliance with the regulations laid down in the in-

struction manual leads to forfeiture of any and all rights
to claims for damages.
The directives, regulations and instructions set forth in
this instruction manual apply to the use of the products
in a member state of the European Union. If the products
are used outside the European Union, the operator is re-
sponsible for making sure that the directives, regulations
and instructions also meet the local/national regulations
applicable at the place of installation and, as the case
may be, the operator must take into account, on own re-
sponsibility, more stringent or deviating regulations.
All work on the pump set must only be performed by pro-
perly trained personnel who are familiar with the dismant-
ling/reassembly work required.
This instruction manual must always be kept close to the
location of operation of the pump set for easy access.
We recommend to call in KSB’s experienced personnel
for installation, commissioning/start--up, maintenance,
and in case of problems.
If our products are connected to components which have
not been supplied by KSB, KSB cannot accept any liabil-
ity for the suitability and freedom from defects of the
components as well as for the functionality of the con-
nections from those components to our products. The
customer, where applicable jointly with the supplier of
those components, is responsible for ensuring in partic-
ular the suitability of the directly connected components
not supplied by KSB.
Baureihe_CHT, HG, HGM
Kap.1_de
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Revisionsdatum_31.10.2009
Chapter 1 General
1. General
1.1 General Information

The descriptions and instructions set forth in this instruction manual apply to the
apply to the type series, pump size and variant included in KSB s scope of supply
and indicated on the front cover. This instruction manual describes the proper and
safe use of the pump (set) in all phases of operation.
The instruction manual does not cover any eventualities or events which might occur
during installation, maintenance, servicing and operation of the machine.
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.
This information must be quoted in all queries and repeat orders and, in particular,
when ordering spare parts.
In case of damage, immediately contact your nearest KSB Service centre to maintain
the right to claim under warranty.
KSB pumps/pump sets are developed in accordance with state--of--the--art techno-
logy, are manufactured with utmost care and subject to continuous quality control.
If they are properly installed, serviced and maintained, the pumps/pump sets will give
reliable and trouble--free operation.
Call in KSB specialist personnel for installation, commissioning/start--up and mainte-
nance. KSB will only assume responsibility for faultless execution of the work and
for the safety of the personnel involved if dismantling/reassembly and maintenance
have been performed by KSB’s specialist personnel.
This pump (set) must not be operated beyond the limit values specified in the data
sheets. Make sure that operation is in accordance with the instructions laid down in
this manual. The Operator must take into account the information set out in chapter
9 or in other parts of the instruction manual or in the contract documentation.
It is of vital importance to observe the specified electrical connection values as well
as the dismantling/reassembly and servicing instructions. IIn particular, it must be
ensured that all necessary measures are taken and the regulations in accordance
with the relevant legislation are complied with.
The operator is responsible for ensuring that the safety regulations applicable at the
place of installation of the pump (set) are observed. All safety instructions in this
instruction manual and all other applicable documents as well as all instructions on
labels, tags and stickers attached to the pump set must be observed. This instruction
manual must always be kept available at the place of operation of the pump (set) for
easy access.
Any work on the pump set exceeding the activities described in this instruction
manual requires special knowledge and shall only be performed by KSB specialist
personnel.
If you need any additional information or instructions and in case of problems, please
contact KSB Service GmbH.
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Chapter 1 General
1.2 Information on the Instruction Manual

This instruction manual describes the design and function of the pump (set). It helps
the operating and maintenance personnel to familiarise with all work to be performed
on the pump (set).
This instruction manual must be read carefully, and it must be ensured that its
contents are fully understood. The instruction manual must always be kept
available at the place of installation of the pump (set) for easy access.
This instruction manual is subdivided into 9 chapters. Every page indicates the
chapter number and the title of the respective chapter in the header. Information on
the type of document, type series, revision status and date of issue is given in the
footer of each page.
1.3 Relevant Documentation

A list of the applicable documents is found at the beginning of chapter 9.
1.4 Declaration of Conformity

The relevant declaration as defined in the EU Machinery Directive (2006/42/EC) is
contained in chapter 9.1
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Chapter 2 Safety
2. Safety

This instruction manual contains fundamental information which must be complied
with during all work on the pump (set).
The instruction manual must be read both by the service engineers and the
responsible trained personnel/operator prior to commencement of installation and
commissioning, and it must always be kept available at the place of installation of
the pump (set) for easy access.
The operator is responsible for ensuring that all local regulations which are not taken
into account in this manual are observed.
The safety instructions in all sections of this manual must be observed.
Instructions (e.g. name plate, arrow indicating the direction of rotation, markings of
connections) attached directly to the pump (set) must always be complied with and
be kept in a perfectly legible condition at all times.
For installation, commissioning/start--up and maintenance, or in case of problems
please contact KSB s customer service.
2.1.1 Key to safety Symbols/Markings
2.1.1.1 Personal injury:

The safety instructions contained in this manual whose non--observance might
cause hazards to persons are specially marked with the following signal words and
hazard symbols:
DANGER
The signal word DANGER indicates an imminent danger which, if not avoided,
will result in death or serious, irreversible injury (disfigurement).
WARNING
The signal word WARNING indicates a potential hazardous situation which, if
not avoided, could result in death or serious, irreversible injury..
CAUTION
The signal word CAUTION indicates a potential hazardous situation which,
if not avoided, could result in minor or moderate, reversible ininjury.
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Chapter 2 Safety
The signal words given above are combined with hazard symbols which specify the
type of hazard:
General hazard symbol

This symbol indicates a potential personal injury hazard which may result in
death or serious injuries.
Electrical hazard symbol

This symbol indicates a potential personal injury hazard involving electrical
voltages which may result in death or serious injury.
Hot surface hazard

This symbol indicates a potential personal injury hazard of hot surfaces which
may cause burns.
Use ear protection!

This symbol indicates a potential personal injury hazard which may result in loss
of hearing or threaten the hearing by noise (noise level ≥ 85 dB(A)).
2.1.1.2 Damage to property:

Safety instructions whose non--observance may cause hazards to the pump (set)
and their functions or the environment are marked with the signal word CAUTION
and the “machine damage” symbol:
NOTICE
The signal word NOTICE indicates a potential hazardous situation which, if not
avoided, may lead to damage to the pump or something in its environment.
2.1.1.3 Other:
NOTE
Recommendations and important information on how to handle the product.
NOTE
Important note on environmental protection
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Chapter 2 Safety
2.2 General Safety Instructions
2.2.1 Intended Use

KSB’s pumps of the CHT, HG and HGM type series are centrifugal pumps for
handling of and increasing the pressure of fluids.
The pump design is found in the data sheets in chapter 9.
To ensure operating reliability, the pump (set) must only be operated in the fields of
application given in the data sheets in chapter 9 and only within the use limits.
As a general rule, all items below must be observed and complied with:
The pumped medium pressure at the discharge nozzle must not exceed the
maximum permissible pump discharge pressure.
The pumped medium pressure at the suction nozzle must not exceed the maxi-
mum permissible pump inlet pressure.
The pumped medium temperature must not exceed the permissible value.
Observe the information on minimum flow rates specified on the data sheet or in
chapter 9.2 (to prevent overheating, damage to seal elements, damage to bea-
rings, cavitation damage, etc.).
Observe the information on maximum flow rates specified on the data sheet
in chapter 9.2 (to prevent overheating, damage to seal elements, cavitation
damage, damage to bearings, etc).
Do not throttle the flow rate on the suction side of the pump (to prevent cavitation
damage).
The pump may only be used to handle the approved medium indicated in chapter
9.2.
Never operate the pump without the fluid to be handled.
The pump must only be operated in the direction of rotation indicated.
The pump must only be operated when in perfect technical condition.
The pump must not be operated in partially assembled condition.
The pump or its components must not be altered in any way.
The pump must not be installed and operated in potentially explosive atmospheres.
The manufacturer’s supervision and servicing specifications as given in chapter 7.1
and chapter 7.2 must be complied with.
Should modes of operation other than those given in the data sheets in chapter 9.2
be requested, these must be checked and approved by the manufacturer.
All safety notes and instructions in this manual and the related documents must be
observed.
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Chapter 2 Safety
2.2.2 Prevention of Foreseeable Misuse

The pump (set) may only be operated in accordance with its ”intended use”. All
specifications given there must be observed and strictly adhered to. Any other use
or use beyond that for which it is intended is deemed impermissible misuse. The
manufacturer shall not accept any liability for damage resulting from misuse.
DANGER
Operation outside the use limits permitted may lead to failure of seal
elements and parts which are subjected to pressure. which might result in
hot or pressurised medium handled escaping.
Danger to life, e.g. cuts caused by fluid jets, burns, scalds, respiratory system
burns.
' The pumped medium pressure at the discharge nozzle must not exceed the
maximum permissible pump discharge pressure.
' The pumped medium pressure at the suction nozzle must not exceed the
maximum permissible pump inlet pressure.
' The pumped medium temperature must not exceed the permissible value.
' Observe the information on minimum flow rates specified on the data sheet or
in chapter 9.2 (to prevent overheating, damage to seal elements, damage to
bearings, cavitation damage, etc.).
' Observe the information on maximum flow rates specified on the data sheet in
chapter 9.2 (to prevent overheating, damage to seal elements, cavitation
damage, damage to bearings, etc).
' The pump may only be used to handle the approved medium indicated in
chapter 9.2.
' Take appropriate measures in accordance with the local regulations to avoid
exceeding of or falling below the permitted use limits due to operating errors,
malfunctions or procedural errors.
' The pump must only be operated when in perfect technical condition. Safety--
relevant faults must be remedied immediately.
' The pump must not be operated in partially assembled condition.
' The pump or its components must not be altered in any way.
' Regularly check that all monitoring and alarm equipment is in perfect condition.
' As a general rule, the use limits permitted for operation and indicated in
chapter 9.2 must always be complied with.
DANGER
Explosion hazard when operating a pump (set) which is not explosion--proof
in potentially explosive atmospheres.
anger of death from explosion! Serious internal and external injuries by mechanical
and thermal effects which could result in death.
' The pump must not be installed and operated in potentially explosive
atmospheres.
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Chapter 2 Safety
2.2.3 Personnel Qualification and Training

All personnel involved in the work to be performed on the pump (set) must be fully
qualified to carry out the work involved.
Personnel responsibilities, competence and supervision must be clearly defined by
the operator.
If the personnel in question does not already possess the requisite know--how,
appropriate training and instruction must be provided.
If required, the operator may commission the manufacturer/supplier of the pump
(set) to take care of such training.
Training on the pump (set) must always be supervised by the technical specialist
personnel.
In addition, the operator is responsible for ensuring that the contents of the instruc-
tion manual are fully understood by the responsible personnel.
2.2.4 Non--compliance with Safety Instructions

Non--compliance with safety instructions can jeopardise the safety of personnel, the
environment and the pump (set) itself.
Non--compliance with safety instructions will lead to forfeiture of any and all rights
to claims for damages.
In particular, non--compliance can, for example, result in:
-- Hazard to persons and property by electrical, mechanical, chemical and/or
thermal effects
-- Hazard to the environment caused by leakage of hazardous substances
-- Failure of important pump (set) functions
-- Failure of prescribed maintenance and servicing practices
2.2.5 Safety Awareness

It is imperative to comply with the safety instructions contained in this manual, the
relevant national health and safety regulations and the operator’s own internal
work, operation and safety regulations.
2.2.6 Safety Instructions for the Operator/User

Any hot or cold components of the pump (set) that could pose a hazard must be
equipped with a guard preventing accidental contact by the Operator.
Guards which are fitted to prevent accidental contact with moving parts must not
be removed whilst the unit is operating.
Leakages of hazardous media handled or consumables must be contained so as
to avoid any hazard to persons and the environment. All pertinent legal provisions
must be adhered to.
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Chapter 2 Safety
Any electrical hazard must be eliminated. In this respect refer to the relevant safety
regulations of the individual countries, the VDE regulations or the safety regulations
laid down by the local energy supply companies.
The Operator is obliged to ensure that all work on the pump (set) be performed
during standstill only. The pump (set) must be depressurised and have cooled
down to a temperature below 50_C. The pump must be drained before dismantling
it.
The drives must have been disconnected from their energy supply (e.g. electrical
power system, steam or fuel supply system) and secured so as to prevent uninten-
tional starting.
Appropriate personal protective equipment must be available and be used.
2.2.7 Safety Instructions for Work on the Pump (Set)

The Operator is responsible for ensuring that all work on the pump (set) be perfor-
med by authorised, qualified specialist personnel who are thoroughly familiar with
the contents of the instruction manual.
Work on the pump (set) must be carried out only during standstill. The pump (set)
must be depressurised and have cooled down to a temperature below 50_C. The
pump must be drained before dismantling it.
The shutdown procedure described in this manual for taking the pump set out of
service must be adhered to without fail.
Pump set components in contact with media injurious to health or harmful to the
environment must be decontaminated by the Operator in accordance with the
applicable local regulations.
As soon as the work is complete, re--install and/or re--activate all safety--relevant
and protective devices.
Observe all instructions set out in chapter 6 before returning the pump (set) to
service.
2.2.8 Unauthorised Modification and Manufacture of Spare Parts

Modifications or alterations of the pump set are only permitted after express appro-
val in writing by the manufacturer.
Original spare parts and accessories authorised by the manufacturer ensure safety.
The use of other parts invalidates any liability of the manufacturer for damage
resulting thereof.
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Chapter 2 Safety
2.3 Pump Signage

For pump signage refer to figure Pump signage.
NOTE
' It is imperative that all signs, plates and labels on the pump (set) be observed.
' The signs, plates and labels must be kept in a perfectly legible condition at all
times.
' Damaged or illegible signs, plates or labels must immediately be replaced by
new ones.
3 1 5 2 1 3
Pump signage
1 Temperature hazard warning sign 4 Weights
2 Instruction manual warning sign 5 Name plate
3 Company plate
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Chapter 2 Safety
2.3.1 Temperature >80_C/176_F:

It is imperative to observe the warning sign on the pump.
Temperature hazard warning sign
2.3.2 Instruction manual

It is imperative to observe the warning sign on the pump.
Instruction manual warning sign
2.3.3 Name plate

See chapter 4.3.
Baureihe_HGM
Kap.2_de
Revisionsstand_00
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3. Transport / Temporary Storage / Disposal

DANGER
Non--compliance with the safety regulations for transport work may lead to
accidents causing serious injuries.
Danger to life from falling parts!
Observe the applicable local occupational safety and accident prevention regula-
tions. In particular, comply with the following instructions:
' Wear appropriate personal protective equipment, e.g. safety helmet, safety
shoes and, if required, protective gloves.
' Use sufficiently dimensioned and suitable lifting accessories. Do not use any
damaged or untested lifting accessories.
' Make sure the lifting accessories are used correctly in accordance with the
manufacturer’s instructions.
' Observe the weights indicated, for example, in the tables of weights and the
installation plan. See chapter 9.1.
' Give due attention to the position of the centre of gravity. See centre of gravity
symbol. Use only the fastening points marked. See chain symbol.
' Observe the load--carrying capacity and the safety instructions of the transport
equipment used.
' The permissible lifting capacity of the lifting equipment must not be exceeded.
' Keep out of the danger area. Work under suspended loads is not permitted.
' Loose parts must be fastened so as to prevent them from falling down.
' Use a guide rope in addition if long objects are handled.
' After fastening the ropes, align the crane hook in such a manner that the
crane hoisting ropes are suspended vertically.
' Loads must be lifted at a right angle to the drum axis of the rope winch. Loads
must not be lifted at an angle.
' Keep the period of time for which the load is in free suspension to a minimum.
' Transport of persons together with the load is not permitted.
' Lower the loads at the lowest lowering speed of the hoist.
WARNING
Lack of stability if stored on insufficiently stable or unpaved foundation.
This may be damaged and the pump set may tip over.
Serious injury, e.g. bruises from parts toppling over.
' Place the pump only on an area designed for this purpose.
' For the weight of pump (set) or packaging unit, please refer to the packing list
or table of weights in chapter 9.
' Comply with the requirements to be met by the load--bearing capacity of the
floor. Check the load--bearing capacity of the floor. Consult the building
drawing and installation plan.
' Give due attention to the position of the centre of gravity of the pump set.
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For the general description of the pump, please refer to chapter 4. Please refer
to chapter 9 for the technical specifications of the pump as well as the pump
set components and accessories supplied by KSB.
3.1.1 Markings
Fastening points
All fastening points for the pump set are provided with
the chain symbol.
Centre of gravity
The centre of gravity of the pump (set) including pump
set components is marked on the common baseplate
with the centre of gravity symbol.
3.1.2 Lifting Accessories (e.g. eyebolt, ropes, lifting gear)
DANGER
Improper selection or handling of lifting accessories may result in the pump
or pump set components falling down.
' Use sufficiently dimensioned and suitable lifting accessories.
' Do not use any damaged or untested lifting accessories.
manufacturer’s instructions (the eyebolts, for example, must be screwed in
flush).
To determine the lifting capacity, give due consideration to the position of the centre
of gravity, the angle of spread α (see sketches) and the permitted bending radii of
the lifting accessories attached to the load to be lifted.
For selection and attachment, only follow the instructions given by the person
responsible for this.
NOTICE
Damage to the pump components!
' Do not place any chains or steel ropes around the pump components with
nothing in between.
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3.1.3 Signals During Transport

Only follow the instructions given by the person responsible for giving signals during
transporting!
3.1.4 Transport Symbols

The pictographs according to DIN 55402 on the packaging must be observed, e.g.:
1 2 3 4 5 6 7
8 9
Transport symbols
1 This way up 6 Centre of gravity
2 Fragile 7 Fasten here
3 Keep dry 8 Do not use forklift truck here
4 Store away from heat 9 Do not destroy barrier
5 No hand hooks
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3.2 Transport of the Packaged Components of the Pump Set
DANGER
The pump (set)/pump set components could slip out of the suspension
arrangement.
' Attach the lifting accessories and any transport device that might be required
always in accordance with the instructions given in this section.
Attach the handling gear and/or transport ropes as shown on the packaging.
Transport of the packaged components of the pump set
NOTES
For weights, please refer the packing list.
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3.3 Transport of the Partly--packaged or Unpackaged Components of

the Pump Set
DANGER
arrangement.
Danger to life from parts falling down or tipping over!
' Attach the lifting accessories and any transport device that might be required
always in accordance with the instructions given in this section.
' Always transport the pump (set) in horizontal position.
' Never attach the suspension arrangement to the free shaft end or bearing
housing of the pump (set) or motor eyebolts.
' Secure the pump (set) against overturning.
NOTICE
Damage to the pump set components and individual parts through
corrosion and dirt.
' Protect the pump set components and individual parts against moisture, dirt
and vermin.
' Protect stored goods against unauthorised access.
' Closed opening must not be opened.
NOTE
Weights, see Table of Weights in chapter 9.1.
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3.3.1 Transport of the Pump Set

For transporting the pump set components mounted on the baseplate, shackles
must be attached to the lifting eyebolts/lugs of the pump/baseplates at the marked
fastening points.
NOTICE
Damage during transport
' Protect built--on accessories and pipes!
Transport of pump sets mounted on baseplates (examples)
Transport frame
∩ Lifting lug
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Transport of pump sets mounted on baseplates (examples)
Transport frame
∩ Lifting lug
3.3.2 Transport of the pump

Attach the lifting accessories as shown in the figure Transport of a pump without
transport frame , Transport of a pump mounted on a transport frame or to the marked
fastening points.
1 2
1 Transport of a pump without transport frame

2 Transport of a pump mounted on a transport frame
Transport frame
∩ Lifting lug
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3.3.3 Transport of the Other Pump Set Components

Transport the other pump set components in accordance with the relevant
manufacturer’s documentation.
If these components are included in KSB s scope of supply, the relevant documents
are contained in chapter 9 of this manual.
3.3.4 Transport of the Pump Rotor
DANGER
The pump rotor can sag (uncontrolled movement) if chains or steel ropes
get out of place. Furthermore, the pump rotor might be damaged. Danger of
death from uncontrolled movement of the pump rotor.
Danger of death from uncontrolled movement of the pump rotor.
' Do not use any steel ropes or chains.
' Always transport the pump rotor in horizontal position.
NOTICE
Damage to the pump rotor
' Do not use any steel ropes or chains.
Attach hemp or plastic ropes as required by the length of the pump rotor and
transport the pump rotor horizontally; see figure Transport of the pump rotor.
Transport of the pump rotor
When setting the pump rotor down, it must be supported so that it is not damaged
and is secured against overturning/rolling.
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3.3.5 Transport of Pump Set Accessories

Attach the lifting accessories as shown in the figure Transport of pump set accessories
and/or in accordance with the relevant manufacturer’s documentation.
NOTICE
Damage to the strainer
' Do not exert pressure on the strainer element and strainer meshes or
damage them!
Transport by hand is recommended.
1 2 3
4 5 6
Transport of pump set accessories

1 Concial strainer 4 Basket strainer
2 Strainer body 5 Y--strainer
3 Minimum flow control valve 6 Cylindrical strainer
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3.4 Temporary Storage
3.4.1 Prerequisites
Check each packaging unit for damage before it is stored In case of transport
damage, assess the exact damage, document it and notify KSB about the damage
in writing immediately.
NOTICE
Openings and connections.
' All openings of the assembled unit components are closed.
' Do not open them before required during installation.
3.4.2 Place of Storage
WARNING
Lack of stability if stored on insufficiently stable or unpaved foundation.
This may be damaged and the pump set may tip over.
Serious injury, e.g. bruises from parts toppling over.
' Place the pump only on an area designed for this purpose.
' For the weight of pump (set) or packaging unit, please refer to the packing list
or table of weights in chapter 9.
floor. Check the load--bearing capacity of the floor. Consult the building
drawing and installation plan.
WARNING
Incorrect storage may impair the sealing function of O--rings. This could
result in escaping of hot and pressurised fluid pumped during operation.
Risk of injury, e.g. cuts caused by fluid jets, burns, scalds, respiratory system
burns.
' Do not store O--rings together with chemicals, solvents, fuels, acids, etc.
' Protect O--rings from light, in particular from direct sun exposure and strong
artificial light high in ultraviolet rays.
' Check O--rings for damage before they are fitted.
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NOTICE
Damage to the pump set components and individual parts through
corrosion and dirt.
' Protect the pump set components and individual parts against moisture, dirt
and vermin.
' Protect stored goods against unauthorised access.
' Closed opening must not be opened.
The entire delivery must be stored in a dry room where the atmospheric humidity is
as constant as possible. In case of outdoor storage it is absolutely necessary to cover
the pump set and crates by waterproof material to avoid any contact with humidity.
3.4.3 Period of Storage up to 12 Months

The pump is supplied by our factory duly preserved for storage up to 12 months.
(Standard preservation)
External preservation: Anticorit BML3 from Fuchs Europe Schmierstoffe GmbH,

Mannheim
To be preserved: All blank and uncoated parts
(e.g. shaft ends, couplings and flange surfaces)
Internal preservation: Anticorit BML3 from Fuchs Europe Schmierstoffe GmbH,

Mannheim
(not applicable to pumps made of non--corroding
materials)
To be preserved: All blank internal parts of the pump
(e.g casing inside, shafts, impellers and diffusers)
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3.4.4 Period of Storage over 12 Months
WARNING
In case of storage periods of more than 5 years, the sealing function of O--rings
may be impaired by, for example, embrittlement. This could result in escaping
of hot and pressurised fluid pumped during operation.
Risk of injury, e.g. cuts caused by fluid jets, burns, scalds, respiratory system burns.
' After a storage period of more than 5 years, the pump must be dismantled before
it is installed, and the O--rings must be replaced.
' Check the O--rings for damage before they are fitted.
WARNING
Improper handling of supplies may lead to contact with hazardous substances.
Risk of injury, e.g. damage to the skin, the eyes and the respiratory tract.
' Observe the relevant safety instructions for the handling of hazardous substances
(wear safety goggles and protective gloves, for example).
If the requisite preservation measures have not been performed by KSB (special
preservation), they must be discussed with and approved by KSB prior to putting the
pump into storage.
No special measures are necessary for pumps with impellers and diffusers made of
chrome steel (material variants 3+4).
1. The pump drain (6B) must be closed.

2. Close the suction nozzle, and the tapping nozzle, if applicable, using the
intended blind flanges.
3. Fill the pump with a glycol/water mixture at a proportion of 1:1.
4. Close the discharge nozzle with the blind flange intended for use.
5. Turn the pump rotor once to twice a month to avoid that the mixture separates.
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3.5 Return to Supplier
DANGER
The pumped medium may be a hazardous substance (e. g. toxic, flammable or
explosive) or be hot Improper handling may lead to contact with hazardous
substances and hot medium pumped.
Risk of injury, e.g. chemical burns on the skin and in the eyes, intoxication and
burns.
' Observe the safety instructions and regulations for the handling of hazardous
substances (wear safety goggles, protective gloves, protective clothing, etc., if
required).
' Remove any residues of the pumped medium completely from the pump, flush
the pump thoroughly.
' Collect the flushing liquid or the residues of the pumped medium, if any, and
dispose of properly.
NOTE
Hazards to the environment from improper handling of hazardous substances.
' The applicable international, national and local legislation, provisions, safety and
environmental protection regulations must be complied with.
' Handling and disposal only by qualified personnel.
1. Drain the pump as per operating instructions.

2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the 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 intert gas must be blown through the pump for
drying purposes.
4. The pump (set) must always be accompanied by a completed certificate of
decontamination. Always indicate any safety and decontamination measures
taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
KSB web site at: www.ksb.com/GRAS--Cert
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3.6 Disposal
NOTE
All parts replaced, all materials and substances shall be disposed of in accordance
with the applicable international, national and local legislation, provisions, safety
and environmental protection regulations.
According to the local anti--pollution regulations

packaging components must be disposed of by the consignee
lubricants no longer used, cleaning material, media handled, electric equipment,
etc.
must be disposed of by the Operator at their own expense.
3.6.1 Oil and Oil--containing Waste

Oil and oil--containing waste (lubricants) constitute a high risk potential for the
environment.
This waste shall be collected and stored in an appropriate container.
The containers shall be marked accordingly.
This waste shall be disposed of by a specialist firm in accordance with the applicable
legislation.
3.6.2 Scrapping
On scrapping of the components of the plant, the laws and regulations applicable at
that time shall be complied with.
It must be made sure that recycling, dismountability and separability of materials and
subassemblies are taken into consideration, as well as ecological menace and
health hazards on recycling and disposal.
Material groups such as plastics and metals of different types shall be sorted before
being recycled or disposed of.
3.6.3 Disposal of Electrotechnical and Electronic Components

Electrotechnical and Electronic Components shall be disposed of in accordance with
the respective laws and/or regional ordinances.
Special instructions given in the manufacturer’s documentation shall be observed.
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4. Description
4.1 General Description
G Horizontal, multitstage, product--lubricated centrifugal pump in ring--section
design
G Pump for handling feed water in power stations as well as boiler feed water and
condensate in industrial plants
4.2 Designation
Example: H G M 4 / 5
Table: Key to the designation
Abbreviation Meaning
HG Type series group (Hochdruck--Gliederpumpe = high--
pressure ring--section pump)
M Type series
4 Size
5 Number of stages
4.3 Name Plate (to TRD401/402)
7
1
HGM 4/5 2009 8
2
42062405000406240407 9
3 9971082685 200 / 01
10
4 115 75
5 11
47 47,7
6
2975
Ident--No.: 00 380 178 ZN 3823 -- D29
Name plate HGM (example)

1 Type series designation 7 Year of construction
2 Product No. 8 Order item No. (three digits)
3 KSB order No. (ten digits) 9 Consecutive number
4 Flow rate 10 Temperature
5 Differential pressure 11 Discharge pressure
(suction/discharge pressure)
6 Speed
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4.4 Design Details
Design
Horizontal, radially split, multi--stage ring--section pump with radial
impellers, single--entry inlet. The joints between the casings are sealed by
O--rings and the casings are clamped together by means of tie bolts.
Pump feet arrangement

The pump feet are arranged at the bottom
of the first and last stage casing each.
Beaerings, lubrication
Medium--lubricated plain bearings, uncooled
Balancing device
G Drum/disc combination on the discharge side where clearance and control
gaps ensure total axial thrust balancing during operation.
Shaft seal
Standardised mechanical seal. Shaft equipped with replaceable shaft
sleeve in the shaft seal area.
Uncooled mechancial seal
Nozzle position
Suction cover: depending on the variant: -- axial (standard)
-- with elbow, rotatable 90_
Discharge casing: Radial, vertically to the top
Tapping nozzle: Radial HGM 1 -- 3 = 45 _ 1)
HGM 4 = 30 _ 1)
1) Position as viewed from the suction side: preferably right, left possible.
Angles measured against the horizontal. A tapping nozzle is not possible
in the first two stages and the last stage.
Flanges
Connecting dimensions to EN, DIN or ASME
Drive
The pump is driven directly by an electric motor (standard)
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4.5 Design
16 14 24 23 22 20 1 17 2 3 7 2 4 6 21
8 15 18 13 12 11 2 4 25 9 10 19 5
Table: List of components
Item Description Item Description
1 Discharge casing 14 Bearing ring carrier

2 Stage casing 15 Mechanical seal
3 Tapping nozzle 16 Shaft seal housing
4 Stage casing 17 Casing wear ring
5 Intermediate piece 18 Shaft sleeve
6 Suction cover 19 Bearing sleeve
7 Diffuser 20 Throttle bush
8 Shaft 21 Bearing bush
9 Impeller 22 Piston
10 Suction impeller 23 Balance drum
11 Thrust bearing ring 24 Balancing pipe
12 Thrust bearing ring 25 Tie bolt
13 Thrust bearing ring
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Function:
The fluid enters the pump via the intermediate piece (5) and is accelerated in a flow
outward by the rotating suction impeller (10).
At the flow contour of the diffuser (7) inserted in a stage casing (2) the kinetic energy
of the fluid is converted into pressure energy and the fluid is routed to the next
impeller (9) via the return guide vanes of the diffuser.
This process is repeated in all stages until the fluid has passed the last diffuser.
It then passes to the discharge casing (1), from where it leaves the pump.
The clearance gap at the casing wear ring (17) prevents any fluid from flowing back
from the stage casing into the suction area of the previous impeller.
A balancing device consisting of piston (22) and throttle bush (20) in combination
with thrust bearing ring (11) and balance drum (23) is fitted after the last impeller,
providing axial thrust balancing by means of hydraulic forces. The axial thrust acting
in the direction of the driven end on starting of the pump due to the inlet pressure is
absorbed in a thrust bearing comprised of 2 thrust bearing rings (12 and 13)
arranged at the rear of the balance drum (23).
Behind the balancing device, the fluid area is closed off by a shaft seal housing (16)
through which the drive shaft (8) passes.
The shaft passage through the shaft seal housing (16) is sealed to the atmosphere
by a dynamic shaft seal (15).
The drive shaft (8) is supported by medium--lubricated plain bearings consisting of
piston (22) and throttle bush (20), and bearing sleeve (19) and bearing bush (21),
respectively, which are located in the discharge casing (1) and suction cover (6).
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4 Description
PUMP DESIGN
Nozzle Design DN Class Drilled acc to Position [°] *)
Inlet Flange 3 in 300 ANSI B 16.5 RF vertically upwards
Outlet Flange 2 in 600 ANSI B 16.5 RF vertically upwards
*) clockwise viewed from the driven end ( 0° = top)
Shaft Seal Manufacturer Type Material Cooling

Mech. seal BURGMANN KB045-H75N16 AQ1EGG No cooling
Axial thrust balancing Hydraulically by means of Single piston
Bearing Design Lubrication Cooling

Radial Plain bearing Medium No
Thrust - - -
Pump Feet Arrangement At bottom
ACCESSORIES
Balancing water pipe – returned to first pump stage
Language for plates: English
Instrumentation acc. to list of measuring points

Baseplate for pump and motor (with foundation bolts)
Intake elbow - ANSI
Standard-Betriebshandbuch Kap. 9_en

4 Description
MATERIAL
Part No. Description Material
107 Discharge casing 1.4008.09 / 1.4317
108.01 Stage casing, first stage 1.4006+QT650
108.02 Stage casing, subsequent stages 1.4006+QT650
162 Suction cover 1.4021+QT800
171 Diffuser 1.4008.09
210 Shaft C45
230 Impeller 1.4008.09
231 Suction stage impeller 1.4008.09
441 Shaft seal housing 1.4021+QT800
502 Casing wear ring RWA 350
523 Shaft sleeve 1.4021+QT800
545 Bearing bush Noricrom®
59-4 Piston 1.4021+QT800/WR 525
603 Balance drum 1.4024.09
905 Tie bolt 1.6772

Check List: Assembly Date:
Name:
Boiler Feed Pump(s) – Set(s)
The manufacturer's documentation is binding for

all work performed on the pump / set!
Work to be performed: Comments:
1. Check the supplied pump / pump set(s) and
accessories for completeness and damage
incurred in transit; see chapters 3 and 5 of the
instruction manual.
2. Check the condition and dimensions of the

foundation for compliance with the installation
plan, see chapter 5 of the instruction manual.
3. Pre-align the foundation (adjusting screws /

shims); see chapter 5 of the instruction
manual.
4. Mount the foundation bolts in the baseplate.
4a. Mount the anchor bolts.

(see chapter 5 of the instruction manual)
5. Place the baseplate + readily mounted

components of the set(s) onto the foundation;
see chapter 5 of the instruction manual.
6. Mount the driver; see chapter 5 of the

instruction manual.
7. Pre-align the components of the set(s); see

chapter 5 of the instruction manual.
8. Grout the foundation bolts.
8a. Grout the anchor bolts.

9. Allow the concrete to set ; see chapter 5 of the

instruction manual.
10. Align the components of the set(s); see chapter

5 of the instruction manual.
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Revisionsdatum - 12.07.2000
Check List: Assembly Date:
Name:
Boiler Feed Pump(s) – Set(s)
11. Tighten the foundation bolts, lock the
adjustment screws with a counter-nut.
11a.Tighten the anchor bolts.
12. Grout the baseplate; see chapter 5 of the

instruction manual.
13. Mount all pipes, valves and fittings; see

14. Check the parallelism of all pipe connections;

15. Fine-align all components making up the set(s)

using a dial gauge with 0.01mm scale
divisions). Record readings in KSB –
alignment record ; see chapter 5 of the
instruction manual.
16. Fix pump / set(s) / baseplate with pins; see

17. Check the variable spring hanger for proper

functioning, remove locking device; see
Please note: Items on this check list that are not found in the instruction manual do not apply.
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5. Installation at Site
WARNING
Lack of stability if installed on insufficiently stable or unpaved foundation.
The foundation may be damaged and the pump set may tip over.
Serious injury, e.g. crushes from pump set tipping over.
' Install the pump only on a foundation designed for this purpose.
floor of the temporary storage space. Check the load--bearing capacity of the
floor. Consult the building drawing.
WARNING
If the baseplate is not included in KSB’s scope of supply, it may be
insufficiently dimensioned for the static and dynamic loads which occur.
The fastening of the baseplate in the foundation can also be insufficient.
The pump’s stability is not ensured. In addition, it might be that the maxi-
mum permissible vibration velocities of the pump are exceeded.
Serious injury, e.g. crushes from pump set tipping over.
' If sufficient dimensioning of the baseplate cannot be proved, evidence
supporting stablity and the compliance with the maxaimum permissible
vibration velocities has to be provided prior to commissioning of the pump.
' Pay attention to vibrations and deformations.
NOTE
The vibration values and noise emissions indicated by KSB are based on proper
installation of the pump (set) in accordance with this chapter.
Improper isolation of pump (set) and building/plant or an inappropriate piping
layout may increase noise emission and/or the vibration level.
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5.1.1 Prerequisites
The following prerequisites apply for safe installation of the pump (set):
The foundation has been prepared and the concrete has set.
The site management has released the foundation and marked the centreline.
The place of installation and the way thereto have been cleared and are suitable
for transport of the pump set components.
Adequate means of transport and lifting accessories including personnel are
available until completion of the installation work.
Adequate alignment devices are available.
The installation may be performed without interruptions.
If welding work is performed on the pump set, we recommend to earth all
baseplates of the pump set.
Check the foundation for compliance with the following criteria:

The dimensions comply with those in the installation plan.
The foundation as a whole and in particular the area surrounding the foundation
holes are truly horizontal and even.
In the area of the baseplate grouting, the foundation must have a rough surface
to allow for better bonding.
If these criteria are not fulfilled, the requisite corrections must be consulted with
the site management and initiated.
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5.2 Preparations
5.2.1 Requisite Documentation

Besides the present instruction manual, the technical documents on the other pump
set components are also needed for the installation and alignment work. Please find
the relevant documentation for the scope of supply in chapter 9 of this instruction
manual.
Chapter 9.1: Installation Plan

Excerpt from DIN 1045
Table of Weights
List of Measuring Points (if applicable)
Tightening Torques
P + I Diagram (if applicable)
List of Valves (if applicable)
Chapter 9.3: Documentation on the Connecting Coupling
Chapter 9.4: Documentation on the Drive
Kapitel 9.5: Documentation on the Minimum Flow System
and the Minimum Flow Valve
Mindestförderstromschema (falls vorhanden)
Kapitel 9.6: Documentation on the Valves and Equipment
Chapter 9.7: Documentation on the Instruments
Chapter 9.8: Documentation on the Gear or Variable Speed Coupling
(if applicable)
5.2.2 Measures to be Taken after Long--term Storage
WARNING
In case of storage periods of more than 5 years, the sealing function of
O--rings may be impaired by, for example, embrittlement. This could result in
escaping of hot and pressurised fluid pumped during operation.
burns.
' After a storage period of more than 5 years, the pump must be dismantled
before it is installed, and the O--rings must be replaced.
NOTE
If the pump has been specially preserved for storage of more than 12 months
or sea transport, the necessary measures for removal of preservation prior to
installation in accordance with chapter 6 must be carried out.
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5.2.2.1 Internal preservation

If the pump has been filled with a glycol/water mixture for preservation, this fill must
be drained before further work is done.
1. Open the pump drain (6B), collect the fill in an appropriate container and dispose
of according to the local anti--pollution regulations.
2. Close the pump drain.
3. Flush sufficiently to remove any residues of the preservative.
4. Remove the grease on the outsides of all pump set components.
5.2.2.2 External preservation

Removal of preservation of the pump set components in accordance with the
relevant manufacturer’s documentation in chapter 9 Relevant Documentation.
Washing the preserved exterior parts with petrol, petroleum, diesel oil or
general--purpose cleaner such as Shell Collina 2306.

Standstill of more than 12 Months
1. Dismantle the pump--end coupling hub.
2. Remove the mechanical seal and check it in accordance with the
3. If the mechanical seal is clean and undamaged, it may be re--installed.
Otherwise a new seal must be installed.
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5.2.4 Transporting the Pump Set Components to the Place of Installation
DANGER
' For all transport activities, it is imperative to comply with the safety
instructions and detailed information in chapter 2 and chapter 3!
Observe the applicable local occupational safety and accident
prevention regulations. In particular, comply with the following
instructions:
installation plan, see chapter 9.1.
' Give due attention to the position of the centre of gravity. Use only the fastening
points marked.
For the details necessary to transport the components properly, please refer
to chapter 3.
5.2.5 Unpackaging the Pump Set Components

If the pump set components are packaged, the packaging should not be removed
until immediately before the installation work starts. When doing so, the pump set
must not be damaged. The consignee of the components supplied is responsible for
disposal of the packaging.
NOTICE
Openings and connections
' All openings of the assembled pump set components are closed.
' Do not open them before required during installation.
' Prior to commissioning/start--up, check on the basis of the information given in
chapter 6 whether the openings must be open or closed.
Completely cover the pump set components on site to protect them against dirt,
spark discharge, grinding dust and other harmful ambient influences.
Take special care to adequately protect instruments, electric cables and wiring ducts.
Spare parts and parts which are not immediately needed must be stored as described
in chapter 3.4.
NOTICE
Damage to pump set components.
' If components of the pump set became damaged, wet or dirty, inform KSB.
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5.2.6 Dismantling the Coupling Guard and Coupling
DANGER
accidents causing serious injuries, e.g. on mounting and dismantling the
coupling and the guards.
' Give due attention to the weights of the components.
Dismantle and store the coupling guards mounted to the pump set.
5.2.6.1 Coupling Guard (standard)

1. Unscrew the tie bolts.
2. Prise apart the guard (680) wide enough to allow for sliding it over the connecting
coupling and removing it.
coupling and removing it.
500
Z
680
Z 5 min.
Z7S001
Z7S002
Coupling guard (standard)

500 Ring
680 Guard
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5.2.6.2 Coupling Guard (explosion protection)

1. Undo and remove the bottom plate.
2. Undo the foot fastening.
3. Remove the coupling guard upwards.
Coupling guard (explosion protection)

1 Bottom plate
2 Foot fastening (lock strip)
5.2.6.3 Dismantling the coupling

Dismantle and store the connecting coupling spacer in accordance with the
5.2.6.4 Mounting the coupling hubs

Mount all coupling hubs which are not mounted as described in chapter 7.3, making
sure the markings of all coupling components to be connected coincide.
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5.2.6.5 Preparing the levelling screws

Prepare the levelling screws and position them in accordance with chapter 9.1 and
as shown on the sketch Preparing the foundation (example) on either side of the
foundation bolts each.
Preparation of the foundation (example)

1 Foundation centreline 4 Baseplate
2 Levelling screws 5 Foundation
3 Bolt holes H = 47 mm max./ 35 mm min.
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5.3 Installation of the Pump Set
DANGER
prevention regulations.
In particular, comply with the following instructions:
installation plan. See chapter 9.1
' Give due attention to the position of the centre of gravity. Use only the
fastening points marked.
' The permissible lifting capacity of the lifting equipment must not be excee-
ded.
NOTICE
A warped baseplate or a warped pump set leads to damage to the pump.
' Align the baseplate and the pump set components accurately and carefully.
5.3.1 Fastening with Foundation Bolts (if applicable)

1. Lift the baseplate.
2. Place the foundation bolts into the baseplate holes and screw on the nuts until
the bolt thread projects by about 10 mm.
3. Place the baseplate onto the levelling screws and align the baseplate using the
screws. Check the alignment in relation to the foot supporting surfaces both
parallel to and 90_ to the foundation centreline using a spirit level (accuracy <
0.3 mm/m). The foundation bolts must be suspended freely in the foundation
holes.
4. Set the pump set components which are not mounted on the baseplate in place
on the baseplate as described in the manufacturer’s documentation.
5. Check the baseplate alignment once again in relation to the foot supporting
surfaces both parallel to and 90_ to the foundation centreline using a spirit level
(accuracy < 0.3 mm/m). Correct any deviations which might have occurred
under the load of the components using the levelling screws.
6. Grouting the foundation bolts with concrete, see chapter 5.6.
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5.3.2 Fastening with Bonded Anchors (if applicable)

1. Lift the baseplate and place it onto the levelling screws. Position the baseplate
so that the holes for the bonded anchors in the foundation may be rough--drilled.
2. Align the baseplate using the levelling screws. Check the alignment in relation
to the foot supporting surfaces both parallel to and 90_ to the foundation
centreline using a spirit level (accuracy < 0.3mm/m).
on the baseplate as described in the manufacturer’s documentation.
5. Spot--drill the holes for the bonded anchors.
6. Lift the baseplate once again.
7. Finish--drill the holes and clean them, see works standard ZN 1505 -- Bonded
Anchors in chapter 9.1.
8. Insert the bonded anchors, see works standard ZN 1505 -- Bonded Anchors in
chapter 9.1.
9. Allow time for curing of the bonded anchors. Then place the baseplate onto the
levelling screws and align the baseplate using the screws. Check the baseplate
alignment once again in relation to the foot supporting surfaces both parallel to
and 90_ to the foundation centreline using a spirit level (accuracy < 0.3 mm/m).
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5.3.3 Fastening with Special Foundation Bolts (if applicable)

1. Lift the baseplate.
2. Place the special foundation bolts into the baseplate holes and screw on the nuts
until the bolt thread projects by about 10 mm.
IIf the crane hook height is not sufficient, insert the special foundation bolts from
the bottom side of the foundation through the special foundation bolt holes into
the baseplate holes and screw on the nuts until the bolt thread projects by about
10 mm.
3. Place the baseplate onto the levelling screws and align the baseplate using the
screws. Check the alignment in relation to the foot supporting surfaces both
parallel to and 90_ to the foundation centreline using a spirit level
(accuracy < 0.3 mm/m). The special foundation bolts must be suspended freely
in the foundation holes.
on the baseplate as described in the manufacturer’s documentation. If coupling
hubs are mounted on the pump set components, the markings on the coupling
components to be connected must be identical.
6. Fasten the plates and nuts of the special foundation bolts at the bottom side of
the foundation to the special foundation bolts.
NOTE
The plates for the special foundation bolts must rest evenly on the foundation!
7. Tighten the nuts of the special foundation bolts with the tightening torque given
in chapter 9.1 .
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5.4 Connecting Coupling Alignment
DANGER
Improper alignment of the coupling can, during operation, lead to
overloading culminating in the destruction of the coupling. This may result
in coupling parts being catapulted off.
Most serious injuries, which might result in death, from fragments being
catapulted off like a bullet.
' Align the coupling properly.
' For the alignment, consider any thermal expansions of the machines to be
coupled.
WARNING
Accidental start--up of the pump set may lead to contact with unprotected,
rotating and projected parts.
Risk of injury: body parts may become entangled, crushed or abraded, for
example.
' Have the drive secured against accidental starting by authorised specialist
personnel, e.g. by removing the master switch and taking appropriate
measures of protection by means of an information label or a lock.
NOTICE
Damage to pump set components
' Incorrect or inadequate aligning of the connecting coupling leads to damage to
and increased wear of the coupling elements, pump components and/or pump
set.
' Also check the coupling of pump sets supplied on a common baseplate.
' Starting up of the unfilled pump can result in damage to pump components.
Align the pump set components in accordance with the manufacturer’s

documentation.
The alignment begins with the pump, which is the reference point for aligning
all other pump set components.
In the case of motors with axial tolerance, their rotors must be placed in the
magnetic centre as described in the manufacturer’s documentation. This rotor
position must not be altered during the full duration of alignment work.
Move the pump shaft in the direction of the suction cover until the rotor abuts.
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NOTE
When aligning the pump set components, it must be born in mind that the
discharge side of the pump has been pinned at the factory.
Z5D003
Pump rotor position
The feet of the individual pump set components must stand evenly on the
locating surfaces of the baseplate.
Check the distance between the coupling hubs for compliance with the
installation plan and adjust it, if required.
In the case of toothed couplings, fix the coupling sleeves on the hubs using
spacer plates (supplied loose), see figure Arrangement of spacer plates.
Arrangement of spacer plates (example)
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5.4.1 Run--out Check of Pump Set Components
5.4.1.1 For coupling hubs with outside step:

Check each coupling hub for run--out using a dial gauge, see figure Run--out check.
The run--out must not exceed 0.05 mm; if it is exceeded, KSB must be informed.
Run--out check (example)
5.4.1.2 For coupling hubs without outside step:

Check the shaft for run--out using a dial gauge; see figure Run--out check. The run--out
must not exceed 0.05 mm; if it is exceeded, KSB must be informed.
Run--out check (example)
NOTICE
Incorrect measurement results and damage to the alignment device may
lead to misalignment and, hence, damage to the pump set.
' The coupling must not be turned by means of the alignment device.
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5.4.2 Alignment of the Coupling Hubs Relative to Each Other
5.4.2.1 Examples of alignment using dial gauges

Perform the alignment with dial gauges in accordance with the manufacturer’s
documentation. The figures below show examples of alignment with dial gauges.
NOTE
Both coupling hubs must be turned together in the same direction by 90_ each in
order to ensure that the measuring points are the same.
Connecting coupling alignment with spacer (example)

A Coupling hub used as a reference point for alignment
B Coupling hub to be aligned
Connecting coupling alignment with spacer (example)

A Coupling hub used as a reference point for alignment
B Coupling hub to be aligned
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5.4.2.2 Alignment of Connecting Coupling Using a Laser Device

(alternative)
WARNING
Radiation damage caused by improper use of the laser device.
Risk of injury by radiation (burns, damage to the eyes and the skin).
' Only use laser devices where unintentional radiation is avoided and no injury
to health is caused by the optical device for setting and observing.
' Prevent injuries to health caused by reflection and effective, leakage or secon-
dary radiation by means of protective screens.
' Observe all warnings in the manufacturer’s operating instructions.
For the procedure, please refer to the description of the laser device used.
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5.4.3 Considering Height and Lateral Displacements of the Pump Set

Caused by Thermal Expansion
5.4.3.1 Determination of the Displacement in Height

In order to ensure unobjectionable operation of the pump set, the height
displacement caused by the operating temperatures of pump and drive must be
considered for alignment.
Read the height displacement of the pump ∆ hP at operating temperature
Change in centreline height
Operating temperature of pump toper.P (°C)
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Read the height displacement of the drive ∆hG at operating temperature (see
Documentation on the Drive, chapter 9.4).
G = housing
Change in centreline height toper.G =100 °C
toper.G =80 °C
toper.G =60 °C
toper.G =40 °C
Centreline height of drive hG (mm)
Height displacement at the connecting coupling ∆hK to be considered at an

ambient temperature of 20_C:
∆hk negative
∆hk positive
Pump Drive
Drive Pump
Example: Drive Housing temperature 60_C Pump Operating temperature 130_C

Centreline height 400 mm Pump type HGM 3
Result: ∆hK is negative, i. e. the drive must stand 0.10 mm higher than the pump
∆hK [mm] Height displacement to be set

hG [mm] Centreline height of drive
hP [mm] Centreline height of pump
toper.G [_C] Temperature of drive housing at intended operation
toper.P [_C] Temperature of pump at intended operation
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5.4.3.2 Example of Adjustment

Example: Height displacement ∆hK= --0.10mm
Dial gauge indication
Height displacement ∆hK= --0.10mm (example)
1: Coupling hub used as a reference point for alignment

2: Coupling hub to be aligned
3: Dial gauge
Use the measurement surfaces for the dial gauges as described in 5.4.1 and 5.4.2.
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5.4.3.3 Permissible Tolerances
Radial displacement
The radial displacement VR must not deviate more than 0.05 mm from the nominal
value, measured at a distance of 90_.
Va
VR
Radial displacement (example)
Angular misalignment
The angular misalignment Vw may be 0.05 mm max. in horizontal and vertical
direction.
Smax
Va S max–S min
Vw =
2
VR
Smin
Angular misalignment (example)
Axial distance
The axial misalignment Va of the various coupling types varies very strongly. For the
dimensions and the permissible tolerances please refer to the installation plan and
the manufacturer’s documentation in chapter 9.3.
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5.4.4 Alignment Corrections

When aligning the pump set components, it must be born in mind that the discharge
side of the pump has been pinned at the factory. Hence, lateral corrections shall
preferably be performed on the electric motor.
5.4.4.1 Height correction on the electric motor

The height of the electric motor is corrected by adding or removing of shims, see
figure Alignment correction on the electric motor
5.4.4.2 Lateral correction of the electric motor

The alignment is corrected by screwing bolts or threaded rods into the designated
nuts (M20) on the outer bearing edges of the baseplate; see figure Lateral correction
of the electric motor.
Alignment correction on the electric motor
Please note!
For fine alignment, the reduced shank bolts can be screwed out of the baseplate so
far that the thread of the reduced shank bolts (nut end) ends above the motor foot.
This enables the largest possible clearance for all--side alignment correction.
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5.4.4.3 Height correction on the pump

The height of the pump is corrected by adding or removing of shims, see figure Height
correction on the pump.
Shims
Height correction on the pump
5.4.4.4 Alignment corrections on the other pump set components

The alignment corrections on the other pump set components shall be performed
in accordance with the relevant manufacturer’s documentation.
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5.5 Drilling the Holes for Fastening the Feet

1. If the baseplate is not provided with tapped holes for fastening the pump set
components, the position of the requisite holes is marked using the holes in the
feet of the pump set components standing on the baseplate as templates.
Because of the thermal expansion of the pump and the associated

displacement of the pump feet, the position of the holes for fastening the pump
must be marked out as shown in the figure Arrangement of stud holes.
Arrangement of stud holes

1 Centre of foot / driven end 4 Hole in baseplate
2 Centre of foot / non--driven end 5 Position of pin hole
3 Stud in pump foot
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2. If the pump was delivered without baseplate, the hole for the parallel pin B must
be marked taking the pin hole in the discharge--side foot as an aid; see table
below and figure Pinning the pump feet.
B
HGM 1
HGM 2 ∅20mm
HGM 3
HGM 4 ∅30mm
Pinning the pump feet
3. Lift the relevant pump set components from the baseplate as described in the
4. Drill the holes and cut the threads.
5. Clean the holes and bearing surfaces from chips and other dirt.
6. Where applicable, place the parallel pin B into the discharge--side foot; see
figure Pinning the pump feet.
7. Place the pump set components onto the baseplate again as described in the
the manufacturer’s documentation.
8. Repeat the connecting coupling alignment as described in chapter 5.4.
9. Tighten the fastening studs so that they are no longer loose, but do not tighten
them finally because the connecting coupling alignment still has to be repeated
several times.
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5.6 Fastening the Baseplate on the Foundation

5.6.1 With Foundation Bolts (if applicable)
1. Grout the foundation bolt holes with non--shrinking concrete, minimum
compressive strength class C 25/30, grain size ≤8 mm according to the excerpt
from DIN 1045. Produce flowability with the help of a solvent.
2. When the grouting compound has set (setting time as indicated by
manufacturer), tighten the nuts of the foundation bolts with the tightening torque
given in the installation plan.
4. Grouting the baseplate with concrete:
-- Prepare the concrete shuttering for the baseplate and foundation pedestals
up to the planned grouting height as shown in the installation plan.
-- Make provisions for the grouting compound to bond with the foundation
concrete.
-- Fill at least 1/3 of each field of the baseplate with non--shrinking grouting
compound (e.g. Pagel concrete grout ), minimum compressive strength
class C 25/30, grain size ≤8 mm. The remaining 2/3 of the fields may be
filled with standard concrete of this quality. KSB recommends to grout all
fields completely with non--shrinking concrete grout. Produce flowability
with the help of a solvent. Complete grouting without major interruptions
-- In order to avoid cavities, the grouting compound must be compacted.
5. When the grouting compound has set, check the nuts of the foundation bolts for
tight fit once again using a torque wrench. For tightening torques, please refer
to the installation plan.
5.6.2 With Bonded Anchors (if applicable)

1. After curing of the bonded anchors (see works standard ZN 1505 in chapter 9.1),
tighten the nuts of the bonded anchors with the tightening torque given in the
installation plan.
2 Repeat the connecting coupling alignment as described in chapter 5.4.
up to the planned grouting height.
-- Make provisions for the grouting compound to bond with the foundation
concrete.
compound (e.g. Pagel concrete grout ), minimum compressive strength class
C 25/30, grain size ≤8 mm. The remaining 2/3 of the fields may be filled with
standard concrete of this quality. KSB recommends to grout all fields completely
with non--shrinking concrete grout. Produce flowability with the help of a solvent.
Complete grouting without major interruptions
4. When the grouting compound has set, check the nuts of the bonded anchors for
tightness once again using a torque wrench. For tightening torques, please refer
to the installation plan.
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5.6.3 With Special Foundation Bolts (if applicable)

1. Fill the special foundation bolt holes with dry sand.
2. Insulate the special foundation bolts in the area between the upper edge of the
foundation and the lower edge of the baseplate with Styrofoam or a similar
material.
up to the planned grouting height as shown in the installation plan.
compound (e.g. Pagel concrete grout ), minimum compressive strength class
C 25/30, grain size ≤8 mm. The remaining 2/3 of the fields may be filled with
standard concrete of this quality. KSB recommends to grout all fields completely
with non--shrinking concrete grout. Produce flowability with the help of a solvent.
Complete grouting without major interruptions.
4. When the grouting compound has set, check the nuts of the special foundation
bolts for tightness once again using a torque wrench. For tightening torques,
please refer to the installation plan.
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5.7 Mounting the Piping
DANGER
Improper mounting of pipes or flanges may cause leaks where hot and
pressurised fluids can escape.
burns.
' 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.
' Take appropriate measures to compensate thermal expansion of the piping.
5.7.1 Prerequisites
DANGER
Voltage--carrying pump set components due to improper or no earthing of
the pump set. Possible damage to pump set components.
Risk of injury from electric shock!
' Ensure proper earthing of the pump set and check regularly, see chapter 7.1.
Carry out earthing of the pump set.

With short pipes in the plant, their nominal diameters should be at least equal
to the nominal diameters of the pump nozzles. For long pipelines, the most
economical nominal diameter has to be determined from case to case.
Adapters to larger diameters should have a diffuser angle of approx. 8_ in order
to avoid any pressure losses caused by the formation of air pockets.
It is recommended to install check and shut--off elements.
The installation plan shows which pipes, valves and instruments are
included in our scope of supply and how they are arranged.
All pipes in the baseplate area have been completely mounted at the factory.
Make and adapt any possibly required connecting pipes in accordance with the
installation plan. Offset at flange connections and pipe unions is not permitted.
Pipes delivered by KSB have been cleaned and closed. Nevertheless their
interiors must be checked for impurities which might have been caused
afterwards and be cleaned, if required.
As a general rule, pipes made on site must be cleaned prior to final mounting.
Do not remove blind flanges or closure covers on pump nozzles and pipe
connections including any packings with dessicants possibly attached to them
until immediately before the relevant pipes are connected. The responsibility for
disposal of the parts supplied lies with the consignee.
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5.7.2 Cleaning the Pipes
NOTICE
Prevent solids from entering the pump, as this would result in increased
wear and blockages.
' When flushing the piping, the pump must as a rule be protected against
welding beads, scale and other impurities. Use of pipe bypasses or filters to
prevent solids from entering the pump.
The pipes may be blown through with compressed air.
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5.7.3 Installation of Strainer
DANGER
Observe the applicable local occupational safety and accident prevention
regulations. In particular, comply with the following instructions:
' Wear appropriate personal protective equipment, e.g. safety helmet, safety shoes
and, if required, protective gloves.
NOTICE
Damage to the strainer
' Do not exert pressure on the strainer element and strainer meshes or damage
them.
' Transport by hand is recommended; if this is not possible due to the weight,
observe chapter 3.3.5.
NOTE
The strainer in the inlet pipe is destined to hold welding beads, scale and other
impurities that come off the piping with time away from the pump.
It is not destined to remove any inadmissible particles entrained in the medium
handled due to an excessive solids content. See also information on the
medium handled in chapter 6.1.
NOTE
Prior to installation of the strainer element, clean the inlet pipe between strainer
and pump.
In addition, perform a visual inspection in the area between strainer and pump
nozzle.
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1. Install the strainer element in the inlet pipe in vertical position and as close as
possible to the pump nozzle.
Installation of the strainer element (example)
2. For differential pressure monitoring in the inlet pipe, provide a hole ahead of the
strainer element, and weld on the welding piece included in the scope of supply.
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Conical strainer
A C
A = inlet pipe
B = suction pipe, pump
C = connection,differential
pressure monitoring
H = approx. 300 mm
B
Y--strainer C
A
A = inlet pipe
C = connection,differential
pressure monitoring
H = approx. 300 mm
Y--strainers can be installed

horizontally and vertically.
The strainer’s distance ahead of
the elbow or intermediate piece
should be at least 2 x DN.
Connection for differential pressure monitoring (example)
3. Fit the minimum flow valve (if applicable) to the pump’s discharge nozzle as
stated in the manufacturer’s documentation.
4. Arrange the minimum flow system (if applicable) as shown on the P + I diagram.
Perform the installation as described in the manufacturer’s documentation.
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5.7.4 Connecting the Pipes to the Pump Nozzles
DANGER
Excessive loads acting on the pump nozzles may cause leaks and d amage
to the pump, which might result in hot or pressurised medium handled
escaping.
Danger to life, e.g. cuts caused by fluid jets, burns, scalds, respiratory system
burns.
' Observe the permissible forces and moments at the pump nozzles as given in
the installation plan in chapter 9.1.
' Connect all pipes in cold condition and without transmitting any stresses or
strains.
' Never use the pump itself as an anchorage point for the piping.
' Anchor the suction and discharge pipes in close proximity to the pump.. Their
weight must not be carried by the pump.
' Take appropriate measures to compensate thermal expansion of the piping.
DANGER
Voltage--carrying pump set components due to improper or no earthing
during welding work.
' If welding work is carried out on the pump set, make sure the pump set is
earthed properly.
' Earth all baseplates of the pump set.
NOTICE
Incorrect earthing during welding work at the piping
Destruction of bearings (pitting effect)!
' Never earth the electric welding equipment on the pump or baseplate.
' Provide the earthing as close as possible to the weld seam.
' Prevent current flowing through the bearings.
Do not remove blind flanges or closure covers on pump nozzles and pipe
connections including any packings with dessicants possibly attached to them
until immediately before the relevant pipes are connected. The responsibility for
disposal of the parts supplied lies with the consignee.
Never use the pump itself as an anchorage point for the piping!
Remove the temporary holders and mount the pipes on the pump nozzles.
The pipes must be fully supported by its permanent spring hangers or designed
supports.
The spring hangers must have full adjustment and must not be at their lower
limit.
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5.7.4.1 Flange end variant
NOTICE
Inadmissible transverse forces at the flange connections of the pump
nozzles lead to overloaded nozzles and leakages.
' It must be possible to insert all bolts of the flanges on the inlet and discharge
pipes into their respective holes and to remove them without becoming bolt
bound (off--set holes).
' If the pipes cannot be brought into installation position with one hand, imper-
missibly high transverse forces exist.
' It must be possible to prise apart the pump nozzle flanges using a large
screwdriver (approx. 300 mm) to insert the flange seal. If this is not possible,
or if the flanges have to be drawn together by means of the flange bolts,
impermissibly high longitudinal forces exist.
NOTICE
Leakages caused by faulty weld seams
' If seal--welded ring gaskets are used for sealing of the flanges, the welding
plan in chapter 9.1 must be observed.
5.7.4.2 Weld end nozzle variant

The joint welds on the pump nozzles are not included in KSB’s scope of services.
NOTICE
Damage through welding particles in the pump.
' When welding the joint welds make sure that no welding particles can get into
the pump. Should this happen nevertheless or if there is suspicion that welding
particles got into the pump, the pump has to be dismantled and cleaned.
5.7.4.3 Minimum flow and balancing liquid pipes
NOTICE
Damage to the balancing device caused by impermissible piping layout.
' When installing the minimum flow pipe and the balancing liquid pipe, the
minimum flow diagram and/or P + I diagram must be observed.
' An orifice shall be installed immediately ahead of the inlet vessel to avoid
vaporisation in the minimum flow line.
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5.8 Final Installation of the Pump Set

Repeat alignment of the connecting coupling as described in chapter 5.4 and enter
the final measuring results in the coordinate system of the alignment/acceptance
certificate of the connecting coupling.
NOTICE
Alignment problems caused by piping not mounted without transmitting any
stresses and strains.
' If the connection of the pipes has altered the pump set’s alignment, the pipes
are not free from stresses or strains.
NOTICE
Avoidance of misalignment
' When aligning the pump set components (if applicable) observe the height
and lateral misalignment as indicated in the work instruction in chapter 9.1 .
5.8.1 Fastening the pump feet:

1. Tighten the nuts on the suction side with the tightening torque according to the
table Fastening of Pump Feet. See chapter 9.1.
2. Tighten the nuts on the suction side only so that the discs may still be moved
by means of slight hammer blows.

1 Pump 4 Stud
2 Nut 5 Baseplate
3 Disc
3. Lock all nuts using an additional nut.

The other pump set components shall be fastened and pinned as described in the
relevant manufacturer’s documentation.
Have the tightening torques of all fastening studs and foundation bolts checked and
confirmed by the responsible site management.
Have the alignment/taking--over certificate confirmed by the responsible site
management.
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5.8.2 Pinning the Pump Feet

If the pump supplied is provided with a baseplate, the parallel pin B has been fitted
at the factory. The hole for the parallel pin A has to be drilled at the place of installation
following the last connecting coupling alignment. Then fit the parallel pin A; see figure
Pinning the pump feet.
A B
HGM 1
HGM 2 ∅20mm
∅10mm
HGM 3
HGM 4 ∅30 mm
A = after re--installation, enlarge the existent

hole for the parallel pin to ∅12 mm and ream it.
L = µ 20 mm
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5.9 Mounting the Instruments

(if applicable, and not fitted at the factory)
WARNING
If operation is effected without monitoring and alarm equipment (provided
this equipment is required according to the list of measuring points in
chapter 9.1), overloading may be caused. Seal elements and pressurised
components may fail, which might result in hot or pressurised medium
handled escaping.
burns.
' Mount the monitoring and alarm equipment necessary to ensure operating
reliability.
NOTE
Choose a pressure gauge with an adequate measuring range.
NOTE
Do not remove the plugs of the connection points until immediately before
mounting.
5.9.1 Pressure gauges

1. Insert the joint ring and screw the special pipe part into the intended connection
point.
2. Mount the lock socket and sealing washer, screw fast the instrument holder.
3. Insert the sealing disc and screw on the lock socket.
4. Mount the shut--off valve.
5. Screw fast the pressure gauge with inserted sealing washer using a lock nut.
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5.9.2 Differential Pressure Monitoring

1. Fasten the differential pressure monitoring equipment to the holder provided on
the baseplate.
2. Screw fast the instrument leads at the intended connection points, see figure
Connection points for differential pressure monitoring, and install them according to
the constraints on site.
3. Have the electric connection cables connected by authorised personnel.
A C A C
D D
C
B
B
C
132 139
1 2
Connection points for differential pressure monitoring

1 Variant with intermediate piece (132)
2 Variant with suction elbow (139)
A = inlet pipe
C = connection for differential pressure monitoring
D = differential pressure monitoring equipment
5.10 Preservation for Standstill

If the pump set is not commissioned immediately after installation, it must be
preserved as described in chapter 6.7.
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Check List: Commissioning Date:
Name:
Boiler Feed Pump(s) – Pump Set(s)
The manufacturer's documentation is binding for

all work performed on the pump / set!
1. Pour-in the oil. Flush oil - check filter; see
(except for pump series HGM)
2. Adjust oil throttling valves (pressure, flow

rate); see chapter 6 of the instruction manual.
(except for pump series HGM)
3. Check the direction of rotation of the driver;

4. Check alignment; see chapter 5 of the

instruction manual.
5. Mount coupling / coupling guard; see chapter

7 of the instruction manual.
6. Check the strainer in the suction pipe; see

7. Prime and vent the system; see chapter 6 of the

instruction manual.
8. Prepare the pump(s)/set(s) for operation, ensure

quantity and quality of oil fills (exept pump
series HGM), check shaft seals, start-up
auxiliary circuits.
9. Check all instruments for proper functioning;

IBS Checkliste Kesselspeisepumpen-e Revisionsstand - 02 Page 1 of 2

Check List: Commissioning Date:
Name:
Boiler Feed Pump(s) – Pump Set(s)
10. Set the oil flow to the correct flow rate; see
chapter 6 of the instruction manual
(except for pump series HGM).
11. Check / adjust all interlocking systems.

Check turning gear (active time: from pump
standstill until start of turning gear); see
chapter 6 of the instruction manual
12. Check gate valve position.

Check minimum flow valve.
13. Start-up pump set; see chapter 6 of the

instruction manual.
14. Fasten / affix the CE – symbol.
Please note: Items on this check list that are not found in the instruction manual do not apply.
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6. Commissioning, Start--up / Operation / Shutdown

For all work to be carried out prior to commissioning/start--up, the following applies:
DANGER
If pumps are driven by electric motor: voltage--carrying pump set
components due to improper connection of the power supply.
' Always have the electrical connections installed by an authorised, trained
electrician.
' The electrical equipment of a pump set must comply with the general
requirements to EN60204--1.
' Observe regulations IEC 60364 (DIN VDE 0100).
' The local regulations for energy supply must be observed.
' Check the available mains voltage against the data on the motor name plate.
DANGER
Observe the applicable local occupational safety and accident prevention regulations.
and, if required, protective gloves.
WARNING
Risk of injury: body parts may become entangled, crushed or abraded, for example.
personnel, e.g. by removing the master switch and taking appropriate measures
of protection by means of an information label or a lock.
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WARNING
Improper handling of supplies may lead to contact with hazardous
substances.
' Observe the relevant safety instructions for the handling of hazardous
substances. (wear safety goggles and protective gloves, for example)
NOTICE
Damage to the pump due to unsuitable medium handled
' The medium handled must conform to the requirements of TRD 611 (German
Steam Boiler Regulations) for the feed water and boiler water of steam
generators of Group IV.
' Recommended solids content: 5 ppm max.
' For other applications please refer to the pump data sheet in chapter 9.2 of this
instruction manual.
NOTE
Hazards to the environment from improper handling of cleaning agents and
supplies.
' Cleaning agents and supplies must be kept out of the soil, groundwater and the
sewer system. Collect and properly dispose of these substances according to the
environmental protection regulations in containers intended for this purpose and
marked accordingly.
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6.2 Work to Be Carried out Prior to Commissioning, Start--up

In addition to this instruction manual, the technical documents on the other pump set
components are also needed for commissioning/start--up and shutdown. If these
components are included in KSB’s scope of supply, the relevant documents are
contained in chapter 9 of this manual.
Chapter 9.1: Installation Plan

Chapter 9.2: Documentation on the Mechanical Seal
Perform all dismantling and reassembly work in accordance with chapter 7.3.
6.2.2 Removal of Preservation
6.2.2.1 Internal preservation:

If the pump has been filled with a glycol/water mixture for preservation, this fill must
be drained before further work is done.
1. Open the pump drain (6B), collect the fill in an appropriate container and dispose
of according to the local anti--pollution regulations.
2. Close the pump drain.
3. Flush sufficiently to remove any residues of the preservative.
4. Remove the grease on the outsides of all pump set components.
6.2.2.2 External preservation:

Removal of preservation of the pump set components in accordance with the
relevant manufacturer’s documentation in chapter 9.
Washing the preserved exterior parts with petrol, petroleum, diesel oil or
general--purpose cleaner such as Shell Collina 2306.

Standstill of more than 12 Months
1. Dismantle the pump--end coupling hub.
2. Remove the mechanical seal and check it in accordance with the
3. If the mechanical seal is clean and undamaged, it may be re--installed.
Otherwise a new seal must be installed.
4. Re--mount the pump--end coupling hub.
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6.2.4 Checking the Direction of Rotation
NOTICE
Damage to the bearings and shaft seals due to wrong direction of rotation.
' The pump’s direction of rotation is indicated by an arrow on the driven--end
bearing housing.
' The direction of rotation of the drive must correspond to the direction indicated in
the installation plan.
If the pump set is driven by an electric motor, the direction of rotation of the motor
must be checked prior to commissioning/start--up.
6.2.4.1 Prerequisites
Check the direction of rotation prior to the final assembly of the connecting
coupling (motor alone is running).
Comply with the manufacturer’s documentation.
The electric motor is provided with a lubricant.
6.2.4.2 Direction of rotation

The motor shaft must rotate in anticlockwise direction, seen from the pump.
1 2
1 Pump
2 Electric motor
6.2.4.3 Checking the Direction of Rotation with a Phase--sequence Indicator

The direction of rotation of the electric motor can be checked by means of an
electromagnetic phase--sequence indicator.
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6.2.4.4 Checking the Direction of Rotation without Phase--sequence Indicator
WARNING
Starting of the motor for checking the direction of rotation may lead to
contact with unprotected, rotating and projected parts (coupling hub, motor
shaft end).
' Remove or fasten any movable parts on the motor shaft.
' Do not touch any unprotected, rotating parts.
1. In the case of toothed couplings, fix the drive--end coupling sleeve on the hub
using spacer plates (supplied loose), see figure Arrangement of spacer plates.
Arrangement of spacer plates (example)
2. Have the electric motor switched on by authorised personnel for a short period
of time.
3. Switch the electric motor off again immediately before the operating speed is
reached.
4. Check the direction of rotation. If wrong, have the terminal connections reversed
by authorised personnel and check the direction of rotation once again.
5. Secure the drive against accidental starting again.
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WARNING
WARNING
Mistake in the electrical connections either leads to a short circuit, a wrong
direction of rotation of the pump or a motor damage.
Risk of injury, e.g. from electric shock.
' Mark the connections in the terminal box!
NOTICE
Bearing damage due to incorrect axial clearance.
' In the case of electric motors with axial tolerance, if applicable, the coupling hub
of the motor shaft must be re--aligned as required by the actual magnetic centre.
If the coupling has a spacer, it must be possible to mount and remove it.
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6.2.5 Rotatability of the Pump Rotor

In the case of toothed couplings, fix the pump--end coupling sleeve on the hub
using spacer plates (supplied loose), see figure Arrangement of spacer plates.
It must be possible to rotate the pump rotor by hand, and it may only be rotated
in the direction of rotation of the pump. If necessary, attach an appropriate tool
at the coupling hub, see figure Rotatability of the pump rotor.
In the case of the variant balance disc without lift--off device, move the
pump rotor towards the driven end by approx. 1 mm before you turn it by hand,
see figure Rotatability of the pump rotor.
Rotatability of the pump rotor (example)

A = approx. 150 mm
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6.2.6 Mounting the Connecting Coupling and Guard Preventing Accidental

Contact
DANGER
6.2.6.1 Mounting the Connecting Coupling

Mount and align the spacer of the connecting coupling as described in the
manufacturer’s documentation and in chapter 7.3.9.3.
6.2.6.2 Mounting the Guard Preventing Accidental Contact
WARNING
Contact with unprotected, rotating and projected parts due to missing
guards.
' Mount all guards properly.
' Operate the pump (set) only when provided with protective equipment.
Mount the coupling guard as described in chapter 7.3.10 and check for correct
functioning.
If the customer specifically requests to deliver the pump (set) without a coupling
guard, then the operator must supply one. For selecting a coupling guard, the
relevant regulations must be observed.
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6.2.7 Functional Test and Adjustment of the Instruments
WARNING
Monitoring and alarm equipment which is set incorrectly may lead to over-
loading during operation. Seal elements and pressurised components may
fail, which might result in hot or pressurised medium handled escaping.
' Connect and activate all monitoring and alarm equipment installed.
' Check all instruments in accordance with the individual manufacturer’s
documentation for correct measuring data and adjust the instruments, if required.
' Set the warning and shutdown values in cooperation with control engineering
specialists.
6.2.8 Shaft Seal

Check the mechanical seal s readiness for operation.
Remove the assembly fixtures, if any.
The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Observe the manufacturer’s documentation., see chapter 9.
6.2.9 Priming the Pump and Piping
NOTICE
Damage to the pump through dry running.
' Never operate the pump without the fluid to be handled.
' Never close the shut--off element in the suction pipe during operation.
1. Close all drains and drain pipes.

2. Open the shut--off valve in the minimum flow pipe.
3. If there is no by--pass, open the shut--off valve in the inlet pipe by 10 to 20 %.
4. Prime the inlet pipe, pump and discharge pipe up to the closed shut--off valve
in the discharge pipe, preferably with cold condensate.
5. Vent all pressure gauge lines until there is no more air to escape.
6. Fully open the shut--off valve in the inlet pipe.
7. Check whether inlet pressure is available.
NOTE
For design--inherent reasons, the existence of some spaces not filled with liquid after
the pump has been filled prior to commissioning cannot be excluded. However, once
the motor is started up the pumping effect will immediately fill these spaces with
pumped fluid.
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6.3 Commissioning, Start--up
6.3.1 Prerequisites
Installation and alignment have been performed in accordance with good
engineering practice, recorded and accepted by the Operator.
The rotatability of the pump rotor has been checked.
The drive has been checked in accordance with the manufacturer’s
documentation.
The direction of rotation of the drive has been checked.
All other pump set components have been checked in accordance with the
relevant manufacturer’s documentation.
All guards preventing accidental contact have been mounted.
All pipes have been cleaned and connected.
All instruments have been fitted and checked for correct functioning.
6.3.2 Checks Prior to Starting
WARNING
Improper mounting of pipes or flanges may cause leaks where hot and
pressurised fluids can escape.
' Prior to and during starting of the pump check all connections, pipes, flanges,
screw/bolt connections and pipe unions for leakage and damage.
' All unused connections must be closed.
NOTICE
Damage to the pump through improper starting of the pump set.
All items mentioned in this section must be complied with.
The inlet vessel is in operational condition.

The inlet pipe, pump and discharge pipe have been primed and vented.
The shut--off valve in the inlet pipe is fully open.
The shut--off valve in the discharge pipe is closed.
The connection for tapping, if applicable, is closed.
The shut--off valves in the minimum flow pipe are open.
All temperatures indicated are below the limit values.
Check all pipes, flanges, screw/bolt connections and pipe unions for leakage.
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6.3.3 Starting and Trial Run
WARNING
It may be that the sound pressure level of 85 dB(A) is exceeded during
operation.
Injury to and impairment of hearing. Hardness of hearing, tinnitus and hearing loss can
be caused.
' Wear ear protection!
' Observe the applicable local occupational health and safety regulations.
WARNING
Should the seal elements on the suction and discharge casing or other
pressurised components fail, hot or pressurised medium handled or vapour
might escape.
' Wear safety goggles!
' Access to the pump is only permitted to authorised specialist personnel.
CAUTION
Hot surfaces. Depending on the degree of insulation and the temperature of
the medium handled, the entire pump and the associated pipes may be hot.
Risk of burns.
' Do not touch hot surfaces.
NOTICE
Temperature differences in the pump lead to deformations which cause
damage to the pump set during operation. Therefore, the temperatures
indicated must be adhered to exactly.
NOTICE
Abnormal noise, vibrations, temperatures or leakage suggest a possible
damage to the pump.
' Switch off the pump immediately.
' Eliminate the causes before returning the pump to service.
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NOTICE
Risk of damage through cavitation.
' The minimum discharge head of 150 m must not be underrun, except in the
start--up and stopping phase!
' The minimum speed of n = 1500 min--1 may only be underrun in the start--up and
stopping phase.
' The minimum speed must be achieved quickly after start--up (< 5 s).
NOTE
Should warning signals or problems occur during starting or trial run, proceed as
described in chapter 8!
1. Switch on the drive as described in the manufacturer’s documentation.

2. Check the temperature and smooth running.
3. Check the pump pressures and differential pressures.
CAUTION
Hot surfaces on the minimum flow pipe and balancing liquid pipe. The
pipes heat up during operation.
Risk of burns.
' Do not touch the pipe surfaces.
4. Make sure the minimum flow valve works (hydrodynamic noise).

5. Check the temperature at the balancing liquid pipe using a contact thermometer
(approx. 10°C higher than operating temperature).
6. Slowly open the valve of the discharge pipe until it is completely open.
7. Permanently monitor the pump set s operating behaviour.
8. Check the mechanical seals. Mechanical seals must not drip.
NOTICE
Damage to the pump through cavitation.
' Observe the permissible inlet pressure and temperature ranges, see chapter 9.1
and chapter 9.2.
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6.4 Operation
6.4.1 Intended Use
DANGER
Operation outside the use limits permitted may lead to failure of seal ele-
ments and parts which are subjected to pressure. which might result in hot
or pressurised medium handled escaping.
Danger to life, e.g. cuts caused by fluid jets, burns, scalds, respiratory system burns.
' The pumped medium pressure must not exceed the maximum permissible pump
discharge pressure.
' The pumped medium temperature must not exceed the permissible value.
damage, damage to bearings, etc)
damage, damage to bearings, etc)
' The pump may only be used to handle the approved medium indicated in chapter
9.2.
' Take appropriate measures in accordance with the local regulations to avoid
exceeding of or falling below the permitted use limits due to operating errors,
malfunctions or procedural errors.
' The pump must only be operated when in perfect technical condition.
Safety--relevant faults must be remedied immediately.
' The pump must not be operated in partially assembled condition.
' The pump or its components must not be altered in any way.
' Regularly check that all monitoring and alarm equipment is in perfect condition.
' As a general rule, the use limits permitted for operation and indicated in chapter
9.2 must always be complied with.
DANGER
Explosion hazard when operating a pump (set) which is not explosion--proof
in potentially explosive atmospheres.
Danger of death from explosion! Serious internal and external injuries by mechanical
and thermal effects which could result in death.
' The pump must not be installed and operated in potentially explosive
atmospheres.
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NOTICE
Damage to the pump due to improper operation of the pump set.
All items mentioned in this section must be complied with.
Never operate the pump without the fluid to be handled.

Do not throttle the pump on the suction side (risk of cavitation damage) and
make sure the strainer in the inlet pipe is clean.
The manufacturer’s supervision and servicing specifications as given in chapter 7.1
and chapter 7.2 must be complied with.
Should modes of operation other than those given in the data sheets in chapter 9
be requested, these must be checked and approved by the manufacturer.
All safety notes and instructions in this manual and the related documents must
be observed.
Observe the pump inlet pressure limits (exceeding of the limits may cause
damage to the thrust bearing, falling below the limit values involves the risk of
cavitation damage).
6.4.1.1 Frequency of starts

Max. 25 starts per day are permitted.
NOTICE
Damage due to excessive frequency of starts.
' An excessive frequency of starts leads to increased wear on the pump’s
balancing devices and bearings.
' The values indicated apply to the pump only. Moreover, the frequency of starts
is determined by the drive and, therefore, has to be checked separately! See the
6.4.1.2 Ambient temperatures

The maximum permissible ambient temperature is 50_C.
Higher temperatures must be discussed and agreed with KSB.
NOTICE
Excessive ambient temperature.
' If the permissible ambient temperature is exceeded, inadequate cooling can lead
to damage to the shaft seal or the bearings.
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6.4.2 Safety Instructions for Operation
DANGER
Even if all safety regulations and instructions are observed and the intended
use is adhered to, there is a general residual risk that components will fail.
This could result in escaping of hot and pressurised fluid pumped during
operation.
' Access to the pump is only permitted to authorised specialist personnel. Minimise
the duration of stay.
and, if required, protective gloves!
' Regularly check the pump (set) for impermissible leakage. In any case, keep
your distance from leakage points!
DANGER
Voltage--carrying pump set components due to improper or no earthing of
the pump set. Possible damage to pump set components.
' Ensure proper earthing of the pump set and check regularly, see chapter 7.1.
WARNING
It may be that the sound pressure level of 85 dB(A) is exceeded during
operation.
Injury to and impairment of hearing. Hardness of hearing, tinnitus and hearing loss can
be caused.
' Wear ear protection!
WARNING
Should the shaft seal fail, hot or pressurised medium handled or vapour
might escape
' Wear safety goggles!
' Regularly check the shaft seal.
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WARNING
guards.
' Regularly check all guards for correct fastening.
' The guards must not be removed while the pump is running.
CAUTION
Risk of burns.
NOTICE
Excessive density of the fluid handled.
Motor is overloaded!
' Observe the information on fluid density in the data sheet.
' Make sure the motor has sufficient power reserves.
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6.5 Shutdown
CAUTION
Risk of burns.
NOTICE
Risk of damage through cavitation
' The minimum discharge head of 150 m must not be underrun, except in the
start--up and stopping phase!
' The minimum speed as indicated in the operating data in chapter 9.1 may only
be underrun in the start--up and stopping phase.
6.5.1 Shutdown -- Pump Set Remains Ready for Operation

1. Close the shut--off valve in the discharge pipe. If a check valve is installed in the
discharge pipe, the valve on the discharge pipe may remain open, provided that
back pressure is available.
CAUTION
Hot surface on the minimum flow pipe. The pipe heats up during operation
via the minimum flow valve.
Risk of burns.
' Do not touch the minimum flow pipe surface.
2. Make sure the minimum flow valve works.

3. Switch off the drive, making sure it runs smoothly down to a standstill.
4. Note the run--down time.
6.5.2 Shutdown For Maintenance of the Pump Set or Prolonged Standstill

1. Close the shut--off valve in the discharge pipe.
CAUTION
Hot surface on the minimum flow pipe. The pipe heats up during operation
via the minimum flow valve.
Risk of burns.
' Do not touch the minimum flow pipe surface.
2. Make sure the minimum flow valve works.

3. Switch off the drive, making sure it runs smoothly down to a standstill.
4. Note the run--down time.
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NOTICE
Accidental start--up of the pump set may lead to damage to the pump.
personnel, e.g. by disconnecting the electrical connections.
5. Close the shut--off valve in the tapping pipe, if any.

6. Close the shut--off valves in the minimum flow pipe.
7. Close the shut--off valve in the inlet pipe.
8. Close the other pipes.
6.6 Work after Shutdown
6.6.1 Work after Shutdown during Readiness for Instant Start--up

General Information
If the period of standstill during readiness for instant start--up is longer than 2 weeks,
the pump set components such as gear or motor must be protected against water
ingress and humidity as described in the manufacturer’s preservation instructions.
Every 4 to 6 weeks
-- Put the pump into operation as described in chapter 6.3.
-- Switch off the pump after approx. 10 minutes as described in chapter 6.5.
-- Check whether the pump rotor runs smoothly down to a standstill.
1. Put the pump into operation as described in chapter 6.3.
2. Switch off the pump after approx. 10 minutes as described in chapter 6.5.
3. Check whether the pump rotor runs smoothly down to a standstill.
6.6.2 Work after Shutdown for Maintenance of the Pump Set
DANGER
The pumped medium may be a hazardous substance (e. g. toxic, flammable
or explosive) or be hot Improper handling may lead to contact with hazar-
dous substances and hot medium pumped.
burns.
required).
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DANGER
Insufficient preparation of work on the pump (set).
Risk of injury.
' Properly take the pump set out of service.
' Close the shut--off valve in the discharge pipe, the tapping pipe (if applicable) and
the inlet pipe.
' Close auxiliary connections, if any.
' Depressurise the pump.
DANGER
Contact with hot pumped fluid if the pump is still too hot on draining.
Furthermore, in a drained, hot pump, the O--rings might be damaged,
resulting in a leakage on returning to service.
burns.
' Let the pump cool down: Casing temperature < 50°C, measured at the pump
nozzles!
WARNING
CAUTION
Hot surfaces on the pump (set).
Risk of burns.
nozzles!
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NOTE
Make sure that the drive cannot be switched on.

Secure all valves against opening.
Open all drains and/or drain pipes.
Collect the fill in an appropriate container and dispose of according to the local
anti--pollution regulations.
If the period of standstill is longer than 2 weeks, the pump set components such as
gear or motor must be protected against water ingress and humidity as described
in the manufacturer’s preservation instructions.
6.6.3 Work after Shutdown for Standstill -- Pump not Ready for Operation
NOTICE
Risk of machine damage!
' In the case of danger of frost and standstill > 2 weeks, the pump must be
drained and preserved as described in chapter 6.7!
6.6.3.1 General Instructions

Secure all valves against opening.
Close all openings and supply pipes.
Protect the pump set components against water ingress and humidity as described
in the manufacturer’s preservation instructions.
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6.7 Detailed Description of Preservation for Standstill
DANGER
DANGER
Insufficient preparation of work on the pump (set).
Risk of injury.
' Properly take the pump set out of service.
' Close the shut--off valve in the discharge pipe, the tapping pipe (if applicable) and
the inlet pipe.
' Close auxiliary connections, if any.
' Depressurise the pump.
DANGER
Contact with hot pumped fluid if the pump is still too hot on draining.
Furthermore, in a drained, hot pump, the O--rings might be damaged,
resulting in a leakage on returning to service.
burns.
nozzles!
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DANGER
The pumped medium may be a hazardous substance (e. g. toxic, flammable
or explosive) or be hot Improper handling may lead to contact with
hazardous substances and hot medium pumped.
burns.
required).
WARNING
WARNING
Improper handling of supplies may lead to contact with hazardous substan-
ces.
CAUTION
Hot surfaces on the pump (set).
Risk of burns.
nozzles!
NOTE
1. Secure all valves against opening.

2. Open all drains and/or drain pipes.
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3. Collect the fill in an appropriate container and dispose of according to the local
anti--pollution regulations.
4. Close all drains and/or drain pipes.
5. Fill the pump with a glycol/water mixture at a proportion of 1:1.
NOTE
This mixture ensures protection against frost up to approx. --42 °C.
6. Dismantle and store the coupling guards mounted to the pump set.
7. Dismantle and store the spacer of the mounted connecting coupling as
described in the manufacturer’s documentation.
8. Rotate the pump rotor once or twice a month to prevent a separation of the
preservation fill, check the fill level and top up, if required.
In the case of toothed couplings, fix the pump--end coupling sleeve on the hub
using spacer plates (supplied loose).
It must be possible to rotate the pump rotor by hand, and it may only be rotated
in the direction of rotation of the pump. If necessary, attach an appropriate tool
at the coupling hub.
In the case of the variant balance disc without lift--off device, move the
pump rotor towards the driven end by approx. 1 mm before you turn it by hand.
6.8 Returning to Service after Storage
WARNING
In case of storage periods of more than 5 years, the sealing function of
O--rings may be impaired by, for example, embrittlement. This could result in
escaping of hot and pressurised fluid pumped during operation.
burns.
' After a storage period of more than 5 years, the pump must be dismantled before
it is installed, and the O--rings must be replaced.
For returning the pump to service observe the items on commissioning/start--up,

chapters 6.1, 6.2 and 6.3.
In addition carry out all servicing/maintenance operations according to chapter 7.2
and chapter 7.3 before returning the pump (set) to service.
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7. Supervision / Servicing / Maintenance

7.1 Supervision
7.1.1 Pump Supervision Plan, HGM

This supervision plan contains the minimum scope of work recommended by
KSB. The time intervals indicated should not be exceeded; shorter intervals
conduce to the operating reliability.
DANGER
Various hazards may be caused when checking a pump whilst it is in
operation: e.g. hot surfaces, excessive sound pressure level, leakage of the
pumped fluid.
Risk of injury.
' The safety instructions in chapter 6.4.2 must be observed when doing any
maintenance work.
' In particular, appropriate personal protective equipment must be used, e.g.
safety goggles must be worn.
Point to be Supervisory
Value to be met Interval
supervised action
Strainer -- inlet pipe, Checking the ∆p < 0.3 bar Weekly
differential pressure differential
gauge pressure ∆ p
(if applicable)
Thrust bearing/radial Checking the TThe pump set shall run Weekly
bearing smooth running smooth and free from
vibrations. Values, see List of
measuring points
(if any) in chapter 9.1
Thrust bearing/radial Checking the Value, see operating data in Every 16.000
bearing clearance increase chapter 9.1 operating hours
Proceed as described in
chapter 7.3.4.2
Mechanical seal (433) Checking the See the manufacturer’s See the
leakage documentation manufacturer’s
documentation
Static seals Checking for No leakage permitted Daily
leakage
Measuring instrument, Checking the Value, see operating data in Weekly
suction side ps pressure chapter 9.1
(instrument holder)
discharge side pd pressure chapter 9.1
(instrument holder)
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Point to be Supervisory
Value to be met Interval
supervised action
tapping pressure chapter 9.1
(instrument holder)
(if applicable)
Connecting coupling Checking for No leakage permitted Weekly
(only applicable to leakage
toothed coupling)
Coupling guard Checking for safety Contact--free installation Monthly
Earth connection Checking for safety Connection must have been Monthly
made and marking applied
Differential pressure Checking the see Operating data in chapter 9.2 Weekly
gauge differential and List of measuring points (if
Strainer -- inlet pipe pressure any) in chapter 9.1
(if applicable)
Drive See the See the manufacturer’s See the
(if applicable) manufacturer’s documentation manufacturer’s
documentation documentation
Thermometer Checking the See Operating data in chapter 9.2 Weekly
(balancing liquid) temperature and List of measuring points (if
(if applicable) any) in chapter 9.1
In case of deviations, proceed in accordance with the table in chapter 8 !
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7.2 Servicing
7.2.1 General Information

We recommend that KSB’s specialist personnel be present during the
performance of servicing work!
WARNING
Unqualified personnel performing work on the pump (set).
Risk of injury!
' Always have repair and servicing work performed by specially trained, qualified
personnel.
WARNING
example.
WARNING
Improper handling of supplies may lead to contact with hazardous substan-
ces.
NOTE
Hazards to the environment from improper handling of cleaning agents and
supplies.
' Cleaning agents and supplies must be kept out of the soil, groundwater and
the sewer system. Collect and properly dispose of these substances according
to the environmental protection regulations in containers intended for this
purpose and marked accordingly.
' The applicable international, national and local legislation, provisions, safety
and environmental protection regulations must be complied with.
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7.2.1.1 Requisite Documentation

In addition to this instructionmanual, the technical documents on the other pump set
components are also needed for servicing of the pump set. If these components are
included in KSB’s scope of supply, the relevant documents are contained in chapter
9 of this manual.
Chapter 9.2: General Drawing, Pump

List of Components, Pump
Documentation on the Mechanical Seal
Chapter 9.5: Documentation on the Minimum Flow System
and the Minimum Flow Control Valve
Chapter 9.6: Documentation on the Valves and Equipment
Chapter 9.8: Documentation on the Variable Speed Geared Coupling
(if applicable)
Chapter 9.9: Documentation on the Guards (if applicable)
7.2.1.2 Prerequisites
The pump set has been taken out of service in accordance with chapter 6.5 and
chapter 6.6 and has been prepared for the servicing work.
The drive has been secured against unintentional starting.
7.2.1.3 Servicing Intervals
NOTE
Perform a visual inspection of the pump set -- as far as accessible -- about 500
operating hours after commissioning/start--up.
The periods of time indicated in the servicing plan apply to normal operating
conditions at trouble--free operation, which have to be adapted to the actual
operating conditions, for example the dirt accumulation, frequency of starts, load,
etc.
In the case of problems and unusual operating conditions that represent electric or
mechanical overloads, off--schedule servicing must be performed.
7.2.2 Dismantling the Guards Preventing Accidental Contact

Dismantle/remove the guards preventing accidental contact mounted on the pump set
as described in chapter 7.3.
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7.2.3 Pump Servicing Plan, HGM

After Commissioning/Start--up and Stand--by
Location to be Servicing
Work Time intervals
serviced action
Connecting coupling Checking the condi-

tion and functioning
Oil- or grease fill See the manufacturer’s See the manufacturer’s

(if applicable) documentation documentation
Pump rotor Checking the axial Measuring the axial clea- After approx. 8.000 operating
movability rance; hours,
see Table of Clearances after 1 year at the latest
in chapter 9
Drive See the manufactu- See the manufacturer’s See the manufacturer’s
rer’s documentation documentation documentation
Instruments Perfect condition and Replacing defective See the manufacturer’s

(if applicable) proper functioning equipment; documentation
see the manufacturer’s
documentation
Mechanical seal See the manufacturer’s documentation
Thrust bearing/ Checking the Checking the diametral After 16.000 operating hours
radial bearing condition clearances, permissible
deviation; see Tables of
Clearances in chapter 9.
In the case of exposed fi-
bres at the bearing surfa-
ces, the relevant parts
must be replaced.
Minimum flow valve See the manufacturer’s documentation
7.2.4 Servicing Work

7.2.4.1 Servicing Work on the Pump
Perform all dismantling and reassembly work as described in chapter 6 and chapter
7.3.
NOTICE
Damage to bearings through damaged bearing surfaces:
' Exposed fibres and fibre ends at the surface of the bearings destroy the
associated counter--surfaces.
' Replace damaged bearings.
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7.3 Maintenance
7.3.1 General Information
DANGER
DANGER
Residues of the pumped fluid and the contents of cooling liquid and injec-
tion pipes may be hazardous substances (e. g. toxic, flammable or explo-
sive) or be hot. Improper handling may lead to contact with hazardous
substances and hot medium pumped.
burns.
required).
' Collect and properly dispose of any liquids.
WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
' Always have repair and maintenance work performed by specially trained, quali-
fied personnel.
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WARNING
Accidental start--up of the pump set may lead to contact with
unprotected, rotating and projected parts.
example.
WARNING
Improper handling of supplies may lead to contact with hazardous
substances.
NOTICE
Damage to the pump due to improper dismantling and reassembly!
' Dismantle/reassemble the pump (set) in accordance with the general rules of
sound engineering practice.
' Use original spare parts only.
' Use the special tools intended.
' Use the removal/forcing threads provided.
NOTE
During the warranty term, pumps must only be dismantled or reassembled by KSB
personnel!
NOTE
Hazards to the environment from improper handling of hazardous
substances, cleaning agents and supplies.
' Hazardous substances, cleaning agents and supplies must be kept out of the
soil, groundwater and the sewer system. Collect and properly dispose of these
substances according to the environmental protection regulations in containers
intended for this purpose and marked accordingly.
' The applicable international, national and local legislation, provisions, safety
and environmental protection regulations must be complied with.
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7.3.1.1 Requisite Documentation
NOTE
The numbers in parentheses, e.g. (412.17), refer to pump components shown in
the general drawings in chapter 9.2.
In addition to this instruction manual, the technical documents on the other pump set
components are also needed for the dismantling and reassembly work. If these
components are included in KSB s scope of supply, the relevant documents are
contained in chapter 9 of this manual.
Chapter 9.1: Table of Weights

Tables of Clearances
Table of Tightening Torques
List of Measuring Points
Table of Threads
for Dismantling/Reassembly Aids
Lubrication and Preservation Instructions
Work Instructions, Assembly Instructions, Assembly Sketches
Sectional Drawing, Mechanical Seal
Chapter 9.8: Documentation on the Gear or Variable Speed Coupling
(if applicable)
Chapter 9.9: Documentation on the Guards (if applicable)
7.3.2 Prerequisites for Dismantling

The pump set has been taken out of service in accordance with chapter 6.5 and
chapter 6.6 and has been prepared for the maintenance work.
All spare parts required are available.
Proper hoisting tackle and means of transport are available and ready for use.
Sufficient room space and appropriate tools are available.
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7.3.3 Dismantling the Guards
DANGER
accidents causing serious injuries, e.g. during dismantling and reassembly
of the coupling and the guards.
' Wear suitable protective clothing, safety helmet and safety shoes with toe cap.
7.3.3.1 Sound Insulating Hood (if applicable)

Dismantle the sound insulating hood as far as necessary as described in the
7.3.3.2 Coupling Guard

Dismantle and store the coupling guard in accordance with chapter 5.2.5.
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7.3.4 Dismantling the Connecting Coupling

As a rule, the manufacturer’s operating instructions in chapter 9.3 must be
observed.
7.3.4.1 Dismantling the Connecting Coupling Spacer
WARNING
Hot surface from heating of the coupling hubs. Risk of injury and fire hazard
from improper handling of naked flames.
Risk of injury, e.g. burns on hands and arms.
' Wear heat--resistant protective gloves.
' Remove flammable substances from the danger zone.
1. Give due attention to markings on the coupling, if any, or mark the coupling to
avoid any mixing up.
X und X = marking
X
Coupling
1. Coupling hub (pump end)
2. Coupling hub (drive end)
3. Spacer
2. Dismantle the connecting coupling spacer as described in the manufacturer’s

documentation.
3. Store the parts appropriately.
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7.3.4.2 Checking the Thrust Bearing Clearance

(only necessary for checking the clearance increase)
1. Fit the dial gauge holder in a fixed point and place the sensing element against
the coupling face.
2. Place the rotor against the discharge--side bearing (386.03) and bring the dial
gauge in the 0--position.
3. Move the rotor towards the suction side until it abuts against the suction--side
thrust bearing (386.01). Read the dial gauge (max. clearance, see Table of
Clearances in chapter 9.1).
Checking the thrust bearing clearance
NOTE
If the pump is filled, an axial force of up to 4000 N is necessary, depending on the
pump size and the geodetic water column.
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7.3.4.3 Removing the Coupling Hubs (keyed connection)
WARNING
WARNING
Coupling parts falling down on dismantling of the coupling.
Risk of injury, e.g. crushing caused by falling parts!
' Secure coupling parts against falling down.
' It is imperative to wear safety shoes.
NOTICE
Impairment of the sealing function of elastomeric parts through heating.
' Elastomeric parts which have been heated must not be used any more.
' Use new parts for reassembly.
NOTICE
Damage to bearings and coupling parts due to improper dismantling.
' Remove the coupling hubs only using the appropriate device to prevent the
shaft bearings from damage by the axial friction force.
' Impacts on the coupling hubs are not permitted.
1. Dismantle the retaining ring, if applicable, from the coupling hub.

2. Remove the grub screws.
3. To facilitate fitting, the coupling hub may be heated uniformly to a temperature
of 80°C max.
4. Remove elastomeric parts before heating!
5. Remove the coupling hubs as shown in the figure Removing the coupling hubs.
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Removing the coupling hubs (example)
6. Mark the keys prior to removing them.

7. Store the coupling hubs and keys appropriately.
7.3.4.4 Run--out Check of the Shaft Ends

1. After removing the coupling hubs check the shaft ends for run--out, see figure
Run--out check of the shaft ends.
2. Permissible tolerance ≤ 0.05 mm; if this value is exceeded, inform KSB.
Run--out check of the shaft ends (example)
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7.3.5 Removing the Pump from the Installation

The work described in sections 5.1 to 5.3 is only required if the pump is to be
removed from the installation for maintenance.
7.3.5.1 Dismantling the Piping and Instruments
NOTE
' Operating fluids can run out when unscrewing the pipes and instruments.
These are to be collected and properly disposed of by the Operator.
1. Fasten the inlet and discharge pipes to temporary holders.

2. Undo the connections between discharge nozzle and discharge pipe and
between suction nozzle and inlet pipe.
3. Dismantle the minimum flow valve, if necessary.
4. Disconnect the tapping pipe, if applicable.
5. Disconnect and dismantle the circulation pipes, if necessary.
6. Dismantle the measuring devices and instruments as far as necessary, and
store them appropriately.
7. Close all openings where pipes have been dismantled.
7.3.5.2 Removing the Pump from the Baseplate

Unscrew the fastening studs at the pump feet; see figure Fastening of the pump feet.
Fastening of the Pump Feet (example)

1 = pump 4 = stud
2 = nut 5 = baseplate
3 = disc
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7.3.5.3 Transporting the Pump to the Place of Dismantling
DANGER
instructions:
DANGER
arrangement.
NOTE
Mark the matching shims (between the pump feet and baseplate) so that they can
be inserted in the same place on subsequent reassembly, and store them
appropriately.
Lift the pump from the baseplate, transport it to the place of dismantling and set it
down on assembly supports.
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7.3.6 Dismantling the Pump
WARNING
Pump parts falling down on dismantling and reassembly.
' Wear safety shoes. Observe the applicable local accident prevention
regulations.
WARNING
Damaged shaft sleeves and mechanical seals may result in leakage or a
sudden failure of the sealing function. This could result in escaping of hot
and pressurised fluid pumped during operation.
burns.
' Replace damaged shaft sleeves and mechanical seals by new
components.
NOTICE
Damage through use of used bearings.
' Re--use only bearings which are in perfect condition.
' In the case of slight discolourations (incl. rust stain) or any damage, the
bearings must be replaced.
' If the contact surfaces do not exhibit any scores or wear, the parts may be
used for reassembly. Otherwise, they must be replaced by new parts
(preferably the counterparts as well).
NOTICE
Damage to the shaft and clearance gaps due to improper dismantling.
' When the bearings are dismantled, the shaft must not be rotated.
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7.3.6.1 Dismantling the Mechanical Seal

1. Dismantle the balancing liquid pipe (710/731) completely.
2. Remove the thrower (507) from the shaft sleeve (523).
3. Loosen the nuts (920.02) and remove them incl. the discs (550.03). Dismantle
the shaft seal housing (441) incl. seat ring (475.21) and O--ring (412.22).
4. Loosen the grub screw (904.21) and remove the tappet (485.21) incl. the spring
(477.21), thrust ring (474.21), O--ring (412.21), backing ring (50--3.22), circlip
(932.21) and spring--loaded ring (472.21) from the shaft sleeve (523).
5. Loosen the shaft sleeve (523) using an open--end wrench (left--hand thread)
and turn it from the shaft in clockwise direction.
6. Check the mechanical seal: If the seal faces are clean and undamaged, the
mechanical seal may be re--installed..
Z7D005
Dismantling the mechanical seal
WARNING
Damaged shaft sleeves may result in leakage or in a sudden failure of the
sealing function. This could result in escaping of hot and pressurised fluid
pumped during operation.
burns.
' Replace damaged shaft protecting sleeves by new ones.
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7.3.6.2 Dismantling the Thrust Bearing, Discharge--side Radial Bearing

and Balancing Device
WARNING
' It is imperative to wear safety shoes. Observe the applicable local accident
1. Remove the bearing ring carrier (391) including thrust bearing ring (386.03),
O--ring (412.12 and 412.62) and parallel pin (562.05 and 562.06) from the shaft
seal housing (411).
2. Remove the balance drum (603) as well as thrust bearing (386.02), parallel pin
(562.61/.63) and O--ring (412.14/.63/.61) from the shaft using screws/bolts in
accordance with the table Threads for Dismantling/Reassembly Aids in chapter 9.1.
3. Remove the piston (59--4) including O--ring (412.15) from the shaft using
screws/bolts in accordance with the table Threads for Dismantling/Reassembly Aids
in chapter 9.1.
Dismantling the thrust bearing, discharge--side radial bearing

and balancing device
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4. Checking the contact surfaces on the thrust bearing and radial bearing:
-- If the contact surfaces of the thrust bearing ring (386.01/.02/.03), balance
drum (603) as well as piston (59--4) and throttle bush (542.02) do not exhibit
any scores, the parts may be used for reassembly.
-- If the contact surfaces are scored, damaged or excessively worn, the bearing
parts have to be reconditioned prior to reassembly.
NOTICE
Check dismantled components for damage. The installation of
damaged parts may lead to increased wear or to failure of the balancing
device and bearings, which results in damage to the pump.
' If scores or wear (permissible clearance increase, see Tables of Clearances in
chapter 9) can be seen on the parts, replace the parts.
' In the case of exposed fibres at the bearing surfaces, replace the relevant
parts (preferably the counterparts as well).
NOTICE
Damage to the shaft and clearance gaps due to improper dismantling.
' When the bearings are dismantled, the shaft must not be rotated.
' Mark the bearings to ensure their correct assignment to the bearing housings.
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7.3.7 Reassembling the Pump

7.3.7.1 General Information on Reassembly
WARNING
The contact of O--rings with oil or grease may result in failure of the
sealing function. This could result in escaping of hot and pressurised fluid
pumped during operation.
burns.
' Do not take the O--rings out of their original packagings until immediately
before they are fitted and protect them from mineral oil and grease!
' Do not fit the O--rings in dry condition but wet them with silicone grease! In
exceptional cases, soapy water may be used.
WARNING
The re--use of used O--rings or gaskets may lead to failure of the sealing
function. This could result in escaping of hot and pressurised fluid pumped
during operation.
burns.
' As a general rule, always use new O--rings and gaskets for reassembly.
NOTICE
Damage to locating and sealing surfaces through improper reassembly.
' Do not damage the locating and sealing surfaces.
Meticulously clean all dismantled components, in particular the fit and sealing
surface areas.
Check all dismantled components for signs of damage.
If required, place new parts available.
Prior to reassembly, coat the screw/bolt connections and pipe unions as well as
the fits of the individual components as described in the work instruction UA4
28700 using the relevant lubricating agent indicated.
Reassembly must be performed in accordance with the rules of sound
mechanical engineering practice
7.3.7.2 Reassembling the Discharge--side Radial Bearing and Thrust

Bearing
NOTICE
Carry out this work with special care in order not to damage the internal
parts.
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7.3.7.2.1 Not Using New Parts
NOTICE
Damage to the throttling distance due to improper reassembly.
' Prior to fitting the piston (59--4), the shaft (210) must be lifted to centreline
position in order to prevent any contact of the surface of the piston (59--4) with
other components such as throttle bush (542.02).
1. Slide the piston (59--4) including O--ring (412.15) over the shaft (210) and key
(940.01).
2. Slide the balance drum (603) including O--ring (412.63) and parallel pin (562.63)
over the shaft (210) until it abuts against the spacer ring (504).
3. Check the thrust bearing clearance according to the following formula:
g -- (f + h) = 1  0.4 mm
Reassembling the discharge--side radial bearing and thrust bearing
4. Slide the bearing ring carrier (391) with inserted O--ring (412.12), parallel pin
(562.05/.62) and thrust bearing ring (386.03) over the shaft until it abuts against
the thrust bearing ring (386.02).
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7.3.7.2.2 Using a New Balance Drum (603) and/or New Thrust Bearing Ring
(386.01)
NOTICE
Damage to the throttling distance due to improper reassembly.
' Prior to fitting the piston (59--4), the shaft (210) must be lifted to centreline
position in order to prevent any contact of the surface of the piston (59--4) with
other components such as throttle bush (542.02).
1. Slide the piston (59--4) including O--ring (412.15) over the shaft (210) and key
(940.01).
2. Slide the thrust bearing ring (386.01) over the throttle bush (542.02) using
screws/bolts in accordance with the table Threads for Dismantling/Reassembly Aids
in chapter 9.1 until it abuts against the discharge casing (107). Pay attention to
the position of the parallel pin (562.03).
3. Adjusting the position of the pump rotor.
Pull the rotor towards the discharge side until it abuts and push it towards the
suction side in accordance with the table.
Rotor adjustment
Pump type Hydraulic system
dimension mm
HGM 1 1.1 2.4 ± 0.3
HGM 2 2.1 and 3.1 2.6 ± 0.3
HGM 3 4.1 and 5.1 4.0 ± 0.3
6.1 and 7.1 4.5 ± 0.3

HGM 4
6.2 and 7.2 3.6 ± 0.3
171.01
108.01 171.02 230
502 108.02 171.03 231
Rotor adjustment dimension
Adjusting the position of the pump rotor
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NOTICE
Damage to pump through incorrect axial adjusting of the rotor.
' This rotor adjustment must not be changed during the entire process of
measuring the spacer ring (504).
8. Determining the length of the spacer ring (504) according to the following
formula:
K -- M = L
K
L
Determining the length of the spacer ring (504)
Shorten the spacer ring (504) to the dimension L. The maximum permissible
deviation from plane parallelism is 0.02 mm.
NOTE
If required, use a new spacer ring (504).
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9. Coat the axial running face of the balance drum (603) thinly with the contact fluid
“engineer’s blue” and slide it without O--ring (412.63) over the shaft (210) as far
as to the spacer ring (504) already fitted.
10. Fit the shaft sleeve (523) without O--ring (412.14) as decribed in chapter 7.3.7.3.
11. For the check with the contact fluid “engineer’s blue”, move the rotor towards the
suction side and turn it slowly. Move the pump rotor towards the discharge side
again.
12. Dismantle the shaft sleeve (523) and balance drum (603).
13. At least 3/4 of the axial running face of the thrust bearing ring (386.01) must have
a uniform print of the contact fluid. If this is not the case, remachine the thrust
bearing ring (386.01) on a lathe and repeat the contact fluid check.
14. After completion of the contact fluid check, clean the axial running faces of thrust
bearing ring (386.01) and balance drum (603).
15. Carry out final assembly of the thrust bearing as described in chapter 7.3.7.2
ausführen.
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7.3.7.3 Mounting the Mechanical Seal
WARNING
' It is imperative to wear safety shoes with toe cap. Observe the local
accident prevention regulations.
WARNING
Damaged shaft sleeves and mechanical seals may result in leakage or a
sudden failure of the sealing function. This could result in escaping of hot
and pressurised fluid pumped during operation.
burns.
' Replace damaged shaft sleeves and mechanical seals by new
components.
NOTICE
' Comply with the specified tightening torques to prevent any damage to the
pump through loose parts.
' Observe the general drawing of the mechanical seal and the manufacturer’s
documentation.
1. Place the O--ring (412.14) into the intended groove of the balance drum (603).
2. In the shaft sleeve area, thinly spray--coat the shaft and thread with UNIMOLY
C220 (molybdenum sulfide lubricant) from M/S Klüber Lubrication!
NOTE
The shaft sleeve (523) has a left--hand thread.
3. Turn the shaft sleeve (523) onto the shaft (210) and tighten it using an
open--ended spanner. Tightening torques, see Table of Tightening Torques in
chapter 9.1. Make sure the O--ring (412.14) fits correctly!
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WARNING
Improperly fitted seal components may result in leakage or a sudden failure
of the sealing function. This could result in escaping of hot and pressurised
fluid pumped during operation.
burns.
' The shaft sleeve (523), balance drum (603) and spacer ring (504) must be
pressed against the shaft shoulder.
' Measure the fitting dimension LG with the balance drum (603) abutting against
the thrust bearing ring (386.01).
4. Slide the complete mechanical seal (433) onto the shaft sleeve (523) and fasten
using the grub screws (904.21). Tightening torque, see Table of Tightening
Torques in chapter 9.1.
The fitting dimension LG of the mechanical seal must be complied with, see
table.
Pump size LG
HGM 1 46 mm
HGM 2 62 mm
HGM 3 65.5 mm
HGM 4 78.5 mm
LG
Fitting dimension LG of the mechanical seal
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5. Fit the seat ring (475.21) with O--ring (412.22) in the shaft seal housing (441).
6. Fit the pre--assembled shaft seal housing (441) with inserted O--ring (412.10)
to the discharge casing (107).
Please note:: The parallel pin (562.05) must engage into the intended hole in
the shaft seal housing (441).
LG
Mounting the Mechanical Seal
7. Fit the discs (550.03) and nuts (920.02). Tighten the nuts (920.02) in diagonally
opposite sequence. Tightening torque, see the relevant work instruction.
8. Slide the thrower (507) over the shaft (523) and check for tight fit.
9. Mount the balancing liquid pipe (710/731) completely.
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7.3.8 Installing the Pump in the Plant
7.3.8.1 Transporting the Pump to the Place of Use
DANGER
instructions:
installation plan. See chapter 9.1
DANGER
arrangement.
WARNING
example.
1. Lift the pump from the assembly supports, transport it to the place of use and
set it down on the baseplate.
2. Mark the matching shims (between the pump feet and baseplate) so that they
can be inserted in the same place on subsequent reassembly, and store them
appropriately.
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7.3.8.2 Aligning the Pump Set Components

Align the pump set components on the baseplate as described in chapter 5.4.4.
7.3.8.3 Mounting the Pipes and Instruments

Re--mount as described in chapter 5.7 (Installation at Site) all pipes and instruments
which were dismantled in connection with maintenance work.
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7.3.9 Mounting the Connecting Coupling
DANGER
When putting into service an improperly or incompletely mounted coupling,
parts being catapulted off may cause serious injuries and damage to
property.
Most serious injuries, which might result in death, from flying parts.
' Only put the coupling into service when it is mounted completely and in
ready--for--operation condition.
WARNING
Unqualified personnel performing work on the pump (set).
Risk of injury!
' Always have repair and servicing work performed by specially trained, qualified
personnel.
WARNING
' It is imperative to wear safety shoes. Observe the applicable local accident
WARNING
example.
As a rule, the manufacturer’s operating instructions in chapter 9.3 must be observed.
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7.3.9.1 Run--out Check of the Shaft Ends
NOTICE
Increased wear or failure of the bearings and/or coupling through operation
at excessive run--out.
' Check the shaft ends for run--out prior to mounting the coupling hubs.
' Permissible tolerance < 0.05 mm (see figure Run--out check of the shaft
ends). If the tolerance is exceeded, please inform KSB.
' Observe themanufacturer’s mounting/dismantling instructions; see chapter
9.3.
' Read the pump shaft’s check values after a 90_turn each.
Run--out check of the shaft ends (example)
7.3.9.2 Fitting the Coupling Hubs (keyed connection)

1. Carefully clean the shaft ends and bores of the coupling hubs and check them
for dimensional accuracy.
2. If the key protrudes from the coupling hub, the protruding part must be adapted
to the shaft diameter.
3. Slightly deburr the hub keyway and insert the key.
4. Check the protrudent dimension of the key. Tolerance in accordance with the
figure Clearance between keyway and key.
Clearance between keyway and key
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WARNING
NOTICE
Damage to the coupling hub through non--uniform or excessive heating.
' Make sure the parts are heated uniformly. Regularly measure the temperature
at various points of the hub bore.
' Do not heat the hub more than required for the joint clearance. See the data
provided by the manufacturer in chapter 9.3.
NOTICE
Impairment of the sealing function of elastomeric parts through heating.
' Elastomeric parts which have been heated must not be used any more.
' Use new parts for reassembly.
6. To facilitate fitting, the coupling hub may be heated uniformly to a temperature

of 80_C max.
7. Remove elastomeric parts before heating!
WARNING
Coupling parts falling down on reassembling of the coupling.
' It is imperative to wear safety shoes with toe cap.
NOTICE
Damage to the bearings and coupling parts due to improper reassembly.
' Fit the coupling hubs only using the appropriate device to prevent the shaft
bearings from damage by the axial friction force.
' Impacts on the coupling hubs are not permitted.
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8. Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft
end and the hub face are in alignment.
X = See table Threads for

Dismantling/Reassembly Aids
Fitting the coupling hub (example)
9. Securely tighten the grub screws.
A = grub screw
Coupling hub with grub screw (example)
10. Fit the retaining ring (if any) on the coupling hub.
7.3.9.3 Mounting the Spacer
WARNING
Coupling parts falling down on reassembling of the coupling.
' It is imperative to wear safety shoes with toe cap.
Mount and align the spacer of the connecting coupling as described in the
manufacturer’s documentation. See chapter 9.3 and chapter 5.4.
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7.3.10 Mounting the Guards Preventing Accidental Contact
WARNING
guards.
example.
' Mount all guards properly.
' Operate the pump (set) only when provided with protective equipment.
At the end of all preparatory work to be carried out for start--up, mount all protective
equipment and check for correct functioning.
If the customer specifically requests to deliver the pump (set) without a coupling
guard, then the operator must supply one. For selecting a coupling guard, the
relevant regulations must be observed.
7.3.10.1 Coupling Guard (standard)

1. Prise apart the ring (500) wide enough to allow for sliding it over the connecting
coupling.
2. Move the ring (500) in axial direction towards the face side of the drive, align it
and close it as shown in the figure.
500
Z
Z 5 min.
Z7S001
Coupling guard (standard)
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coupling.
4. Align the guard (680) over the connecting coupling so that on the pump side the
guard rests against the shaft seal housing (441) and on the drive side against
the ring (500).
5. Fasten the guard (680) with the respective bolts as shown on the figure
Mounting the guard.
680
Z7S002
Mounting the guard
7.3.10.2 Coupling Guard (explosion protection)

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

1 Bottom plate
2 Lock strip
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7.3.11 Maintenance of the Other Pump Set Components

See the manufacturer’s documentation.
7.3.12 Maintenance of the Connecting Coupling

7.3.13 Maintenance of the Drive

7.3.14 Maintenance of the Minimum Flow System and the Minimum Flow
Valve
7.3.15 Maintenance of the Instruments

Maintenance is not required. In the case of malfunction, the instruments are
replaced.
7.3.16 Spare Parts
7.3.16.1 Ordering Spare Parts

Always quote the following data when ordering spare parts (also those supplied with
the pump):
Pump type series or required pump set component
KSB order number
Order item number
Consecutive number
Refer to the name plate for all data (chapter 4.3).
Also supply the following data:

Description
Part No.
Quantity of spare parts
Shipping address
Mode of dispatch (freight, mail, express freight, air freight)
Refer to the general drawings for part numbers and descriptions
(chapter 9.2).
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7.3.16.2 Spare Parts Stock

For quick elimination of possibly occurring problems, we recommend to keep a stock
of spare parts. The requested scope of spare parts can be individually discussed and
agreed with KSB and usually is based on DIN 24296.
Preconfigured spare parts packages recommended by KSB (for 1 pump each):
7.3.16.2.1 Commissioning/start--up
Part No. Description Quantity
99--9 Set of seal elements 1

433 Mechanical seal 1
7.3.16.2.2 Two years’ operation (small spare parts kit)

386 Thrust bearing ring 1
412.04 O--ring 1
412.05 O--ring 4)
420 1) Shaft seal ring 1

502 2) Casing wear ring 4)
504 3) Spacer ring 1

523 Shaft sleeve 1
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7.3.16.2.3 Two years’ operation (large spare parts kit)
Rotor, preassembled 1
386.01 Thrust bearing ring 1
412.04 O--ring 1
412.05 O--ring 4)

529 5) Bearing sleeve 1

542.02 Throttle bush 1
545 Bearing bush 1
7.3.16.2.4 Large spare parts kit (only rotating parts)
Rotor, preassembled 1
529 5) Bearing sleeve 1
7.3.16.2.5 Large spare parts kit (only stationary parts)

412.04 O--ring 1
412.05 O--ring 4)
542.02 Throttle bush 1

545 Bearing bush 1
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7.3.16.2.6 Spare parts kit (rotor)
59--4 Piston 1
210 Shaft 1
230 Non--suction impeller 4)
231 / 529 Suction impeller / bearing sleeve 1

504 3) Spacer ring 4)
523 Shaft sleeve 1

562.61 Parallel pin 1
562.63 Parallel pin 1
603 Balance drum 1
914.01 Socket head cap screw 1
940.01 Key 1
940.03 Key 2
940.03 Key for coupling 2
1) Only for cooled variant

2) Only in special case of repair:
-- Impellers made of 1.4008 are equalised at the impeller neck. Casing wear
rings with smaller inside diameters are employed and adapted to the impeller
neck diameter if required.
-- Impellers made of GJL 250 are always repalced by new ones and the
associated casing wear rings are supplied with finished diameters.
3) In max. length
4) Depending on the number of stages; the quantity is transferred by the selection
program.
5) Bearing sleeve already fitted to suction impeller. Additional bearing sleeves
(non--fitted) can be ordered, however, they must be ordered separately.
Special tools are not required. Standard tools can generally be used.
7.3.16.3 Storage
The parts should be stored as described under Temporary Storage in chapter 3.4.
Store the spare parts in accordance with chapter 3.4.
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KSB Aktiengesellschaft
Abt. T356 ; Ersatzteile / Gewährleistungen
D-67227 Frankenthal Johann–Klein–Straße 9
Tel.: (+49) 6233/862952 / Fax: (+49) 6233/863464 / eMail: Troubleshooting@KSBGroup.com
Meldung Betriebsstörung (soweit zutreffend, bitte vollständig ausfüllen)

Baureihe: HG..; WKT; CHT..; YNK;
Failure Report (please fill in completely where appropriate) Datum der Störung /
Type series: HG..; WKT; CHT..; YNK;: Date of failure: __________________
Kunde/Name/Anschrift Tel.-Nr.: Fax-Nr.: E-Mail:

Customer/Name/Address Phone No.: Fax No.: e-mail:
KSB - Werk-Nr.: Pumpentyp:

KSB Serial No.: Pump type:
Betriebsdaten zum Zeitpunkt der Störungen: / Operating data at the time of failure:
Druck / Pressure: Saugseite / Suction side PS bar

Druckseite / Discharge side PD bar
Entlastungswasser / Balancing water PE bar
Temperatur: Lager Saugseite / Suction side °C
Temperature: Bearings
Druckseite / Discharge side °C
Axiallager / Thrust bearing °C
Zulaufbehälter / Deaerator °C
Drehzahl: Pumpe
-1
Speed: Pump min
Fördermenge:
Flow rate: m³/h
Fördermedium: pH-Wert / pH-value
Pumped medium: O2 -Gehalt / O2-content ppm
Inbetriebnahme: Datum
Commissioning: Date
Betriebsstunden:
Operating hours: h
Leckage Stopfbuchse/Gleitringdichtung: ja / yes nein / no
Leakage – gland packing/mechanical seal:
Lärmpegel steigt / Increasing noise level: ja / yes nein / no
Schwingungswerte steigen / Increasing vibration values: ja / yes nein / no
Kurzbeschreibung der Betriebsstörung / Brief description of operational failure
Bereits eingeleitete Maßnahmen / Measures initiated
Welche Teile sind zu ersetzen? / Gilt als offizielle Bestellung

Which parts have to be replaced? / This is an official purchase order
Teile-Nr. Bezeichnung Stück Teile-Nr. Bezeichnung Stück
Part No. Description Quantity Part No Description Quantity
1 4
2 5
3 6
Datum / Date: Unterschrift / Signature:
Meld-Betriebsstör-HG_d-e Revisionsstand – 01 (08.02.2002) Seite 1 von 1

Revision status – 01 (Febr.08, 2002) Page 1 of 1
8. Trouble--shooting
NOTE
During the warranty term, pumps must only be dismantled by KSB personnel!

For the elimination of problems described in the table below, the technical
documentation of the other pump set components is required in addition to this
instruction manual. If these components are included in KSB’s scope of supply, the
relevant documents are contained in chapter 9 of this manual.
Chapter 9.1: Technical Data

Operating Data
Installation Plan
Tables of Clearances
Tightening Torques
Sectional Drawing, Mechanical Seal
Work Instructions, Assembly Instructions, Assembly Sketches
Chapter 9.9: Documentation on the Sound Insulating Hood
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8.1.2 Prerequisites
All spare parts required are available.
Proper hoisting tackle and means of transport are available and ready for use.
Sufficient room space and appropriate tools are available.
Perform all work on the pump set required by the table below in accordance with
the preceding chapters or the manufacturer’s descriptions in chapter 9.
For the work required by the table below, the pump set has been taken out of
service in accordance with chapter 6.5 and chapter 6.6.
NOTE
Before rectifying any faults, check all measuring instruments for proper
functioning.
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8.1.3 Trouble--shooting
In case of problems not described in the following table, consultation with KSB’s
customer service is required.
Problem (what) Possible causes Remedies
Flow rate of pump < Pump delivers against an Open the valve in the discharge pipe further until
specified value excessively high discharge the duty point is adjusted
pressure
Excessive back pressure Mount larger impeller(s)
Contact KSB’s service centre
Increase the speed of the drive
Check the system for impurities
Pump and/or piping are not Vent/prime

completely vented and/or primed.
Inlet pipe or impeller(s) clogged Remove deposits in the pump and/or piping
Formation of air pockets in the Alter piping layout

piping
Fit a vent valve
NPSHavailable too low (inlet) Correct the fluid level
Fully open the valve in the inlet pipe
Change the inlet pipe, if the resistances in the

inlet pipe are too high
Check any strainers installed
Excessive speed of pressure fall Observe the permissible speed of pressure fall
Wrong direction of rotation Interchange 2 phases of the power supply
Speed is too low Increase the speed
Increase the voltage
Wear of internal pump parts Replace defective parts

(check in accordance with Table
of Clearances in chapter 9.1) Contact KSB’s service centre
Motor is running on two phases Replace defective fuses

only
Check the power cable connections
Pump discharge pressure Speed is too high Alter the impeller diameter
pd> specified value
Damaged measuring instrument Replace the measuring instrument
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customer service is required!
Inlet pressure ps < Damaged measuring instrument Replace the measuring instrument
specified value
Differential pressure in the Dismantle and clean the strainer element
strainer element is too high
Valve in the inlet pipe is not fully Open the valve

open
Pressure in the inlet vessel is too Check the inlet vessel and/or increase the
low pressure
Pump discharge pressure Damaged measuring instrument Replace the measuring instrument
pd <specified value
Speed is too low Check the drive
Inlet pressure is too low Check the inlet pressure and inlet vessel
In the case of tapping, quantity Throttle the quantity tapped

tapped is too high
Temperature of the medium Reduce the temperature

pumped is too high
Defective minimum flow system Check the minimum flow system
Mechanical seal leakage Defective mechanical seal Check; replace, if required
Score marks or roughness on Check the shaft protecting sleeve (524) and/or
shaft protecting sleeve (524) and/ shaft sleeve (523), replace, if required
or shaft sleeve (523)
Pump set alignment Check the coupling; re--align if required
Pump is warped Check the piping connections and the fastening of

the pump
Leakage, mechanical seal Mechanical seal must run in Running--in operation of 30 minutes
> specified value for
commissioning
Leakage, mechanical seal Excessive thrust bearing clea- Check the bearing clearance
> specified value rance
See chapter 7.3.4.2
Pump leakage Defective O--rings and/or metallic Replace the O--rings and/or remachine the metal-
g surfaces
sealing lic sealing surfaces
Tie bolts have worked loose Tighten bolts
in accordance with the relevant work
instruction in chapter 9.2
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Pump runs rough Pump and/or piping are not Vent and/or prime
completely vented and/or primed
NPSHavailable too low (inlet) Correct the fluid level
Fully open the valve in the inlet pipe
Change the inlet pipe, if the resistances in the

inlet pipe are too high
Check any strainers installed
Wear of internal pump parts Replace defective parts

(check in accordance with Table
of Clearances in chapter 9.1 ) Contact KSB’s service centre
Back pressure of pump is lower Adjust the duty point accurately by means of the
than specified in the purchase valve in the discharge pipe
order
In the case of persistent overloading, turn down
the impeller(s), if necessary
Pump set alignment Check the coupling; re--align if required

the pump
Unbalance of the pump rotor Clean the pump rotor
Balance the pump rotor
Flow rate < specified value Flow rate ≥ Qmin
Excessive thrust bearing Check the bearing clearance

clearance
See chapter 7.3.4.2
Excessive radial bearing Have the bearing clearances checked by KSB

clearance personnel
Minimum flow rate is too low Check the valves in the minimum flow pipe
Check the minimum flow valve
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Excessive temperature of Heat exchanger is dirty Clean the heat exchanger

the circulation liquid
Valve is defective/closed Check/open the valve
Cavitation noise in the Damaged/dirty inlet pipe Check the inlet pipe
the pump and/or piping
Valve in the inlet pipe is not fully Open the valve
open
Pressure in the inlet vessel is too Check the inlet vessel and/or increase the
low pressure
NPSHavailable/NPSHrequired too Check the inlet pipe

low
Alter the inlet pipe
Air intake at seal elements, Check the piping; check shaft seal for leakage
valves and shaft seal
Pump and/or piping are not Vent and/or prime

completely vented
Excessive pumped medium Reduce the temperature

temperature
Pump suddenly blocks Mechanical blocking of the rotor Interrupt the energy supply, interlock and
depressurise the pump
Drive is overloaded Wear of internal parts Replace defective parts

(check in accordance with the
Table of Clearances in chapter
9.1) Contact KSB’s service centre
Back pressure of pump is lower Adjust the duty point accurately by means of the
than specified in the purchase valve in the discharge pipe
order
In the case of persistent overloading, turn down
the impeller(s), if necessary
Density or viscosity of the Contact KSB’s service centre

medium pumped is higher than
stated in the purchase order
Speed is too high Alter the impeller diameter
Reduce the speed of the drive

the pump
Operating voltage is too low. Check the power cable connections
Motor is running on two phases Replace defective fuses

only
Check the power cable connections
Baureihe_HGM
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9 Relevant Documentation

Baureihe_HG Datum_
Werk-Nr._
9.1 Pump Set

Declaration of conformity according to
EC machinery directive 2006/42/EC
Installation plan / E-Motor UG1 587630
Installation plan / Turbine UG1 592485
Characteristic curve
Table of weights
Table of clearances
Table of tightening torques
Excerpt from DIN 1045

Baureihe_HG Datum_
Werk-Nr._

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7KHPDQXIDFWXUHUKHUHZLWKGHFODUHVWKDWthe pump:

HGM 2/9

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9973105255 KSB order item number: 000100 / 1 & 000300 / 1
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Table of Weights HGM 2

Weights ² 25 kg
NOTE
The total pump weight is indicated on the plate at the stage casing.
The total weight of the pump set is given in the installation plan in
chapter 9.1, and the weight of the pump set components in the
manufacturer’s documentation in chapters 9.3 to 9.9.
Pump Components
Weights (refence values in kg)

P tN
Part No. D i
Designation
ti Material variants Material variants
1 -- 4 5 and 11
107 Discharge casing 55 60
108.11/.13 Stage casing 33 52
441 Housing for shaft seal 26
Rotor 4--stage 38
each additional stage 4,5
Pump
Weights (reference values in kg)
Number Pump without water fill

of stages
Material variants Material variants W t fill
Water
1 -- 4 5 and 11
4 349 344 10,3
5 381 377 12,4
6 413 410 14,6
7 444 443 16,8
8 476 475 19,0
9 507 509 21,2
10 539 542 23,4
11 570 575 25,6
12 602 608 27,8
13 633 641 30,0
14 665 674 32,2
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Weights (reference values in kg)
Number Pump without water fill

of stages
Material variants Material variants W t fill
Water
1 -- 4 5 and 11
15 696 707 34,4
16 728 740 36,6
17 759 773 38,8
18 791 806 41,0
Baureihe_HGM
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Table of Clearances
Diametral Clearances
Nenn Durchmesserspiel [mm]

Nenn-Durchmesserspiel
Pump p S2 S3
size
i Max.clear.
Max clear Max.clear.
Max clear Max.clear.
Max clear
S1 GG Chrome GG Chrome
S1 S2 S3
(cast iron) steel (cast iron) steel
0,3 -- 0,40 --
1 0,27 -- 0,90 1,0
0,18 -- 0,40 -- 0,366 0,516
0,222 0,30 -- 0,500 0,45 --
2 0,27 0,90 1,0
0,40 0,530
0,22 -- 0,40 -- 0,3 -- 0,45 --
3 0,32 0,90 1,0
0,270 0,30 -- 0,550 0,386 0,536
0,26 -- 0,45 0,45 -- 0,45 --
4 0,37 0,95 1,0
0,319 0,563 0,535
S1
2
Clearance between bearing sleeve and bearing bush
S S
3
2 2
2
Clearance between impeller and casing wear ring as well as impeller

and diffuser
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Discharge--side Bearings
As -new
As- new diametral clearance [mm]
Pump
p size
S4 Max clearance S4
Max.
1 0,15 -- 0,189 0,24
2 0,18 -- 0,222 0,27
3 0,18 -- 0,222 0,27
4 0,18 -- 0,227 0,28
Thrust bearing Clearance
As new diametral clearance [mm]

Pump
p size
S5 Max clearance S5
Max.
1 -- 4 1 ± 0,4 2,5
S4
2
S5
Clearance between piston and throttle bush
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Theoretical Total Axial Clearance:
Sa1 + Sa2 [mm]

Pump
p size Hydraulics
y Impeller material
GG (cast iron) Chrome steel
1 1.1 5,0 -- 6,5 5,0 -- 6,5

2.1
2 4 5 -- 6
4,5 6,0
0 4 5 -- 6
4,5 6,0
0
3.1
4.1
3 7 0 -- 8
7,0 8,5
5 7 0 -- 8
7,0 8,5
5
5.1
6.1
7 5 -- 9
7,5 9,0
0 7 5 -- 9
7,5 9,0
0
4 7.1
6.2
8 0 -- 9
8,0 9,5
5 8 0 -- 9
8,0 9,5
5
7.2
Total axial clearance of pump rotor
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Threads for Dismantling/Reassembly Aids
Threads
Part No.
HGM 1 HGM 2 HGM 3 HGM 4
(107)
M 12 M 16 M 20
Discharge casing
(108.02)
------ M 12 M 16
Stage casing
(108.11/.13)
M 12 M 16
Stage casing
(162)
------ M 20
Suction cover
(171.03)
M6 M8 M 10 M 12
Diffuser last stage
(386.01)
M5 M8 M8
Thrust bearing ring
(386.02)
Force off using a crowbar--type tool
Thrust bearing ring
(386.03) Force off using a

Force off using a wire ø4
Thrust bearing ring crowbar--type tool
(391)
M8
Bearing ring carrier
(545) Force off using a

M5 M6
Bearing bush crowbar--type tool
(59--4)
M6 M12
Piston
(603)
M8 M 12
Balance drum
Shaft end,
M 12 M 16
coupling--side
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Table of Tightening Torques

Tightening Torques [Nm]
Perequisites
The threads of the screws/bolts and nuts are not damaged.
The threads and bearing surfaces of the screws/bolts and nuts are plane,
deburred and cleaned thoroughly.
The threads move smoothly.
The discs are plane, deburrred and cleaned thoroughly.
HGM 1
Tightening Torque
Part No. Thread Material
TA [Nm]
523 100
901.01 150 M 20 5.6
904.21 (GLRD) 10
914.01 250 M 20 C3--80
920.02 100 M 16 8
Foundation bolts *)
70 M 20 ¢ 400
(anchoring of baseplate)
Fastening of pump feet
190
(discharge side)
HGM 2
Tightening Torque
TA (Nm)
523 100
901.01 150 M 20 5.6
904.21 (GLRD) 10
914.01 400 M 24 C3--80
920.02 100 M 16 8
Foundation bolts *)
70 M 20 ¢ 400
190
(discharge side)
HGM 3
Tightening Torque
TA (Nm)
523 100
901.01 150 M 20 8.8
904.21 (GLRD) 10
914.01 800 M 30 ¢ 2 C3--80
920.02 100 M 16 8
Foundation bolts *)
70 M 20 ¢ 400
190
(discharge side)
Baureihe_HGM
Schraubenanzugstabelle_en
Revisionsstand_00
1
HGM 4
Tightening Torque
TA (Nm)
523 100
901.01 150 M 20 8.8
904.21 (GLRD) 10
914.01 1 300 M 36 ¢ 3 C3--80
920.02 100 M 16 8
Foundation bolts *)
70 M 20 ¢ 400
650
(discharge side)
*) 3 fastening methods:
Foundation bolts
Bonded anchors
Special foundation bolts
In the present manual, reference is always made to the tightening torques given
in the installation plan.
Baureihe_HGM
Revisionsstand_00
2
Bolts for Flange Connection, Discharge Nozzle and

Tapping Nozzle
The tightening torques apply only to bolts and screws that are part of KSB’s
scope of supply!
HGM 1--4
Nominal diameter Rated pressure Tightening torque
DN [mm] PN [bar] TA [Nm]
25 64 80
25 100 80
25 120 1) 80
50 64 160
50 100 240
50 120 1) 240
65 64 140
80 64 140
80 100 250
80 120 1) 250
100 64 240
100 100 350
100 120 1) 350

DN [inch] PN [class] TA [Nm]
1 600 80
1 900 1) 240
2 600 80
2 900 1) 240
2 1/2 600 140
2 1/2 900 1) 240
3 600 140
3 900 1) 240
4 600 240
4 900 1) 490
1) Max. pressure for the HGM type series when a flange rated at a pressure of
PN 160 or Class 900 is used.
Baureihe_HGM
Revisionsstand_00
3
Bolts for Flange Connection, Suction Nozzles

The tightening torques apply only to bolts and screws that are part of KSB’s
scope of supply!
HGM 1--4
DN [mm] PN [bar] TA [Nm]
65 16 70
80 16 50
125 16 70
150 16 130

DN [inch] PN [class] TA [Nm]
2 1/2 300 90
3 300 90
5 300 120
6 300 120
Baureihe_HGM
Revisionsstand_00
4
Tie bolts (905 / 920.01)

The tie bolts have to be tightened in accordance with the scale graduation marks
(slots on tightening nut). The requisite scale graduations are given in the table
below or stamped on the pump in the discharge nozzle area. The thread has to be
greased in accordance with the lubricant instruction.
Prior to tightening in accordance with the scale graduation marks, the tie bolts have
to be pre--loaded with 30 Nm to make sure that the casings have metal--to--metal
contact in the axial direction.
In addition, the tightening nuts have to be tightened in accordance with the scale
graduation marks indicated in the table.
8x 8x 8x 12 x
Tie bolt
M20 x 1,5 M24 x 1,5 M24 x 1,5 M24 x 1,5
Pump size HGM 1 HGM 2 HGM 3 HGM 4
No. of stages Skale graduation marks (SKT)
3 -- -- 7 8
4 8 6 9 11
5 9 7 10 13
6 11 9 12 15
7 12 10 14 17
8 14 11 15 20
9 15 12 17 22
10 17 13 19 24
11 18 14 21 26
12 20 15 -- --
13 21 16 -- --
14 23 18 -- --
15 25 19 -- --
16 26 20 -- --
17 -- 21 -- --
18 -- 22 -- --
Baureihe_HGM
Revisionsstand_00
5
Excerpt from DIN 1045 *
1. Admixtures
Admixtures are substances which are added to the concrete and which, by chemi-
cal or physical action or both, change the properties of the concrete, e.g. its
workability, hardening or setting. They provide negligible bulk.
2. Strength Class
Exposure Minimum com- Cylinder Cube

class pressive compressive compressive
strength
g class strength strength
[N/mm2] [lb/sq in] [N/mm2] [lb/sq in]
XC4 C25/30 25 3626 30 4351
3. Addition Agents
1. For concrete and cement mortar -- also for placing any reinforcement in posi-
tion -- only admixtures as per item 2 and exhibiting a valid test symbol must be
used, and only under the conditions stated in the test certificate.
2. Chlorides, chloride--containing or other substances expediting the corrosion
of steel must not be added to reinforced concrete as well as concrete and
mortar coming into contact with reinforced concrete.
4. Minimum Cement Content

allowing for admixtures
Minimum compres- Minimum cement con- Water cement value

sive strength class tent in kg per m3 / (WZ) w for Z 35
lb per yd3 of com-
pacted concrete
C25/30 270 / 455 ≤ 0,60
5. Consistence of Concrete
Concrete with the consistence F2, propagation value 35 to 41 cm / 14 to 16 inch
shall be used.
Baureihe_CHT/HG/HGM
DIN_1045_de
Revisionsstand_00
1
9.2 Pump
Operating data
Noise data
Sectional drawing pump UG1 476706
Sectional drawing mechanical seal 5177909601
List of components
Work instruction UA4 28700

Baureihe_HG Datum_
Werk-Nr._
P.O. No. P/O-LMW-DEL PK No.: 4500040694 Page No. 1
Date 21.01.2016 Pump: HGM 2/9
Customer Descon Engineering Ltd. Order No. 9973105255
Code name DM.15207 / Engro Works No. / E-Motor 9973105255 000100 / 1
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
Dept. / In charge TSS Eng.PP Ludwig Rau Component 42048409110011061003
Pump type Horizontal ring-section pump

Pump size / stages HGM 2/9 Quantity 2
Drive Electric motor 1 Pos. 100
Drive Turbine 1 Pos. 300
OPERATING DATA
Application/Medium handled: Boiler feed water
Conditioning AF Alkaline composition with salt-free water
pH value at 25°C >9.0 O2 contents mg/l <= 0.02
Operating point Operation Guarantee point
Unit Design point to ISO 9906 / 1B Min. flow ***)
Operating temperature °C 105 105
Density kg/dm3 0.954 0.954
Pressure in inlet vessel bara 1.209
NPSH available m 5
bar 0.468
NPSH required at Qs **) m 2.221
bar 0.208
Pressure at suction nozzle bar g 0.677
Mass flow rate at disch. t/h 23
Capacity m3/h 24.1 11.25
Total head m 697.69 717.2
bar 65.3 67.13
Pump discharge pressure bar g 66 ****)
Efficiency *) % 55.87
Pump input power kW 78.27
Pump speed 1/min 2970 2970
Direction of rotation clockwise as viewed from the driven end
ADDITIONAL DATA
Nozzle discharge pressure at Q=0, coldwater Pump discharge nozzle
bar g (+/- 3 %) 69.99
*) Efficiency improvement acc. to Karassik

**) without strainer loss
***) For pump protection only. Not for continuous operation.
****) 1 bar added for arc valve loss
Date 21.01.2016 Pump: HGM 2/9
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
OPERATING DATA
Operating point Start-up Minimum Max. Design
Unit
Operating temperature °C 105 105 105
Density kg/dm3 0.954 0.954 0.954
Pressure in inlet vessel bara 1.209 1.209 1.209
NPSH available m 5 5 5
bar 0.468 0.468 0.468
NPSH required at Qs **) m 2.229 2.234 2.316
bar 0.209 0.209 0.217
Pressure at suction nozzle bar g 0.677 0.677 0.677
Mass flow rate at disch. t/h 30 17.03 ***) 36
Capacity m3/h 31.43 17.85 37.72
Overall head m 668.29 711.21 629.36
bar 62.55 66.57 58.91
Pump discharge pressure bar g 63.23 67.25 59.58
Efficiency *) % 61.63 48.43 64.39
Pump input power kW 88.63 68.14 95.75
Pump speed 1/min 2970 2970 2970
Direction of rotation clockwise as viewed from the driven end
*) Efficiency improvement acc. to Karassik

**) without strainer loss
***) 17,03 t/h = 10,73 t/h (bypass flow) + 6,3 t/h (process flow)
Date 21.01.2016 Pump: HGM 2/9
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
Noise Data
1. Explanatory Notes
The noise data below conform to DIN standard 45635 - Measurement of noise emitted by machines - Part 1 – Airborne noise emission,
Enveloping surface method, Basic method divided into 3 grades of accuracy and Part 24 – Measurement of airborne noise emitted by
machines, Enveloping surface method, Liquid pumps.
The noise data meet the requirements of accuracy grade 2.
DIN 45635 standards for measurement largely correspond to international stipulations such as EN ISO 3744-09.1994 and
ISO 11201-12.1995.
The equipment used for measurements meet the requirements placed on precision sound level meters DIN EN 60651.
It was submitted to the standardising authority for examination within the required period of 2 years.
The non-weighted and A-weighted sound pressure levels were used as acoustic measurands expressed in dB.
The frequency weighting curve A is defined in DIN EN 60651.
2. Prerequisites
The noise data refer to the pump without sound insulation.
The data apply with / without electric motor.
The noise particulars apply to the normal operating range of the pump, i.e. Q/Qopt = 0.8 – 1.2
No allowance is made for operation under extreme part-load, overload or cavitation conditions.
3. Definitions
The surface sound pressure level LpA is the A-weighted sound pressure level averaged over the measurement surface S, expressed in dB.
The measurement surface ratio LS is calculated from the measurement surface S, whose size depends on the position of the measuring
points.
The measurement distance is typically chosen to be 1 m from the machine outline.
LS is expressed in dB.
The A-weighted sound power level LWA is the rate of the total noise radiated by the machine into the ambient air, expressed in dB.
The air-borne sound octave spectrum supplements the surface sound pressure level LpA data and provides information on the noise
composition in the acoustic frequency range from 63 Hz to 8 kHz.
This frequency range is subdivided in octave bands characterised by their centre frequency.
4. Noise Characteristic Values
The following values are expected noise values and cannot be warranted. The values indicated do not include the measurement tolerance.
If the values are to be warranted, an allowance for design and measurement tolerances of +3 dB has to be made.
Noise Characteristics for Operating Point (expected values)

Operating point - pump: Q [m3/h] H [m] P [kW]
24.1 697.69 78.27
It. Pump set component Description N LpA LS LWA
[1/min] [dB] [dB] [dB]
1 Pump HGM 2/9 2970 78 14 92
Total of items 1 78 14 92
Air-borne sound octave spectr. in 63 Hz 125 Hz 250 Hz 500Hz 1000 2000 4000 8000
for item 1 69 69 69 72 75 75 71 67
Einzelteilverzeichnis HGM 2/9, Var. 3
Schutzvermerk ISO 16016
Part list Copyright to ISO 16016
En accord avec ISO 16016
Auftrags-Nr. / Pos. Serien-Nr. Name Stellenkurzz. Datum
Order number / item. Serial number Name Dept. code Date
N° de commande / Pos. N° de fabrication Nom Sigle Date
9973105255 / 100 9973105255 000100 01 Karla Veit ECO1O211 26.01.2016
9973105255 / 300 9973105255 000300 01
Teile-Nr. ME Menge/Einh. Bennennung Werkstoff
Part number Quantity/unit Description Material
Repère Quant./Pompe Désignation Matériaux
97-2 GESAMTZEICHNUNG UG1476706

PUMPE
GENERAL DRAWING
PUMP
97-2 GESAMTZEICHNUNG 5177909601
GLRD
GENERAL DRAWING
MECHANICAL SEAL
1M.1 ST 1 DRUCKMESSGERAET
ANSCHLUSS
PRESSURE MEASURING
INSTRUMENT
CONNECTION
1M.3 ST 1 DRUCKMESSGERAET
ANSCHLUSS
PRESSURE MEASURING
INSTRUMENT
CONNECTION
6B ST 1 FOERDERFLUESSIGKEI
T ABLASS
PUMPED LIQUID DRAIN
8B ST 2 LECKFLUESSIGKEIT
ABLASS
LEAKAGE LIQUID
DRAIN
14E ST 1 ENTLASTUNGSFLUESSI
GK. EINTRITT
BALANCE LIQUID INLET
14A ST 1 ENTLASTUNGSFLUESSI
GK. AUSTRITT
BALANCE LIQUID
OUTLET
26M.1 ST 1 SCHWINGUNGSMESSU
NG ANSCHL.
VIBRATION
MEASUREMENT
CONNECTION
26M.2 ST 1 SCHWINGUNGSMESSU
NG ANSCHL.
VIBRATION
MEASUREMENT
CONNECTION
Seite 1 von 6
9973105255 / 100 9973105255 000100 01 Karla Veit ECO1O211 26.01.2016
9973105255 / 300 9973105255 000300 01
107 ST 1 DRUCKGEHAEUSE DN 50 1.4008

DISCHARGE CASING
108.01 ST 1 STUFENGEHAEUSE 95/ 320X 57,8 1.4006+QT650
STAGE CASING
108.02 ST 6 STUFENGEHAEUSE 95/ 321X 75 1.4006+QT650
STAGE CASING
108.03 ST 1 STUFENGEHAEUSE 95/ 320X 75 1.4006+QT650
STAGE CASING
139 ST 1 EINLAUFKRUEMMER A105
SUCTION ELBOW
162 ST 1 SAUGDECKEL 146/ 405X 70 1.4021+QT800
SUCTION COVER
171.01 ST 1 LEITRAD DIA 290/231 1.4008
DIFFUSER
171.02 ST 7 LEITRAD DIA 290/231 1.4008
DIFFUSER
171.03 ST 1 LEITRAD DIA 290/232 1.4008
DIFFUSER
210 ST 1 WELLE 50X 909 C45+SH+SR
SHAFT
230 ST 8 LAUFRAD 230X 6,5-13 1.4008.09
IMPELLER
231 ST 1 SAUGLAUFRAD 230X 6,5-13 1.4008.09
IMPELLER, SUCTION
STAGE
386.01 ST 1 AXIALLAGERRING 104/ 150X 32 RWA 350
THRUST BEARING RING
386.02 ST 1 AXIALLAGERRING 70/ 100X 12 WR 575
THRUST BEARING RING
386.03 ST 1 AXIALLAGERRING 69/ 100X 12 NORICROM1.4475
THRUST BEARING RING
391 ST 1 LAGERRINGTRAEGER 70/ 165X 18 1.4021+QT800
BEARING RING
CARRIER
411.01 ST 1 DICHTRING A4
SEALING RING
SEALING RING
Seite 2 von 6
9973105255 / 100 9973105255 000100 01 Karla Veit ECO1O211 26.01.2016
9973105255 / 300 9973105255 000300 01
SEALING RING
412.01 ST 1 O-RING EPDM 80PEROXYD
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
412.21 ST 1 O-RING E
O-RING
412.22 ST 1 O-RING E
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
Seite 3 von 6
9973105255 / 100 9973105255 000100 01 Karla Veit ECO1O211 26.01.2016
9973105255 / 300 9973105255 000300 01
433 ST 1 GLRD-BURGMANN AQ1EGG

MECHANICAL SEAL-
BURGMANN
441 ST 1 GEHAEUSE FUER 46/ 240X 141 1.4021+QT800
DICHTUNG
SHAFT SEAL HOUSING
472.21 ST 1 GLEITRING A/G1
PRIMARY RING
474.21 ST 1 DRUCKRING G
THRUST RING
475.21 ST 1 GEGENRING Q1
MATING RING
477.21 ST 1 FEDER G
SPRING
485.21 ST 1 MITNEHMER G
TAPPET
502 ST 1 SPALTRING 95/ 120X 16 RWA 350
CASING WEAR RING
CASING WEAR RING
CASING WEAR RING
504 ST 1 ABSTANDRING 39/ 50X 16,5 ZS 15 V
SPACER RING
507 ST 1 SPRITZRING ST
THROWER
515.01 ST 1 SPANNRING 390X 390X 60 S355J2+N
TAPER LOCK RING
515.02 ST 1 SPANNRING 395X 390X 60 S355J2+N
TAPER LOCK RING
520.21 ST 1 HUELSE G
SLEEVE
523 ST 1 WELLENHUELSE 36/ 59X 135 1.4021+QT800
SHAFT SLEEVE
529 ST 1 LAGERHUELSE 83/ 120X 53 1.4021-WR525
BEARING SLEEVE
542.02 ST 1 DROSSELBUCHSE 83/ 120X 70 NORICROM1.4475
THROTTLE BUSH
Seite 4 von 6
9973105255 / 100 9973105255 000100 01 Karla Veit ECO1O211 26.01.2016
9973105255 / 300 9973105255 000300 01
545 ST 1 LAGERBUCHSE 120/ 155X 59 NORICROM1.4475

BEARING BUSH
550.01 ST 8 SCHEIBE ST
WASHER
550.02 ST 16 SCHEIBE ST+PHR
WASHER
550.03 ST 8 SCHEIBE ST+PHR
WASHER
561 ST 1 KERBSTIFT A4
GROOVED PIN
GROOVED PIN
GROOVED PIN
562.01 ST 1 ZYLINDERSTIFT 1.4305
PARALLEL PIN
562.03 ST 1 ZYLINDERSTIFT A4
PARALLEL PIN
PARALLEL PIN
PARALLEL PIN
PARALLEL PIN
PARALLEL PIN
PARALLEL PIN
PARALLEL PIN
PARALLEL PIN
59-4 ST 1 KOLBEN 50/ 83X 70 1.4021-WR525
PISTON
603 ST 1 ENTLASTUNGSKOLBEN 39/ 153X 59 1.4024.09
BALANCE DRUM
710 ST 1 ROHR 25X 2X1100 1.4571+CFD
PIPE
Seite 5 von 6
9973105255 / 100 9973105255 000100 01 Karla Veit ECO1O211 26.01.2016
9973105255 / 300 9973105255 000300 01
720 ST 1 FORMSTUECK 20/ 45X 65 1.4571

SPECIAL PIPE PART
731.01 ST 1 VERSCHRAUBUNG 1.4571
PIPE UNION
731.02 ST 1 VERSCHRAUBUNG 1.4571
PIPE UNION
901.01 ST 8 SECHSKANTSCHRAUBE 5.6
HEXAGON HEAD
SCREW
902.01 ST 8 STIFTSCHRAUBE 5.8
STUD
903.01 ST 1 VERSCHLUSSSCHRAUB A4
E
SCREW PLUG
903.02 ST 1 VERSCHLUSSSCHRAUB A4
E
SCREW PLUG
904.21 ST 1 GEWINDESTIFT G
GRUB SCREW
905 ST 8 VERBINDUNGSSCHRAU 1.6772
BE
TIE BOLT
914.01 ST 1 ZYLINDERSCHRAUBE C3-80
HEXAGON SOCKET
HEAD CAP SCREW
920.01 ST 16 6KT-MUTTER 1.7709+QT
HEXAGON NUT
920.02 ST 8 SECHSKANTMUTTER 8 +A2A
HEXAGON NUT
940.01 ST 10 PASSFEDER 1.4057+QT800+C
PARALLEL KEY
940.03 ST 1 PASSFEDER C45+C
PARALLEL KEY
Seite 6 von 6
9.3 Connecting Coupling

Datasheet TSCHAN Nor-Mex H 148-82
Dimensional drawing ZN 865
Assembly and operating instructions

Baureihe_HG Datum_
Werk-Nr._
Date 21.01.2016 Pump: HGM 2/9
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
Shaft Couplings
Pump - motor Pump - turbine
Manufacturer TSCHAN TSCHAN

Type / size NOR-MEX H 148-82 NOR-MEX H 148-82
Coupling type Flexible coupling Flexible coupling
Mass 20.6 20.6 20.6
Quantity 1 1
Spacer for 180 mm 180 mm
Shaft distance
Retaining ring No No
Lubrication None None
Max. bore 65 mm 65 mm
Spacer plates Not necessary Not necessary
Coupling guard Sheet steel Sheet steel
Balancing quality Q 2,5 Q 2,5
WERKNORM November 2008
Flexible Couplings ZN
Tschan, design Nor-Mex Combinations E and H 865
Flexible couplings
Accouplements élastiques
Teile-Nr.: 842 Claw coupling Dimensions in mm

867 Intermediate ring
CHARACTERISTIC VALUE ASSIGNMENT HAS TO BE

EFFECTED IN THE ORDER PARTS LIST (see page 6)
Previous Editions
ZN 865: 1988--02; 1988--06; 1989--03; 1989--10; 1990--09; 1994--10; 1996--03; 1997--04; 2002--07; 2005--02
Amendments
Compared with the February 2005 edition the following amendments were made:
-- Page 3: Variant F (holes for fan wheel) for type H included.
-- Page 4: Hole pattern for fan wheel and table 1 included.
Schutzvermerk ISO 16016 bachten
-- Page 5: Designation example for type H with variant F added.

-- Type FEH removed from this standard.
-- Annex A included.
Continued on pages 2 to 9
KSB Aktiengesellschaft P 221 Cicak

Page 3
ZN 865: 2008--11
Type H with spacer, electrically insulated
Non--drive end (pump) Drive end (motor)
l3 l4
1 grub screw per coupling half
l6
2 bores inter-
spaced by 180_ d5
d3 d6
d4
d1
d4 d2
l5
l1
l2
Type H...F with spacer, electrically insulated, with holes for fan wheel (code F)
(holes for fan wheel necessary for HGM pump type series with air cooling)
Non--drive end (pump)
View Z, see page 4
Missing data, see type H

Page 5
ZN 865: 2008--11
Designation
Designation of a flexible Nor-Mex coupling type H, nominal size 112--82--180 2), coupling halves made of lamellar graphite
cast iron GJL (JL/Cast Iron):
CLAW COUPLING ZN 865 -- H112-- 82-- 180 - JL/CAST IRON 1)
Designation of a flexible Nor-Mex coupling type H, nominal size 112--82--180 2), pump--side coupling half with holes for fan
wheel (code F), variant 1 (acc. to table 1), coupling halves made of lamellar graphite cast iron GJL (JL/Cast Iron):
CLAW COUPLING ZN 865 -- H112-- 82-- 180-- F1 - JL/CAST IRON 1)
Table 3
m deviation
Bore Holes for
Nominal
Nominal
moment of
minal size
torque
3)
Weight 5)
Max. removal Intermediate
value
ertia 4)
speed ring
Mass
Nominal size
Nomin
We
Ma
mo
ine
Perm
TkN d1 d2
PN/n [Nm] [min --1] min. max. d5 d6 l1 2) [kgm2] 2)
2)
d3 d4 l2 l3 l4 l5 l6 [kg]
112--82--140 150 140 260 68 68 7 0.0136 9.2 112--82

0 024
0.024 6000 48 112 79 62 18
112--82--180 229 M8 300 0.0166 11.2 112--82
128--82--180 0.038 363 5000 55 128 90 68 180 320 88 22 0.0310 14.8 128--82
+1
148--82--180 340 0.0570 20.6
148--82--200 0.060 573 4500 65 148 107 86 200 25 148--82

hrt
108 0 063
0.063 22 2
22.2
geboh
148--82--250 250 360

88 7
ung
168--82--180 180 88 0.0938 28.2 168--82

0 100
0.100 955 4000 75 168 124 95 M10 28
168--82--200 200 108 0.103 30.0 168--82
380
194--82--180 180 88 +1.5 0.1768 39.2
194 82
194--82
194--82--200 0.161 1538 3000 85 194 140 108 200 30 0.1865 41.4
400 108
194--82--250 250 0.21 45.0 194--82
1) Parts list data required for purchase order, see page 8.

2) The nominal size is composed of the outer diameter d3, the hardness of the flexible intermediate ring
and the clearance for removal l1 for the spacer.
3) H7 fit recommended.
4) Mass moments of inertia refer to maximum bores.
5) Weights refer to the coupling without bores.
Page 6
ZN 865: 2008--11
Part No.: 867
Intermediate ring
(spare part for Nor-Mex coupling type E and H)
d3
Designation
Designation of an intermediate ring, nominal size 194--82 1), made of NBR 82:
INTERMEDIATE RING ZN 865 - 194-- 82 - NBR 82
1) The nominal size is composed of the outer diameter d3 and the hardness of the flexible intermediate ring.
Page 7
ZN 865: 2008--11
Marking
The position of the fitted coupling halves relative to each other has to be marked by means of figure stamps on the coupling
hubs prior to balancing.
On spacer--type couplings (type H), the spacer also has to be marked.
Balancing
Drill hole for grub screw before balancing. Fit grub screw as far as the bottom of the hole (hub hole).
Non--drive end coupling hub (pump)

In general dynamic balancing should be carried out prior to keyway milling.
This corresponds to balancing with half key (DIN ISO 8821).
Drive end coupling hub (electric motor, turbine)

The balancing method depends on how the drive rotor is balanced.
(The rotors of the standardized HGM series motors are generally balanced prior to keyway milling).
Table 4
Drive rotor Coupling hub
Prior to keyway milling=half--key balancing (H) Prior to keyway milling, dynamic=half--key balancing (H)
After keyway milling = full key balancing (F) After keyway milling, dynamic
full key fitted
The balancing method for the drive--end coupling hub is to be specified in the text line (UA work instructions = 78) for item 0155
of the order--related parts list (see page 8).
After half--key balancing, the coupling halves must be permanently marked with the letter H close to the keyway.
Table 5
Balancing quality accor- Speed or circumferential velocity
ding to ISO 1940-1
n u at dmax.
max
G
[min --1] [m/s]
2.5 2800 -- 6000 30 -- 100
1 > 6000 >100
(turbo design)
Material
Type E Type H
Table 6
Coupling halves Coupling halves
GJL GJS GJL
Nom. Nenn--
(JL/Cast Iron) (JS/Duct. Iron) (JL/Cast Iron)
size größe
(material ident. (material ident. (material ident.
code 1800) code 1895) code 1800)
82--82 112--82--180
112--82 128--82--180
128--82 148--82--180
148--82 X 148--82--200
X
168--82 168--82--180
194--82 168--82--200
214--82 194--82--180
240--82 X 194--82--200
Intermediate ring of NBR 82 (highly damping, oil--resistant elastomer with Shore hardness 82, temperature--stable up to 60
°C)
BAWN 007-GBR-1
10/2008
Assembly and operating instructions TSCHAN®

Flexible coupling
®
Nor-Mex H
TSCHAN GmbH Zweibrücker Straße 104 D-66538 Neunkirchen-Saar

Telefon: +49(0) 6821 866 0 Telefax: +49(0) 6821 883 53 www.tschan.de
Content
Chapter Page
1 Notes on safety................................................................................................................. 2
2 Function............................................................................................................................ 3
2.1 Appropriate Use......................................................................................................... 3
3 Marking of the coupling..................................................................................................... 3
4 Storage ............................................................................................................................. 4
5 Construction ..................................................................................................................... 5
6 Technical data .................................................................................................................. 6
7 Assembly .......................................................................................................................... 7
7.1 Pay attention before the assembly ............................................................................ 7
7.2 Finished borehole ...................................................................................................... 8
7.3 Installing coupling ...................................................................................................... 9
8 Adjusting coupling .......................................................................................................... 11
8.1 Angular misalignment ∆Kw ....................................................................................... 12
8.2 Radial displacement ∆Kr .......................................................................................... 12
8.3 Axial displacement................................................................................................... 13
9 Operation........................................................................................................................ 14
9.1 Sense of rotation test............................................................................................... 17
10 Maintenance .................................................................................................................. 19
10.1 Wear Inspection on the Buffer Ring......................................................................... 19
10.2 Wear limit of elastic buffers...................................................................................... 20
10.3 Changing the elastic intermediate ring .................................................................... 20
11 Waste Disposal .............................................................................................................. 21
1 Notes on safety
The present assembly and operating instruction (AOI) constituents a part of the coupling
supply. Always keep the AOI near the coupling well accessible.
The German version of this manual is the predominant and binding version.
Make sure that all persons charged with the assembly, operating, service, and maintenance
have read and understood the AOI and follow all the points:
- Avert hazards for body and live of the user and third parties.
- Ensure the operating safety of the coupling.
- Avoid the loss of use and environmental impairment through false handling.
In the case of transport, mounting, dismounting and maintenance, attention is to be paid to

the relevant regulations for industrial safety and for environmental care.
The coupling may only be operated, mounted, serviced and maintained by authorised and
trained personnel.
The user must take into account that the bolting elements of coupling parts may be adversely
affected by the heat produced by a brake disk/ brake drum due to the resultant friction. Make
sure that the combination of the employed brake lining with the material of the brake disk/
brake drum does not lead to sparks or impermissible thermal growth. The brake disk is
bawn007-gbr-1 Nor-Mex H -2-

normally made of steel, and the brake disk is normally made of cast iron with nodular graph-
ite. In case of any doubt, please consult the supplier!
In the interest of further development, we reserve the right to make changes which serve
technological progress.
By the use of accessories and spare parts, which were not originally manufactured by
TSCHAN GmbH, we are not responsible for any resulting damage or liability or guarantee.
2 Function
The coupling Nor-Mex® H is a torsionally elastic and puncture-proof claw coupling with a
removable intermediate piece, mainly for the drives of pumps.
It levels out angular, radial and axial shaft misalignments within defined ranges. The coupling
transfers the torque via pressure loadable, elastic buffers of Perbunan (Pb) which are joined
together as an intermediate ring.
The elastic intermediate ring can cushion impacts and torsional vibrations; it is oil-tight and
electrically conductive
Both coupling halves are divided in two, which enables a radial installation and de-installation
of the reduction sleeve. The de-installation measurement between the flange hubs allows the
changing of the elastic intermediate ring or the dismounting of the bearing block of a centrifu-
gal pump without moving the motor. The de-installation measurement between the flange
hubs allows the changing of the elastic intermediate ring or the dismounting of the bearing
block of a centrifugal pump without moving the motor. The coupling is usable in every sense
of rotation and installation position.
2.1 Appropriate Use
• In order to ensure a faultless, lasting operation of the coupling, it must be laid out accord-
ing to the instructions e.g. DIN 740 part 2 (or also catalogue Nor-Mex ) with an operat-
ing factor corresponding to its operating conditions.
• The coupling must only be operated in normal industrial atmospheres. Since aggressive
media may attack the coupling components, screws and elastic buffer rings, they repre-
sent a risk for the operational safety of the coupling. Consult TSCHAN GmbH in such
cases.
• Apart from incorporating a finished borehole with parallel key slot (see “7.2 Finished
borehole”) no further changes can be carried out on the coupling.
• The coupling may only be used within the framework of the conditions defined in the
performance and delivery contract.
• Every change of the conditions of use or the operating parameters necessitates a new
verification of the coupling layout.
3 Marking of the coupling

®
The product line Nor-Mex has its hardness in Shore (A) indicated on the elastic interme-
diate ring.

4 Storage
On receipt of the goods, the supply is to be checked immediately for completeness and
correctness. Possible damages incurred during transit and / or missing parts are to be
notified in writing.
The coupling parts can be stored in their delivered standard-state for 6 months in a dry,
roofed place at normal room temperature. For a longer storage duration a long-term preser-
vation is necessary (consult TSCHAN GmbH). The elastic intermediate ring must not be
subjected to ozone containing mediums, direct solar influence or strong light sources with
ultraviolet-light. The relative humidity must not exceed 65%. In the case of proper storage the
characteristics of the elastic intermediate ring remain unchanged for almost up to three years.

5 Construction
1 Pan-head screw DIN 912

2 Locking washer (caging-washer)
3 Flange hub part 105
4 Removable intermediate piece part 112-118
5 Elastic intermediate ring part 010
®
Fig. 1 Construction Nor-Mex H
Reference:
Flange hubs (Pos. 3) and removable intermediate piece (Pos. 4) are always delivered
screwed together.
Balanced parts are position marked to each other.

6 Technical data
®
Fig. 2 Nor-Mex H
Table 1 Technical data:

Size TCnom TCpeak TCnom TCpeak nmax d1 d3 d5 L z x M x Ls SH
Nor-Mex Pb72 Pb72 Pb82 Pb82 max
-1
H [Nm] [Nm] [Nm] [Nm] [min ] [mm] [mm] [mm] [mm] [mm]
67 22 45 35 75 10000 28 45 67 30 4 x M 6 x 20 5
82 48 100 75 160 8000 32 53 82 40 4 x M 8 x 25 5
97 96 200 150 340 7000 42 66 97 50 5 x M 8 x 25 5
112 150 310 230 540 6000 48 79 112 60 6 x M 8 x 25 7
128 250 500 380 860 5000 55 90 128 70 6 x M 8 x 25 7
148 390 800 600 1350 4500 65 107 148 80 7 x M10 x 35 7
168 630 1300 980 2250 4000 75 124 168 90 8 x M10 x 35 7
194 1050 2000 1650 3630 3500 85 140 194 100 9 x M10 x 35 7
214 1500 3100 2400 5400 3000 95 157 214 110 9 x M12 x 40 7
240 2400 4800 3700 8650 2750 110 179 240 120 10 x M12 x 40 8
265 3700 7500 5800 13500 2500 120 198 265 140 10 x M14 x 45 8
295 4900 10000 7550 18000 2250 130 214 295 150 10 x M14 x 50 10
330 6400 13000 9900 23400 2000 150 248 330 160 10 x M16 x 55 10
370 8900 18200 14000 32750 1750 170 278 370 180 11 x M16 x 55 10
415 13200 27000 20500 49000 1500 190 315 415 200 12 x M16 x 55 10
Size S3=100mm S3=120mm S3=140mm S3=180mm S3=250mm S3=300mm

Nor-Mex H m [kg] m [kg] m [kg] m [kg] m [kg] m [kg]
67 2,5 2,8 3,1
82 4,0 4,4 4,9
97 6,4 7,0 7,7
112 9,5 10,3 11,1
128 13,2 14,1 15,1 17,0
148 19,4 20,6 21,8 24,3
168 27,5 28,9 30,3 33,2
194 37,7 37,0 44,6 50,7
214 50,5 50,2 58,9 66,2
240 70,5 74,1 78,8 86,6
265 97,0 89,2 105,0 115,4
295 131,1 137,8 147,8
330 182,2 191,0 205,8
370 240,2 250,9 291,4
415 306,1 314,1 319,5

The torque TCnom and TCpeak is valid for:
- Intermediate rings of Perbunan Pb72 and/or Pb82,
- Ambient temperatures of -40 °C to +60 °C,
- Operation within the stipulated alignment values.
Weights are specified for couplings without bores in the hubs.
During the layout of the coupling according to DIN 740 part 2 (or also catalogue
Nor-Mex ®) different factors must be considered:
- with higher temperatures a corresponding temperature factor Sυ
- according to the starting frequency a starting factor Sz
- in dependence of the operating conditions an impact factor, SA, SL
With circumferential speeds of more than 22 m/s, we recommend to balance the coupling.
7 Assembly
7.1 Pay attention before the assembly
• Danger of injuries!
• Disconnect the drive before carrying out any work on the cou-
pling!
• Secure the drive against unintentional re-start and rotation!
• Incorrectly tightened bolts can cause serious personal injuries and
property damages!
• In compliance with accident prevention regulations, you are
obliged to protect all freely rotating parts by means of permanently
installed guards/ covers against unintentional contact and falling
down objects.
• To avoid sparks, the covers for couplings used in explosive
atmospheres should be made of stainless steel!
• As a minimum, the covers have to fulfil the requirements of
protection type IP2X.
• The covers have to be designed to prevent dust from depositing
on the coupling.
• The cover must not contact the coupling or impair the proper
function of the coupling.
• Make sure that the speeds, torques and ambient temperatures as stated in chapter 6
‘Technical Data’ are not exceeded.
• The maximum permissible bore diameters must not be exceeded.
• Check whether the shaft-hub connections safely transmit the occurring operating torques.
• The standard tolerance of TSCHAN for finish bores is fit H7.
• Standard keyways comply with DIN 6885, sheet 1.
• Check the dimensions and tolerances of shafts, hub bores, keys and keyways.
• Set screws as required.

7.2 Finished borehole
For the completion of a finished borehole in a flange hub pay attention to following procedure:
• Clean the coupling hub of preservatives.
• Tighten the flange hub to the faces labelled with and carefully align the flange hub.
• The indicated values in table 1 for ød1max are valid for a parallel key connection according
to DIN 6885/1 and must not be exceeded.
• Choose the borehole fit so that during the union with the shaft a tolerance wringing fit
and/or interference fit as for example with H7/m6 is made.
• Provide an axial securing of the hub, where appropriate with a setscrew on the hub back
above the parallel key slot.
In the case of other shaft hub connections consultation with TSCHAN GmbH is necessary.
• The maximum indicated bore diameters are valid for a parallel key
connection according to DIN 6885/1 and must not be exceeded.
• In the case of transgression of these values the coupling can
sever.
• Due to flying away fragments danger exists!

7.3 Installing coupling
• Take out the elastic intermediate ring

(Figure 3, Pos. 1).
• Clean the boreholes of the flange
hubs and the shaft ends before in-
stalling. The surfaces must be clean,
dry and grease-free.
• Use suitable installation aids and
hoists such as cranes or pulley
blocks in the case of bigger cou-
plings.
• Pull the flange hubs with the reduc-
tion sleeve onto the shaft ends to its
provided position (Figure 3, Pos. 2).
Fig. 3
Reference:
For easier installation a uniform warming of the hub from 80 °C to 120 °C is safe.
Warning!
Only work with gloves as a protection against hot parts of the

coupling!
• Mount the hubs so that the shaft

ends are flush with the interior
borehole openings (Figure 4).
Overlapping shaft ends prevent the
radial installation and de-
installation of the reduction sleeve.
Pay attention to possible differing
agreements!
• Secure possible available set-
screws when tightening with an
adhesive e.g. Loctite 222 against
automatic loosening and flying out.
Fig. 4

ATTENTION!
Let the hot hubs cool off to ambient temperature before the introduction of the inter-
mediate ring.
• For easier mounting the elastic

intermediate ring can be provided
with a slip additive (e.g. Talcum)
before introduction).
• Fit the intermediate ring into one
half of the coupling
• Push together the shaft ends with
the mounted half of the clutch (Fig-
ure 5).
• Adjust the coupling according to the
following specifications in “8 Cou-
pling adjustment".
Fig. 5
Reference:
If the shaft distance is already adjusted to the de-installation measurement of the
reduction sleeve:
• Firstly disassemble the reduction sleeve from the flange hubs.
• Pull the flange hubs separately onto the shaft ends.
• If setscrews are available, secure these against automatic loosening and flying out
with an adhesive e.g. Loctite 222.
Attention!
The bearing surfaces of the reduction sleeves and flange hubs must be clean, dry and
grease-free. Balanced parts are position marked to each other.
• Position the transition pieces in their

respective marked position. Pay at-
tention that, the parts do not tilt dur-
ing the joining on the centering seat.
• Tighten the screws slightly and
uniformly.
• Tighten up the bush screw fitting with
the tightening torque MA as stipulated
in table 2 (Figure 6).
• Adjust the coupling according to the
following specifications in “8 Coupling
adjustment".
Fig. 6
Table 2 Tightening torques MA of the bush screw fitting:

Size 67 82 97 112 128 148 168 194 214 240 265 295 330 370 415
DIN 912- 8.8 M6 M8 M8 M8 M10 M10 M10 M10
DIN 912-10.9 M12 M12 M14 M14 M16 M16 M16
MA [Nm] 10 25 25 25 25 49 49 49 125 125 200 200 310 310 310
bawn007-gbr-1 Nor-Mex H - 10 -
8 Adjusting coupling
Injury hazard!
Switch-off the drive before all work on the coupling!

Secure the drive against unintentional switching on and rotating!
Reference:
An exact alignment of the coupling increases the service life of the
elastic intermediate ring and lessens hazards by use.
Do not exceed the maximum permissible displacement values. An
overstepping of these values results in coupling damage and
breakdown!
• When aligning the cold equipment take into account the expected thermal growth of the
components, so that the permissible misalignment values for the coupling are not
exceeded in operation.
• Be aware that the coupling under misalignment imposes restoring forces on the adjacent
shafts and bearings. Take into account that the larger the misalignment, the greater the
restoring forces will be.
• The displacement values indicated in the tables 3 to 5 are maximum permissible guide
numbers.
We recommend not to fully utilise these values during the alignment, so that in operation
sufficient reserves remain for thermal expansions, foundation settlements etc.
• In special cases with high demands on quiet running or high rotating speeds it is possible
that, in the three displacement levels, an alignment accuracy of ≤ 0,1 mm is necessary.
• If the coupling is mounted in a closed housing / casing so that a subsequent alignment is
not possible any more, it must be guaranteed that the geometry and fit accuracy of the
contact surfaces in operation aligns the shafts exactly within the mentioned tolerances.
8.1 Angular misalignment ∆Kw
• Measure on the face of the external
diameter a complete rotation (360°).
Determine in this case the greatest
deviation ∆Kw1 as well as the small-
est deviation ∆Kw2 (Figure 7).
• Calculate the angular misalignment
∆Kw = ∆Kw1 - ∆Kw2.
• The values in table 3 are valid for a
reference rotation speed of
1500 min-1.
Fig. 7
Table 3 Maximum permissible displacement values - angular:

Size 67 82 97 112 128 148 168 194 214 240 265 295 330 370 415
∆Kw max [mm] 0,2 0,2 0,2 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3
8.2 Radial displacement ∆Kr
• Measure a complete rotation

(360°). Determine in this case the
greatest deviation ∆Kr1 as well as
the smallest deviation ∆Kr1 Kr2 (Fig-
ure 8).
• Calculate the radial displacement
∆Kr = 0,5 x (∆Kr1 - ∆Kr2). Pay atten-
tion to the operational sign of the
measured values.
• The values in table 4 are valid for a
reference rotation speed of
1500 min-1.
Fig. 8
Table 4 Maximum permissible displacement values - radial:

Size 67 82 97 112 128 148 168 194 214 240 265 295 330 370 415
∆Kr max [mm] 0,2 0,2 0,2 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3
8.3 Axial displacement
• Measure, according to Figure 9 the

axial gap measurement SH.
• Keep to the maximum permissible
tolerance X according to table 5,
when aligning the gap measure-
ment SH.
ATTENTION!
If the installation dimension re-
mains under SH, the intermediate
pieces can not be lifted out!
If during operation greater axial
displacements are expected, then
consultation with TSCHAN GmbH is Fig. 9
necessary.
Table 5 Recommended alignment values - axial:

Size 67 82 97 112 128 148 168 194 214 240 265 295 330 370 415
SH [mm] 5 5 5 7 7 7 7 7 7 8 8 8 10 10 10
X [mm] +0,5 +1,0 +1,0 +1,0 +1,0 +1,0 +1,5 +1,5 +1,5 +1,5 +2,5 +2,5 +2,5 +2,5 +2,5
9 Operation
When using the coupling, attention is to be paid to its rating (see “6 Technical data").
This cannot in no case be exceeded without written permission from TSCHAN GmbH.
In order to ensure a faultless, lasting operation of the coupling, it must be laid out according
to the instructions e.g. DIN 740 part 2 (or also catalogue Nor-Mex ) with an operating
factor corresponding to its operating conditions.
Every change of the conditions of use or the operating parameters makes an inspection of
the coupling layout urgently necessary.
Injury hazard!
Due to incorrectly tightened screws parts can fly away and cause
serious injuries to persons and material damage!
Check before commissioning the coupling its alignment and all
screw fixings for their specified tightening torque and/or firm seat-
ing!
Before commissioning the plant all protective devices against
unintentional touching of free moving and/or rotating parts must be
installed.
To avoid sparks coverings in stainless steel should be used!
The coverings must fulfil at least the demands of protection type
IP2X.
The covering is to be so designed that it does not deposit dust onto
the coupling parts.
The coverings must not touch the coupling or influence it in its
functioning.
Pay attention during the operation of the coupling to:

Changed running noises
Occurring vibrations
Attention!
• If irregularities are found during the operation of the coupling, the drive must be
immediately switched off.
• Detect according to the following table 6 “Operating faults and their possible causes" the
fault cause and remove them
The listed faults are some examples which are supposed to facilitate fault location.
• For fault finding and elimination, all machine components and operating states are
to be considered!
Table 6 Operating faults and their possible causes:
Trouble Cause Risk Warning Correction
Irregular Alignment fault Considerable - Disconnect drive
running increase in cou- - Remove cause for alignment fault
noises/ pling temperature. - Re-align coupling
vibrations Premature wear of - Inspect elastomer for wear
elastic buffers.
Increased reaction
forces act on
connected ma-
chines.
Elastomer worn Coupling claws - Disconnect drive
out strike against each - Check coupling components for
other. Spark damages and replace parts, if
formation, claw necessary
fracture, increased - Replace elastomer
reaction forces.
Unbalance Considerable - Disconnect drive
increase in cou- - Verify balance state of plant
pling temperature. components and correct it, if nec-
Premature wear of essary
elastic buffers. - Inspect elastomer for wear
Increased reaction
forces act on
connected ma-
chines
Loose screw Flying off parts can - Disconnect drive

connections cause serious - Check coupling parts for damages,
injuries and replace parts, if necessary
considerable - Verify alignment of coupling
damages. - Tighten screws to the specified
tightening torque and secure them
against working loose, if necessary,
- Inspect elastomer for wear
Premature Alignment fault Considerable - Disconnect drive
wear of increase in cou- - Remove cause for alignment fault
elastomer pling temperature. - Re-align coupling
Increased reaction - Inspect elastomer for wear
forces act on
connected ma-
chines.
Unacceptable Material properties - Disconnect drive

temperatures of elastic buffers - Replace elastomer
change. The torque - Re-align coupling
transmission - Adjust ambient temperature
capability is
adversely affected.
Trouble Cause Risk Warning Correction
Contact with Material properties - Disconnect drive
aggressive of elastic buffers - Check coupling parts for damages
products change. The torque and replace parts, if necessary
transmission - Replace elastomer
capability is - Verify alignment of coupling
adversely affected. - Prevent contact with aggressive
products
Torsional Considerable - Disconnect drive
vibrations in the increase in cou- - Analyse and eliminate cause for
drive line pling temperature. torsional vibrations
Premature wear of - Check coupling parts for damages
elastic buffers. and replace parts, if necessary
Increased reaction - Replace elastomer and consult
forces act on TSCHAN GmbH concerning even-
connected ma- tual use of another Shore-hardness
chines. - Verify coupling alignment
Claw Wear limit Coupling is - Disconnect drive

breakage of elas- destroyed. Con- - Replace coupling
tomer nected machines - Inspect the elastomer for wear at
exceeded can be affected, shorter intervals
===> too.
contact of
claws
Overload Coupling is - Disconnect drive
due to too destroyed. Con- - Verify coupling design in coopera-
high torque nected machines tion with TSCHAN GmbH
can be affected, - Replace coupling
too. - Install larger coupling, if necessary
9.1 Sense of rotation test
Injury hazard!
Due to incorrectly tightened screws parts can fly away and cause
serious injuries to persons and material damage!
Check before commissioning the coupling its alignment and all
screw fixings for their specified tightening torque and/or firm seat-
ing!
Before commissioning the plant all protective devices against
unintentional touching of free moving and/or rotating parts must
be installed.
To avoid sparks coverings should be of stainless steel!
IP2X.
The covering is to be so designed that it does not deposit dust
onto the coupling parts.
The coverings must not touch the coupling or influence it in its
functioning.
• Remove the holding-down bolts of

the reduction sleeve
• Push together the intermediate
pieces (Part 112-118) of the cen-
tring flange hubs (Part 105) with the
elastic intermediate ring.
• Lift-out the intermediate pieces
together with the elastic intermedi-
ate ring (Figure 10).
Use in the case of bigger couplings
suitable installation aids and hoists
such as cranes or pulley blocks.
• Install after the sense of rotation test
a new intermediate ring.
• For easier mounting, the new inter- Fig. 10
mediate ring can be provided with a
slip additive before introduction (e.g. Talcum).
Attention!
respective marked position. Pay at-
tention that, the parts do not tilt dur-
ing the joining on the centering seat.
• Tighten the screws slightly.
• Tighten up the bush screw fitting
with the tightening torque MA stipu-
lated in table 7 (Figure 11).
• Check the alignment of the coupling
according to „8 Coupling adjust-
ment”.
Fig. 11
Table 7 Tightening torques MA of the sleeve threaded joints:

Size 67 82 97 112 128 148 168 194 214 240 265 295 330 370 415
DIN 912- 8.8 M6 M8 M8 M8 M10 M10 M10 M10
DIN 912-10.9 M12 M12 M14 M14 M16 M16 M16
MA [Nm] 10 25 25 25 25 49 49 49 125 125 200 200 310 310 310
10 Maintenance
The elastic coupling Nor-Mex ®-H has in operation a low-maintenance.

Reaching the wear limit of the elastic intermediate ring depends on the operating parameters
and the conditions of use.
In the case of routine monitoring work on the plant check:
• Alignment of the coupling
• Elastomer state
• Remove dust deposits from the coupling parts and the intermediate ring
10.1 Wear Inspection on the Buffer Ring
Injury hazard!
Perform a visual inspection and a wear inspection of the buffer ring after
2000 hours, or after 3 months at latest, after the first start-up of the equip-
ment. If only minor wear or no wear is observed, further inspections of the
plant can be carried out at regular intervals of 4000 hours, however, at least
once a year, if the operating modes and conditions of the plant remain
unchanged. However, should you observe excessive wear on the occasion
of this first inspection already, check whether the cause for the problem is
listed in table 6 “Operation faults and possible causes”. In such a case, the
inspection intervals must be adapted to the prevailing service conditions.
On the occasion of routine inspections or maintenance work on the drive equipment, or after
3 years at latest:
• Replace the elastic buffer ring.
• If the wear limit has been reached or exceeded, replace the buffer ring immediately,
irrespective of the inspection intervals of the equipment.
• Check the alignment of the coupling.
• Remove dust deposits from the coupling components and buffer ring.
10.2 Wear limit of elastic buffers
Replace the elastic buffer ring as soon as the

coupling has a distinct torsional backlash, or if
the minimum buffer thickness (PDmin, Fig. 12)
acc. to table 8 has been reached.
Fig. 12 Buffer thickness

Table 8 Minimum buffer thickness PDmin:
Size 67 82 97 112 128 148 168 194 214 240 265 295 330 370 415
PDmin [mm] 6 8 9 9 9 10 10 10 10 11 12 13 14 16 17
10.3 Changing the elastic intermediate ring
Injury hazard!
• Remove the holding-down screws of

the reduction sleeve
• Push together the intermediate
pieces (Part 112-118) of the cen-
tring flange hubs (Part 105) with the
elastic intermediate ring (Figure 13).
• Lift-out the intermediate pieces
together with the elastic intermedi-
ate ring. Use suitable installation
aids and hoists such as cranes or
pulley blocks in the case of bigger
couplings.
• For easier mounting, the new
intermediate ring can be provided with Fig. 13
a slip additive before introduction (e.g.
Talcum).
• Install the new intermediate ring.
Attention!

respective marked position. Pay attention that, the parts do not tilt during the joining on the
centering seat.
• Tighten the screws slightly
• Tighten up the bush screw fitting with the tightening torque MA as stipulated in table 2
(Figure 6).
• Check the alignment of the coupling according to "8 Coupling adjustment".
Warning!
Before commissioning the plant, install all protective devices

against unintentional touching of free rotating parts.
To avoid sparks coverings in stainless steel should be used.
IP2X.
The covering is to be so designed that it does not deposit dust
onto the coupling parts.
The covering must not touch the coupling or influence it in its
function.
In the case of use of accessories and spare parts, which were not originally manufactured by
TSCHAN GmbH, no liability or guarantee will be accepted for any resulting damage.
11 Waste Disposal
The waste disposal has to occur according to the specific regulations of the respective user
country.
9.4 Drive
Data sheet Siemens Loher DNGW-315 MN-02A
Dimensional drawing
Wiring diagram
Curves
Operating instructions
Inspection Certificate

Baureihe_HG Datum_
Werk-Nr._
Datenblatt
data sheet
Motor Typ
DNGW-315MN-02A MLFB 1PS5315-0BD90-4AA3-Z
Motor type
IEC-Baugröße Polzahl Meßflächen -Schalldruckpegel Leerlauf Last

315M 2
IEC-Size Number of poles LpA in db(A) nach DIN 45 635 No load Load
Bauform Schutzart Average sound pressure level 80+3

IM B3 IP 65
Mounting design Type of enclosure LpA acc. DIN 45 635
Kühlart Drehrichtung (von AS gesehen) beide

IC 411
Cooling type Direction of rotation (viewed from DE) both
Ex-Schutzart Lager AS/BS 6316 /C3

II 2G Ex d e IIC T4 Gb
Ex-Protective system Bearing DE/NDE 6316 /C3
Betriebsart Einschaltung direkt Schmiermittel
S1 Shell Gadus S2 V100 3
Duty type Starting d.o.l Lubricant
Umgebungstemperatur Schmierart Nachschmierung

KT -20 / +55 °C
Ambient temperature Type of lubrication Regreasing
Wärmeklasse Ausnutzung Nachschmierfrist Menge
155(F) 130(B) 2000 h 35 g
Thermal classification Utilisation Relubrication term Quantity
Therm. Wicklungsschutz 3KL130 Massblatt Nr.:

MLD31-0223-M01
Therm. winding protection 3PTC130 Outline dimension drawing No.
Therm. Lagerschutz --- Lage des Klemmenkastens oben

Therm. bearing protection Location of terminal box on top
Bemessungsleistung Klemmenzahl
115 kW 6+4
Rated output Number of terminals
Bemessungsspannung Kabeleinführungsgew.
440 V 2xM63x1,5+2xM20x1,5
Rated voltage Cable entry thread
Schaltung Gewicht ca
D 1160 kg
Connection Net weight approx.
Frequenz Hz Sonstige Daten und Bemerkungen:

50
Frequency c/s Additional data and remarks:
Drehzahl 1/min Heizung / Heater 210-250V / 100W

2980
Speed rpm Wirkungsgradklasse IE2 gemäß DIN EN 60034-30
Bemessungsstrom Efficiency class IE2 acc. DIN EN 60034-30
178 A
Rated current (CR)
Anlaufstrom
760 %
Starting current
Leistungsfaktor (cos ϕ ) 4/4 3/4 1/2

Power factor
0,88 0,87 0,82
Wirkungsgrad (%) 4/4 3/4 1/2

Efficiency
95,3 95,2 94,4
nach/ acc. to EN60034-2-1
Bemessungsmoment
(M N ) 481 Nm
Rated torque
Anzugsmoment
M A / MN = 245 %
Starting torque
Kippmoment
M K / MN = 270 %
Break-down torque
Trägheitsmoment
2,2 kgm² Motor-Nr./Motor-No. LDX/30005643
Moment of inertia
BVS 12 ATEX E 051 X
Drehmomentkurve-Nr.
--- LIAZ/EP-Nr. 8940580-010 / L1-100057647
Torque characteristic-No.
Tag; Date Name; Name

Toleranzen nach/ Tolerances acc. to Nr.
Bearb.; Design. 23.02.16 Z002U1CE-SPBI
DIN EN 60 034-1 No. DBL 79560
Gepr.; Checked 23.02.16 Z001MKBY-PFRO
Passfeder DIN 6885 Schutzdeckel nur bei Bauform IM V5
Key to DIN 6885 oder auf besondere Bestellung
Protection hood only with mounting IM V5
Klemmenkasten um je 90° drehbar or upon special request on order
Terminal box can be turned 90° in each direction
1) Abweichende Gewindegrößen nach Kunden-Auftrag

Other thread sizes acc. customer order
Schwerpunkt 1422
Centre of gravity O 622
1304
486
630
401 195 313
140
1) 2xM63x1,5
DS M20 DIN332
O 65 m6
max. 975
69 R1
,6
606
15
18
125 7,5
315
40
165 O 28 125
Erdung / Earth terminal max.150mm² 59 508
216 457
630
575
Tolerance Surface Material Weight Scale
1:10
mm
DNG.-315M.-02. Author
IMT26KA detail drawing MLD31-0223-M01
1PS531.../1MD531... Creator 2015-07-13 Spieleder mounting: IM B3, IM V5, IM V6
RHF Spezifikationen
Zeichnungsnr.
Approval
Massblatt MLD31-0223-M01
DrawingNo. MLD31-0223-M01 Neuer Zeichnungsrahmen
Department Bauform: IM B3, IM V5, IM V6
Teileklasse
Part class 20501 Change Order P5A00134254 MLFB Doc Type TB MB
Sprache
Language de,en Doc State Released Item No Paper Size
A3
Revision Index RS Doc No 1st Language en
Zusatz
Add. 001 AG 385011_S77 2nd Language de
Blatt
Sheet 1 © SIEMENS AG 2013 - 2015Project No Ref No Sheet 1 OF 1
Strom-Drehmoment-Kennlinie
Current-Torque-Curve
1) M (100% Un)
3 8
2) I (100% Un)
3) M (80% Un)
2 4) I (80% Un)
7
5) M (Load)
6
4
2
1
5
M/Mn
I/In
4
3
3
1
0 0
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
n/ns
Bemerkung
Remark
Bemessungsspannung Bemessungsleistung MLFB 1PS5315-0BD90-4AA3-Z
440 V 115 kW
Rated voltage Rated output LIAZ 8940580-000010
Frequenz Hz Bemessungstrom Motor-Typ
50 178 A DNGW-315MN-02A
Frequency c/s Rated current Motor type
Drehzahl 1/min Leistungsfaktor Motor-Nr.
2980 0,88 LDX/30005643
Speed rpm Power factor Motor-No.
Polzahl Schaltung Bemessungsmoment
2 D 481 Nm
Number of poles Connection Rated torque
Datum; Date 23.02.16 Rev. Bemerkung / Remark Toleranzen nach / Tolerances acc. to
Bearb.; Design. Z002U1CE-SPBI
AB . IEC/EN 60034-1 SDK 29301
Gepr.; Check. Z001MKBY-PFRO
Strom-Anlaufzeit-Kennlinie
Current-starting time characteristic
Anlaufstrom/Starting current (100% Un) Anlaufstrom/Starting current (80% Un)
5
Ia/In
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2
tA [s]
Bemerkung
Remark
440 V 115 kW
50 178 A DNGW-315MN-02A
2980 0,88 LDX/30005643
2 D 481 Nm
AA IEC/EN 60034-1 SAK 10118
Drehzahl-Anlaufzeit-Kennlinie
Speed-starting time characteristic
Drehzahl/Speed (100% Un) Drehzahl/Speed (80% Un)
3500
3000
2500
1/min
2000
1500
1000
500
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2
tA [s]
Bemerkung
Remark
440 V 115 kW
50 178 A DNGW-315MN-02A
2980 0,88 LDX/30005643
2 D 481 Nm
AA IEC/EN 60034-1 DAK 10038
For employment in zone 1 or zone 2 (IEC/EN 60079-10-1)
II 2G Ex d IIB/IIC T. Gb
0102
Optional: For use in Zone 21 or 22 (IEC/EN 60079-10-2)

II 2D Ex tb IIIA/B/C T...°C Db or
0102
II 3D Ex tc IIIA/B/C T...°C Dc
LOHER CHEMSTAR
Induction motor
Type 1PS4/1PS5
Operating Instructions / Installation Instructions N-R 601d
Edition 05/2015
Answers for industry.

13.07.2015 16:59
V8.00
Introduction 1
Safety notes 2
Description 3
Induction motor
Preparations for use 4
LOHER CHEMSTAR
1PS4/1PS5 5
Assembling
Electrical connection 6
Operating Instructions
Installation Instructions
Commissioning 7
Operation 8
Maintenance 9
Spare parts 10
Disposal 11
For employment in zone 1 or zone 2 (IEC/EN Service and Support A

60079-10-1)
II 2G Ex d IIB/IIC T. Gb
0102
Technical data and drawings B

Optional: For use in Zone 21 or 22 (IEC/EN 60079-10-2)
0102
II 2D Ex tb IIIA/B/C T...°C Db or
II 3D Ex tc IIIA/B/C T...°C Dc
Quality documents C
Edition 05/2015
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG Order number: N-R 601d Copyright © Siemens AG 2015.

Process Industries and Drives Ⓟ 05/2015 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 Introduction.................................................................................................................................................11
2 Safety notes................................................................................................................................................13
2.1 Information for the nominated person in control of the electrical installation.........................13
2.2 The five safety rules...............................................................................................................13
2.3 Qualified personnel................................................................................................................14
2.4 Safe handling.........................................................................................................................14
2.5 Use in hazardous areas.........................................................................................................16
2.6 Electrostatic sensitive devices...............................................................................................17
2.7 Electromagnetic compatibility.................................................................................................18
2.8 Interference immunity.............................................................................................................18
2.9 Interference voltages when operating the converter..............................................................18
2.10 Electromagnetic fields when operating electrical power engineering installations.................19
2.11 Ventilation..............................................................................................................................19
3 Description..................................................................................................................................................21
4 Preparations for use...................................................................................................................................27
4.1 Safety-related aspects to consider when configuring the plant..............................................27
4.2 Machines without final paint coating......................................................................................27
4.3 Ensuring adequate cooling.....................................................................................................28
4.4 Thermal motor protection.......................................................................................................28
4.5 Interlock circuit for anti-condensation heating........................................................................28
4.6 Interlock circuit for the external fan motor..............................................................................28
4.7 Noise emissions.....................................................................................................................29
4.8 Voltage and frequency fluctuations during line operation......................................................29
4.9 Protection against impermissible temperature rise................................................................29
4.10 System-inherent frequencies.................................................................................................30
4.11 Transport and storage............................................................................................................30
4.11.1 Transport markings................................................................................................................30
4.11.2 Checking the delivery.............................................................................................................31
4.11.3 Checking the load handling attachments...............................................................................31
4.11.4 Lifting and transportation........................................................................................................31
4.11.5 Attaching the rotor shipping brace prior to storage................................................................33
4.11.6 Storage for up to two years....................................................................................................34
4.11.6.1 Storage conditions.................................................................................................................34
4.11.6.2 Storing motors with water cooling down to -20 °C.................................................................34
LOHER CHEMSTAR 1PS4/1PS5

Operating Instructions 05/2015 5
Table of contents
4.11.7 Storage for between two and four years................................................................................34

4.11.8 Storage at low temperatures..................................................................................................35
4.11.9 Storing motors together with the driven machine...................................................................35
4.11.10 Storage outdoors....................................................................................................................35
4.11.11 Commissioning after storage.................................................................................................36
4.11.11.1 Insulation resistance and polarization index..........................................................................36
4.11.11.2 Lubricating the roller bearings ...............................................................................................36
4.11.11.3 Regreasing roller bearings after storage periods of up to two years......................................36
4.11.11.4 Regreasing roller bearings after storage periods of between two and four years..................37
4.12 Converter operation...............................................................................................................37
4.12.1 Reducing bearing currents during operation on the converter ..............................................39
4.12.2 Insulated bearings when operating the converter..................................................................40
5 Assembling.................................................................................................................................................43
5.1 Preparations for installation....................................................................................................43
5.1.1 Safety instructions for installation...........................................................................................43
5.1.2 Requirements for installation..................................................................................................44
5.1.3 Prepare the mating faces for wall mounting ..........................................................................45
5.2 Lift the machine to where it will be installed, and position it...................................................45
5.2.1 Preconditions for correct alignment and secure attachment .................................................45
5.2.2 Checking the load handling attachments...............................................................................45
5.2.3 Lifting and transportation........................................................................................................46
5.2.4 Setting down the machine......................................................................................................47
5.2.5 Roughly aligning the machine................................................................................................47
5.3 Installing the machine............................................................................................................48
5.3.1 Preconditions for smooth, vibration-free operation................................................................48
5.3.2 Aligning the machine to the driven machine and mounting....................................................48
5.3.2.1 Horizontal types of construction with mounting feet...............................................................48
5.3.2.2 Vertical types of construction with flange...............................................................................48
5.3.3 Removing the rotor shipping brace........................................................................................49
5.3.4 Alignment accuracy................................................................................................................50
5.3.5 Mounting the output elements................................................................................................50
5.3.6 Axial and radial forces ...........................................................................................................52
5.4 Cooling water supply for machines with water cooling...........................................................52
6 Electrical connection...................................................................................................................................55
6.1 Preparation.............................................................................................................................55
6.1.1 Selecting cables.....................................................................................................................55
6.2 Connecting.............................................................................................................................56
6.2.1 Installing intrinsically safe circuits..........................................................................................56
6.2.2 Terminal boxes with type of protection "Ex d" .......................................................................56
6.2.3 Terminal boxes with type of protection "Ex e" .......................................................................57
6.2.4 Connecting the grounding conductor.....................................................................................57
6.2.5 Circuit diagram in the terminal box cover...............................................................................58
6.2.6 Terminal designation..............................................................................................................58
6.2.7 Connecting the machine for a specific direction of rotation....................................................58
6.2.8 Terminal box..........................................................................................................................58
6.2.9 Minimum air clearances.........................................................................................................59
6.2.10 Cable ends with wire end sleeves..........................................................................................60
6.2.11 Connection with terminal board..............................................................................................60

6 Operating Instructions 05/2015
Table of contents
6.2.12 Tightening torques for cable glands ......................................................................................61

6.2.13 Connecting aluminum conductors..........................................................................................62
6.2.14 O-ring seal .............................................................................................................................62
6.2.15 Finishing connection work......................................................................................................63
6.2.16 Internal equipotential bonding ...............................................................................................63
7 Commissioning...........................................................................................................................................65
7.1 Checks to be carried out prior to commissioning ..................................................................65
7.2 Testing the securing and alignment.......................................................................................65
7.3 Insulation resistance and polarization index..........................................................................67
7.4 Testing the insulation resistance and polarization index........................................................67
8 Operation....................................................................................................................................................71
8.1 Safety instructions during operation.......................................................................................71
8.2 Switching on the machine......................................................................................................73
8.3 Switching off the external fan.................................................................................................73
8.4 Switching off the water-cooling system..................................................................................73
8.5 Switching on again after an emergency switching-off............................................................73
8.6 Stoppages..............................................................................................................................73
8.6.1 Switching on the anti-condensation heater............................................................................73
8.6.2 Avoidance of frost and corrosion damage in the cooling system...........................................74
8.6.3 Avoidance of damage to roller bearings during stoppages....................................................74
8.7 Decommissioning the machine..............................................................................................75
8.8 Re-commissioning the machine.............................................................................................75
8.9 Faults.....................................................................................................................................75
8.9.1 Inspections in the event of faults............................................................................................75
8.9.2 Electrical faults.......................................................................................................................75
8.9.3 Mechanical faults...................................................................................................................76
8.9.4 Roller bearing faults...............................................................................................................77
8.9.5 Faults at the external fan........................................................................................................78
9 Maintenance...............................................................................................................................................79
9.1 Inspection and maintenance..................................................................................................79
9.1.1 Inspections in the event of faults............................................................................................81
9.1.2 First inspection.......................................................................................................................82
9.1.3 General inspection.................................................................................................................82
9.1.4 Servicing the roller bearings...................................................................................................83
9.1.5 Bolt grade...............................................................................................................................83
9.1.6 Mechanical explosion protection for roller bearings...............................................................84
9.1.7 Maintenance...........................................................................................................................84
9.1.7.1 Explosion protection for machines with type of protection "Ex d"..........................................84
9.1.7.2 Explosion hazard due to increased surface temperature.......................................................85
9.1.7.3 Insulation resistance and polarization index..........................................................................85
9.1.7.4 Grease service life and fill quantities......................................................................................87
9.1.7.5 Grease stability times and fill quantities.................................................................................88
9.1.7.6 Regreasing intervals and types of grease for operating rolling-contact bearings..................88
9.1.7.7 Alternative types of grease for the operation of roller bearings..............................................90

Table of contents
9.1.7.8 Maintenance and repair for machines of protection type "Ex d" ...........................................91
9.1.7.9 Maintaining terminal boxes....................................................................................................93
9.1.7.10 Touch up any damaged paintwork.........................................................................................93
9.1.7.11 Repainting..............................................................................................................................94
9.2 Repair.....................................................................................................................................94
9.2.1 Anti-condensation heating spare parts...................................................................................95
9.2.2 Insulated roller bearings.........................................................................................................95
10 Spare parts.................................................................................................................................................97
10.1 Ordering data.........................................................................................................................97
10.2 Replacing roller bearings.......................................................................................................97
10.3 Using commercially available spare parts..............................................................................98
10.4 Anti-condensation heating spare parts ..................................................................................98
10.5 Spare parts list, frame sizes 071 to 132.................................................................................99
10.6 Spare parts list, frame sizes 160 to 280...............................................................................100
10.7 Spare parts list, frame size 315............................................................................................103
10.8 Spare parts list, frame size 355............................................................................................104
10.9 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 071-160. .....106
10.10 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 071-160. .....107
10.11 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 180-225 . ....108
10.12 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 180-225. .....109
10.13 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 250 to 355....110
10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355....111
11 Disposal....................................................................................................................................................113
11.1 Introduction..........................................................................................................................113
11.2 Preparing for disassembly....................................................................................................113
11.3 Dismantling the machine......................................................................................................114
11.4 Disposal of components.......................................................................................................114
A Service and Support.................................................................................................................................117
A.1 Siemens Industry Online Support........................................................................................117
A.2 RoHS - restricting the use of certain hazardous substances...............................................118
B Technical data and drawings....................................................................................................................119
B.1 Tightening torques for screw and bolt connections..............................................................119
C Quality documents....................................................................................................................................121
C.1 IECEx certificate...................................................................................................................121
C.2 EC Declaration of Conformity...............................................................................................122
C.3 EC Declaration of Conformity, Zone 21 or 22......................................................................125
C.4 Data......................................................................................................................................128

Table of contents
Index.........................................................................................................................................................129
Tables
Table 3-1 Marking for machines with type of protection Ex d for Zone 1....................................................22
Table 3-2 Marking for machines with Ex tb type of protection for zone 21..................................................23
Table 3-3 Marking for machines with Ex tc type of protection for Zone 22 without certificate....................23
Table 3-4 Machine design ..........................................................................................................................23
Table 3-5 Machine design with type of protection Ex t ...........................................................................24
Table 3-6 Machine version with type of explosion protection Ex d..............................................................24
Table 5-1 Recommended alignment accuracy............................................................................................50
Table 6-1 Electrical data..............................................................................................................................56
Table 6-2 Determining the cross-section of the grounding conductor.........................................................57
Table 6-3 Terminal designations using the 1U1-1 as an example..............................................................58
Table 6-4 Minimum air clearance dependent on rms value of the alternating voltage Urms.........................59
Table 6-5 Tightening torques for standard cable glands [Nm] ................................................................61
Table 7-1 Stator winding insulation resistance at 40° C..............................................................................68
Table 8-1 Electrical faults .......................................................................................................................76
Table 8-2 Mechanical faults .....................................................................................................................76
Table 8-3 Roller bearing faults ...............................................................................................................77
Table 8-4 Cooling system faults ...............................................................................................................78
Table 9-1 Checks after installation or repair ...............................................................................................82
Table 9-2 Checks that have to be performed during the general inspection...............................................82
Table 9-3 Bolt grade BG071 to BG315 ....................................................................................................83
Table 9-4 Bolt grade BG315 to BG910.......................................................................................................83
Table B-1 Tightening torques for bolted connections with a tolerance of ±10%........................................119
Figures
Figure 4-1 Schematic representation of a single drive.................................................................................40

Figure 4-2 Schematic representation of a tandem drive...............................................................................41
Figure 5-1 Balancing type on the drive-end side..........................................................................................50
Figure 6-1 Example for conductor connection..............................................................................................60
Figure 6-2 Example for conductor connection..............................................................................................61
Figure 10-1 D-DN000-0007............................................................................................................................99
Figure 10-2 E-DN000-0008..........................................................................................................................101
Figure 10-3 E-AN000-0009...........................................................................................................................103
Figure 10-4 E-DN000-0010..........................................................................................................................104
Figure 10-5 E-9-101_162-0002.....................................................................................................................106

Table of contents
Figure 10-6 E-9-108_213-0001.....................................................................................................................107

Figure 10-7 E-9-101_208-0002.....................................................................................................................108
Figure 10-8 E-9-108_213-0002.....................................................................................................................109
Figure 10-9 E-9-101_285-0002.....................................................................................................................110

Introduction 1
These instructions describe the machine and explain how to handle it, from initial delivery to
final disposal of the equipment. Keep these instructions for later use.
Read these operating instructions before you handle the machine and follow the instructions
to become familiar with its design and operating principles and thus ensure safe, problem-free
machine operation and long service life.
If you have suggestions for improving the document, please contact the Service Center
(Page 117).
Text format features

The warning notice system is explained on the rear of the inside front. Always follow the safety
instructions and notices in these instructions.
In addition to the safety-related warning notices which you must read, you will find the text in
these instructions is formatted in the following way:
1. Handling instructions are always formatted as a numbered list. Always perform the steps
in the order given.
● Lists are formatted as bulleted lists.
– Lists on the second level are hyphenated.
Note
A Note is an important item of information about the product, handling of the product or the
relevant section of the document. Notes provide you with help or further suggestions/ideas.

Introduction

Safety notes 2
2.1 Information for the nominated person in control of the electrical
installation
This machine has been designed and built in accordance with Directive 94/9/EC ("Explosion
Protection Directive") and is intended for use in industrial plants with potentially explosive
atmosphere.
Commissioning in the European Community in accordance with directive 2006/42/EU
("Machine Directive") is forbidden until the plant into which the machine will be installed has
been shown to conform with this directive. Please observe the country-specific regulations
when using the machine outside the European Community.
WARNING
Commissioning prior to determining the conformance
If the machine is commissioned prior to determining the plant conformance, the explosion
protection of the plant is not guaranteed. An explosion can result that can lead to death,
serious injury or material damage.
Commission the machine only when the plant conformance with the explosion protection
directive has been confirmed.
2.2 The five safety rules

For your personal safety and to prevent material damage when carrying out any work, always
observe the safety instructions and the following five safety rules, according to EN 50110‑1
"Dead working". Apply the five safety rules in the sequence stated before starting work.
Five safety rules

1. Disconnect completely.
Disconnect the auxiliary circuits, for example anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
4. Carry out earthing and short-short-circuiting.
5. Provide protection against adjacent live parts.
To energize the system, apply the measures in reverse order.

Safety notes
2.4 Safe handling
2.3 Qualified personnel

All work at the machine must be carried out by qualified personnel only. For the purpose of
this documentation, qualified personnel is taken to mean people who fulfill the following
requirements:
● Through appropriate training and experience, they are able to recognize and avoid risks
and potential dangers in their particular field of activity.
● They have been instructed to carry out work on the machine by the appropriate person
responsible.
2.4 Safe handling

Workplace safety depends on the attentiveness, care, and common sense of the personnel
who install, operate, and maintain the machine. In addition to the safety measures cited, as a
matter of principle, the use of caution is necessary when you are near the machine. Always
pay attention to your safety.
Also observe the following to prevent accidents:
● General safety regulations applicable in the country where the machine is deployed.
● Manufacturer-specific and application-specific regulations
● Special agreements made with the operator
● Separate safety instructions supplied with the machine
● Safety symbols and instructions on the machine and its packaging
WARNING
Live parts
Electric machines contain live parts.
Fatal or severe injuries and substantial material damage can occur if the covers are removed
or if the machine is not handled, operated, or maintained properly.
● Always observe the "five safety rules (Page 13)" when carrying out any work on the
machine.
● Only remove the covers using the methods described by these operating instructions.
● Operate the machine properly.
● Regularly and correctly maintain the machine.

Safety notes
2.4 Safe handling
WARNING
Rotating components
Electric machines contain dangerous rotating parts.
Fatal or severe injuries and substantial material damage can occur if the covers are removed
or if the machine is not handled, operated, or maintained properly.
● Perform regular maintenance on the machine.
● Secure free-standing shaft ends.
WARNING
Hot surfaces
Electric machines have hot surfaces. Do not touch these surfaces. They could cause burns.
● Allow the machine to cool before starting work on the machine.
CAUTION
Hazardous substances
Chemical substances required for the setup, operation and maintenance of machines can
present a health risk.
Poisoning, skin damage, cauterization of the respiratory tract, and other health damage may
result.
● Read the information in these operating instructions and the product information supplied
by the manufacturer.
● Observe the relevant safety regulations and wear the personal protective equipment
specified.
CAUTION
Flammable substances
Chemical substances required for the setup, operation and maintenance of machines may
be flammable.
Burns and other damage to health and material may result.
● Read the information in these operating instructions and the product information supplied
by the manufacturer.
● Observe the relevant safety regulations and wear the personal protective equipment
specified.

Safety notes
2.5 Use in hazardous areas
WARNING
Noise emissions
During operation, the machine's noise emission levels can exceed those permitted at the
workplace, which can cause hearing damage.
Take steps to reduce noise, such as introducing covers and protective insulation or adopting
hearing protection measures, so that the machine can be operated safely within your system.
2.5 Use in hazardous areas

Electrical systems in hazardous zones must be assembled, installed, and operated by the
applicable responsible persons in accordance with the applicable rules and regulations.
Note
The basic requirements relating to electrical systems and their operation in hazardous areas
are described, for instance, in EU Directive 1999/92/EC as well as in IEC / EN 60079-14.
Ignition hazards
The assessment of operating risks and local operating conditions and the necessary
monitoring methods must be clarified and made binding by the system operator in consultation
with the responsible supervisory authority. The required measures must be adhered to at all
times. The machine manufacturer cannot provide any generally applicable recommendations.
Please observe the information in these operating instructions.
Note
The basic requirements relating to the assessment of ignition hazards arising from electrical
equipment and their operation in hazardous zones are specified, for instance, in 94/9/EC and
1999/92/EC directives as well as in the IEC / EN 60079 series of standards.
If a third-party certification is available for the machine, then carefully comply with the technical
data defined in it and any special conditions.
The certificate must be available before commissioning.

Safety notes
2.6 Electrostatic sensitive devices
2.6 Electrostatic sensitive devices
ESD protective measures
NOTICE
Electrostatic discharge
Electronic modules contain components that can be destroyed by electrostatic discharge.
These modules can be easily destroyed by improper handling.
To protect your equipment against damage, follow the instructions given below.
● Never touch electronic modules unless absolutely necessary in the course of maintenance
and repair procedures.
● If the modules have to be touched, the body of the person concerned must be
electrostatically discharged immediately beforehand and be grounded.
● Electronic modules should not be brought into contact with electrically insulating materials
such as plastic film, plastic parts, insulating table supports or clothing made of synthetic
fibers.
● Always place electrostatic sensitive devices on conductive bases.
● Always pack, store and transport electronic modules or components in conductive
packaging, e.g. metallized plastic or metal containers, conductive foam material or
domestic aluminum foil.
The necessary ESD protective measures for electrostatic sensitive devices are illustrated once
again in the following drawings:
(1) Sitting (2) Standing (3) Standing/sitting

a = conductive floor surface b = ESD table c = ESD shoes
d = ESD overall e = ESD wristband f = cabinet ground connection
WARNING
Risk of explosion due to electrostatic discharge
Electrostatic discharge poses a potential ignition source. In an explosive atmosphere, there
is a risk of an explosion. This can result in death, serious injury or material damage.
Please comply with ESD protective measures.

Safety notes
2.9 Interference voltages when operating the converter
2.7 Electromagnetic compatibility

This machine is designed in accordance with IEC/EN 60034 and when used as prescribed it
satisfies the requirements of European Directive 2004/108/EC on Electromagnetic
Compatibility.
2.8 Interference immunity

The machine fulfills the requirements regarding interference immunity in accordance with IEC/
EN 61000‑6‑2.
For machines with integrated sensors (e.g. PTC thermistors), the manufacturer of the complete
system must ensure sufficient interference immunity by selecting suitable sensor signal leads
and evaluation units.
2.9 Interference voltages when operating the converter
WARNING
Interference voltages when operating the converter
When a converter is in operation, the emitted interference varies in strength depending on
the converter (manufacturer, type, interference suppression measures undertaken). On
machines with integrated sensors (e.g. PTC thermistors), interference voltages caused by
the converter may occur on the sensor lead. This can cause faults which can result in eventual
or immediate death, serious injury or material damage.
In order to avoid exceeding the limit values set for the drive system (machine and converter)
in IEC/EN 61000-6-3, the EMC information provided by the converter manufacturer must be
observed. You must put appropriate EMC measures in place.

Safety notes
2.11 Ventilation
2.10 Electromagnetic fields when operating electrical power engineering

installations
WARNING
Interference to electronic devices caused by electrical power equipment
Electrical power equipment generate electric fields during operation. Potentially lethal
malfunctions can occur in medical implants, e.g. pacemakers, in the vicinity of electrical power
equipment. Data may be lost on magnetic or electronic data carriers.
● It is forbidden for people with pacemakers to enter the vicinity of the machine.
● Protect the personnel working in the plant by taking appropriate measures, such as
erecting identifying markings, safety barriers and warning signs and giving safety talks.
● Observe the nationally applicable health and safety regulations.
● Do not carry any magnetic or electronic data media.
2.11 Ventilation
NOTICE
Ventilation
● Do not obstruct ventilation.
● Prevent the air expelled by neighboring equipment from being immediately drawn in again.
● On the vertical type of machine construction with air intake from above, protect the air
inlets from the ingress of foreign bodies and water.
● If the shaft extension is facing upwards, liquid must be prevented from entering by moving
along the shaft.

Safety notes
2.11 Ventilation

Description 3
Applications
This electrical machine is designed for driving rotating machines in industrial environments
and also for energy conversion. It is characterized by a high level of safety, long lifetime, and
overall reliability.
The machine was designed in accordance with the ordering party's specification and may only
be used for the contractually agreed purpose.
Explosion protection type (Ex d)

This machine is constructed in the "explosion proof" type of protection (Ex d) in accordance
with IEC / EN 60079‑1. It may therefore be operated in hazardous areas of Zone 1 and 2
according to IEC / EN 60079‑10‑1.
Type of protection Ex tb, Ex tc

This machine has been designed in accordance with the "Protection by enclosure" (Ex t) type
of protection according to IEC / EN 60079‑0 and IEC / EN 60079‑31 . It may therefore be
operated in hazardous areas of Zones 21 and 22 in the Ex tb type of protection and Zone 22
in the Ex tc type of protection according to IEC / EN 60079‑10-2.
Use in hazardous areas

Explosion-proof electrical machines correspond to standards of the IEC / EN 60034 and IEC /
EN 60079 series. Only operate the machine in hazardous areas, strictly complying with the
specifications of the responsible supervisory authority. The relevant supervisory authority is
responsible for determining the hazard level of each area and classifying the zones. The type
of protection as well as special regulations are stamped on the rating plate or in the test
certificate. If the certificate number is supplemented by an X, to safely operate the machine
observe the special notes in the operating instructions or if available in the EC type examination
certificate or in the IECEx Certificate of Conformity. Operation with a converter must be
certified. It is essential that you observe the separate manufacturer's information and
instructions.

Description
DANGER
Explosion hazard from hybrid mixtures
Hybrid mixtures are mixtures of flammable dusts with explosive gas/air atmospheres which
can together create a dangerous explosive atmosphere if they occur at the same time.
Changes can arise in the safety characteristics here, such as a change in the zonal
classification, increase in the explosion pressure, reduction in the minimum ignition energy
and a reduction in the maximum temperatures to be observed.
An explosion can result. This can result in death, serious injury or material damage.
● For this reason, the relative characteristics must be considered both for gas (zones 0, 1
and 2) and for dust (zones 20, 21 and 22) where hybrid mixtures arise. It is necessary for
a competent assessor to determine in the individual case whether the parameters
determining ignition are unfavorably affected in a particular hybrid mixture.
● Motors with dual plates for G ("Gas") andD ("Dust") may only be used where these two
simultaneously occur after the user has first analyzed the properties of the hybrid mixture.
NOTICE
Use of machines without CE marking
Machines without CE marking are intended for operation outside the European Economic
Area (EEA). Do not use any machines without a CE marking in the EEA!
The roller bearing machines with Ex d type of protection can have the following Ex marking:
Table 3-1 Marking for machines with type of protection Ex d for Zone 1
Directive Ex marking
Directive 94/9/EC with EC 0102
II 2G Ex d IIC T3 to T6 Gb 0102
II 2G Ex d IIB T3 to T6 Gb
type-examination certificate 0102
II 2G Ex d e IIC T3 to T6 Gb 0102
II 2G Ex d e IIB T3 to T6 Gb
0102
II 2G Ex d ib IIC T3 to T6 Gb 0102
II 2G Ex d ib IIB T3 to T6 Gb
0102
II 2G Ex d e ib IIC T3 to T6 Gb 0102
II 2G Ex d e ib IIB T3 to T6 Gb
IECEx-Scheme with Certifi‐ Ex d IIC T3 to T6 Gb or Ex d IIB T3 to T6 Gb
cate of Conformity Ex d e IIC T3 to T6 Gb Ex d e IIB T3 to T6 Gb
Ex d ib IIC T3 to T6 Gb Ex d ib IIB T3 to T6 Gb
Ex d e ib IIC T3 to T6 Gb Ex d e ib IIB T3 to T6 Gb

Description
Machines with Ex t type of protection can be marked as follows:
Table 3-2 Marking for machines with Ex tb type of protection for zone 21
Directive 94/9/EC with EC type-examination certificate 0102
II 2D Ex tb IIIC T... °C Db
0102
II 2D Ex tb IIIB T... °C Db
0102
II 2D Ex tb IIIA T... °C Db
IECEx-Scheme With Certificate of Conformity Ex tb IIIC T... °C Db
Ex tb IIIB T... °C Db
Ex tb IIIA T... °C Db
Table 3-3 Marking for machines with Ex tc type of protection for Zone 22 without certificate
Directive 94/9/EC II 3D Ex tc IIIC T... °C Dc
II 3D Ex tc IIIB T... °C Dc
II 3D Ex tc IIIA T... °C Dc
IECEx-Scheme with Certificate of Conformity Ex tc IIIC T... °C Dc
Ex tc IIIB T... °C Dc
Ex tc IIIA T... °C Dc
Machine design
The regulations and standards used as the basis to design and test this machine are stamped
on the rating plate.
The machine design basically complies with the subsequent standards. Please refer to the EC
Declaration of Conformity for the versions of the harmonized standards referenced.
Table 3-4 Machine design
Feature Standard
Rating and performance IEC/EN 60034‑1
Degree of protection IEC/EN 60034‑5
Cooling IEC/EN 60034‑6
Type of construction IEC/EN 60034‑7
Terminal markings and direction of rotation IEC/EN 60034‑8
Noise emission IEC/EN 60034‑9
Starting characteristics, rotating electrical machines IEC/EN 60034‑12*
Vibration severity grades IEC/EN 60034‑14
Vibration limits DIN ISO 10816-3
* For machines in line operation only

Description
See also
Quality documents (Page 121)
The following standards additionally apply for explosion-proof motors:
Table 3-5 Machine design with type of protection Ex t
Feature Standard
Type of protection Ex t ①
IEC / EN 60079-0
IEC / EN 60079-31
①
Optional (depending on order)
Additionally, the following standards apply to these explosion-protected machines:
Table 3-6 Machine version with type of explosion protection Ex d
Characteristic Standard
Type of protection Ex d IEC / EN 60079‑0
IEC / EN 60079‑1
Rating plate
The rating plate shows the identification data and the most important technical data. The data
on the rating plate and the contractual agreements define the limits of proper usage.
Motor enclosure with surface, hollow-rib or tube cooling

Depending on their size, the stator frame and bearing shields are manufactured out of cast
iron or steel. The fan cover is made of sheet steel. The stator frame surface has cooling ribs,
hollow ribs, or tubes and mounted terminal box.
Cooling for machines with surface cooling, hollow rib cooling or tube cooling
For machines with rib, hollow rib or tube cooling, the cooling air is drawn in through openings
in the fan cover. The air is blown over the surface or through the cooling tubes of the stator
frame. With hollow-fin or tube cooling, a closed cooling air circuit inside the motor assists with
heat dissipation.
Stator winding
The stator winding has a temperature class according to EN 60034-1, see rating plate. High-
quality enameled wires, suitable surface insulating materials, and the type of impregnation
guarantee great mechanical and electrical stability together with a high utility value and a long
service life.

Description
Rotor
The rotor has a squirrel cage rotor manufactured out of die-cast aluminum or a brazed copper
rotor. The rotor is dynamically balanced. The balance condition is stated on the shaft end face
or rating plate.
Bearings
The motors are equipped with grease-lubricated roller bearings.
● The bearings of the standard version motors (up to size 280) are permanently lubricated.
● The bearings of motors from size 315 upwards have a relubrication facility and automatic
grease quantity control.
Terminal boxes
In the motor terminal box, additional connecting terminals are available if required for
monitoring equipment. For larger machines, an additional terminal box can be optionally
mounted. You can see the number of available terminals in the circuit diagrams.
Paint finish
The machine is painted according to the instructions in your order.
Monitoring equipment
Monitoring equipment is provided corresponding to what has been ordered. KTY83 and KTY84
semiconductor sensors are electrostatic sensitive devices (ESD). These elements can be
damaged by electrostatic discharge. Observe the ESD protective measures (Page 17).
DANGER
Risk of explosion during operation due to too high surface temperature
This can result in death, serious injury, or material damage.
• Prevent the maximum surface temperature from being exceeded by maintaining the
specified operating conditions.
• Monitor the coil temperature. Use the temperature sensor that is built into the stator winding
for this as specified on the rating plate or extra rating plate.
External fan
The machine can be fitted with an external fan. For IC 666, there are two external fans. The
electrical connection data are stamped on the rating plate of the external fan.

Description
Anti-condensation heating
The machine can be fitted with anti-condensation heating. The connection data is listed on an
additional plate on the machine.

Preparations for use 4
Good planning and preparation of machine applications are essential in terms of keeping
installation simple and avoiding errors, ensuring safe operation, and allowing access to the
machine for servicing and corrective maintenance.
This chapter outlines what you need to consider when configuring your plant in relation to this
machine and the preparations you need to make before the machine is delivered.
4.1 Safety-related aspects to consider when configuring the plant

A number of residual risks are associated with the machine. These are described in the chapter
titled "Safety information" and in related sections.
Take appropriate safety precautions (covers, barriers, markings, etc.) to ensure the machine
is operated safely within your plant.
Observing the operating mode

Observe the machine's operating mode. Use a suitable control system to prevent overspeeds,
thus protecting the machine from damage.
4.2 Machines without final paint coating

For machines, which are only delivered with primer, you must paint them to comply with the
applicable guidelines for the specific application. The primer alone does not provide adequate
corrosion protection.
The paint applied must conform to the requirements to avoid electrostatic charging, see
EN 60079-0.
Note
Please contact the Service Center for recommendations relating to the paint finish.
See also
Repainting (Page 94)

Preparations for use
4.6 Interlock circuit for the external fan motor
4.3 Ensuring adequate cooling

Ensure that the machine is sufficiently cooled by the cooling air flow at the installation site:
● Ensure that the cooling air can flow in and out unobstructed. The full air flow provided by
the fan is only possible if air can freely enter the impeller. Maintain a clearance of at least
1 x inlet diameter in the axial direction.
● Make sure that the machine does not draw in the hot discharged air again.
● For machines with a vertical type construction with an air intake from above, ensure that
the air inlets are protected against the ingress of foreign bodies and water.
4.4 Thermal motor protection

The machine can optionally be equipped with PTC thermistors, PT100 or micro-thermal NC
contacts. Thermal motor protection by directly monitoring the winding temperature is
permissible if this is certified and indicated on the rating plate.
PTC thermistors as sole protection guarantee explosion protection in conjunction with function
tested tripping devices with type of protection marking II (2) G. No voltage > 2.5 V may be
applied for any continuity test required on the temperature sensor.
For pole-changing motors, use a direct temperature monitoring sensor as stated on the rating
plate, e.g. thermistor according to DIN 44081/44082, for each speed level in addition to the
separate, mutually interlocked motor protection relays.
4.5 Interlock circuit for anti-condensation heating

If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine.
● Install an interlock circuit that switches off the anti-condensation heating once the main
machine is switched on.
● Only operate anti-condensation heating when the machine is switched off.
4.6 Interlock circuit for the external fan motor

For machines with external fans, install an interlock circuit that prevents the main machine
being switched on if the external fan is not operational.

4.9 Protection against impermissible temperature rise
4.7 Noise emissions
WARNING
Noise emissions
During operation, the machine's noise emission levels can exceed those permitted at the
workplace, which can cause hearing damage.
Take steps to reduce noise, such as introducing covers and protective insulation or adopting
hearing protection measures, so that the machine can be operated safely within your system.
4.8 Voltage and frequency fluctuations during line operation

Unless stated otherwise on the rating plate, the permissible voltage fluctuation is ± 10% and
the permissible frequency fluctuation is ± 2%.
The following always applies: Under practical operating conditions, a machine may sometimes
have to be operated outside the tolerance limits. Exceptions of this sort should be limited with
regard to the values that arise, how often and for how long they occur. Where possible and
within a reasonable time take corrective actions such as reducing the power. Such actions can
avoid thermal ageing leading to a reduction in the service life of the machine.
NOTICE
Overheating of the winding
Exceeding the permissible tolerances for voltage and frequency can lead to an impermissibly
high temperature rise in the windings and thus cause long-term damage to the machine.
4.9 Protection against impermissible temperature rise

Every machine must be protected against an inadmissible temperature rise. Observe the
following notes:
● Protect every machine according to IEC / EN 60079–14 using a current-dependent,
delayed, circuit breaker with phase failure protection corresponding to IEC / EN 60947 or
a similar device in all phases.
● Set the protective device to the rated current (value is stamped on the rating plate).
● Select the protective device so that the motor is thermally protected even with a locked
rotor.

4.11 Transport and storage
● For explosion-protected electrical machines with type protection "Increased safety", also
monitor the starting (starting monitoring with EC type examination certificate according to
Directive 94/9/EC or IECEx–Scheme with Certificate of Conformity). When the rotor is
locked, the protective device must trip within the tE time (safe locked rotor time). This
requirement is satisfied if the tripping time is not longer than the specified tE time.
● Protect the windings in a delta connection in such a way that the tripping unit or relay is
connected in series with the winding phases. When selecting and setting the tripping unit,
define the rated value of the phase current. The phase current is 0.58 times the rated motor
current. Any thermal motor protection via direct temperature monitoring to be used in
addition to the motor starter protector is stated on the rating plate if required.
4.10 System-inherent frequencies
NOTICE
Machine damage caused by system resonances
The system consisting of the foundation and machine set must be configured and matched
in such a way that no system resonances can arise and result in the permissible vibration
levels being exceeded. Excessive vibrations can damage the machine set. The vibration limit
values according to DIN ISO 10816-3 must not be exceeded.
4.11.1 Transport markings

The packing differs depending on the transport type and size. If not otherwise contractually
agreed, the packaging corresponds to the packing guidelines for International Standards for
Phytosanitary Measures (ISPM).
Comply with the images shown on the packaging. Their meaning is as follows:
This Fragile goods Keep dry Keep cool Center of Do not use Attach here
way up gravity hand hook
When carrying out any work on the machine, observe the general safety instructions and the
specifications contained in EN 50110‑1 regarding safe operation on electrical equipment.

4.11.2 Checking the delivery

The components are assembled on an individual basis. When you take receipt of the delivery,
please check immediately whether the scope of the delivery matches up with the
accompanying documents. No claims relating to defects/items missing from the delivery will
be accepted if they are submitted at a later date.
● Report any apparent transport damage to the delivery agent immediately.
● Immediately report any apparent defects/missing components to your contact partner.
These Operating Instructions are part of the scope of delivery; keep them in a location where
they can be easily accessed.
4.11.3 Checking the load handling attachments

Inspect the load handling attachments such as the load stands, lifting eyes and ring bolts and
also the lifting gear, before lifting the machine:
● Inspect the load handling attachments on the machine for possible damage. Replace any
load handling attachments that are found to be damaged.
● Check before use that the load handling attachments are correctly secured.
● When lifting the machine, use only approved and undamaged lifting gear of sufficient rated
capacity. Check these before using them.
WARNING
The machine can be dropped
If the load handling attachments and lifting gear are damaged or not correctly secured,
the machine may be dropped during lifting. This can result in death, serious injury or
material damage. Inspect the load handling attachments and lifting gear before use.
4.11.4 Lifting and transportation

● Persons driving cranes and fork lift trucks must hold appropriate qualifications.
● When lifting the machine, use only approved and undamaged sling guides and spreaders
of sufficient rated capacity. Check these before using them. The weight of the machine is
stated on the rating plate.

● When lifting the machine, refer to the information on the lifting plate:
– Comply with the specified spreading angles.
– Lift the machine without jerking it.
● When lifting, use only the load handling attachments on the stator casing, such as lifting
eyes or eye bolts.
WARNING
Transporting or lifting the machine
The machine or the machine set may be transported and lifted only using the load handling
attachments.
Otherwise, death, serious injury, or material damage may result.
1. Always use the load suspension device provided on the stator frame to lift the motor.
2. Use suitable rope guidance or spreading devices. The weight of the machine is stated
WARNING
Center of gravity when transporting or lifting the motor
If the center of gravity of a load is not located centrally between the attachment points,
the motor can tip over or slip out of the lifting gear when it is being transported or lifted.
1. Always take account of the center of gravity when transporting or lifting the machine.
The machine's center of gravity is indicated in the relevant dimension diagram.
2. Observe the handling instructions on the motor when transporting it. If the center of
gravity is not located centrally between the attachment points, then position the hoisting
hook above it.
3. Be aware of the possibility of different loads on the sling ropes or lifting straps and the
carrying capacity of the lifting equipment.
WARNING
Falling down of the machine
The lifting lugs on the machine are designed only for the weight of the machine. If a machine
set is lifted and transported on a single machine, this can lead to mechanical failure of the
lifting lug. The machine or machine set may fall. This can result in death, serious injury or
material damage.
● Do not lift machine sets by attaching lifting tackle to the individual machines.
● Use only the equipment provided, e.g. the openings or lugs on the base plates, for
transporting machine sets. Note the maximum capacity of the lifting lug.

Note
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.
Note
Place the machine in a secure and raised position
In order to obtain easy and safe access to the underside of the machine, place it in a secure
and raised position.
DANGER
Standing under suspended loads
If the lifting gear or load handling attachments were to fail, the machine could fall. This can
result in death, serious injury or material damage.
Never remain under or in the immediate vicinity of the machine when it is raised.
4.11.5 Attaching the rotor shipping brace prior to storage
NOTICE
Bearing damage caused by vibration
If storage conditions are inappropriate there is a risk of bearing seizure damage. This can
result in material damage, such as damage to bearings caused by vibration.
● On machines that have been supplied with a rotor shipping brace, secure the rotor as per
the notes on transportation.
● Protect the machine against strong radial vibrations, since the rotor shipping brace might
not absorb these completely.
NOTICE
Bearing damage when being transported
If the customer has already mounted parts, for example coupling, belt pulley, etc., the bearing
can be damaged during transport.
● In this case, make sure that the customer uses a rotor shipping brace.

4.11.6 Storage for up to two years
4.11.6.1 Storage conditions
● Store the machines in a dry, dust-free room where the temperature is controlled. Special
packing is therefore not necessary. In all other cases, pack the machines in a plastic film
with a substance that absorbs moisture, e.g. Branogel, or in hermetically sealed welded
foil. Use a protective cover to protect against sun and rain.
● Store the machines only in vibration-free rooms in order to avoid consequential damage to
the bearings due to vibration at standstill.
WARNING
Risk of explosion due to damaged sealing materials
Storing the machine at temperatures that do not fall within the specified limits can damage
the material of the seals and cause them to fail. As a result, a potentially explosive gaseous
atmosphere can enter the machine and be ignited during commissioning. Explosions can
occur. This can result in death, serious injury or material damage.
The materials used are specially designed for the temperature range required by the
customer. Do not store the motor in conditions that lie outside the specified temperature limits.
The relevant temperature limits are specified on the rating plate.
4.11.6.2 Storing motors with water cooling down to -20 °C

If a water-cooled machine is stored at temperatures down to -20 °C, then also please note the
following:
● Completely drain the coolers.

● Completely dry the coolers with warm air up to a max. 60 °C.
● After drying, seal off the coolers.
● Store machines with coolers in a dry and dust-free room.
4.11.7 Storage for between two and four years
If machines are to be stored for between 2 and 4 years, then also observe the following:
When ordering, the manufacturer must know the storage time.

Grease caps must be available at the shaft outlet and at the terminal box cover. Do not rotate
the motor shaft before commissioning as the protective grease coating will be destroyed. If
rotating parts have to be turned, then apply a new protective coating of grease.

4.11.8 Storage at low temperatures
If machines are stored at temperatures of down to -50° C, then also take into account the
following:
● The normal roller bearing grease of machines is suitable for operating temperatures of
between -30 °C and +130° C. Temperatures down to ‑50° C are harmless for the roller
bearing grease if the machine is non operational or is in storage.
For operation at -50 °C, the bearings have a special grease, e.g. Aeroshell Grease 7.
● Machines with regreasing system must be regreased when commissioning. Double the
amount of grease that is specified on the lubricant plate.
4.11.9 Storing motors together with the driven machine
● Before mounting the motors, grease the free parts of the shaft extension, as well as all
other bare metal parts, such as mounting foot surfaces, flange surfaces, terminal box and
cover contact surfaces. Attach caps filled with roller bearing grease to the shaft output gland
to provide protection against dust and humidity.
● Fill the terminal boxes of the machines with a substance that will absorb moisture, e.g.
Branogel.
● Store the machines in a dry, dust-free room where the temperature is controlled.
4.11.10 Storage outdoors
If the machine is stored outdoors, then the following should additionally be observed:
● Provide protective cover against the effects of sun and rain. Air must freely circulate to
avoid condensation forming.
● Every two months check the following:
– Free parts of the shaft extension and other bare metal parts, e.g. mounting foot surfaces
or the flange faces, terminal box and cover contact surfaces must be greased.
– Caps filled with grease attached to the shaft output gland to provide protection against
the ingress of dust and moisture are still effective.

4.11.11 Commissioning after storage
4.11.11.1 Insulation resistance and polarization index

Measuring the insulation resistance and polarization index (PI) provides information on the
condition of the machine. It is therefore important to check the insulation resistance and the
polarization index at the following times:
● Before starting up a machine for the first time
● After an extended period in storage or downtime
● Within the scope of maintenance work
The following information is provided regarding the state of the winding insulation:
● Is the winding head insulation conductively contaminated?
● Has the winding insulation absorbed moisture?
As such, you can determine whether the machine needs commissioning or any necessary
measures such as cleaning and/or drying the winding:
● Can the machine be put into operation?
● Must the windings be cleaned or dried?
Detailed information on testing and the limit values can be found here:
"Testing the insulation resistance and polarization index" (Page 67)
4.11.11.2 Lubricating the roller bearings

If you correctly store the machine for a longer period of time, it can be assumed that within a
period of two years, the grease in the bearings will not deteriorate.
● For motors with thermal class 155, for normal ambient temperatures, use a lithium-soap
roller bearing grease with a melting point of at least 180° C.
● For machines with thermal class 180, and for certain special machines, use the special
grease specified on the machine lubricant plate.
4.11.11.3 Regreasing roller bearings after storage periods of up to two years

● For machines with regreasing systems, briefly lubricate both bearings after commissioning
with the motor running as a precautionary measure.
● Grease type, grease quantity and relubrication intervals for the regreasing system are
stamped on a supplementary plate attached to the machine.

4.12 Converter operation
4.11.11.4 Regreasing roller bearings after storage periods of between two and four years
● For machines with regreasing system, lubricate machines immediately after commissioning
while the machine is running with approximately twice the grease quantity. This causes the
old grease to be spun out.
● Then regrease the bearings with the amount of bearing grease specified on the lubricant
plate.
Note
Increased bearing noise
Increased bearing noise can occur while the bearings are being run in The bearing noise is
not dangerous, if the operating temperature has not yet been reached and the noise is caused
by the viscosity and the dynamic viscosity of the bearing grease.

When controlling explosion-protected machines from a converter, carefully observe R-No.
20000 (Page 128)

Speed/torque characteristic for operation with a SINAMICS converter

The load characteristics show the permanent permissible load torque as a function of the speed
and the cooling method. The load torque is specified as a percentage referred to the maximum
torque according to the supplementary plate for converter operation.

00PD[

11V\QF

① Force ventilated, external and internal

② Surface cooled, self-ventilated
Converter operation
• If the motor design requires a special converter assignment, you can find the appropriate
supplementary data on the additional plate for the converter.
• Correctly parameterize the converter. Information about the parameters is available in the
operating instructions for the converter.
WARNING
Exceeding limit values
It is not permissible that the maximum speed and torque values stamped on the
supplementary plate for converter operation are exceeded.

4.12.1 Reducing bearing currents during operation on the converter

Taking the following actions will reduce the bearing currents:
● Ensure that the contacts are established over a large area. Solid copper cables are not
suitable for high frequency grounding because of the skin effect.
Equipotential bonding conductors:

Use equipotential bonding conductors:
● Between motor and driven machine
● Between motor and converter
● Between the terminal box and the RF grounding point at the motor enclosure.
Selecting and connecting the cable:

As far as possible, use symmetrically arranged, shielded connection cables. The cable
shielding, made up of as many strands as possible, must have good electrical conductivity.
Braided shields made of copper or aluminum are very suitable.
● The shield is connected at both ends, at the motor and converter.
● To ensure good discharging of high-frequency currents, provide contacting over a large
surface area:
– as contact established through 360° at the converter
– at the motor, for instance with EMC glands at the cable entries
● If the cable shield is connected as described, then it ensures the specified equipotential
bonding between the motor enclosure and converter. A separate RF equipotential bonding
conductor is then not necessary.
/ / /
3( 3(
/ / / / / /
3( 3(
Concentric copper or aluminum shield Steel armor
● If the cable shield is not connected due to special secondary conditions, or not adequately
connected, then the specified equipotential bonding is not provided. In this particular case,
use a separate RF equipotential bonding conductor:
– Between the motor enclosure and protective ground rail of the converter.
– Between motor enclosure and driven machine
– Use braided flat copper straps or high-frequency cables with finely-stranded conductors
for the separate RF equipotential bonding cable. Solid copper cables are not suitable
for high frequency grounding because of the skin effect.
– Ensure that the contacts are established over a large area.

Overall system design

To specifically reduce and prevent damage caused by bearing currents, you must consider
the system as a whole, which comprises the motor, converter, and driven machine. The
following precautions help to reduce bearing currents:
● In the overall system, set up a properly meshed grounding system with low impedance.
● Use the common-mode filter (damping cores) at the converter output. The Siemens sales
representative is responsible for selection and dimensioning.
● Limit the rise in voltage by using output filters. This dampens the harmonic content in the
output voltage.
Note
Converter documentation
The operating instructions for the converter are not part of this documentation. Refer also to
the configuration information for the converter.
4.12.2 Insulated bearings when operating the converter

Depending on the machine's size and design, an insulated bearing and an insulated
tachometer can be fitted at the non-drive end.
Comply with the plates on the machine relating to bearing insulation and possible bridges.
① Driving machine ④ Insulated bearings

② Motor ⑤ Insulated tachometer fitting
③ Coupling
Figure 4-1 Schematic representation of a single drive
NOTICE
Bearing damage
The bearing insulation must not be bridged.
Damage may be caused to the bearings if there is a flow of current.

Tandem operation
If you connect two motors in series in "tandem operation", install an insulated coupling between
the motors.
① Driving machine ④ Insulated bearings

② Motor ⑤ Insulated tachometer fitting
③ Coupling ⑥ Insulated coupling
Figure 4-2 Schematic representation of a tandem drive
NOTICE
Bearing damage
If the coupling between the motors of the tandem drive is not insulated, bearing currents can
cause damage to the drive-end bearings of both motors.
Use an insulated coupling to link the motors.
WARNING
Dangerous voltage via the converter
As long as the feeding converter is switched on, or the DC link of the converter is not
discharged, there can be a voltage at the motor terminals even when the rotor is not moving.
The voltage is up to 1000 V, depending on the converter type.
Ensure that the five safety rules are followed before working on the motor.


Assembling 5
When carrying out any work on the machine, observe the general safety instructions
(Page 13) and the specifications contained in EN 50110‑1 regarding safe operation on
electrical equipment.
5.1 Preparations for installation
5.1.1 Safety instructions for installation
WARNING
Danger caused by inappropriate fastening material
If screws of an incorrect property class have been selected or if they have been fastened to
an incorrect tightening torque, they may break or become loose. This will cause the machine
to move, which could damage the bearings. The rotor could smash into the machine enclosure
and machine parts could be flung out of place. This can result in death, serious injury or
material damage.
● Comply with the required property classes for screwed connections.
● Tighten the screwed connections to the specified tightening torques.
WARNING
Tensions on the fastening parts
If the machine has not been properly aligned, this will mean the fastening parts are subjected
to stress/distortion. Screws may become loose or break, the machine will move, machine
parts could be flung out of place. This can result in death, serious injury or material damage.
● Carefully align the machine to the driven machine.
NOTICE
Damage to the mounted parts
Mounting parts such as temperature sensors or speed sensors are attached to the machine
and could be ripped off or destroyed as a result of improper handling. This could lead to
machine malfunctions, extending even to total loss of the machine.
● Where necessary, use suitable steps when performing installation work on the machine.
● Do not stand on cables or attachments during installation. Do not use attachments as
steps.

Assembling
5.1 Preparations for installation
Note
Loss of conformity with European directives
In the delivery state, the machine corresponds to the requirements of the European directives.
Unauthorized changes or modifications to the machine lead to the loss of conformity with
European directives and the loss of warranty.
5.1.2 Requirements for installation

The following requirements must be satisfied prior to starting installation work:
● Staff have access to the operating and installation instructions.
● The machine is unpacked and ready for mounting at the installation location.
Note
Measure the insulation resistance of the winding before starting installation work
Wherever possible, measure the insulation resistance of the winding before starting
installation work. If the insulation resistance lies below the specified value, take appropriate
remedial measures. These remedial measures may necessitate the machine being
removed again and transported.
NOTICE
High temperatures
The motor components get very hot during operation. High temperatures can damage
mounting parts such as the cable insulation.
● Temperature-sensitive parts such as normal cables or electronic components must not
rest against or be attached to mounted machine parts.
● Only use heat-resistant mounting parts. The connecting cables and cable entries must be
suitable for the ambient temperature.
WARNING
Explosion hazard when making modifications to the machine
Substantial modifications to the machine are not permitted – or may only be performed by
the manufacturer. Otherwise an explosion can occur in an explosive atmosphere. This can
Please contact the Service Center, if necessary.

Assembling
5.2 Lift the machine to where it will be installed, and position it
5.1.3 Prepare the mating faces for wall mounting

● Ensure that the wall surface is flat and free of contaminations.
● Check the dimensions of the mounting-foot holes.
● Support the machine from below, e.g. using a wall bracket or by bolting it.
5.2.1 Preconditions for correct alignment and secure attachment

Detailed specialist knowledge of the following measures is required in order to correctly align
and securely fit the equipment.
● Preparing the foundation
● Selecting and mounting the coupling
● Measuring the concentricity and axial eccentricity tolerances
● Positioning the machine
If you are not familiar with the prescribed measures and procedures, then you can make use
of the services offered by the local Service Center.
5.2.2 Checking the load handling attachments

Inspect the load handling attachments such as the load stands, lifting eyes and ring bolts and
also the lifting gear, before lifting the machine:
● Inspect the load handling attachments on the machine for possible damage. Replace any
load handling attachments that are found to be damaged.
● Check before use that the load handling attachments are correctly secured.
● When lifting the machine, use only approved and undamaged lifting gear of sufficient rated
capacity. Check these before using them.
WARNING
The machine can be dropped
If the load handling attachments and lifting gear are damaged or not correctly secured,
the machine may be dropped during lifting. This can result in death, serious injury or
material damage. Inspect the load handling attachments and lifting gear before use.

Assembling
5.2.3 Lifting and transportation

● Persons driving cranes and fork lift trucks must hold appropriate qualifications.
● When lifting the machine, use only approved and undamaged sling guides and spreaders
of sufficient rated capacity. Check these before using them. The weight of the machine is
stated on the rating plate.
● When lifting the machine, refer to the information on the lifting plate:
– Comply with the specified spreading angles.
– Lift the machine without jerking it.
● When lifting, use only the load handling attachments on the stator casing, such as lifting
eyes or eye bolts.
WARNING
Transporting or lifting the machine
The machine or the machine set may be transported and lifted only using the load handling
attachments.
Otherwise, death, serious injury, or material damage may result.
1. Always use the load suspension device provided on the stator frame to lift the motor.
2. Use suitable rope guidance or spreading devices. The weight of the machine is stated
WARNING
Center of gravity when transporting or lifting the motor
If the center of gravity of a load is not located centrally between the attachment points,
the motor can tip over or slip out of the lifting gear when it is being transported or lifted.
1. Always take account of the center of gravity when transporting or lifting the machine.
The machine's center of gravity is indicated in the relevant dimension diagram.
2. Observe the handling instructions on the motor when transporting it. If the center of
gravity is not located centrally between the attachment points, then position the hoisting
hook above it.
3. Be aware of the possibility of different loads on the sling ropes or lifting straps and the
carrying capacity of the lifting equipment.
Note
Place the machine in a secure and raised position
In order to obtain easy and safe access to the underside of the machine, place it in a secure
and raised position.

Assembling
DANGER
Standing under suspended loads
If the lifting gear or load handling attachments were to fail, the machine could fall. This can
Never remain under or in the immediate vicinity of the machine when it is raised.
5.2.4 Setting down the machine
Requirements
The following preconditions must be satisfied before setting down the machine at the
installation location:
● The mating faces must be clean.
● The anti-corrosion protection paint has been removed from the mating faces, such as the
machine mounting feet, flange, ...
Setting down the machine

Set down the machine slowly and carefully at the installation location to avoid any impact.
5.2.5 Roughly aligning the machine
Requirement
The transmission element such as a coupling half has already been pulled on.
Roughly aligning the machine

● For horizontal positioning, push the motor sideways across the foundation. When doing so,
ensure that the axial position is maintained.

Assembling
5.3 Installing the machine
5.3.1 Preconditions for smooth, vibration-free operation

Preconditions for smooth, vibration-free operation:
● Stable foundation design
● Precise alignment of the machine
● Correct balancing of parts to be fitted to the shaft end.
● Maintaining the vibration velocity according to ISO 10816‑3
5.3.2 Aligning the machine to the driven machine and mounting
5.3.2.1 Horizontal types of construction with mounting feet

1. Refer to any instructions for aligning the driven machine and those of the coupling
manufacturer.
2. Align the machines with coupling output to the driven machine in such a manner that the
center lines of the shafts are parallel with no offset. This ensures that no additional forces
affect their bearings during operation.
3. For the vertical positioning (x→0) place thin shims under the machine feet. The number of
shims should be kept as low as possible, i.e. stack as few as possible. This also prevents
the machine being subjected to any stress/distortion. If available, use the existing tapped
holes for the forcing-off bolts to somewhat raise the machine.
4. When positioning the machine, ensure that a uniform axial gap (y→0) is maintained around
the coupling.
5. Fix the machine to the foundation. The choice of fixing elements depends on the foundation
and is the plant operator's responsibility.
Note
Machine expansion
When aligning, make allowance for the thermal expansion of the machine when the
temperature increases.
5.3.2.2 Vertical types of construction with flange

The standard flange is provided with a centering. The choice of fit for the mating flange on the
driven machine is the system manufacturer's or the plant operator's responsibility.
Note
If the machine is not fitted with a standard flange, align the machine to suit the driven machine.

Assembling
Procedure
The machine axis must be vertical when it is lifted and the flange must be parallel to the mating
flange, so as to avoid seizing and stressing. Otherwise damage to the centering will result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw in two studs into tapped holes on opposite sides of the driven machine flange. The
studs act as positioning aids.
3. Lower the machine slowly toward the driven machine and into the centering, so that the
flanges do not quite touch. Lowering too quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Lower the machine completely onto the mating flange so that it is fully in contact; then
remove the studs.
6. Fix the machine using the flange fixing bolts.
NOTICE
Damage to the bearing
Dismantling the rotor shipping brace when the machine is in a horizontal position could
damage the bearings.
Only remove the rotor shipping brace when the machine is in a vertical position.
NOTICE
Damage to the bearing
Failure to fit the rotor shipping brace can result in damage to the bearings while the machine
is being turned onto its side.
Fix the rotor in place before you turn the machine into a horizontal position.
5.3.3 Removing the rotor shipping brace

If a rotor shipping brace is attached to the machine, remove it at the last possible moment,
for example, when you are ready to push on the output or drive element.
Note
Store the rotor locking device
Be sure to store the rotor locking device. It must be remounted for possible disassembly and
transport.

Assembling
5.3.4 Alignment accuracy

The alignment accuracy required depends essentially on the configuration of the overall
machine train. Observe the required alignment accuracy of the coupling manufacturer in all
cases when aligning the machine.
Table 5-1 Recommended alignment accuracy
Speed [rpm] Parallel offset [mm] Angular offset [mm per 100 mm cou‐
pling diameter]
750 0.09 0.09
1500 0.06 0.05
3000 0.03 0.025
5.3.5 Mounting the output elements
Balance quality
The rotor is dynamically balanced. For shaft extensions with feather keys, the balancing type
for machines with a frame size < 100 is stamped on the rating plate. For machines with a frame
size >= 100, the balancing type is specified using the following marking on the face of the drive
end of the shaft:
● "H" means balancing with a half feather key
● "F" means balancing with a whole feather key.
Figure 5-1 Balancing type on the drive-end side

Assembling
Pushing on the power output elements

● Prerequisites:
– The coupling and/or the output element must be appropriately dimensioned for the
operating case at hand. The balance quality must satisfy the following requirements.
– Comply with the coupling manufacturer's instructions.
– Make sure that the balancing type of the transmission element correctly matches the
type of balance of the rotor.
– Use only ready drilled and balanced transmission elements. Check the hole diameters
and the balancing status before pulling them on. Thoroughly clean the shaft extension.
● Pulling on:
– Warm up the transmission elements to expand them before pulling them on. Select the
temperature difference for the heating process to suit the coupling diameter, fit and
material. See the coupling manufacturer's instructions.
– Power output elements may only be pushed on or pulled off with the correct equipment.
The transmission element must be pulled on in one continuous operation via the front
thread holes in the shaft or pushed on by hand.
– Do not strike it with a hammer, as this would damage the bearings.
Shaft extensions with feather key

To maintain the balancing quality, you have the following options:
● If the transmission element is shorter than the feather key with balancing type "H", then you
must machine off the section of feather key protruding from the shaft contour and
transmission element in order to maintain the balance quality.
● If the transmission element is drawn up on to the shoulder of the shaft, you must ensure
that the part of the coupling groove where the feather key is not inserted is taken into
consideration when balancing the coupling.
The following applies for all 2-pole machines and 4-pole machines with a frequency ≥ 60 Hz:
● The feather key must be shortened if the coupling hub is shorter than the feather key.
● The center of gravity of the coupling half should be within the length of the shaft end.
● The coupling used must be prepared for system balancing.
The number of poles of the machine is specified on the rating plate (in the designation of
the motor type).

Assembling
5.4 Cooling water supply for machines with water cooling
WARNING
The feather key can fall out
The feather keys are only locked against falling out during shipping. If a machine with two
shaft extensions does not have an output element on one shaft extension, the feather key
can fall out during operation.
Death or serious injury can result.
● Do not operate the machine unless the transmission elements have been pulled on.
● On shaft extensions without output element, make sure that the feather key cannot fall
out and shorten it by approximately half for balance type "H".
5.3.6 Axial and radial forces

You can obtain the permissible values for axial and radial forces by contacting the Siemens
Service Center or referring to the machine catalog.
NOTICE
Damage to bearings or the shaft
Large output masses and their centers of gravity outside the shaft extensions can lead to
resonance in operation. This can result in damage to the bearings and shaft.
Ensure that the permissible loads for the forces on the shaft extension are adhered to in
accordance with the catalog data or configuration data.

Seen from the shaft extension, connection of the water is possible from the right and from the
left.
NOTICE
Cooling water connection pipe
If the cooling water cannot flow freely, the machine will not be cooled properly. The machine
will overheat, which could result in material damage or even a write-off.
● Remove the flange cover plate.
● Insert the gaskets correctly.

Assembling
1. For the pipes, select materials with the required chemical composition in accordance with
the water conditions. Also consider the pressure load and compatibility with the materials
from which the cooler is made.
2. Route and support the water pipes so that the connecting flanges are not exposed to
excessive stress or strain or vibration loads.
3. Rinse out the water circuit before you connect the cooling water supply to the motor. This
removes deposits and foreign bodies so that they cannot make their way into the cooling
circuit.
4. Should there be a possibility of the cooling water containing dirt and foreign bodies, install
suitable filters in the cooling-water feed pipe.
5. Connect the cooling circuit to the machine.
Filling the cooling circuit

1. Fill the cooling circuit with water until the air is completely forced out of the cooling circuit.
2. Perform a pressure check to see whether the cooling water supply is airtight. In doing so,
do not exceed the maximum test pressure. The maximum permissible pressure can be
found on the rating plate.
If you do not then put the machine into operation, you must implement the measures necessary
during stoppages.
NOTICE
Bleed air from the cooling ducts
If the cooling ducts are not completely filled with water, sufficient machine cooling cannot be
guaranteed and the machine may overheat.
Ensure that the air is bled from the cooling ducts during filling and that the cooling ducts are
completely filled with water.

Assembling

Electrical connection 6
Note
Service Center
If you require support when electrically connecting up the machine, please contact the Service
Center (Page 117).
WARNING
Connected parts can loosen
If you use fixing elements made from the wrong material or apply the wrong tightening torque,
this could impair current transfer or cause connecting parts to become loose. Fastening
elements can work loosely, so that the minimum air clearances are no longer maintained.
Sparking formation may occur, in an explosive atmosphere it can lead to an explosion. This
could result in death, serious injury or material damage to the machine or even in failure,
which could in turn lead indirectly to material failure of the system.
● Tighten the screwed connections to the specified tightening torques.
● Observe any specifications regarding the materials from which fixing elements must be
made.
● When performing servicing, check the fastenings.
6.1 Preparation
6.1.1 Selecting cables

Take the following criteria into account when selecting the connecting cables:
● Rated current
● Rated voltage
● If required, service factor
● System-dependent conditions, such as ambient temperature, routing type, cable cross-
section as defined by required length of cable, etc.
● Requirements according to IEC/EN 60204‑1

Electrical connection
6.2 Connecting
● Requirements according to IEC/EN 60079-14 when used in Zones 1, 2 or 21, 22

● Configuration notes
6.2 Connecting
6.2.1 Installing intrinsically safe circuits

There must be potential equalization along the entire length of the intrinsically safe electrical
circuits when intrinsically safe circuits are involved.
A stranded wire is used as the potential equalizing cable. A copper braided strip is used to
ensure potential equalization between the cable entry plate and the terminal box enclosure.
Table 6-1 Electrical data
Non-intrinsically safe power circuit Um = 700 V alternating voltage

Intrinsically safe power circuit in "fail-safe" type of protection
Ex ib IIB/IIC, only connected to certified intrinsically safe circuits that are galvan‐
ically isolated from ground.
Maximum values for total:
IIB IIC
e.g. at T4: Ui = 28 V Ui = 24 V
Ii = 300 mA Ii = 170 mA
Pi = 1,3 W Pi = 1,3 W
The effective internal inductance and capacitance are negligibly small.
The intrinsically safe circuits are safely galvanically isolated from all non-intrinsically safe
circuits up to a peak value for the rated voltage of 1000 V. Please refer to the additional plate
on the machine for the maximum values for "intrinsically safe power circuits".
6.2.2 Terminal boxes with type of protection "Ex d"

With terminal boxes of protection type "Ex d", the type and size of the cable entry threads and
the type of protection are specified on the terminal box.
WARNING
Loss of type of protection "Ex d" when using cable and conductor entries, piping systems as
well as screw plugs with a basic design.
An explosion can occur. This can result in death, serious injury, or material damage.
Only use sealing plugs with type of protection "Ex d" that have been tested and certified in
accordance with IEC / EN 60079-1 to close openings that are not to be used.

6.2 Connecting
6.2.3 Terminal boxes with type of protection "Ex e"
WARNING
If the seal of the pressure relief flap (preset breaking point) in the lower section of the terminal
box is damaged, then the explosion type of protection is no longer guaranteed.
An explosion may occur during operation. This can result in death, serious injury or material
damage.
The damaged seal may only be repaired with original sealing material.
WARNING
No cable or line entries or simple designs of sealing plug may be used on terminal boxes with
the "Ex e" type of protection.
An explosion may occur during operation. This can result in death, serious injury or material
damage.
● Use only cable entries that have been tested and certified in accordance with
IEC / EN 60079–7 .
● Use only sealing plugs that have been tested and certified in accordance with
IEC / EN 60079–7 to close openings that are not to be used.
CAUTION
Working on terminal boxes of the "Ex e" type of protection with undrilled cable entry plate
This can result in death, serious injury or material damage.
Ensure that the cable entry plate is still strong enough after drilling the threads.
6.2.4 Connecting the grounding conductor

The cross-section of the machine grounding conductor must comply with the installation
regulations and also with IEC / EN 60204-1.
Table 6-2 Determining the cross-section of the grounding conductor
External cable cross-section S Cross-section of the grounding conductor [mm²]

S ≤ 16 mm² S
16 mm² < S ≤ 35 mm² 16 mm²
S > 35 mm² S/2
A terminal strip for grounding is fitted either on the stator casing or on the flanged endshield,
depending on the frame size. The grounding point is marked.
The terminal strip is suitable for connecting stranded cables with cable lugs or connecting flat
straps. In addition, all motors have a PE terminal within the terminal box.

6.2 Connecting
When connecting up the grounding conductor, ensure that the contact surface of the
connection is bare and protected against corrosion using a suitable agent, e.g. with acid-free
Vaseline.
6.2.5 Circuit diagram in the terminal box cover

Data on the connection and connecting the motor winding can be found in the circuit diagram
in the cover of the terminal box.
6.2.6 Terminal designation

According to IEC / EN 60034‑8, the following basic definitions apply to the terminal
designations for 3-phase machines:
Table 6-3 Terminal designations using the 1U1-1 as an example
1 U 1 - 1 Designation
x Index for pole assignment for pole-changing machines where applicable. A lower
index signifies a lower speed. Special case for split winding.
x Phase designation U, V, W
x Index for winding start (1) or end (2) or if there is more than one connection per
winding
x Additional indices for cases in which it is obligatory to connect parallel power feed
cables to several terminals with otherwise identical designations
6.2.7 Connecting the machine for a specific direction of rotation

If the machine has one shaft extension or two shaft extensions with different diameters, the
direction of rotation when looking at the front of the single or the thicker shaft extension is
defined as follows:
● If you are connecting power supply cords with a phase sequence of L1, L2, L3 at U, V, W,
the resulting rotation will be clockwise.
● If you transpose two connections, e.g. L1, L2, L3 at V, U, W, the resulting rotation will be
counter-clockwise.
Machines which must run only in one specific direction of rotation are marked with a direction
of rotation arrow.
6.2.8 Terminal box

● The number and size of the cable entry tapped holes can be found in the machine dimension
drawing.
● Only use cable entries that are suitable for the cable.

6.2 Connecting
● Only use suitable cable entries and cables for the prevailing ambient temperature.
● Check the cable glands and cables to ensure that they are correctly sealed and firmly
seated.
● Correctly close and seal threads or holes that are not being used ensuring that the IP degree
of protection is maintained. The IP degree of protection is specified on the rating plate.
Please note the following points for explosion-protected machines:
● Replace the cable glands that are not being used by appropriately certified screw plugs.
● If you are using cable glands, use only appropriately certified cable glands with strain relief.
Comply with the installation and operation conditions specified in the certificate for these
cable glands and check that they have been fully complied with.
Note
Undrilled entry plate
If the entry plate is undrilled, you should match the number and size of the cable glands to the
operating conditions. Not applicable for terminal boxes of the Ex d type of protection.
1. Unscrew the cable entry plate.

2. Drill the required number of holes or threads in the required size into the cable entry plate.
The thickness of the plate is selected in such a way as to give a sufficient number of turns
when the holes are tapped.
Please note that you are responsible for ensuring that the entry plate still has sufficient
strength after the holes have been drilled and tapped.
3. Mount the cable entry plate and the cables with the cable glands onto the terminal box.
After the cables have been inserted into the terminal box, tighten the cable glands and parts
for strain relief to the torque specified by the manufacturer.
4. Seal the screwed sockets on the cable glands in accordance with the degree of protection.
Use only sealing plugs, cable entries and conductor entries, that are certified and marked for
use in the respective hazardous area (the zone).
6.2.9 Minimum air clearances

After proper installation, verify that the minimum air clearances between non-insulated parts
are maintained. Be aware of any protruding wire ends.
Table 6-4 Minimum air clearance dependent on rms value of the alternating voltage Urms
Rms value of the alternating voltage Vrms Minimum air clearance

≤ 500 V 8 mm
≤ 630 V 10 mm
≤ 800 V 12 mm

6.2 Connecting
≤ 1000 V 14 mm
≤ 1250 V 18 mm
Values apply at an installation altitude of up to 2000 m.

When determining the required minimum air clearance, the voltage value in the table may be increased
by a factor of 1.1, so that the rated input voltage range is taken into account during general use.
6.2.10 Cable ends with wire end sleeves

Preferably use end sleeves instead of soldering cable ends. Before connecting, correctly clamp
the end sleeve onto the cable to establish a connection capable of conducting current.
WARNING
Securely and reliably clamping and enclosing the end of the conductor
If the end of the conductor is not correctly enclosed by the end sleeve, but is clamped together
with it, then this can lead to overheating. The temperature class of the machine can be
exceeded. This can trigger ignition of an explosive mixture. This can result in death, serious
injury or material damage.
● Insert only one conductor end into each end sleeve. Attach the end sleeve correctly.
6.2.11 Connection with terminal board

Note that for terminal boards with U-shaped terminal clamps, the conductors to be connected
must be placed under the terminal clamps in a U shape. Alternatively, with multi-stranded and
finely-stranded conductors, evenly divide the conductor (into two parts) and lay in a straight
line under the U-shaped terminal clamps.
See sketch!
Figure 6-1 Example for conductor connection

6.2 Connecting

1 Hexagonal nut – DIN934

2 Spring washer – DIN128
3 or alternatively a spacer washer – DIN125 Cu (for a star connection)
4 alternatively a circuit connection
5 Terminal clamp
6 alternatively a spacer washer Cu
7 Angled cable lug
8 Washer – DIN125 St
Figure 6-2 Example for conductor connection
6.2.12 Tightening torques for cable glands

● Tighten the cable gland and the parts of terminal box intended to act as a strain relief to
the appropriate torque as specified by the manufacturer after inserting the feeder cables.
The tightening torques depend on the cable gland used and the cable or wire used.
● Tighten the standard cable glands supplied with the motor in accordance with the following
table.
Table 6-5 Tightening torques for standard cable glands [Nm]
Nominal size Cable gland for Ex e II Cable gland for Ex e / Ex d IIC

TypeHSK-M Type ADE 1F, ADE 4F R... / B...
Union nut Connection thread Union nut / connection Union nut / connection
thread thread
M12 x 1.5 5 7 7.5 -
M16 x 1.5 5 7 12.5 17

6.2 Connecting
Nominal size Cable gland for Ex e II Cable gland for Ex e / Ex d IIC

TypeHSK-M Type ADE 1F, ADE 4F R... / B...
Union nut Connection thread Union nut / connection Union nut / connection
thread thread
M20 x 1.5 5 7 20 23
M25 x 1.5 7 10 30 29
M32 x 1.5 7 10 55 33
M40 x 1.5 7 10 75 41
M50 x 1.5 7 10 100 50
M63 x 1.5 7 10 135 75
M75 x 1.5 - - 175 100
6.2.13 Connecting aluminum conductors

If you are using aluminum conductors, comply in addition with the following:
● Use only cable lugs that are suitable for connecting aluminum conductors.
● Immediately before inserting the aluminum conductor, remove the oxide layer from the
contact areas on the conductor and/or the mating piece, by brushing or filing.
● Then grease the contact areas immediately using neutral vaseline in order to avoid re-
oxidation.
NOTICE
Aluminum flow due to contact pressure
Aluminum flows following installation due to the contact pressure. The connection with the
clamping nuts can loosen as a result. The contact resistance would increase and the
current-carrying impeded; as a consequence the terminal box and the surrounding
components could burn. This could result in material damage to the machine or even in
total failure, which could in turn lead to indirect material damage to the system.
Retighten the clamping nuts after approximately 24 hours and then again after
approximately four weeks. Make sure that the terminals are de-energized before you
tighten the nuts.
6.2.14 O-ring seal

If O-ring seals are present, you should check that they are in perfect condition and that the O-
ring seals are properly seated in the grooves between the components. Replace any damaged
O-ring seals.
O-ring seals can be present on the following components, for instance:
● Tapers
● Cable glands
● Bearing seals

6.2 Connecting
● Bearing plate seals

● Terminal box seals
● Cable glands
● etc.
6.2.15 Finishing connection work

1. Before closing the terminal box, please check that:
– The electrical connections in the terminal box are tight and in full compliance with the
specifications above
– The motor is connected so that it rotates in the direction specified
– The inside of the terminal box is clean and free of any cable debris
– All gaskets and seals are intact
– Unused cable glands must be replaced with certified closures or closed with other
suitable closure types. Comply with the installation and operation conditions specified
in the certificate for these plug elements and check that they have been complied with.
– The pressure relief device is intact Depending on the type of terminal box being used,
the pressure relief device can be implemented either by sealing the slots or by using a
pressure relief diaphragm.
WARNING
Damaged pressure relief device
Water and foreign bodies can penetrate the enclosure if the pressure relief device is
damaged: The degree of protection of the terminal box is no longer guaranteed, a short-
circuit can occur, which can result in death, serious injury or material damage.
● Do not operate the machine with a damaged pressure relief device.
● Any damage may only be repaired after prior discussion with the person responsible
for the safety of the plant or system and only using original parts. Any damage may
only be repaired after prior discussion with the person responsible for the safety of
the installation and only by using original parts.
2. Close the terminal box.

See section "Tightening torques for screw and bolt connections" for the tightening torque
of the fixing bolts for the cover.
6.2.16 Internal equipotential bonding

The equipotential bonding between the ground terminal in the terminal box enclosure and the
motor frame is established via the terminal box metallic contact faces. The contact faces are
protected against corrosion.

6.2 Connecting
The equipotential bonding is achieved by means of a stranded wire. A copper braided strip, a
stranded wire or a metal contact is used to ensure potential equalization between the cable
entry plate and the terminal box enclosure.

Commissioning 7
7.1 Checks to be carried out prior to commissioning

Once the system has been correctly installed, you should check the following prior to
commissioning:
Note
Checks to be carried out prior to commissioning
The following list of checks to be performed prior to commissioning does not claim to be
complete. It may be necessary to perform further checks and tests in accordance with the
specific situation on-site.
7.2 Testing the securing and alignment

● The machine is undamaged.
● The machine has been correctly installed and aligned, the transmission elements are
correctly balanced and adjusted.
● All fixing screws, connection elements, and electrical connections have been tightened to
the specified tightening torques.
● The operating conditions match the data provided in accordance with the technical
documentation, such as degree of protection, ambient temperature, etc..
● Moving parts such as the coupling, brake, etc. move freely.
● If the second shaft extension is not in use, its feather key is secured to prevent it from being
thrown out, and cut back to roughly half its length if the rotor has balancing type "H"
(standard type).
● All touch protection measures for moving and live parts have been taken.
WARNING
Risk of losing the IP degree of protection as a result of damaged shaft sealing rings
Replace damaged components immediately.

Commissioning
7.2 Testing the securing and alignment
● The rotor can spin without coming into contact with the stator.
● The bearing insulation is not bridged.
● Appropriately configured control and speed monitoring functions ensure that the the
permissible speeds specified on the rating plate cannot be exceeded.
● Any supplementary motor monitoring devices and equipment have been correctly
connected and are fully functional.
Force-ventilated motors
● All external fans are ready for operation and have been connected. The external fans are
bidirectional as standard. For unidirectional ventilation systems, the direction of rotation is
stated on the extra rating plate of the machine.
● The flow of cooling air is not impeded.
● The grounding and equipotential bonding connections have been made correctly.
● The machine is connected so that it rotates in the direction specified.
● Appropriately configured control and speed monitoring functions ensure that the motor
cannot exceed the permissible speeds specified in the technical data. For this purpose,
compare the data on the rating plate or, if necessary, the system-specific documentation.
● The minimum insulation resistance values are within tolerance.
● Minimum air clearances have been maintained.
connected and are functioning correctly.
● All brakes and backstops are operating correctly.
● At the monitoring devices, the values for "Warning" and "Shutdown" are set.
Converter operation
● If the design of the motor requires connection to a particular converter type, the rating plate
will contain corresponding additional information.
● The converter is correctly parameterized. The parameterization data is specified on the
rating plate of the machine. Information about the parameters is available in the operating
instructions for the converter.
connected and are functioning correctly.
● In continuous operation, the motor cannot exceed the specified upper speed limit nmax or
undershoot the lower speed limit nmin.
● The permissible acceleration time to the limit speed nmin depends on the parameter
assignment.

Commissioning
7.4 Testing the insulation resistance and polarization index
7.3 Insulation resistance and polarization index

"Testing the insulation resistance and polarization index"
WARNING
Hazardous voltage at the terminals
During and immediately after measuring the insulation resistance or the polarization index
(PI) of the stator winding, hazardous voltages may be present at some of the terminals.
Contact with these can result in death, serious injury or material damage.
● If any power cables are connected, check to make sure line supply voltage cannot be
delivered.
● Discharge the winding after measurement until the risk is eliminated, e.g. using the
following measures:
– Connect the terminals with the ground potential until the recharge voltage drops to a
non-hazardous level
– Attach the connection cable.
Measure the insulation resistance

1. Before you begin measuring the insulation resistance, please read the operating manual
for the insulation resistance meter you are going to use.
2. Make sure that no power cables are connected.

Commissioning
3. Measure the winding temperature and the insulation resistance of the winding in relation
to the machine enclosure. The winding temperature should not exceed 40° C during the
measurement. Convert the measured insulation resistances in accordance with the formula
to the reference temperature of 40° C. This thereby ensures that the minimum values
specified can be compared.
4. Read out the insulation resistance one minute after applying the measuring voltage.
Limit values for the stator winding insulation resistance

The following table specifies the measuring voltage and limit values for the insulation
resistance. These values correspond to IEEE 43‑2000 recommendations.
Table 7-1 Stator winding insulation resistance at 40° C
VN [V] VMeas [V] RC [MΩ]

U ≤ 1000 500 ≥5
1000 ≤ U ≤ 2500 500 (max. 1000) 100
2500 < U ≤ 5000 1000 (max. 2500)
5000 < U ≤ 12000 2500 (max. 5000)
U > 12000 5000 (max. 10000)
Urated = rated voltage, see the rating plate

Umeas = DC measuring voltage
RC = minimum insulation resistance at reference temperature of 40° C
Conversion to the reference temperature

When measuring with winding temperatures other than 40° C, convert the measuring value to
the reference temperature of 40° C according to the following equations from IEEE 43-2000.
(1) RC Insulation resistance converted to 40° C reference temperature

kT Temperature coefficient according to equation (2)
RC = KT · RT RT Measured insulation resistance for measuring/winding temperature T
in °C
(2) 40 Reference temperature in °C
10 Halving/doubling of the insulation resistance with 10 K
KT = (0.5) (40-T)/10 T Measuring/winding temperature in °C
In this case, doubling or halving the insulation resistance at a temperature change of 10 K is

used as the basis.
● The insulation resistance halves every time the temperature rises by 10 K.
● The resistance doubles every time the temperature falls by 10 K.

Commissioning
For a winding temperature of approx. 25° C, the minimum insulation resistances are 20 MΩ
(U ≤ 1000 V) or 300 MΩ (U > 1000 V). The values apply for the complete winding to ground.
Twice the minimum values apply to the measurement of individual assemblies.
● Dry, new windings have an insulation resistance of between 100 and 2000 MΩ, or possibly
even higher values. An insulation resistance value close to the minimum value could be
due to moisture and/or dirt accumulation. The size of the winding, the rated voltage and
other characteristics affect the insulation resistance and may need to be taken into account
when determining measures.
● Over its operating lifetime, the motor winding insulation resistance can drop due to ambient
and operational influences. Calculate the critical insulation resistance value depending on
the rated voltage by multiplying the rated voltage (kV) by the specific critical resistance
value. Convert the value for the current winding temperature at the time of measurement,
see above table.
Measuring the polarization index

1. To determine the polarization index, measure the insulation resistances after one minute
and ten minutes.
2. Express the measured values as a ratio:
PI = Rinsul 10 min / Rinsul 1 min
Many measuring devices display these values automatically following the measurement.
For insulation resistances > 5000 MΩ, the measurement of the PI is no longer meaningful and
consequently not included in the assessment.
R(10 min) / R(1 min) Assessment

≥2 Insulation in good condition
<2 Dependent on the complete diagnosis of the insulation
NOTICE
Damage to insulation
If the critical insulation resistance is reached or undershot, this can damage the insulation
and cause voltage flashovers.
● Contact the Service Center.
● If the measured value is close to the critical value, you must subsequently check the
insulation resistance at shorter intervals.
See also
Insulation resistance and polarization index (Page 36)
Limit values of the anti-condensation heating insulation resistance

The insulation resistance of the anti-condensation heating with respect to the machine housing
should not be lower than 1 MΩ when measured at 500 V DC.

Commissioning

Operation 8
8.1 Safety instructions during operation
WARNING
All terminal boxes must be closed
Terminal boxes contain live electrical parts. Death, serious injury or material damage can
result if terminal box covers are removed.
When the machine is in operation, the terminal boxes must remain closed at all times.
Terminal boxes may be opened only when the machine is stopped and de-energized.
WARNING
Do not remove covers when the motor is running
Rotating or live parts are dangerous. Death, serious injury or material damage can result if
the required covers are removed.
Any covers that prevent live electrical or rotating parts from being touched, or that ensure
compliance with a particular degree of protection or are required for ensuring proper air flows,
and hence effective cooling, must not be opened during operation.
WARNING
Faults in operation
Deviations from normal operation such as increased power consumption, temperatures or
vibrations, unusual noises or odors, tripping of monitoring devices, etc., indicate that the
machine is not functioning properly. This can cause faults which can result in eventual or
immediate death, serious injury or material damage.
● Immediately inform the maintenance personnel.
● If you are in doubt, immediately switch off the motor, being sure to observe the system-
specific safety conditions!

Operation
8.1 Safety instructions during operation
CAUTION
Fire hazard
Certain parts of the motor may reach temperatures above 50° C. Touching them can result
in burns.
● Check the temperature of the parts before touching them and take appropriate protective
measures if necessary.
CAUTION
Terminal boxes with current transformers
If you are using current transformers, make sure that the secondary circuit from the current
transformer is protected against unintentional opening while the equipment is in use.
DANGER
Explosion hazard if the bridging is removed from the insulated bearing
Removing the factory-fitted bridging of the insulated bearing leads to potential differences
between the rotor and the grounded motor. This can cause the generation of sparks, which
especially in an explosive atmosphere can ignite surrounding dust or combustible gases.
Explosions can occur. There is also a risk of an electric shock. Death, serious injury, or
material damage will result.
Do not open the bridging of the bearing insulation during operation.
NOTICE
Excessive machine temperature
If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine. This can result in material damage.
● Make sure that the anti-condensation heating is switched off before the machine is
switched on.
● Only operate anti-condensation heating when the machine is switched off.
WARNING
Explosion hazard
If the anti-condensation heating is switched on during operation, the temperature class or the
maximum surface temperature of the machine can be exceeded.
In an explosive atmosphere, there is a risk of an explosion. This can result in death, serious
Only switch the anti-condensation heating on after the motor has been switched off.

Operation
8.6 Stoppages
8.2 Switching on the machine

1. If at all possible, run the machine without load and check that it is running smoothly.
2. If it runs perfectly, connect a load.
3. If this is possible using the available measuring equipment, check the bearing and stator
winding temperatures.
8.3 Switching off the external fan

If the controller does not switch off the external fan automatically, switch it off when the machine
is stopped.
8.4 Switching off the water-cooling system

If the controller does not switch off the air-to-water heat exchanger automatically, switch it off
when the machine is stopped.
8.5 Switching on again after an emergency switching-off

● Check the machine before recommissioning the driven machine after an Emergency Off.
● Eliminate all the causes that have led to the emergency off
8.6 Stoppages
The stoppage is a shutdown for a period of time, during which the machine is stopped but
remains at the location of use.
Under normal ambient conditions, e. g. the stopped machine is not exposed to any vibration,
no increased level of corrosion, etc. in general, the following measures are necessary during
stoppages.
8.6.1 Switching on the anti-condensation heater

If the machine has anti-condensation heating, then switch it on when the machine is not in
operation.

Operation
8.6 Stoppages
WARNING
Explosion hazard
If the anti-condensation heating is switched on during operation, the temperature class or the
maximum surface temperature of the machine can be exceeded.
In an explosive atmosphere, there is a risk of an explosion. This can result in death, serious
Only switch the anti-condensation heating on after the motor has been switched off.
8.6.2 Avoidance of frost and corrosion damage in the cooling system

● For avoidance of frost and corrosion damage, completely drain the water from the cooling
system. Then blow air through the cooling system to dry it.
If the cooling system cannot be drained because standby capability is required at short
notice, protect the cooling circuit against frost and corrosion damage. To do this, add
suitable additives to the cooling water.
NOTICE
Impairment of the heat transport
Additives such as anti-freeze and corrosive inhibitor can impair the heat transport.
Operate the motor only with the contractually agreed water quality.
For avoidance of deposits, the cooling water circuit must then be kept running. So as to be
certain of excluding the possibility of formation of condensation within the machine, the anti-
condensation heating should also remain switched on (if fitted).
8.6.3 Avoidance of damage to roller bearings during stoppages

Extended stoppages at the identical or almost identical resting position of the roller bearings
can lead to damage such as brinelling or formation of corrosion.
● During stoppages, regularly start the machine up for a brief period once a month, or at least
turn the rotor over several times.
If you have uncoupled the machine from the driven machine and secured the rotor with a
rotor shipping brace, then remove this before turning the rotor over or starting the machine
up.
Make sure that the resting position of the roller bearings after the rotor has been turned
over is different from what it previously had been. Use the fitted key or the coupling halves
as reference markers.
● During re-commissioning, refer to the information in the "Commissioning" section.

Operation
8.9 Faults
8.7 Decommissioning the machine
NOTICE
Damage as a result of an extended period out of service
If the machine is going to be out of service for longer than six months, then take the necessary
measures for preservation and storing. Otherwise damage to the machine will result.
Record the decommissioning steps. This log will be useful upon recommissioning.
8.8 Re-commissioning the machine

When you re-commission the machine, proceed as follows:
● Study the record made when the machine was decommissioned, and reverse the measures
that were taken for conservation and storage.
● Perform the measures listed in the "Commissioning" section.
8.9 Faults
8.9.1 Inspections in the event of faults

Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.
Correct the cause of the fault as described in the respective remedial measures section. Repair
any damage to the machine.
8.9.2 Electrical faults
Note
If you are operating the motor with a converter, the operating instructions of the converter must
also be observed if electrical faults occur.

Operation
8.9 Faults
Table 8-1 Electrical faults
↓ Motor fails to start

↓ Motor accelerates sluggishly
↓ Rumbling noise during startup
↓ Rumbling noise during operation
↓ High temperature rise during no-load operation
↓ High temperature rise with load
↓ High temperature rise of individual winding sections
Possible causes of faults Remedial measures
X X X X Overload Reduce the load.
X Interrupted phase in the supply cable Check the switches and cables.
X X X X Interrupted phase in the feeder cable af‐ Check the switches and cables.
ter switching on
X Mains voltage too low, frequency too high Check the power supply conditions.
X Mains voltage too high, frequency too low Check the power supply conditions.
X X X X X Stator winding incorrectly connected Check the winding connection in the terminal box.
X X X X Winding short circuit or phase short cir‐ Determine the winding resistances and insulation
cuit in stator winding resistances. Carry out repair work after consulta‐
tion with the manufacturer.
X Incorrect direction of rotation Check the connection.
8.9.3 Mechanical faults
Table 8-2 Mechanical faults
↓ Grinding noise
↓ Radial vibrations
↓ Axial vibrations
X Rotating parts grind Establish the cause and realign the parts.
X Stator or coupling not balanced. Disconnect the stator or coupling and rebalance.
If the machine has two shaft ends, and a transmission element is
only fitted to one end, secure the fitted key at the other end to prevent
it from being thrown out. If the rotor has balance type "H" (standard
type), the fitted key must be cut back to roughly half of its length.
X Rotor out of true, shaft bent Consult the manufacturing plant.
X X Poor alignment Align the machine set; check the coupling. (1)
X Coupled machine not balanced Rebalance the coupled machine.
X Shocks from coupled machine Investigate the coupled machine.
X X Uneven running of gear unit Fix the gearing.
X X Resonance of the overall system com‐ Stabilize the foundation following consultation.
prising motor and foundation

Operation
8.9 Faults
↓ Grinding noise
↓ Radial vibrations
↓ Axial vibrations
X X Changes in foundation Establish the cause of the changes and eliminate them if necessary;
realign the machine.
(1)
Take any changes into account when warming up the machine.
8.9.4 Roller bearing faults
Note
Damage to roller bearings can be difficult to detect in some cases. If in doubt, replace the
bearing. Use other bearing designs only after consulting the manufacturer.
Table 8-3 Roller bearing faults
↓ Bearing overheats
↓ Bearing "whistles"
↓ Bearing "knocks"
X High coupling pressure Align the machine more accurately.
X Belt tension too high Reduce the drive belt tension.
X Bearing contaminated Clean the bearing or replace it. Check the seals.
X High ambient temperature Use a suitable high-temperature grease.
X X Insufficient lubrication Grease the bearings as instructed.
X X Bearing canted Properly install the bearing.
X X Insufficient bearing play Only after consultation with the manufacturer: Fit a bearing with
greater play.
X Excessive bearing play Only after consultation with the manufacturer: Fit a bearing with
lower play.
X X Bearing corroded Replace the bearing. Check the seals.
X Too much grease in bearing Remove surplus grease.
X Wrong grease in the bearing Use the correct grease.
X Friction marks on raceway Replace the bearing.
X Scoring (brinelling) Replace the bearing. Avoid any vibration at standstill

Operation
8.9 Faults
8.9.5 Faults at the external fan

The following table shows the possible causes of and remedial measures for faults on forced-
ventilated machines.
Table 8-4 Cooling system faults
↓ High temperature rise with load

X Wrong direction of rotation of the external fan Check the electrical connections to the external fan.
X External fan is not running Check the external fan and its connections.
X Reduced air flow Check the air ducts; clean the machine.

Maintenance 9
Through careful and regular maintenance, inspections, and overhauls you can detect faults at
an early stage and resolve them. This means that you can avoid consequential damage.
Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals can be specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).
Comply with the IEC / EN 60079‑17 standard during all service and maintenance work on the
machine.
Note
Service Center
Please contact the Service Center, if you require support with servicing, maintenance or repair.
9.1 Inspection and maintenance
WARNING
Rotating and live parts
Electric machines contain live and rotating parts. Fatal or serious injuries and substantial
material damage can occur if maintenance work is performed on the machine when it is not
stopped or not de-energized.
● Perform maintenance work on the machine only when it is stopped. The only operation
permissible while the machine is rotating is regreasing the roller bearings.
● When performing maintenance work, comply with the five safety rules.
WARNING
Machine damage
If the machine is not maintained it can suffer damage. This can cause faults which can result
in eventual or immediate death, serious injury or material damage.
Perform regular maintenance on the machine.

Maintenance
CAUTION
Dust disturbances when working with compressed air
When cleaning with compressed air, dust, metal chips, or cleaning agents can be whirled up.
Injuries can result.
When cleaning using compressed air, make sure you use suitable extraction equipment and
wear protective equipment (safety goggles, protective suit, etc.).
NOTICE
Damage to insulation
If metal swarf enters the winding head when cleaning with compressed air, this can damage
the insulation. Clearance and creepage distances can be undershot. This may cause damage
to the machine extending to total failure.
When cleaning with compressed air, ensure there is adequate extraction.
NOTICE
Machine damage caused by foreign bodies
Foreign bodies such as dirt, tools or loose components, such as screws etc., can be left by
accident inside the machine after maintenance is performed. These can cause short circuits,
reduce the performance of the cooling system or increase noise in operation. They can also
damage the machine.
● When carrying out maintenance work, make sure that no foreign bodies are left in or on
the machine.
● Securely attach all loose parts again once you have completed the maintenance
procedures.
● Carefully remove any dirt.
Note
Operating conditions and characteristics can vary widely. For this reason, only general
intervals for inspection and maintenance measures can be specified here.
WARNING
Explosion hazard
Components within the machine may be hotter than the maximum permissible surface
temperature of the enclosure. In an explosive atmosphere, dust can ignite and an explosion
● Do not open the machine in an explosive and dusty atmosphere when it is still at normal
operating temperature.
● Allow the machine to cool down before opening it.
● When disassembling, ensure that the parts necessary to seal the enclosure are not
damaged, for example seals, face/plane mating surfaces. Perform a new routine test for
the parts that have been repaired if these parts are crucial to ensure dust protection.

Maintenance
WARNING
Explosion hazard due to overheating of the machine caused by a layer of dust
Layers of dust thicker than 5mm can insulate the machine, resulting in overheating. The
maximum surface temperature of the machine cannot be adhered to. The dust can ignite,
resulting in an explosion. This can result in death, serious injury or material damage.
Dust the machine regularly. Do not allow dust layers thicker than 5 mm to build up on the
machine surface. Do not switch the machine on until the dust has been removed.
WARNING
Risk of explosion due to excessive bearing temperature
The surface temperature cannot be maintained within maximum permissible limits if the
bearing becomes too hot. The dust can ignite, resulting in an explosion. This can result in
death, serious injury or material damage.
● Always check the bearing temperature.
● In addition to the current-dependent overload protection device located in the three phases
of the connecting cable, we recommend that you also monitor the temperature rise in the
motor with the aid of the temperature sensors built into the stator winding.
WARNING
Risk of explosion when cleaning with compressed air
If you clean the machine with compressed air, plastic components may become statically
charged and ignite a potentially explosive atmosphere; an explosion can occur. This can
Do not use compressed air to clean plastic parts in an explosive atmosphere. When cleaning
the machine, make sure that the air in the vicinity of the motor is free of gas and dust.
9.1.1 Inspections in the event of faults

Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.

Maintenance
9.1.2 First inspection

Perform the following checks after approximately 500 operating hours or one year, whichever
comes first:
Table 9-1 Checks after installation or repair
Check When the At stand‐

motor is still
running
The electrical parameters are maintained. X
The permissible bearing temperatures are not exceeded. X
The smooth running characteristics and machine running noise have not X
deteriorated.
The motor foundation has no cracks and indentations. (*) X X
(*) You can perform these checks while the motor is at standstill or, if required, while running.
Further checks
Further checks may be required if so specified in supplementary instructions or in accordance
with the plant-specific conditions.
NOTICE
If you detect any deviations during the inspection, you must rectify them immediately. They
may otherwise damage the motor.
9.1.3 General inspection

Check that the installation conditions are observed. We recommend that the following checks
are performed after approx. 16 000 operating hours or at the latest after two years:
Table 9-2 Checks that have to be performed during the general inspection
Checking When the At stand‐

motor is still
running
The electrical parameters are maintained X
The permissible bearing temperatures are not exceeded X
The smooth running characteristics and machine running noise have not X
deteriorated
The motor foundation has no cracks and indentations (*) X X
The machine is aligned within the permissible tolerance ranges X
All the fixing bolts/screws for the mechanical and electrical connections have X
been securely tightened
All the potential connections, grounding connections and shield supports are X
correctly seated and properly bonded
The winding insulation resistances are sufficiently high X

Maintenance
Checking When the At stand‐

motor is still
running
Any bearing insulation is fitted as shown on the plates and labels X
The CABLES and insulating parts and components are in good condition X
and there is no evidence of discoloring
(*) You can perform these checks while the motor is at standstill or, if required, while running.
NOTICE
Machine damage
When carrying out the inspection, if you detect any impermissible deviations from the normal
state, you must rectify them immediately. They may otherwise cause damage to the machine.
9.1.4 Servicing the roller bearings

When inspecting rolling-contact bearings, it is generally not necessary to dismantle the
machines. The motor only has to be dismantled if the bearings are to be replaced.
9.1.5 Bolt grade

Check that all the bolts for attaching the bearing shields, bearing cover, gland plates, and
terminal boxes are present and properly tightened. Replace damaged bolts with identical bolts
of a perfect quality.
Depending on the ambient temperature, only bolts with the bolt grade according to the following
table are permissible for motors without heating.
Table 9-3 Bolt grade BG071 to BG315
Type/size Bolt grade for ambient temperature Tu

≥ -40 °C -55 °C ≤ Tu < -40 °C
Standard Stainless steel bolts Standard
071, 080, 090, 100, 112, 132, 8.8 A4-70 A4-70
160, 180, 200, 225, 250, 280, 315
180.B 8.8 A4-80 A4-80
Table 9-4 Bolt grade BG315 to BG910
Type/size Bolt grade for ambient temperature Tu

≥ -20 °C -40 °C ≤ Tu < -20 °C
Standard Stainless steel Standard Stainless steel
bolts bolts
315.B, 315.C, 315.D, 315.E 8.8 A4–70 8.8 A4–70

Maintenance
355.K, 355.L, 355.M, 355.N, 355.X 8.8 A4–70 8.8 A4–70

355.A, 355.B, 355.C, 355.D 8.8 A4–70 8.8 A4–80
400.K, 400.L, 400.M, 400.N, 400.X 8.8 A4–70 8.8 A4–70
450.K, 450.L, 450.M, 450.N, 450.X 8.8 A4–70 8.8 A4–80
500.K, 500.L, 500.M, 500.N, 500.X
560.K, 560.L, 560.M, 560.N, 560.X
630.K, 630.L, 630.M, 630.N, 630.X 8.8 A4–80 8.8 A4–80
710.A, 710.B, 710.C, 710.X 8.8 A4–70 8.8 A4–80
800.A, 800.B, 800.C, 800.D type of protec‐ 8.8 A4–70 / A4-80 8.8 A4–80
tion IIB / IIC
910.A, 910.B, 910.C, 8.8 A4–70 8.8 A4–80
9.1.6 Mechanical explosion protection for roller bearings

All machines marked in accordance with directive 94/9/EG must be regularly inspected for
mechanical damage that could constitute a risk of ignition in accordance with IEC / EN
60079‑17 .
● Comply with the following intervals:
– Bearing replacement intervals
– Relubrication intervals
– Grease replacement intervals
– Oil change intervals
● Roller bearing service life
– Replace the roller bearings once the nominal service life is reached. Alternatively, you
can verify they are free of mechanical damage as part of an inspection.
– In the case of roller bearings without a regreasing system, it is ensured that the nominal
service life will only be achieved clearly after achievement of the service life of the grease
in the bearings.
– The roller bearing service life under full specified load is at least 20 000 hours for
machines subject to radial or axial forces.
– The nominal roller bearing service life of machines which are not subject to any forces
is at least 40 000 hours.
● For roller bearings with external oil supply, monitor that lubrication is maintained.
9.1.7 Maintenance
9.1.7.1 Explosion protection for machines with type of protection "Ex d"
For explosion-protected motors with type of protection "flameproof enclosure" according to
IEC / EN 60079–0 and IEC / EN 60079–1, observe the following:

Maintenance
It is not permissible to subsequently machine or paint contact and mating surfaces of the parts
listed below:
● Stator frame
● End shields
● Bearing covers
● Motor shaft
● Gland plate
● Terminal box base
● Terminal box cover
● Gland plates for additional terminal boxes, where present
Keep these surfaces clean and protect them against corrosion by applying a thin coating of
grease. It is not permissible that any seals are fitted between the surfaces that guarantee that
flame is not transmitted.
9.1.7.2 Explosion hazard due to increased surface temperature
WARNING
Explosion hazard
Components within the motor may be hotter than the maximum permissible surface
temperature for the enclosure. In an explosive atmosphere, dust can ignite and an explosion
● Do not open the motor in an explosive and dusty atmosphere when it is still at normal
operating temperature.
● Allow the machine to cool down before opening it.
9.1.7.3 Insulation resistance and polarization index


Maintenance
"Testing the insulation resistance and polarization index"

Maintenance
9.1.7.4 Grease service life and fill quantities

Standard roller bearings
Size Grease stability time for permanent lubrication or relubrication in‐ Grease filling quantity for permanent
terval lubrication or grease quantity for relubrica‐
for a regreasing system in operating hours at rated speed tion in g per bearing
Horizontal type of construction Vertical type of construction (V) Permanent lubrica‐ Relubrication
(B) tion
3000 1500 ≤1000 3000 1500 ≤1000 3000 ≤1500 3000 ≤1500
rpm rpm rpm rpm rpm rpm rpm rpm rpm rpm
71 3 3 - -
80 3 3 - -
90 4 4 - -
100 33000 24000 33000 9 9 - -
112 9 9 - -
132 18 18 - -
160 32 32 - -
180 51 51 - -
200 40000 40000 40000 63 63 - -
225 79 79 - -
250 24000 16000 26000 99 99 - -
280 99 132 - -
315 - - 35 25
4000 8000 11000 2800 5600 8000
355 4000 5600 - - 35 50
The specified grease stability times and/or relubrication intervals are valid for maximum
ambient temperatures of 40 °C. Reduce the lubrication interval for a 10 °C increase in
temperature by a factor of 0.7 of the value listed in the table (max. 20 °C = factor 0.5). With an
ambient temperature <= 25° C, twice the grease stability time can be expected; but a maximum
of 40000 hours. Times for operation on 60 Hz systems on request. With pure coupling operation
with flexible coupling, the calculated bearing life is L10h greater than 50000 hours. Comply
with the grease service life and relubrication intervals.

Maintenance
Reinforced roller bearings
Size Grease stability time for permanent lubrication or relubrication interval Grease quantity for relu‐
for a regreasing system in operating hours at rated speed brication in g per bearing
Horizontal type of construction (B) Vertical type of construction (V)
3000 1500 ≤1000 3000 1500 ≤1000 3000 ≤1500
rpm rpm rpm rpm rpm rpm rpm rpm
180 17 17
200 20 20
225 2800 5600 8000 2000 4000 5600 25 25
250 25 25
280 25 35
315 4000 1400 2800 4000 35 25
355 2000 2800 5600 35 50
The specified relubrication intervals are valid for maximum ambient temperatures of 40 °C.
Reduce the relubrication intervals for a
10°C increase in temperature by a factor of 0.7 of the value listed in the table (max. 20
°C = factor 0.5). Times for operation on 60 Hz systems on request.
9.1.7.5 Grease stability times and fill quantities

The details for the grease stability times and relubrication intervals are stated on the lubrication
rating plate of the machine. The specified grease stability time applies to the ambient
temperature range stated on the rating plate. Reduce the lubrication interval for a 10° C
increase in temperature by a factor of 0.7 of the value listed in the table (max. 20° C = factor
0.5). Irrespective of the operating hours, the roller bearing grease and the bearing (2Z bearing)
must be replaced after four years of service.
9.1.7.6 Regreasing intervals and types of grease for operating rolling-contact bearings
Regreasing intervals
The regreasing intervals for roller bearings in operating hours and the grease types are stated
on the machine's lubricant plate. Regardless of the actual number of operating hours reached,
the machine must be regreased at least once a year. The lubrication information can be found
on the lubricant plate.
Note
Observe the regreasing intervals for the roller bearings
The regreasing intervals for roller bearings are different from the service/inspection intervals
for the machine. Failure to regrease the roller bearings at the specified intervals can result in
bearing damage.

Maintenance
Regreasing
The spent grease chamber is designed to accommodate the spent grease for a computed,
rated service life of 40000 operating hours.
● Clean the grease nipples before regreasing and then gradually press in an appropriate type
and amount of grease, as described on the lubricant plate. The shaft must then be rotated
so that the new grease can be distributed throughout the roller bearing. The roller bearing
temperature rises sharply at first, then drops to the normal value again after the excess
grease has been displaced out of the bearing.
– If the machine is fitted with grease removal sliders :
After the bearings have been regreased, with the motor running, the used grease should
be removed by pulling the slider fitted to the bearing to its stop several times.
– If the machine is fitted with grease collection chambers :
Unbolt the grease collection chambers at the intervals shown on the notice plate with
the motor stopped, and remove the used bearing grease. If this is not done, the grease
will clog and the bearings will overheat.
WARNING
Rotor can fall out
If the machine is in a vertical position, the rotor can fall out while work is being performed
on the locating bearing. This can result in death, serious injury or material damage.
Support or relieve the rotor when carrying out work with the machine in a vertical
position.
Grease types
For the standard operating range, a grease for temperatures down to ‑20 °C is normally used
for the initial greasing of roller bearings. If the machine has been ordered for use in the
extended temperature range of below ‑20 °C, the permissible type of grease is indicated on
the lubricant plate.
Note
Grease quantity control
The grease quantity control only operates correctly if the specified greases are used. This is
specified on plates attached to the machine.

Maintenance
9.1.7.7 Alternative types of grease for the operation of roller bearings
In the following table, you will find a list of approved alternative types of grease.
Filling with oil for the first time Alternative permissible greases
Shell Gadus S2 V100 3 Aral Aralub HL3
BP Energrease LS3
Castrol Optimol Olista Longtime 3
Exxon Mobil Beacon EP3
Mobilux EP3
OMV Signum L3
SKF LGMT 3
Shell Gadus S5 V42P 2.5 Currently no comparable grease with Dm*n≥1,000,000 is known.
Aeroshell Gadus S7
Shell Gadus S5 V100 2 Exxon Mobil Mobilith SHC 100

Esso Unirex N3 Exxon Mobil Mobilgrease XHP 103
Shell Gadus S5 V100 2
Shell Gadus S3 T100 2 BP Energrease SY2202
Castrol Firetemp XT2
Chevron Grease SRI2
Klüber Petamo GHY 133N
SKF LGHP 2
Exxon Mobil Polyrex EM
Observe the following when changing over to an alternative type of grease that is permitted according
to the table:
Bearings with permanent lubrication:

● Completely remove the old grease from the bearing before regreasing it.
● Fill roller bearings completely with grease and cavities in the bearing cover only up to one
third.
Bearings with regreasing:

If complete replacement of grease and cleaning of the bearing is not possible, keep the
operating time to a minimum when different greases are mixed. To do this, thoroughly grease
the bearing when the machine is running with about twice the amount of grease until spent
grease has been removed from the greasing ducts. Then regrease 4x at intervals of ¼ of the

Maintenance
normal greasing interval. During this time, very carefully monitor the bearing locations involved.
Then resume the normal greasing intervals.
NOTICE
Damage due to mixing grease types
If you mix greases and oils with different soap or oil bases, then the lubricating properties
may no longer be guaranteed.
Mixing low-temperature grease with normal temperature grease can cause lumps to form in
the lubricant. The consequence can be damage to the roller bearings due to overheating.
Never mix greases that have different thickening agents and different base oils.
Cleaning
● To ensure problem-free machine cooling, the air ducts (ventilation grilles, channels, cooling
fins, tubes) must be free of any dirt.
WARNING
Explosion hazard
Cleaning the machine in an explosive atmosphere is forbidden. This can result in death,
serious injury or material damage.
Surfaces can become statically charged and discharge to ignite potentially explosive
atmospheres.
9.1.7.8 Maintenance and repair for machines of protection type "Ex d"
The machine marking based on IEC / EN 60079–0 was added with the "X" symbol.
Maintain the special conditions for repairs. The gap dimensions for the electric machine do not
comply with the standardized values in IEC / EN 60079–1. For repair work, obtain the gap
dimensions of the electrical machine from the manufacturer.
Perform maintenance, repair and modification work on explosion-protected machines in strict
compliance with the corresponding national health and safety legislation, the safety
instructions and descriptions in the general maintenance instructions.
Work influencing explosion protection must be carried out by the manufacturer or by a specialist
workshop for electrical machinery authorized by the manufacturer. This includes the following
operations, for example:
● Repairs to the stator or rotor windings and to the terminals
● Repairs to the ventilation system
● Repairs to the bearings
● Dismantling machines with flameproof enclosures
● Connection work carried out in the terminal box

Maintenance
The operations must be identified by an additional repair plate carrying the following
information:
● Date
● Company carrying out repair
● Type of repair
● Reference number of the repair technician regarding repair work
Testing after repair shall be carried out in accordance with EU directives.
DANGER
Gap dimensions
Changing ignition gap geometries (gap dimensions) as part of repair work according to the
minimum specifications of IEC / EN 60079–1 is not permissible.
This can result in death, serious injury or material damage.
Obtain the gap dimensions of the electrical machine from the manufacturer for the repair or
restoration of ignition gap geometries.
WARNING
Rotating or live parts
Live electrical parts are dangerous. Contact with them can cause death, serious injury or
material damage.
Before carrying out any maintenance work on the external fan, disconnect it from the mains,
particularly before opening the terminal box. Make sure that the device cannot be switched
back on.
Servicing the external fan

The external fan is essentially maintenance-free. However, dirt and dust deposits on the
impeller and the motor, particularly in the gap between the impeller and the inlet nozzle can
impair its function.
● Remove the dirt and dust deposits regularly; the intervals depend on how dirty the
surrounding area is.
● Make sure that the impeller is evenly cleaned, as irregular deposits can lead to an
imbalance.
Note
Flowrate
The full flowrate is only achieved if the inward flow of air to the impeller is unrestricted.

Maintenance
Servicing the external fan motor

● Perform an occasional visual inspection of the external fan motor and check it electrically
and mechanically every time the roller bearings are replaced.
● Replace permanently lubricated roller bearings in the external fan motor as specified in the
operating instructions for the external fan motor.
9.1.7.9 Maintaining terminal boxes
Requirement
The machine is de-energized.
Checking the terminal box

● Terminal boxes must be regularly checked for tightness, undamaged insulation, and tight
terminal connections.
● If dust or humidity have infiltrated the terminal box, this should be cleaned and dried
(particularly the insulators).
Check all the seals and sealing surfaces and address the cause of the leakiness.
● Check the insulators, connectors and cable connections in the terminal box.
● Line entries inside the terminal box are part of the regular inspection in accordance with
IEC/EN 60079-17.
● Replace the damaged components if necessary.
WARNING
Short-circuit hazard
Short-circuits can occur as a result of damaged components that can lead to death, serious
Replace damaged components.
9.1.7.10 Touch up any damaged paintwork

If the paint is damaged, it must be repaired in order to protect the unit against corrosion.
Note
Paint system
Contact the Service Center before you repair any paint damage. They will provide you with
more information about the correct paint system and methods of repairing paint damage.

Maintenance
9.2 Repair
9.1.7.11 Repainting
WARNING
Repainting explosion-proof motors
The paint coat can become electrostatically charged where there is a thick coat. Electrostatic
discharges can occur. There is a risk of explosion if potentially explosive mixtures are also
present at this moment. This can result in death, serious injury or material damage.
You must comply with one of the following requirements when you repaint painted surfaces:
● Limit the total paint coating thickness according to the explosion protection group:
– IIB: Total paint coating thickness ≤ 2 mm
– IIC: Total paint coating thickness ≤ 0.75 mm for motors of group II (gas)
– III: Total paint coating thickness ≤ 0.45 mm for group III motors (dust)
According to tests, paint repair work up to the total paint coating thickness of the non-
conductive paint coating listed has also been examined and is harmless.
● Limit the surface resistance of the paint used:
– IIB, IIC, III: Surface resistance ≤ 1 GΩ for motors of groups II and III (gas and dust)
● Breakdown voltage ≤ 4 kV for explosion group III (dust only)
● Charge transfer limit:
– IIB: Limit value for the largest transferred charge < 30 nC
– IIC: Limit value for the largest transferred charge < 10 nC for group II motors (gas)
– III: Limit value for the largest transferred charge < 200 nC for group III motors (dust)
● Incapability, dangerous charge to be saved:
– IIB: Limit value for the maximum capacity ≤ 15 pF
– IIC: Limit value for the maximum capacity ≤ 5 pF for group II motors (gas)
– III: Limit value for the maximum capacity ≤ 10 pF for group III motors (dust)
See also
Machines without final paint coating (Page 27)
9.2 Repair

Maintenance
9.2 Repair
Note
If the motor has to be transported, please observe the information and instructions in the
"Transport" section.
Note
Service Center
Please contact the Service Center, if you require support with servicing, maintenance or repair.
9.2.1 Anti-condensation heating spare parts
WARNING
Risk of explosion
If repairs to the anti-condensation heating are not carried out correctly, e.g. if unauthorized
or untested spare parts are used, this can result in explosions during operation in a potentially
explosive gaseous atmosphere. This can result in death, serious injury or material
damage.
Repairing and mounting the anti-condensation heating and the subsequent routine testing
must always be undertaken by experts from the Service Center, because this work requires
extensive specialist knowledge. Only authorized and tested spare parts may be used.
9.2.2 Insulated roller bearings

If roller-contact bearings with an insulated design are installed, use roller bearings of the same
type as spare parts. This will prevent any bearing damage being caused by bearing currents.

Maintenance
9.2 Repair

Spare parts 10
10.1 Ordering data
When ordering spare parts, in addition to the precise designation of the spare part, specify the
motor type and the serial number of the motor. Ensure that the spare part designation matches
the designation in the spare part lists and add the associated part number.
Example:
Bearing shield, drive end (Part 105)
Machine type DNGW-315ML-04A
Serial numberLDX/30000001
The machine type and serial number can be found on the rating plate data and in the technical
data. The serial number is also stamped on the end face of the shaft extension at the drive
end.
10.2 Replacing roller bearings
Rolling-contact bearings
When ordering roller bearings, in addition to the bearing identification code, the supplementary
specifying code is also necessary for the bearing version. Both of these codes are stamped
on the lubricant plate and specified in the motor documentation, or can also be taken from the
installed bearings.
If roller-contact bearings with an insulated design are installed, use roller bearings of the same
type as spare parts. This will prevent any bearing damage being caused by bearing currents.

Spare parts
10.4 Anti-condensation heating spare parts
10.3 Using commercially available spare parts
WARNING
Risk of explosion
If you use parts other than the original spare parts, the type of protection can no longer be
guaranteed. This can result in an explosion during operation in a potentially explosive
gaseous atmosphere. This can result in death, serious injury or material damage.
● Use only original spare parts for explosion-proof machines; this also applies to
components such as seals, terminals, cables and cable entries. Should you have any
questions, please contact the Service Center .
● Commercially available equivalent standard parts such as screws may be used.
10.4 Anti-condensation heating spare parts
WARNING
Risk of explosion
If repairs to the anti-condensation heating are not carried out correctly, e.g. if unauthorized
or untested spare parts are used, this can result in explosions during operation in a potentially
explosive gaseous atmosphere. This can result in death, serious injury or material
damage.
Repairing and mounting the anti-condensation heating and the subsequent routine testing
must always be undertaken by experts from the Service Center (Page 117), because this
work requires extensive specialist knowledge. Only authorized and tested spare parts may
be used.

Spare parts
10.5 Spare parts list, frame sizes 071 to 132

,0%

,0%

Figure 10-1 D-DN000-0007
Parts Designation Parts Designation

Number Number
1.03 Stator laminated core with winding 4.18 Grease slinger
1.06 Stator frame 4.24 Gamma ring
2.00 Shaft with rotor 4.34 Spacer washers
2.01 Feather key 4.44 Gamma ring
3.01 End shield, drive end 5.10 Fan cover
3.08 Flange plate 5.11 Protective cover
3.21 End shield, non-drive end 5.56 Fan
4.01 Roller bearing, DE 6.00 Terminal box
4.05 Roller bearings, NDE

Spare parts

Spare parts

,0%

,0%

Figure 10-2 E-DN000-0008

Spare parts

Number Number
1.03 Stator laminated core with winding 4.24 Gamma ring
1.06 Stator frame 4.18 Grease slinger
1.10 Housing foot, right 4.24 Gamma ring
1.10 Housing foot, left 4.30 Outer grease chamber cover, NDE
2.00 Shaft with rotor 4.32 Inner grease chamber cover, NDE
2.01 Feather key 4.38 Grease slinger
3.01 End shield, drive end 4.44 Gamma ring
3.08 Flange plate 4.54 Grease nipple
3.21 End shield, non-drive end 4.54 Regreasing assembly
4.01 Roller bearing, DE 5.10 Fan cover
4.10 Outer grease chamber cover, DE 5.11 Protective cover
4.12 Inner grease chamber cover, DE 5.56 Fan
4.18 Grease slinger 6.00 Terminal box

Spare parts
10.7 Spare parts list, frame size 315

,0%

,0%

Figure 10-3 E-AN000-0009

Number Number
1.03 Stator laminated core with winding 4.18 Grease slinger DE
2.00 Rotor, complete (balanced) 4.24 Sealing ring DE, outer
2.01 Keyway 4.32 Grease chamber cover NDE, inner
3.01 Bearing shield DE 4.38 Outer grease chamber cover
3.08 Flange plate DE 4.44 Sealing ring NDE, outer
3.21 Bearing shield NDE 4.54 Relubrication NDE

Spare parts

Number Number
4.00 Bearing shield NDE 5.10 Complete fan cowl
4.01 Bearing DE 5.11 Protective cover
4.05 Bearing NDE 5.56 Fan, complete
4.12 Grease chamber cover DE, inner 6.00 Terminal box

,09%

,0%

Figure 10-4 E-DN000-0010

Spare parts

Number Number
2.00 Rotor, complete (balanced) 4.25 Compression spring
2.01 Keyway 4.30 Grease chamber cover NDE, outer
3.01 Bearing shield DE 4.32 Grease chamber cover NDE, inner
3.02 Flange bearing shield DE 4.35 Snap ring
3.08 Flange plate DE 4.38 Grease slinger NDE
3.21 Bearing shield NDE 4.44 Sealing ring NDE, outer
4.00 Grease nipple 5.01 Fan cowl, complete
4.01 Bearing DE 5.04 Fan hub NDE
4.05 Bearing NDE 5.11 Protective cover
4.10 Grease chamber cover DE, outer 5.56 Fan, complete
4.12 Grease chamber cover DE, inner 6.00 Terminal box
4.13 Grease slinger DE
4.24 Sealing ring DE, outer

Spare parts
10.9 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 071-160
10.9 Spare parts list for terminal boxes with type of protection "Ex e", frame
sizes 071-160

Figure 10-5 E-9-101_162-0002
Part num‐ Designation Part num‐ Designation

ber ber
6.03 Terminal box base 6.15 Complete terminal board
6.05 Terminal box cover 6.17 Additional terminal
6.13 Terminal box seal

Spare parts
10.10 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 071-160
10.10 Spare parts list for terminal boxes with type of protection "Ex d", frame
sizes 071-160

Figure 10-6 E-9-108_213-0001

ber ber
6.07 Gland plate

Spare parts
10.11 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 180-225
sizes 180-225

Figure 10-7 E-9-101_208-0002

ber ber
6.10 Gland plate

Spare parts
10.12 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 180-225
sizes 180-225

Figure 10-8 E-9-108_213-0002

ber ber
6.07 Gland plate

Spare parts
10.13 Spare parts list for terminal boxes with type of protection "Ex e", frame sizes 250 to 355
sizes 250 to 355

Figure 10-9 E-9-101_285-0002

ber ber
6.03 Terminal box base 6.15 Gland terminal
6.05 Terminal box cover 6.16 Complete terminal board
6.07 Gland plate 6.17 Additional terminal

Spare parts
10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355
sizes 250 to 355


Spare parts
10.14 Spare parts list for terminal boxes with type of protection "Ex d", frame sizes 250 to 355

ber ber
6.07 Gland plate

Disposal 11
11.1 Introduction
Protecting the environment and preserving its resources are corporate goals of the highest
priority for us. Our worldwide environmental management system to ISO 14001 ensures
compliance with legislation and sets high standards in this regard. Environmentally friendly
design, technical safety and health protection are always firm goals even at the product
development stage.
Recommendations for the environmentally friendly disposal of the machine and its components
are given in the following section. Be sure to comply with local disposal regulations.
11.2 Preparing for disassembly

Disassembly of the machine must be carried out and/or supervised by qualified personnel with
appropriate expert knowledge.
1. Contact a certified waste disposal organization in your vicinity. Clarify what is expected in
terms of the quality of dismantling the machine and provision of the components.
2. Follow the five safety rules (Page 13).
3. Disconnect all electrical connections and remove all cables.
4. Remove all liquids such as oil and cooling liquids. Collect the liquids separately and dispose
of them in a professional manner.
5. Detach the machine fixings.
6. Transport the machine to a suitable location for disassembly.
See also
Maintenance (Page 79)

Disposal
11.4 Disposal of components
11.3 Dismantling the machine

Dismantle the machine using the general procedures commonly used in mechanical
engineering.
WARNING
Machine parts can fall
The machine is made up of heavy parts. These parts are liable to fall during dismantling. This
can result in death, serious injury or material damage.
Before you release any machine parts, secure them so that they cannot fall.
Components
The machines consist mainly of steel and various proportions of copper and aluminum. Metals
are generally considered to be unlimitedly recyclable.
Sort the components for recycling according to whether they are:
● Iron and steel
● Aluminum
● Non-ferrous metal, e.g. windings
The winding insulation is incinerated during copper recycling.
● Insulating materials
● Cables and wires
● Electronic waste
Process materials and chemicals

Sort the process materials and chemicals for recycling according to whether they are for
example:
● Oil
● Grease
● Cleaning substances and solvents
● Paint residues
● Anti-corrosion agent
● Coolant additives such as inhibitors, antifreeze or biocides
Dispose of the separated components according to local regulations or via a specialist disposal
company. The same applies for cloths and cleaning substances which have been used while
working on the machine.

Disposal
Packaging material
● If necessary, contact a suitable specialist disposal company.
● Wooden packaging for sea transport consists of impregnated wood. Observe the local
regulations.
● The foil used for water-proof packaging is an aluminum composite foil. It can be recycled
thermally. Dirty foil must be disposed of via waste incineration.

Disposal

Service and Support A
A.1 Siemens Industry Online Support
Details regarding the design of this electrical machine and the permissible operating conditions
are described in these instructions.
On-site service and spare parts

If you wish to request local service or order spare parts, please contact your local Siemens
sales office. This office will contact the responsible service center on your behalf.
Technical queries or additional information

If you have any technical queries or you require additional information, please contact the
Siemens Service Center.
Please have the following machine data ready:
● Machine type
● Machine number
You can find this data on the rating plate of the machine.
Contact at Central Technical Support for our customers in Germany
+49 911 895 7222

+49 911 895 7223
support.automation@siemens.com (mailto:support.automation@siemens.com)
Outside Germany, you can find your contact partners here:
http://support.automation.siemens.com/WW/view/de/16604999 (http://
support.automation.siemens.com/WW/view/en/16604999)
You can also call the following numbers directly during local working hours to reach a contact
partner who speaks the corresponding national language.
Americas
+1 423 262 5710

+1 423 262 2231
support.america.automation@siemens.com
(mailto:support.america.automation@siemens.com)

Service and Support
A.2 RoHS - restricting the use of certain hazardous substances
Asia/Pacific
+86 10 6475 7575

+86 10 6474 7474
support.asia.automation@siemens.com
(mailto:support.asia.automation@siemens.com)
See also
http://www.siemens.com/automation/support-request (http://www.siemens.de/automation/
support-request)
A.2 RoHS - restricting the use of certain hazardous substances

In compliance with RoHS ("Restriction of certain Hazardous Substances" ) we replace
substances that are damaging to the environment by those that are not based on state-of-the-
art technology. In doing so, safety in operation and handling will take priority at all times.

Technical data and drawings B
B.1 Tightening torques for screw and bolt connections
Bolt locking devices
● Refit nuts or bolts that are mounted together with locking, resilient, and/or force-distributing
elements with identical, fully-functional elements when re-assembling. Always renew keyed
elements.
● When screwing together threads secured with a liquid adhesive, use a suitable medium
such as Loctite 243.
Tightening torques
The bolted connections with metal contact surfaces, such as end shields, bearing cartridge
parts, terminal box parts bolted onto the stator frame, should be tightened to the following
torques, depending on the thread size:
Table B-1 Tightening torques for bolted connections with a tolerance of ±10%.
Case M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 M42 M48 M56
A 1.2 2.5 4 8 13 20 40 52 80 150 - - - - Nm
B 1.3 2.6 4.5 11 22 38 92 180 310 620 108 170 260 420 Nm
0 0 0 0
C 3 5 8 20 40 70 170 340 600 120 200 310 470 750 Nm
0 0 0 0 0
Applications
The above-mentioned tightening torques apply for the following applications:
● Case A
Applies to electrical connections in which the permissible torque is normally limited by the
bolt materials and/or the current carrying capacity of the insulators, with the exception of
the busbar connections in case B.
● Case B
Applies to bolts screwed into components made from materials with lower property class
(e. g. aluminum) and to bolts with property class 8.8 according to ISO 898-1.
● Case C
Applies to bolts with property class 8.8 or A4-70 according to ISO 898-1, however only to
bolts screwed into components made from materials with higher property class, e.g. cast
iron, steel or cast steel.
Note
Non-standard tightening torques
Different tightening torques for electrical connections and bolted connections for parts with
flat seals or insulating parts are specified in the relevant sections and drawings.

Technical data and drawings
B.1 Tightening torques for screw and bolt connections

Quality documents C
C.1 IECEx certificate
If available, you can obtain the IECEx certificate on the Internet at the following address:
Http://iecex.iec.ch/iecex/iecexweb.nsf/home?openform
TheIECEx ID for the IECEx certificate can be found on the rating plate of the machine or on
the extra plate for explosion protection.
1. Enter the IECEx ID in the "Quick access" field.
You then have access to the certificate.
2. If you scroll down completely to the bottom of the page shown, you can open the certificate
as a PDF file and download it.

Quality documents
C.2 EC Declaration of Conformity

Quality documents
Anlage zur EG Konformitätserklärung

Druckfeste Kapselung „d”
Appendix to EC Declaration of Conformity
Flameproof Enclosure “d”
Gerät EG-Baumusterprüf- Gasgruppe Temperatur-

Equipment bescheinigung gas group klasse
Typ Alternativer Typ Lagerung EC-Type Examination temperature
IIB IIC
type alternative type bearing Certificate class
PTB 10 ATEX 1007 X x T3 - T6
1PS*07*-*****-****
D***-071**-** anti-friction BVS 11 ATEX E 053 X x x T3 - T6
1MD*07*-*****-****
BVS 13 ATEX E 129 X x x T3 - T6
PTB 09 ATEX 1091 X x T3 - T6
1PS*08*-*****-****
1MD*08*-*****-****
PTB 08 ATEX 1021 X x T3 - T6
1PS*09*-*****-****
1MD*09*-*****-****
_ BVS 13 ATEX E 098 X x x T3 - T6
PTB 09 ATEX 1087 X x T3 - T6
1PS*10*-*****-****
1MD*10*-*****-****
PTB 08 ATEX 1123 X x T3 - T6
1PS*11*-*****-****
1MD*11*-*****-****
PTB 08 ATEX 1119 X x T3 - T6
1PS*13*-*****-****
1MD*13*-*****-****
PTB 08 ATEX 1103 X x T3 - T6
1PS*16*-*****-****
1MD*16*-*****-****
PTB 09 ATEX 1044 X x T3 - T6
1PS*18*-*****-****
1MD*18*-*****-****
PTB 08 ATEX 1054 X x T3 - T6
1PS*20*-*****-****
1MD*20*-*****-****
PTB 08 ATEX 1107 X x T3 - T6
1PS*22*-*****-****
1MD*22*-*****-****
PTB 09 ATEX 1046 X x T3 - T6
1PS*25*-*****-****
1MD*25*-*****-****
PTB 09 ATEX 1070 X x T3 - T6
1PS*28*-*****-****
1MD*28*-*****-****
PTB 08 ATEX 1037 X x T3 - T6
1PS*31*-*****-****
1MD*31*-*****-****
DJS*-315**-** 1PS*31*-*****-**** anti-friction BVS 12 ATEX E 077 X x x T3 - T6
Rev. AS-1
Seite 2 von 3

Quality documents

Druckfeste Kapselung „d”
Flameproof Enclosure “d”
Gerät EG-Baumusterprüf- Gasgruppe Temperatur-

Equipment bescheinigung gas group klasse
Typ Alternativer Typ Lagerung EC-Type Examination temperature
IIB IIC
type alternative type bearing Certificate class
PTB 08 ATEX 1077 X x T3 - T6
1PS*35*-*****-**** PTB 08 ATEX 1078 X x T3 - T6
D***-355**-** 1MD*35*-*****-**** anti-friction PTB 08 ATEX 1079 X x T3 - T6
1MV*35*-*****-**** BVS 11 ATEX E 003 X x x T3 - T6
PTB 07 ATEX 1060 X x T3 - T6
1PS*40*-*****-****
D***-400**-** anti-friction PTB 07 ATEX 1047 X x T3 - T6
1MV*40*-*****-****
_ D*T*-400**-** 1PS440*-*****-****
sleeve BVS 11 ATEX E 029 X x T3 - T6
D*V*-400**-** 1MV440*-*****-****
1PS*45*-*****-**** PTB 07 ATEX 1068 X x T3 - T6
D***-450**-** anti-friction
1MV*45*-*****-**** BVS 11 ATEX E 084 X x x T3 - T6
D*T*-450**-** 1PS445*-*****-****
sleeve BVS 11 ATEX E 067 X x T3 - T6
D*V*-450**-** 1MV445*-*****-****
1PS*50*-*****-**** PTB 08 ATEX 1035 X x T3 - T6
1MV*50*-*****-**** PTB 08 ATEX 1036 X x T3 - T6
D*T*-500**-** 1PS450*-*****-**** PTB 07 ATEX 1074 X x T3 - T6
sleeve
D*V*-500**-** 1MV450*-*****-**** BVS 10 ATEX E 142 X x T3 - T6
1PS*50*-*****-****
D*W*-500**-** anti-friction BVS 09 ATEX E 159 X x x T3 - T6
1MV*50*-*****-****
1PS*56*-*****-**** PTB 07 ATEX 1042 X x T3 - T6
1MV*56*-*****-**** PTB 07 ATEX 1043 X x T3 - T6
D*T*-560**-** 1PS456*-*****-**** PTB 07 ATEX 1046 X x T3 - T6
sleeve
D*V*-560**-** 1MV456*-*****-**** BVS 12 ATEX E 092 X x T3 - T6
1PS*63*-*****-**** PTB 06 ATEX 1028 X x T3 - T6
1MV*63*-*****-**** PTB 06 ATEX 1022 X x T3 - T6
D*T*-630**-** 1PS463*-*****-****
sleeve PTB 07 ATEX 1075 X x T3 - T6
D*V*-630**-** 1MV463*-*****-****
1PS471*-*****-**** anti-friction PTB 09 ATEX 1009 X x T3 - T6
D***-710**-**
1MV471*-*****-**** sleeve BVS 13 ATEX E 045 X x T3 - T6
1PS*80*-*****-**** PTB 09 ATEX 1078 X x T3 - T6
1MV*80*-*****-**** BVS 11 ATEX E 170 X x T3 - T6
1PS480*-*****-****
D*Q*-800**-** sleeve PTB 06 ATEX 1049 X x T3 - T6
1MV480*-*****-****
1PS491*-*****-****
D*Q*-910**-** sleeve BVS 10 ATEX E 103 X x T3 - T6
1MV491*-*****-****
Rev. AS-2
Seite 3 von 3

Quality documents
C.3 EC Declaration of Conformity, Zone 21 or 22

Quality documents
Industry

Geräte-Staubexplosionsschutz durch Gehäuse "tb"
Equipment dust ignition protection by enclosure "tb"
Gerät EG-Baumusterprüf- Gerät EG-Baumusterprüf-

Equipment bescheinigung Equipment bescheinigung
Typ Alternativer Typ EC-Type Examination Typ Alternativer Typ EC-Type Examination
type alternative type Certificate type alternative type Certificate
A***-071**-** BVS 11 ATEX E 006 A***-280**-** BVS 11 ATEX E 125
1PS*07*-*****-**** 1PS*28*-*****-****
E***-071**-** BVS 14 ATEX E 101 E***-280**-** BVS 12 ATEX E 113
1PS*07*-*****-**** BVS 11 ATEX E 053 X 1PS*28*-*****-**** BVS 11 ATEX E 051 X
D***-071**-** D***-280**-**
1MD*07*-*****-**** BVS 13 ATEX E 129 X 1MD*28*-*****-**** BVS 12 ATEX E 029 X
A***-080**-** BVS 11 ATEX E 014 A***-315**-**
1PS*08*-*****-**** 1PS*31*-*****-**** BVS 11 ATEX E 123
E***-080**-** BVS 14 ATEX E 092 E***-315**-**
D***-080**-** D***-315**-**
1MD*08*-*****-**** BVS 13 ATEX E 128 X 1MD*31*-*****-**** BVS 12 ATEX E 051 X
A***-090**-** BVS 11 ATEX E 092 A***-355**-** 1PS*35*-*****-****
1PS*09*-*****-**** BVS 10 ATEX E 077
E***-090**-** BVS 14 ATEX E 089 E***-355**-** 1MV*35*-*****-****
D***-090**-**
1MD*09*-*****-**** BVS 13 ATEX E 098 X D***-355**-** 1MD*35*-*****-****
A***-100**-** BVS 11 ATEX E 105 1MV*35*-*****-**** BVS 13 ATEX E 120 X
1PS*10*-*****-****
E***-100**-** BVS 14 ATEX E 079 A***-400**-** 1PS*40*-*****-****
1PS*10*-*****-**** BVS 10 ATEX E 155 X BVS 10 ATEX E 078
D***-100**-** E***-400**-** 1MV*40*-*****-****
1MD*10*-*****-**** BVS 13 ATEX E 127 X 1PS*40*-*****-****
A***-112**-** BVS 11 ATEX E 112 D***-400**-** BVS 11 ATEX E 162 X
1PS*11*-*****-**** 1MV*40*-*****-****
E***-112**-** BVS 14 ATEX E 070 1PS*45*-*****-****
D***-450**-** BVS 11 ATEX E 084 X
1PS*11*-*****-**** BVS 10 ATEX E 159 X 1MV*45*-*****-****
D***-112**-**
1MD*11*-*****-**** BVS 13 ATEX E 126 X A***-500**-** 1PS*50*-*****-****
BVS 13 ATEX E 114
A***-132**-** BVS 11 ATEX E 118 E***-500**-** 1MV*50*-*****-****
1PS*13*-*****-****
E***-132**-** BVS 14 ATEX E 053
1PS*13*-*****-**** BVS 10 ATEX E 123 X Rev. AQ-1
D***-132**-**
1MD*13*-*****-**** BVS 13 ATEX E 099 X
A***-160**-** BVS 11 ATEX E 126
1PS*16*-*****-****
E***-160**-** BVS 13 ATEX E 086
1PS*16*-*****-**** BVS 11 ATEX E 012 X
D***-160**-**
1MD*16*-*****-**** BVS 13 ATEX E 019 X
A***-180**-** BVS 11 ATEX E 010
1PS*18*-*****-****
E***-180**-** BVS 13 ATEX E 077
1PS*18*-*****-**** BVS 11 ATEX E 047 X
D***-180**-**
1MD*18*-*****-**** BVS 13 ATEX E 017 X
A***-200**-** BVS 11 ATEX E 005
1PS*20*-*****-****
E***-200**-** BVS 13 ATEX E 056
1PS*20*-*****-**** BVS 11 ATEX E 020 X
D***-200**-**
1MD*20*-*****-**** BVS 13 ATEX E 012 X
A***-225**-** BVS 11 ATEX E 017
1PS*22*-*****-****
E***-225**-** BVS 13 ATEX E 095
1PS*22*-*****-**** BVS 11 ATEX E 046 X
D***-225**-**
1MD*22*-*****-**** BVS 12 ATEX E 103 X
A***-250**-** BVS 11 ATEX E 034
1PS*25*-*****-****
E***-250**-** BVS 12 ATEX E 109
1PS*25*-*****-**** BVS 11 ATEX E 030 X
D***-250**-**
1MD*25*-*****-**** BVS 11 ATEX E 045 X
Seite 2 von 2

Quality documents

Quality documents
C.4 Data
C.4 Data
Siemens Aktiengesellschaft
R-No. 20000h Postfach 1164

D-94095 Ruhstorf SIEMENS
INVERTER OPERATION OF EXPLOSION-PROTECTED LOW VOLTAGE THREE-PHASE MOTORS IN
PROTECTION TYPE FLAMEPROOF ENCLOSURE AND PROTECTION TYPE N (NON-SPARKINGl FOR THE
TEMPERATURE CLASSES TI-T4
Inverter operation of explosion-protected motors is allowed, when the following requirements are met:
I. The output voltage of the inverter is to be adjusted in such a way that in the frequency range up to the rated frequency
of the motor an almost linear relationship between the (fundamental) voltage and the (fundamental) frequency is kept,
i.e. the practically constant motor tlux must be kept in accordance with the rated data.
Motors operating above the 1. 1 fold rated frequency are only permitted if a corresponding rating plate for inverter
operation is fixed on the motor.
2. IcOflti'l. is the value to which the inverter management limits the current in continuous duty.
Icontin. is to be adjusted to the continually pennitted motor rated current as a maximum in accordance with the rating plate
for inverter operation attached to the motor or in conformity with the value detennined in the describing documents for
inverter operation (R-No.).
3. l'hO<l is the value to which the inverter management limits the eurrent in case of a short-time overload for a period of
max. tshon-
Ishon is to be adjusted to 1.5 x Icontin. at a maximum.
4. tshort is the period for which the inverter allows an exceeding of lcontin..
tshon is to be adjusted to 60 s at a maximum.
5. The built-in temperature sensors (PTC thermistors) which must be suitable for sole protection are to be connected to a
tripping device provided with the EC type examination certificate, like e.g. CK140: PTB 04 ATEX 3038 or CKI44/145:
PTB 02 ATEX 3059, according to Directive 94/9/EC.
6 . Voltage peaks (especially for PWM inverters with long motor cable)
a) The design of the terminal box conceming the air and creepage distances allows the inverter operation with
voltage peaks (OLL �Maximum value of the conductor-to-conductor voltage and OLE Maximum value ofthe �
line-to-earth voltage) up to 0 � 1866 V which is not allowed to be exceeded for explosion protection reasons.
b) To avoid the formation of partial discharges it is required for Ex nA machines that the voltage at the motor terminals
is limited, depending on the rise time to values which are below the characteristic curve of the chart "Dielectric
strength curve" (see diagram below). In order not to limit the service life this is recommended for Ex d motors.
Ruhstorf, 20 12-09-10 Siemens Aktiengesellschaft
$pUn".,Ilr.. Ughlll��'u:
"00 �� --� -��--

C�. : :- :�:-:---
-: --
, :
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;.v,
Dr. Klaus Neupert
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t.;
K ·
'(Lw," -
ofbauer
,_ ····+·+·· �·· 1··+·+··; ..·j..·;··.;.··.(.··�··-; ., ·t ·t---l----:--·,· , - ,...� -:-

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·;·· ·· L·
>Ci. " .,... i... ,' . . i'.. i . ,.. ' .., ... j... i ...i . ' .i . "
;,-· "" i , ... , -+- . I
:: n>' ; " . . . . .... . . .
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::: ::::;1'y. + ; ···;·""· ·H···;··,;,,·, ···, ·· ·:·""H· '· ·;···; , -'. :..+ ,...;'..;...'..+..;..! . . ..
,
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� : :-i::::::::::::::r:::::::::,:::::::::::: :: :i ::t: : ;: !: r:: "L:·::: :;::':;::;::r:j::: j
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. . . . .. . . ..• .. ... .. . . . ... ..
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J:\LGR08\QM\QME\PrOffeld\FORM\r·nr\r·nr.20000h_EN.doc

Index
A D
Aligning, 47, 48 Damage during transportation, 31
Prerequisites, 45 Damping cores, 40
Alternative types of grease, 90 Delivery, 31
Aluminum conductors, 62 Direction of rotation, 58
Anti-condensation heating, 28, 72, 73 Disassembly
Insulation resistance, 69 Disposal, 113
Mounting, 95, 98 Disposal
Repairs, 95, 98 Chemicals, 114
Anti-freeze protection, 74 Components, 114
Applications, 21
Axial force, 52
Axial gap, 48 E
Electrical faults, 76
Electromagnetic compatibility, 18
B Electromagnetic fields, 19
Balance quality, 50 Emergency off, 73
Bearing currents Emitted interference, 19
Reduction, 39 Equipotential, 63
Bearing insulation, 40 Equipotential bonding conductor, 39
Bolt grade, 83 ESD guidelines, 17
Bolt locking device, 119 Ex marking, 22
Exceeding the tolerances, 29
Explosion hazard, 22, 85
C Bridging the insulated bearing, 72
electrostatic discharge, 17
Cable entries, 57
External fan, 25, 28
certified, 59
Maintenance, 92
Center of gravity, 32, 46
turning off, 73
Centering flange, 48
Checks to be carried out prior to commissioning, 65
Circuit diagram, 58
Common-mode filters, 40
F
Connecting cables faults
Selection of, 55 Mechanical, 76
Connection, 52 Faults, 71
Contacts, 117 Cooling system, 78
Converter documentation, 40 Electric, 76
Cooling system Inspection, 75, 81
faults, 78 Roller bearings, 77
Cooling water supply, 53 Feather key, 52
Correct usage, 24 Filling, 53
Corrective maintenance Filter, 53
Initial inspection, 82 Five safety rules, 13
Corrosion protection, 74 Flammable substances, 15
Cross-section of the grounding conductor, 57
Current transformer, 72

Index
Machine design, 24
IEC, 23
G Machine expansion, 48
Machine marking, 91
General inspection, 82
Maintenance
Grease caps, 34
Maintenance intervals, 79
Grease quantity, 87
Mechanical faults, 76
Grease service life, 87
Minimum air clearances, 59
Grease types, 89
More information, 117
Grounding system
Mounting parts, 44
Meshed, 40
Mounting-foot hole dimensions, 45
H
N
Hazardous substances, 15
Noise emissions, 16, 29
Hearing damage, 16, 29
Hot surfaces, 15
Hybrid mixtures, 22
O
Operating mode, 27
I O-ring seals, 62
Output element, 51
IECEx certificate, 121
Overspeeds, 27
Ignition hazard, 16
Inspection
Faults, 75, 81
Installation
P
Initial inspection, 82 Paint finish, 25
Insulated bearings, 40, 72 Paint system, 93
Insulated coupling, 41 Paintwork damage, 93
Insulation resistance, 36, 67, 85 Permanent lubrication, 87
Anti-condensation heating, 69 Polarization index, 36, 67, 69, 85
measure, 67 Positioning, 48
Interference immunity, 18 Precision alignment, 48
Interference voltages, 18 Preparations for assembly, 44
Interlocking circuit Pressure load, 53
Anti-condensation heating, 28 Pressure relief device, 63
External fan, 28
Intrinsically safe circuits, 56
Q
Qualified personnel, 14
L
Lifting eye, 31, 32, 46
Limit speed, 66 R
Local service, 117
Radial force, 52
Lubricant plate, 88
Rating plate, 24
Re-commissioning, 75
Regreasing, 89
M Regreasing interval, 87
Machine Regreasing interval, 88
Aligning to the driven machine, 48 Regreasing system, 36, 37
setting down, 47 Repainting, 94

Index
Residual risks, 27 Terminal box

Restriction of certain Hazardous Substances, 118 close, 63
RF grounding point, 39 Maintaining, 93
Risk of explosion, 34, 95, 98 Terminal designation, 58
Bearing temperature, 81 Test pressure, 53
Cleaning with compressed air, 81 Thermal motor protection, 28
Layer of dust, 81 Tightening torques, 55
Spare parts, 98 Bolted connection, 119
RoHS, 118 Standard cable glands, 61
Roller bearings Transporting, 32, 46
faults, 77 Turning the machine on to its side, 49
Rolling-contact bearing Type of balancing, 50
Replacement, 97 Type of protection, 57, 98
Rolling-contact bearings Type of protection Ex t, 24
Inspection, 83
Rotating components, 15
Rotor shipping brace, 33, 49 U
Remove, 49
Undrilled entry plate, 57
S V
Safety instructions
Vibration values, 30
Flammable substances, 15
Voltage via the converter, 41
Hazardous substances, 15
Hot surfaces, 15
Live parts, 14
Maintenance work, 79
W
Rotating components, 15 Wall faces, 45
Sealing plug Wall mounting, 45
certified, 59 Water connection, 52
Service Center, 117
Setting down, 47
Spare parts, 98, 117
Spare parts ordering, 97
Standard cable glands, 61
Standard flange, 48
Stoppages, 73, 74
Roller bearings, 74
Storage, 34
Switching off, 73
Switching on, 73
System resonances, 30
System-inherent frequencies, 30
T
Tandem operation, 41
Temperature class, 72, 74
Temperature limits, 34
Terminal board, 60

Index

AE EC-Declaration of Conformity (U161)
AD EC-Declaration of Conformity (U163)
AA R-No.20000h (U165)
Siemens AG
Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
www.siemens.com/drives
Abnahmeprüfzeugnis
Inspection Certificate
acc. EN 10204 - 3.1
Typ/ Type DNGW-315MN-02A Masch.-Nr/Motor No.: LDX/30005643

Bauform/ Mounting : IM B3 Auftr.Nr./ Order No.: 8940580
Leistung/ Output : 115 kW cos phi/ Power factor: 0,88
Spannung/ voltage : 440 V D Frequenz/ frequency: 50 Hz
Strom/ current : 178 A Drehzahl/ Speed: 2980 1/min/rpm
Iso. Kl./ Insul. class: F-B Betriebsart/ Duty: S1
Schutzart/ Class of protection : IP 65 Kühlmitteltemp./ -20/+55 °C
Vorschriften/ Rules: EN 60034-1 EN 60079 Ambient temp.:
Ex Schutz/ Ex protection: Heizung/Heater: 210-250V/100W

BVS 12 ATEX E 051 X II 2G Ex de IIC T4 Gb
Messergebnisse/ Results
Leerlauf/ No Load: Kurzschluss/Locked rotor:
2 -polig/pole 440 V D 45,7 A 4334 W 3000 1/min/ rpm 111 V D 301 A
Widerstände/ Resistanceb 2 -polig/ pole 0,018 0,018 0,018 Ohm Schaltung/ connection D
bei 20 °C / at 20°C
Bemerkung/ remark: SPM AS/DE: 9 dBN SPM BS/NDE: 10 dBN
Schleuderprobe/ Overspeed test: 3600 1/min/ rpm für/ for:2min
Hochspannungsprüfung/ High voltage test (50Hz) Schwingungsmessung/ Vibration test:
Spannung Dauer Isol.Widerstand A 0,40 mm/s D 0,50 mm/s

voltage duration Insu.resistance B 0,60 mm/s E 0,70 mm/s
Stator 2000 V 60 s >500 MOhm C 0,40 mm/s
Rotor V s MOhm E D
Heizung/Heater 1500 V 60 s >500 MOhm
KL/ PTC 1500 V 60 s >500 MOhm
PT100 Wicklg./ Windg. V s MOhm C
PT100 Lager/ Bearing V s MOhm

LOHER
Lagerisol./ Bearing ins V s MOhm
FB/ forced ventilat. V s MOhm A
Ruhstorf, 21.04.2016
QA-Dept
QM 1 Hofmann
Dieses Dokument wurde maschinell erstellt und ist ohne Unterschrift gültig/This document has been produced automatically and is valid without signature
9.5 Minimum Flow System

Datasheet Schroedahl TDM086UVWAW-CS
Flow diagram UA4 30281 01 EN
Datasheet
Dimensional drawing
General drawing
Parts list
Installation and Maintenance Instructions for Type TDM with start-up branch
EC Declaration
EC Conformity Declaration

Baureihe_HG Datum_
Werk-Nr._
Date 21.01.2016 Pump: HGM 2/9
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
Minimum Flow Control Valve

The minimum flow valve protects the pump against overheating during operation in the low load range.
Increased wear on the pump and the minimum flow system is not avoidable.
If the installation's mode of operation requires low load, at flow rates below 1.35 x Qmin (e.g. operation at
extremely low flow, filling of the boiler, stand-by heating and minimum flow rate, etc.), notification thereof
shall be given. In this case, a minimum flow valve with branch for manual operation must be used.
The characteristics of the boiler control valve can influence the behaviour of the minimum flow valve, and
the valve must be suitable for low flow operation.
2 Minimum flow control valve
Manufacturer: SCHROEDAHL
Type series: TDM AA Scheme No. UA430281
Inlet branch DN 2 in class 600

Outlet branch DN 2 in class 600
Bypass DN 1 in class 600
Hand-operated branch DN 1 in class 600
including screws/bolts and seal elements for the connection pump – minimum flow control valve
Date 21.01.2016 Pump: HGM 2/9
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
MINDESTFÖRDERSTROMVENTIL
MINIMUM FLOW DEVICE
Blende zur Vermeidung der Ver
dampfung in der Leitung. So
nahe wie möglich am Zulaufbe
hälter.
Orifice to prevent evaporation
in the line. Located as close as
possible to the feed water
tank.
∆= 2.5 bar
p
∆
p = 36.25 psi
Handfahrleitung
Manually operated line
Zulaufbehälter
Feed water tank
Mindestförderstrom zum Zulaufbehälter

Minimum flow outlet to feed water tank
B
A
AB nur bei Mindestförderstromventil

SMA63
B A B only for minimum flow valve
A SMA63
B
A
Absperrventil, geschweißt
Stop valve, welded
Rückschlagventil, geschweißt
Non-return valve, welded
Blende
Orifice
Flanschverbindung
Flange connection
B Liefergrenze, A = KSB, B = Kunde

A Limits of scope of supply, A = KSB, B = Customer
BENENNUNG/DENOMINATION
Fließschema
Flow Diagram
04 neues Original 02.04.13 Stahl
NR./NO. BLATT-NR.
INDEX
ÄNDERUNG DATUM NAME SHEET-NO.

ALTERATION DATE
UA4 30281 01 EN
NORM 1
STANDARD
SCHUTZVERMERK ISO 16016 ANZ. D.
GEPRÜFT BLÄTTER
APPROVED 02.04.13 Meyer COPYRIGHT ACCORDING TO ISO 16016
NO. OF
BEARB. SHEETS
ERS. FÜR/REPL. FOR ENTST. AUS/ORIGINAT. FROM
PREPARED 02.04.13 Stahl
DATUM NAME
T-MP132-G DATE 1
Datasheet Page 1
SA.TD.058311 from 1
Rev.0
Customer KSB Aktiengesellschaft Order K16-0109.1

Order No 001/4503368202/9973105255 prev. Order No
Certificates PED97/23 EC_EN10204-3.1 Quantity 1.00
Project ENGRO
Pump protection valve TDM086UVWAW-CS

Valve Design
Connect. nom. Size Press. acc. Schedule Surface Installation P - R
P Inlet 2" 600lbs ASME B16.5 80 RF
R
B
Outlet
Bypass
2"
1"
600lbs
600lbs
ASME B16.5
ASME B16.5
80
80
RF
RF
V
A Startup 1" 600lbs ASME B16.5 80 RF unterhalb TD-AU
Painting customer specification

Material / Medium / Design Data
Body Check Valve Internals nuts/bolts Seals
A105 1.4404 SS; Cr>13% 1.7709 EPDM-01
Medium Boiler Feed Water Design Temp. 120.00 [°C]
S.G. 0.9550 Design Press.
Remark:
Painting acc. ZN35-4 ES1N B

RAL5002
Operating Data
Work Case RPM Flow Rate Pressure Suction Press. Back Pressure Diff. Pressure Temperature S.G. Kv
1/min m³/h m bar g bar g bar °C -

QM 11.25 717.20 1.34 2.84 65.67 105.00 0.9550 1.3567
Q100 24.10 698.00 1.34 105.00 0.9550
QA 11.25 717.20 1.34 2.84 65.67 105.00 0.9550 1.3567
Q0 0.00 719.90 1.34 105.00 0.9550
Revision Date Description Name

0 Jan 28, 2016 Prepared MARTINA.BECKER
SCHROEDAHL GmbH
A subsidiary of CIRCOR international
Alte Schönenbacher Str. 4 · 51580 Reichshof-Mittelagger
Telefon +49 2265 9927-0 · Telefax +49 2265 9927-927
eMail: schroedahl@circor.com · www.schroedahl.com
Pump Protection Valve
TDM086UVWAW-CS
P = Pump End L = 300.0 mm
R = Pipeline End S = 193.0 mm
B = By-Pass End H = 110.0 mm
A = Startup End
Installation P-R: Vertical
NPS 2" - CLASS 600lbs - Sched. 80 / RF

Order K16-0109/SA.TD.058311
PO No. 001/4503368202/9973105255
Project: ENGRO
Quantity: 1.0
Weight 48.0 kg
TAG-No:
d:\applus\pdf\as.pdf
SCHROEDAHL-Arapp Spezial-Armaturen GmbH & Co KG

Schönenbacher Str. 4 - D-51580 Reichshof-Mittelagger
Telefon + 49-2265-9927-0 - Telefax + 49-2265-9927-27
Internet: www.schroedahl.de email: info@schroedahl.de
P = Pump End
R = Pipeline End
B = By-Pass End
A = Startup End
Installation P-R:
Vertical
L = 300.0 mm
S = 193.0 mm
H = 110.0 mm
Weight: 48.0 kg
PO No.:
001/4503368202/9973105255
Project:
ENGRO
TAG-No:

Subject to change without prior notice!
scale com-no. K16-0109.1

All rights reserved! general tolerance
Materials Quantity: 1.0
ISO 2768 - m
Date Name
Gepr.
Pump Protection Valve
TDM086UVWAW-CS
d:\applus\pdf\TDMCkAu.pdf
Edited
Bl
SCHROEDAHL GmbH 4TDM086UVWAW-CS-00 Fro
I1 = technical layout after design layout Zust Change Name Date D-51580 Reichshof-Mittelagger
m
Item List K16-0109.1 / TDM086UVWAW-CS
Item Qty Name Material near. ASTM Mat Desc.
01 1.0 LOWER BODY A105 C22.8N
02 1.0 UPPER BODY A105 C22.8N
03 2.0 STEMGUIDE 1.4408 A351 CF8M G-X6CrNiMo 18 10
04 1.0 GUIDE BOLT 1.4021 A276 (420) X20Cr 13
06 1.0 SPRING 1.4310 AISI 302 X12CrNi17 7
07 1.0 HD-CHECK VALVE 1.4404 A182-F316L X2CrNiMo 17 13 2
08 1.0 LINER 1.4300 ~A304 X12CrNi 18 8
09 1.0 BYPASS-BRANCH A105 C22.8N
10 1.0 VORTEX BUSHING 1.4122 ~AISI 420 X39CrMo 17-1
11 1.0 CONTROL HEAD 1.4122 ~AISI 420 X39CrMo 17-1
12 1.0 VORTEX PLUG 1.4122 ~AISI 420 X39CrMo 17-1
13 1.0 LEVER 1.4313 A182 F6NM X5CrNi 13 4
14 1.0 PIVOT PIN 1.4021 A276 (420) X20Cr 13
15 1.0 BUSHING 1.4122 ~AISI 420 X39CrMo 17-1
16 1.0 BALANCE BOLT 1.4122 ~AISI 420 X39CrMo 17-1
19 1.0 HOLDER 1.4122 ~AISI 420 X39CrMo 17-1
20 1.0 SPLINT 1.4300 ~A304 X12CrNi 18 8
21 1.0 THREAD RING 1.4122 ~AISI 420 X39CrMo 17-1
23 1.0 NOZZLE 1.4122 ~AISI 420 X39CrMo 17-1
23.1 1.0 NOZZLE 1.4122 ~AISI 420 X39CrMo 17-1
25 1.0 GUIDE A2 A2
26 16.0 SCREW 1.7709 A193 B16 21CrMoV 5 7
27 4.0 SCREW 1.7709 A193 B16 21CrMoV 5 7
27.1 4.0 SCREW 1.7709 A193 B16 21CrMoV 5 7
28 16.0 HEXAGON NUT 1.7218 ~AISI 4130 25CrMo 4
29 4.0 HEXAGON NUT 1.7218 ~AISI 4130 25CrMo 4
29.1 4.0 HEXAGON NUT 1.7218 ~AISI 4130 25CrMo 4
30 1.0 O Ring EPDM-01
31.1 2.0 O Ring EPDM-01
32.1 1.0 O Ring EPDM-01
33.1 1.0 GLYD-RING PTFE/CARBON
36.1 1.0 O Ring EPDM-01
Order K16-0109.1 PO No.: 001/4503368202/9973105255
Project: ENGRO
TAG No:
Weight [kg]: 48.0 Quantity: 1.0
SCHROEDAHL GmbH
Alte Schönenbacher Str. 4 - 51580 Reichshof-Mittelagger
Telefon +49-2265-9927-0 - Telefax +49-2265-9927-927
Internet: www.schroedahl.de email: schroedahl@circor.com
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TDM A/E 1 15
Installation and Maintenance

Instructions
for Type TDM
with start-up branch
Com.-No. :
Plant :
Order-No. :
Rev. Page Name Instruction
Depart Date/Firm Maintenance-Dep. Date

Verkauf 20.08./Gösselkeheld
Schroedahl-Arapp Spezial-Armaturen GmbH & Co KG - Postfach 10 08 44 - D-51608 Gummersbach

Hausanschrift: Schönenbacher Str. 4 - 51580 Reichshof - Mittelagger
Telefon (02265) 99 27 -0 - Telefax (02265) 99 27 27
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TDM A/E 2 15
CONTENTS
1. Dangers and safety precautions
2. Valve description
3. Condition at delivery and marking
4. Assembly and disassembly
5. Commissioning
6. Maintenance instructions
7. Conditions of warranty
8. Instruction in case of damages
9. Customer services
10. Attachments:
-Cross sectional drawing of the bypass type TDM

-Overall cross sectional drawing valve type TDM
- Material / Parts list

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TDM A/E 3 15
1.0 Dangers and safety precautions
Minimum flow valves have the same potential danger as pressure vessels.
Therefore planning, installation, operation and maintenace shall be done according
the necessary safety precautions.
1.1. Danger to persons and materials
The minimum flow valves should only be operated within their limits of
design and layout.
No changes are to be made without our approval.
Only use original spare parts.
Safety regulations, site regulations and installation safety precautions are

to be followed.
Please follow the instructions as given in this „Installation-, Maintenance

and Assembly instructions“.
1.2 Avoid dangers

Maintenance of the Automatic Recirculation Valve shall only be done by
trained personnel.
Before disassembly, the installation has to be shut off and the valve
pressureless and cooled down. Please make sure that these safety precautions
can only be cancelled after ending the assembly of the valve.
Please be aware that also in a pressureless valve there might still be medium.
Wear protective clothing.

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TDM A/E 4 15
2. Description
The Schroedahl automatic-recirculation-valve model TDM is applied

in centrifugal pump systems in order to provide an automatic
leak-off flow in case of low load conditions.
The application range of the series TDM with a multistage pressure

let-down section is, independent of the temperature, for the
operating pressures from 64 bar (a) to 250 bar (a) (900 psig to 3600 psig).
The valve consists of an upper and a lower housing, each provided

with a flange. The bypass housing and also the start-up housing, are located
horizontally at the side of the valve. The valve trim comprises a check
valve as also a control- and throttle section.
The valve protects centrifugal pumps, especially boiler feed pumps,

against overheating, by maintaining, automatically, a minimum flow.
At flows, lower than the required minimum flow the check valve
activates, by means of a lever, a vortex plug.
When lifted of its seat, the vortex plug allows a flow through the
pressure reduction section to the suction tank (or condensate tank).
The opening characteristic is linear; the bypass flow increases when

the check valve moves from its switch point further into the closes
position. Because of the modulation bypass control, the total of
process flow and minimum flow remains approximately constant.
The check valve, shaped like a differential control piston and spring
loaded, has such a high own frequency, tha waterhammer is avoided
(German patent 1072887). The check valve dampens pulsations because of
its throttling effect on the mainflow (German patent 1078445), and
stabilises unstable pump characteristics in the partial load range.
The housing is made from forged steel and is provided with a chromium
steel liner in the check valve area.
All moving parts and guides consist of alloy steel which are
compatible. Alternative materials are available as options

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TDM A/E 5 15
(see drawings and parts lists).
3. Packing and marking

The automatic recirculation valve is shipped, depending on size, in
an aluminium box (reusable), skid-carton or in a wooden crate.
The standard factory conservation is sufficient to protect the valve
for a period of approx. 6 month (the stocking area should be dry and ventilated).
If special packing or conservation is required, this should be stated
with the order.
Specific valve data are indicated on the valve nameplate as per sample
below. The valve nameplate is made from aluminium and attached to every
valve housing.
If spare parts are required, the following valve date should be

provided with the inquiry (order) :
production number K ........ (stamped in valve body), valve model
number and part number (check parts list).

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TDM A/E 6 15
4. Assembly and disassembly

The automatic recirculation valve type TDM (called hereafter TDM) is
usually installed vertically, with the mainflow upward, and direktly on the pump
discharge flange.
The bypass housing is connected to the bypass piping (and the piping
consequently to the feedwater tank or orther tank), so that a
recirculation flow will be possible.
Other installation positions of the valve (horizontal, upside-down) are
possible, if so ordered only!
No special tools are required for the installation, assembly or dissassembly
of the valve.
4.1 Installation at the jobsite
In order to prevent damage to the flange finish and/or the bolts the
complete valve should be installed in the piping free of
tension/ stress. Before tightening the bolts with a torque wrench
(torques as recommended by the factory!), please ensure that
the machined flange surfaces and packing rings are clean.
4.2 Disassembly of the TDM

- Depressurize the System. Remove the TDM from the piping system.
- Disassemble bypass housing Pos. 09.
- Pull the bypass trim "M" out of the assembly (careful!).
Apply a screwdriver between the collar of the control head (pos. 11)
and the valvebody (pos. 1).
- Remove the upper body (pos. 2) from the lower body (pos. 1) by
loosening the hexagon nuts (pos. 28).
- The check valve (pos. 7) and spring (pos. 6) can now be removed
from the lower body (pos. 1).
- Clean all parts and check for any damages. In case of damaged
seats (check valve seat or bypass seat), this should be repaired
by lapping the respective parts on the seats. Replace ring (pos. 30) if required.

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TDM A/E 7 15
4.3 Assembly of the TDM

- Replace the check valve (pos. 5/7) with the spring (pos. 6) in the
lower body (pos. 1).
- Now the upper body (pos. 2) is placed on the lower body (pos. 1)
and the hexagon nuts (pos. 28) are tightened (check cross sectional
drawing!).
- Carefully insert the bypass section "M" in the valve body and
as certain, that lever (pos. 13) fits (slides) in the slot in the
check valve (pos. 5/7).
- The bypass housing (pos. 9) with the bypass orifice (pos. 23) is now
carefully replaced and tightened to the housing (pos. 1) with the
hexagon nuts (pos. 29).
4.4 Disassembly of the bypass section
Occasionally, and because of contamination of the fluid, a complete

disassembly of the bypass trim may be required. At each inspection
the bypass should be checked for proper operation. In case of
damages, the bypass section should be removed, disassembled and
the damaged parts replaced.
Carefully study the bypass cross sectional drawing!
With the exception of the bushing (pos. 15), the vortex plug
(pos. 12) and the vortex nut (pos. 21), which are form-locked by the pin,
all parts can be taken apart.
In order to disassemble pos- 15, 12 and 21, the pin should be
removed by drilling (or by knocking it out).
- Check Glyd-rings Pos. 33.1; 34.1 and 35.1 for damage. When replacing the
seals (O- and Glyd-rings), ensure that they are reinstalled in the right place.
Do not use seal rings which are damaged. If possible replace the complete
seal set.
- Check bypass orifice pos. 23 for damage.
4.5 Assembly of the bypass sections

Proceed in the reverse order as per disassembly instruction above.

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TDM A/E 8 15
4.6 Dissassembly of the start-up device

- Loosen hexagon nuts (Pos. 29)
- Take off side branches (Pos. 09)
- Remove splint (Pos. 20) and screw out vortex plug (Pos. 18)
Checks
- In case of any damages on the vortex plug (Pos. 18) or vortex bushing
(Pos. 10) the complete start-up insert including bypass orifice (Pos. 23)
has to be replaced.
- The O-rings (Pos.31,32 and 36) have to be renewed in any case.
4.7 Assembly of the start-up device

Proceed in the reverse order as per disassembly instructions above.
5. Commissioning of the TDM

The valve is commissioned together with the pump. When the main
shut-off valve in the pump discharge piping (to the boiler or process)
the specified bypass flow is maintained through the bypass section
(and to the piping of the bypass system).
By closing or opening the main shut-off valve, the opening and closing
of the bypass can be checked. The switch point of the valve can be
established acoustically (use a technical stethoscope or even a
scewdriver to the ear will do).
The correct functioning of the valve can be further checked by
measuring the flow in the main piping. In case a manual start-up
connection is provided on the valve, the minimum flow is achieved
through this section. The automatic bypass is closed during
commissioning and the manual start-up is opened. The automatic
bypass section is spared (protected) during commissioning in this
way, as the fluid might still be contaminated and/or carry solids!

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TDM A/E 9 15
6. Maintenance instructions
The TDM has been designed so, that no special maintenance is required.
Maintenance is restricted to cleaning the trim together with the pump
at regular intervals.
After disassembly of the valve, all seals should be replaced (by new
seals) before re-assembly of the valve.
7. Warranty conditions
If no special conditions have been agreed upon the order, the warranty
is limited to 24 month after shipment or 8000 hours of operation.
The warranty does not include damage caused by improper handling, dirt
in the system or normal wear.
8. Instructions in case of damages

In order to judge the damages (and the cause), the following
information is required:
1) The production number of the valve (K .....).

This number is stamped on each valve body.
2) Valve model number and size

e.g. TDM (or TDL, TDK, MRM or other series)
3) A description of the system in which the valve is installed.

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TDM A/E 10 15
9. Customer services
In case information is required, or in case of breakdown, the following
persons can be addressed during office hours:
Manufacturer : Schroedahl-Arapp
Spezialarmaturen GmbH & Co.KG
D - 51580 Reichshof-Mittelagger
Mr. Gösselkeheld Tel. 02265 - 992721

Mr. Blossey Tel. 02265 - 992726
Factory fax number 02265 - 992727
Outside of
the office hours:
Mr. Gösselkeheld Tel. 0171-5353287
International
sales organisation Schroedahl International B.V.
NL - 4611 MK Bergen op Zoom
Phone number (31 +) - 1642- 55040

Fax number (31 +) - 1642- 59885

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TDM A/E 11 15
10. Attachments
- Cross sectional drawing of the bypass type TDM
- Overall cross sectional drawing valve type TDM
- Material / Parts list

Telefon (02265) 99 27 -0 - Telefax (02265) 99 27 27
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TDM A/E 12 15

Telefon (02265) 99 27 -0 - Telefax (02265) 99 27 27
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TDM A/E 13 15

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TDM A/E 14 15
Housing
Pos Pc Description Standard - materials Recommend
CS SS Spare parts
01 1 Lover body 1.0460 1.4550
02 1 Upper body 1.0460 1.4550
03 2 Valve stemguide 1.4552 1.4552
04 1 Guide bolt 1.4021 6) 1.4021 6) X
06 1 Spring 1.4310 1.4310
07 1 Check valve (assy.) 1.4550 1.4550 X
07.1 1 Check valve 1.4550 1.4550
07.2 1 Stem 1.4550 7) 1.4550 7)
08 1 Liner 1.4300 9) 1.4300 9)
09 1 Bypass branch 1.0460 1.4550
25 1 Guide pin 1.4571 1.4571
26 8) Bolt 1) 4)
27 8) Bolt 1) 4)
28 8) Hexagon nut 2) 5)
29 8) Hexagon nut 2) 5)
30 1 O-Ring 3) 3) X
Bypass
CS SS Spare parts
10 1 Vortex bushing 1.4122 1.4122 X
11 1 Control head 1.4122 1.4122 X
12 1 Vortex plug 1.4122 1.4122 X
13 1 Lever 1.4313 1.4313 X
14 1 Ivot pin 1.4021 1.4021 X
15 1 Bushing 1.4122 1.4122 X
16 1 Piston 1.4122 1.4122 X
21 1 Disc 1.4122 1.4122 X
23 1 Bypass orifice 1.4122 1.4122 X
31 1 O-Ring 3) 3) X
32 2 O-Ring 3) 3) X
33 1 O-Ring 3) 3) X
33.1 1 Glyd-Ring PTFE/Carbon PTFE/Carbon X
34 1 O-Ring 3) 3) X
35 1 O-Ring 3) 3) X
36 1 O-Ring 3) 3) X

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TDM A/E 15 15
Start-up device

CS SS Spare parts
10 1 Vortex bushing 1.4122 1.4122 X
18 1 Vortex plug 1.4122 1.4122 X
19 1 Linkage 1.4122 1.4122 X
20 1 Pin 1.4300 1.4313 X
23 1 Bypass orifice 1.4122 1.4021 X
31 2 O-Ring 3) 3) X
32 1 O-Ring 3) 3) X
36 1 O-Ring 3) 3) X
1. 8.8 to DN 150 PN 40, DIN 1.7709 from PN 63 and from DN 200 PN 10

2. 8 to DN 150 PN 40, W-NR. 1.7258 from PN 63 and from DN 200 PN 10
3. EPDM, BUNA, VITON,ZALAK,KALREZ
4. same as under 1) only galvanised and olive chromated
5. same as under 2) only galvanised and olive chromated
6. made from SS acc. DIN 1.4550 with ceramic coating in case of horizontal installation
7. With ceramic coating in case of horizontal installation

Telefon (02265) 99 27 -0 - Telefax (02265) 99 27 27
9.6 Valves and Equipment (Y-strainer)

Data sheet YFRF6-CL150
Dimensional sheet ZN 1652
Installation & Maintenance Manual

Baureihe_HG Datum_
Werk-Nr._
Date 21.01.2016 Pump: HGM 2/9
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
Strainers
Main pump
Type Y-type strainer

Standard ZN 1652
Manufacturer CDB / Italy
Type YFRF6-CL150
Quantity 2
Installation Horizontal or vertical
Weight kg 70
DN NPS: 6 in
PN ANSI Class 150
Type Fine wire mesh 0.5 mm
Material CrNiSt
Length mm 406
Head loss m 0.1 (with clean strainer)
WERKNORM / WORKS STANDARD September 2013
Y-Siebe / Y-Strainers
für horizontalen und vertikalen Einbau ZN
for horizontal and vertical installation
Fabrikat CDB / Make CDB
1652
Teile-Nr.: 758 Maße in mm Part No.: 758 Dimensions in mm

The comma is used as decimal marker.
PLM--Materialklasse: CRV1CVX91 PLM Material class: CRV1CVX91
Änderungen Amendments
Gegenüber der Ausgabe August 2013 wurden fol- Compared with the edition August 2013 the following
gende Änderungen vorgenommen: amendments were made:
Schutzvermerk ISO 16016 beachten / Copyright acc. to ISO 16016
a) Nr. 1: Hinweis aufgenommen. a) No. 1: Note has been included.

b) Nr. 5: Maß b und Fußnote 1) ergänzt. b) No. 5: Dimension b and footnote 1) have been
Spalte mit Maß b in Tabelle 5 und 6 er- included. Column with dimension b has
gänzt. been added in table 5 and 6.
Frühere Ausgaben Previous Editions

ZN 1652: 2011-01; 2011-03; 2011-04; 2011-09; ZN 1652: 2011-01; 2011-03; 2011-04; 2011-09;
2012-03; 2013-01; 2013-04; 2013-08 2012-03; 2013-01; 2013-04; 2013-08
1 Anwendungsbereich 1 Scope
Y--Siebe nach dieser Norm werden vorzugsweise Y-strainers in accordance with this standard are pre-
in Zulaufleitungen zu Pumpen zwecks Zurückhal- ferably used in pump inlet pipes to retain residues and
tung von Rückständen und Verunreinigungen aus impurities resulting from installation of the plant.
der Anlagenmontage eingesetzt.
Hinweis: Note:
Die direkte Montage auf den Pumpenflansch ist Direct mounting on the pump flange is not possible
nicht bei allen Baureihen möglich (z.B. Baureihe on all type series (e.g. HGB/HGC), if there is not
HGB/HGC), wenn nicht genügend Montageraum enough space for fitting the flange connecting
für die Flanschverbindungsschrauben vorhanden screws.The space available for direct mounting
ist. has to be checked and, if necessary, a dismantling
Die Platzverhältnisse für eine direkte Montage sind joint has to be fitted between pump flange and
zu prüfen und ggf. ist ein Ausbaustück zwischen Y--strainer.
Pumpenflansch und Y--Sieb vorzusehen.
2 Druckgeräterichtlinie 97/23/EG 2 Pressure Equipment Directive

97/23/EC
Y-Siebe nach dieser Norm müssen in der Ausfüh- The design of strainer bodies according to the present
rung den Bestimmungen der Druckgeräterichtlinie standard must comply with the provisions of the Pres-
97/23/EG entsprechen. sure Equipment Directive 97/23/EC.
Medium Medium
Medium Gruppe 2 (z.B. Kesselspeisewasser) nach Fluid Group 2 (e.g. boiler feed water) according to arti-
Artikel 9 der Druckgeräterichtlinie, max. Medium- cle 9 of the Pressure Equipment Directive, max. me-
temperatur 200 _C. dium temperature 200 _C.
Fortsetzung Seite 2 bis 11 / Continued on pages 2 to 11
KSB Aktiengesellschaft T-MP132-G Stahl

Seite / Page 2
ZN 1652: 2013-09
3 Normative Verweisungen 3 Normative References

Diese Norm enthält Verweisungen und Festlegungen This Standard contains references and definitions from
aus anderen Normen. Diese normativen Verweisun- other standards. These normative references are quoted
gen sind an den jeweiligen Stellen im Text zitiert, und in the text and the standards are listed below. For all
die Normen sind nachstehend aufgeführt. Bei den these references, the latest edition of the standard re-
Verweisungen gilt die letzte Ausgabe der in Bezug ferred to shall apply.
genommenen Norm.
API 598 API 598
Valve Inspection and Testing Valve Inspection and Testing
ASME B16.5 ASME B16.5
Rohrflansche und Flanschfittings: NPS 1/2 bis 24 Me- Pipe Flanges and Flanged Fittings: NPS 1/2 through
trisch/Inch Standard NPS 24 Metric/Inch Standard
EN 1092-1 EN 1092-1
Flansche und ihre Verbindungen -- Runde Flansche Flanges and their joints -- Circular flanges for pipes,
für Rohre, Armaturen, Formstücke und Zubehörteile valves, fittings and accessories, PN designated --
nach PN bezeichnet -- Teil 1: Stahlflansche Part 1: Steel flanges
Seite / Page 5
ZN 1652: 2013-09
5 Maße 5 Dimensions
Maschenweite = 0,5 L
2 mm für/for DN ≤8 Inch / DN 200 x x
3 mm für/for DN ≥10 Inch / DN 250 Wire mesh 0,5
b1) b1)
Pos. Benennung / Description B 1
1 Gehäuse / Body
2 Siebeinsatz / Screen
3 Deckel / Cover 9 9
4 Stiftschrauben/Muttern / Bolts/Nuts
5 Spiraldichtung / Gasket
6 Nippel / Nipple
7 Absperrschieber / Gate valve 2
8 Verschlussschraube / Plug 3/4 NPT
9 Gewindebohrung G 1/2 für Differenzdruckmessung,
mit Verschlussschraube inkl. Dichtung verschlossen.
Tapped hole G 1/2 for differential pressure
measurement, closed with screw plug H
including seal B
H1 5
1) Flanschanschluss ASME B16.5:
B--B 4
Flanschdicke nach ASME B16.5
Flanschanschluss EN 1092-1: 9 3
Flanschdicke nach ASME B16.5
Die erforderliche Schrauben-
länge muss entsprechend fest-
gelegt werden. 7
6 8
1) Flange connection ASME B16.5:
Flange thickness ASME B16.5
Flange connection EN 1092-1:
Flange thickness ASME B16.5
The required screw length must be
defined accordingly.
Tabelle 5 -- Maße für Ausführung mit Anschlussflansch nach ASME B16.5

Table 5 -- Connection dimensions ASME B16.5
Nenngröße / Nominal size Gew.
b
DN H H1 L x Weight
W i h
Class +3
NPS ¶ kg
150 19,0 210 203 50 15
2 300
300 22,2 215 267 60 20
150 22,2 235 325 216 55 20
2 1/2
300 25,4 260 365 318 65 33
150 23,8 255 355 241 60 27
3
300 28,6 260 365 318 70 35
150 23,8 295 420 292 65 40
4
300 31,7 330 440 356 75 62
150 23,8 350 515 356 70 60
5
300 36,5 440 625 445 70 100
150 25,4 395 570 406 75 70
6
300 36,5 440 625 445 80 105
150 28,6 485 700 495 80 135
8
300 41,3 480 665 559 90 200
150 30,2 600 900 85 220
10 622
300 47,6 630 920 100 295
150 31,7 700 1060 699 90 340
12
300 50,8 730 1075 711 110 410
Seite / Page 7
ZN 1652: 2013-09
6 Sieb-Druckverlust 6 Pressure drop of strainer

Die Kennlinien beziehen sich auf Wasser ohne Ver- The characteristic curve is for non-contaminated water
schmutzung mit einer Dichte von ρ = 1 kg/dm3. with a density of ρ = 1 kg/dm3.
Tabelle 7 -- Zeta-Werte
Table 7 -- Zeta values
NPS 2 2 1/2 3 4 5 6 8 10 12
DN -- -- -- 100 125 150 200 250 300
j 4,10 4,96 4,45 4,35 4,46 4,71 4,28 3,83 3,73
m3/h
Class 150 / PN 16 1)
1905
1305
790
424
302,5
196
109
71,7
71
50,5
48
29,5
1) DN 50/65/80
15,1 siehe/see
Class 300 / PN 25,40
11,3
7,3
4,1
2,9
1,9
1
0,1
0,5
0,01
0,05
0,001
0,005
bar
Seite / Page 9
ZN 1652: 2013-09
7 Ausführung 7 Design
F Feinsieb alle DN Lochplatte, F Fine strainer all DN Perforated plate,
Dicke 2 mm (DN ≤ 8 Inch) thickn. 2 mm (DN ≤ 8 Inch)
Dicke 3 mm (DN ≤ 10 Inch) thickn. 3 mm (DN ≤ 10 Inch)
Lochweite 0,5 mm width of a hole 0.5 mm
8 Flanschanschluss 8 Flanged connection

Flansche: ASME B16.5 Pipe Flanges: ASME B16.5
Rauhigkeit der Dichtfläche: 125 bis 250 minch (AARH) Flange Facing Finish: 125--250 AARH
Flansche: EN 1092-1 Pipe Flanges: EN 1092-1
Rauhigkeit der Dichtfläche: 3,2 bis 12,5 mm (Ra) Flange Facing Finish: 3.2 bis 12.5 mm (Ra)
9 Werkstoff 9 Material
Pos. Benennung Werkstoff Ersatzteil Pos. Description Material Spare
1 Gehäuse ASTM A216 WCB parts
2 Siebeinsatz S.S. 304 X 1 Body ASTM A216 WCB
3 Deckel ASTM A105 2 Screen S.S. 304 X
4 Stiftschraube ASTM A193 3 Cover ASTM A105
Mutter A194 2H 4 Bolts / Nut ASTM A193 / A194 2H
5 Spiraldichtung mit Metallkern aus SS316, mit 5 Camprofile Gasket with METAL CORE in
konzentrischen Rillen und SS316 with concentric
Dichtlagen aus flexiblem Gra- grooves and Sealing layers
fit of Flexible Graphite
6 Nippel unlegierter Stahl 6 Nipple Crb.steel
7 Absperrschieber ASTM A105 7 Gate Valve ASTM A105
8 Stopfen ASTM A105 8 Plug ASTM A105
9 Anschluss für ASTM A105 9 Pressure Drop ASTM A105
Diff.-druckmessung Connection
10 Prüfungen 10 Inspections
Prüfungen und Bescheinigungen nach den Bestimmun- Examinations and certificates under the provisions of the
gen der Druckgeräterichtlinie 97/23/EG Pressure Equipment Directive 97/23/EC
Druckprüfung gemäß API 598 Hydrotest acc. API 598
Standard Prüfumfang: Standard scope of testing:
Druck-, Sicht- und Maßprüfung Hydraulic test, visual, dimensional
Materialprüfung mit Bescheinigung 3.1 Materials testing with certificates 3.1
11 Anstrich 11 Painting
Untergrundbehandlung: Surface preparation:
Strahlen SA 2 1/2 Blasting SA 2 1/2
Grundierung: Primer:
75 mm HEMUDUR 18500 75 mm HEMUDUR 18500
(wasserbasierender, zweikomponentiger, polyamin-ge- (water-borne two-component polyamine cured epoxy
härteter Epoxidprimer mit einer Inhibitor-Korrosions- primer containing zinc phosphate as corrosion inhibiting
schutzpigmentierung) pigment)
11.1 KSB-interner Hinweis 11.1 KSB internal information

Für den Deckanstrich bei KSB sind Materialnummern Material numbers for the finish coat of paint are available
vorhanden. at KSB.
Diese ermöglichen den Lackierprozess für die Siebe in These enable on-schedule planning of the painting pro-
der Spritzerei termingerecht zu planen. cess in the paint shop.
Mögliche Varianten nach Zeichnung UG1398993. Possible variants as per drawing UG1398993.
Seite / Page 10
ZN 1652: 2013-09
12 Ersatzteile 12 Spare Parts

12.1 Dichtung Pos. 5 12.1 Gasket Pos. 5
Tabelle 9 -- Dichtungsgrößen
Table 9 -- Gasket sizes
Nenngröße Außendurchmesser Innendurchmesser Dicke

Nominal size Outside diameter Inside diameter Thickness
NPS Class DN PN d1 d2 t
150 -- --
2 82 64
300 50 16 / 25 / 40
150 -- -- 98 78
2 1/2
300 65 16 / 25 / 40 112 92
150 -- -- 110 90
3
300 80 16 / 25 / 40 112 92
150 -- 16
4 136 116
300 100 25 / 40
150 -- 16 164 142
5 3
300 125 25 / 40 194 170
150 -- 16 182 158
6
300 150 25 / 40 194 170
150 -- 16 237 212
8
300 200 25 / 40 247 222
150 -- 16
10 292 262
300 250 25 / 40
150 -- 16 312
12 346
300 300 25 / 40 313
Seite / Page 11
ZN 1652: 2013-09
Anhang A Appendix A
Technische Angaben zur Anwendung der Technical information on how to use the
Y--Siebe: Y-- strainers
Zum Schutz vor Fremdteilen im Anlagenkreislauf und Strainers are often required for protection against fo-
zum Schutz vor Verunreinigungen der Spalte zwischen reign particles in the plant circuit and for protection
stehenden und rotierenden Teilen von Kreiselpumpen, against impurities in the clearence gaps between statio-
sind häufig Siebe erforderlich. nary and rotating parts of centrifugal pumps.
Dies trifft vor allem dann zu, wenn vor der Inbetrieb- This above all applies when tank, pipes, etc. were not
nahme von Anlagen, Behälter, Rohrleitungen usw. satisfactorily cleaned by pickling and blow-out opera-
durch Beiz- und Ausblasebetrieb nicht ausreichend ge- tion prior to commissioning/start-up. Furthermore, weld
reinigt wurden. Außerdem lösen sich Schweißperlen, splatters, scale and other impurities often come off after
Zunder und andere Verunreinigungen oft erst nach ge- a fairly long time and can be encountered after mainte-
raumer Zeit und können nach Wartungs- und Reparatu- nance an repair work.
rarbeiten erneut anfallen.
Zwischen Krümmern und dem Siebgehäuse soll eine Between the elbows and the strainer body, a straight
gerade Rohrstrecke von mindestens 2 x DN vorhanden pipeline of at least 2 x DN shall be provided.
sein.
Der Differenzdruck des Schmutzfängers (Y--Sieb) The maximum permissible differential pressure of the
sollte nicht mehr als 0,2 bar betragen. Y--strainer should not exceed 0.2 bar.
Der max. zulässige Differenzdruck darf die Sicherheit The maximum permissible differential pressure must
im NPSH-Wert der Anlage nicht überschreiten. not exceed the margin of safety of the NPSHavailable va-
lue.
Bei automatischem Betrieb wird eine Siebüberwa- For automatic operation, strainer monitoring by diffe-
chung durch Differenzdruckmessgeräte mit Kontaktge- rential pressure gauges with contact mechanism is re-
ber empfohlen. commended.
Spec. Rev. Date
MM-FYC 0 20.05.07
Installation & Maintenance Sheet: 1 of 3
Manual
ENGINEERING Spa
READ CAREFULLY BEFORE USING THE PRODUCT
Before reading the instructions please consider the drawings are an integral part of this manual
and that all information & limitations contained in these drawings are applicable.
The supplied strainers are designed and manufactured to retain impurities according to the
required filtration grade. They shall be used only for the medium and within the
pressure/temperature limits indicated on the drawings as well as the name plates fixed on the
strainers. Exceeding such pressure /temperature limits is not allowed and may be very dangerous.
The strainers are supplied without safety devices. It is the user responsibility to adopt safety
procedures and regulations in order to prevent the improper use of the strainers.
The life expectancy of the filters is 10 years.
INSTALLATION INSTRUCTION
For a proper installation ensure that the following recommendations are followed:
1. Before installation carefully inspect the strainer for possible damage during transportation
or handling.
2. Check the inside of the strainer for foreign objects that may have fallen inside.
3. When installing the strainer in the pipeline the arrow on the body must point to the direction
of the flow.
4. When installing the strainer make sure that a space for the withdrawal of the screen (2) is
allowed.
1
MAINTENANCE ISTRUCTIONS
Maintenance on the strainer as per instruction here below is recommended after start up during
any plant shutdown and anytime pressure drop is too high.
A quick clean up system is to blow off small impurities through the drain valve/plug (6/7).
For a complete maintenance follow the points here below:
1. Make sure the line is shut off before starting any operation.
2. Open the drain plug (7) and valve (6) to release the pressure and let all liquid out of the body.
3. Unscrew and remove nuts (4).
4. Remove cover (3).
5. Before remove the filtering element unscrew the bolts that keep it in place (if any).
6. Withdraw the filtering element and carefully inspect it for damages. If any hole in the screen is
found obstructed, clean it with compressed air and/or any suitable tool. If the screen is broken
in any part replace it with a new one. Never reinstall a damaged screen.
7. Carefully clean the inside of the strainer body.
8. Install the new the screen (2) or the cleaned one.
9. Install a new gasket (5).
10. Reinstall the cover (3) and tighten nuts (4).
11. Close the drain valve (6), install and tighten drain plug (7).
12. Slowly give pressure to the line checking for leakage from cover (3) or drain plug (7).
13. Write the latest date of this operation on a metal tag firmly attached to the strainer body.
2
3
Spec. Rev. Date/Datum
Installation & Maintenance MM-FYC 0 18.06.12
Manual / Sheet/Blatt: 1 of 2
Installations- und Wartungs-
ENGINEERING Spa anleitung File/Datei: TEC-doc-tec-manuali
READ CAREFULLY BEFORE USING THE PRODUCT /

VOR DEM GEBRAUCH DES PRODUKTES AUFMERKSAM LESEN
Before reading the instructions please consider the drawings are an integral part of this manual
and that all information & limitations contained in these drawings are applicable.
The supplied strainers are designed and manufactured to retain impurities according to the
required filtration grade. They shall be used only for the medium and within the
pressure/temperature limits indicated on the drawings as well as the name plates fixed on the
strainers. Exceeding such pressure /temperature limits is not allowed and may be very dangerous.
The strainers are supplied without safety devices. It is the user responsibility to adopt safety
procedures and regulations in order to prevent the improper use of the strainers.
The life expectancy of the filters is 10 years.
Bevor Sie die Anleitung lesen, beachten Sie bitte, dass die Zeichnungen ein wesentlicher
Bestandteil dieser Anleitung sind und dass sämtliche darin enthaltenen Informationen und
Einschränkungen maßgeblich sind.
Die mitgelieferten Siebe sind dafür ausgelegt und hergestellt, Verunreinigungen mit der
geforderten Filterfeinheit zurückzuhalten. Sie sollten nur für das Medium und innerhalb der Druck-
/Temperaturgrenzen verwendet werden, die auf den Zeichnungen sowie auf den Typenschildern
an den Sieben angegeben sind. Das Überschreiten dieser Druck-/Temperaturgrenzen ist
unzulässig und kann sehr gefährlich sein.
Die Siebe werden ohne Sicherheitsvorrichtungen geliefert. Es liegt in der Verantwortung des
Nutzers, Sicherheitsmaßnahmen und -vorschriften anzuwenden, um eine unsachgemäße
Nutzung der Siebe zu verhindern.
Die erwartete Lebensdauer der Filter liegt bei 10 Jahren.
INSTALLATION INSTRUCTION / INSTALLATIONSANLEITUNG
For a proper installation ensure that the following recommendations are followed:
1. Before installation carefully inspect the strainer for possible damage during transportation
or handling.
2. Check the inside of the strainer for foreign objects that may have fallen inside.
3. When installing the strainer in the pipeline the arrow on the body must point to the direction
of the flow.
4. When installing the strainer make sure that a space for the withdrawal of the screen (2) is
allowed.
Für die richtige Installation müssen die folgenden Empfehlungen befolgt werden:
1. Das Sieb vor der Installation sorgfältig auf mögliche Transport- oder Handhabungsschäden
prüfen.
2. Das Innere des Siebs auf Fremdkörper prüfen, die hineingefallen sein könnten.
3. Bei der Installation des Siebs in der Leitung muss der Pfeil am Gehäuse in Fließrichtung
zeigen.
4. Bei der Installation des Siebs sicher gehen, dass Platz für den Rückzug des Siebs (2)
vorhanden ist.
1
MAINTENANCE ISTRUCTIONS / WARTUNGSANLEITUNG
Maintenance on the strainer as per instruction here below is recommended after start up during
any plant shutdown and anytime pressure drop is too high.
A quick clean up system is to blow off small impurities through the drain plug (7). This operation
will be easier and quicker if a valve (6) is installed at the drain connection.
For a complete maintenance follow the points here below:
1. Make sure the line is shut off before starting any operation.
2. Open the drain plug (7) and valve (6) to release the pressure and let all liquid out of the body.
3. Unscrew and remove nuts (4).
4. Remove cover (3).
5. Withdraw the filtering element and carefully inspect it for damages. If any hole in the screen is
found obstructed, clean it with compressed air and/or any suitable tool. If the screen is broken
in any part replace it with a new one. Never reinstall a damaged screen.
6. Carefully clean the inside of the strainer body.
7. Install the new the screen (2) or the cleaned one.
8. Install a new gasket (5).
9. Reinstall the cover (3) and tighten nuts (4) (Driving torque as per table page no.3).
10. Close the drain valve (6), Install and tighten drain plug (7).
11. Slowly give pressure to the line checking for leakage from cover (3) or drain plug (7).
12. Write the latest date of this operation on a metal tag firmly attached to the strainer body.
Die im Folgenden beschriebene Wartung wird nach der Inbetriebnahme infolge eines
Anlagenstillstands und immer dann empfohlen, wenn der Druckverlust zu hoch ist.
Zur schnellen Reinigung des Systems können geringfügige Verunreinigungen durch die
Ablassschraube (7) ausgeblasen werden. Dieser Vorgang geht dann leichter und schneller, wenn
ein Ventil (6) am Ablass installiert ist.
Für eine komplette Wartung wie folgt vorgehen:
13. Vor jeglichen Arbeiten sicher gehen, dass die Anlage abgeschaltet ist.
14. Die Ablassschraube (7) und das Ventil (6) öffnen, um den Druck abzulassen und die gesamte
Flüssigkeit aus dem Gehäuse abfließen zu lassen.
15. Die Muttern (4) abschrauben und entfernen.
16. Die Abdeckung (3) entfernen.
17. Das Filterelement zurückziehen und sorgfältig auf Schäden untersuchen. Verstopfte Löcher im
Sieb mit Druckluft und/oder einem geeigneten Werkzeug reinigen. Sollte das Sieb kaputt sein,
muss es mit einem neuen ersetzt werden. Nie ein kaputtes Sieb einsetzen.
18. Sorgfältig das Innere des Siebgehäuses reinigen.
19. Das neue bzw. das gereinigte Sieb (2) einbauen.
20. Eine neue Dichtung (5) einbauen.
21. Die Abdeckung (3) wieder einsetzen und die Muttern (4) anziehen (für die Drehmomente siehe
Tabelle auf Seite 3).
22. Das Ablassventil (6) schließen. Die Ablassschraube (7) einsetzen und festziehen.
23. Die Anlage langsam mit Druck versorgen und auf Lecks an der Abdeckung (3) oder der
Ablassschraube (7) prüfen.
24. Das Datum der Wartung auf der Metallmarke vermerken, die fest am Siebgehäuse angebracht
ist.
2
NUTS DRIVING TORQUE TABLE
Material : ASTM A193 B7 / A194 2H
Size FYC Dia x thr Driving Torque

Class
Size/DN (inch) (Nm)
2”/50 150 ½”UNC 73
2.½”/65 150 ½”UNC 73
3”/80 150 ½”UNC 73
4”/100 150/PN.16 ½”UNC 73
5”/125 150/PN.16 ½”UNC 73
6”/150 150/PN.16 ⅝”UNC 142
8”/150 150/PN.16 ¾”UNC 251
10”/150 150/PN.16 ¾”UNC 251
12”/150 150/PN.16 ⅞”UNC 396
Size FYC Dia x thr Driving Torque

Class
Size/DN (inch) (Nm)
2”/50 300/PN.16-25-40 ½”UNC 73
2.½”/65 300/PN.16-25-40 ½”UNC 73
3”/80 300/PN.16-25-40 ½”UNC 73
4”/100 300/PN.25-40 ¾”UNC 251
5”/125 300/PN.25-40 ¾”UNC 251
6”/150 300/PN.25-40 ¾”UNC 251
8”/150 300/PN.25-40 ⅞”UNC 396
10”/150 300/PN.25-40 ⅞”UNC 396
12”/150 300/PN.25-40 1”-8UN 607
3
4
9.7 Instruments
Pressure gauge
Technical Information
Operating Instructions
Suction pressure PI 101
Discharge pressure PI 102
SPM-Nipple YE 103 & YE 104

Baureihe_HG Datum_
Werk-Nr._
Date 21.01.2016 Pump: HGM 2/9
Works No. / Turbine 9973105255 000300 / 1
Product No. Pump 42042409000302130203
Measuring Instrument Remarks

Meas. Location of measuring point Pcs Type Measuring Feeler Indication / Make
point per range length Interlocking Drawing No.
No. Medium/Material pump Scope of supply Housing Diameter DIN No.
diameter d Ident. No.
Threaded
connect.
PI Pump suction pressure 1 Pressure gauge 0 - 6 bar Local WIKA With
101 Suction nozzle KSB 100 mm manome1.doc pressure
Feed pump G 1/2 A ZN 16064 gauge valve
Feed water 00402206
PI Pump discharge pressue 1 Pressure gauge 0 - 100 bar Local WIKA With
102 Discharge nozzle KSB 100 mm manome1.doc pressure
Feed pump G 1/2 A ZN 16064 gauge valve
Feed water 00402210
YE Shock pulse measurement 1 SPM nipple -
103 Driven end KSB schwin9.doc
M8 ZN 407
00129477
YE Shock pulse measurement 1 SPM nipple -
104 Non-driven end KSB schwin9.doc
M8 ZN 407
00129477
Technical
Information
Selection, Installation, Handling and Operation of Elastic

Element Pressure Gauges
WIKA Data Sheet IN 00.05
In general Pressure gauge cocks. The handle features 3 positions:
The user must ensure that the appropriate pressure gauge  Off The pressure medium is barred and the pressure
with regard to scale range and performance is selected. element is open to the atmosphere.
The optimum selection of the scale range is given if the  On The pressure gauge is connected to the pressure
operating pressure is in the middle third of the scale range. medium.
 Vent The pressure gauge is isolated but the pressure

system is vented and the medium can escape into
the atmosphere.
Pressure gauge valves without or with test connector

(DIN 16 270 or 16 271 resp.) are equipped with a ven-
ting plug between valve body and pressure connection.
Release of the venting plug enables controlled venting
through the thread.
Local safety codes such as for pressure or steam vessels

may specify isolating devices enabling on-site testing of
the pressure gauge. The test connector of the pressure
gauge valve according to DIN 16 272 can be closed with
an additional shut-off device.
The pressure gauge should be installed such as to avoid
exposure to heat and vibration and to enable easy obser- Pressure gauge mounting provisions
vation of the dial indication.
If the pressure system or tail pipe is not sufficiently rigid to
The pressure connections have to be sealed.
accept the weight of the gauge, particularly where vibra-
It is common practise to install the pressure gauge by tion exists, the gauge should be mounted by means of a
means of an isolating device to facilitate replacement while mounting device for surface or pipe mounting, if necessary
the system is pressurised and to set the gauge inoperative with capillary extension.
when reading is not required.
Damping of vibration
Isolating devices
If the pressure gauge is exposed to vibration or pulsating
The isolating device may be either a pressure gauge cock pressure or both, then a liquid filled pressure gauge may
or a pressure gauge valve, depending on operating conditi- provide considerably better performance and readability.
ons and requirements.
WIKA Data Sheet IN 00.05 ∙ 10/2005 Page 1 of 4

Effects of temperature should be sloped (recommended inclination 1:15). With
gaseous pressure media the line should feature a draining
The operating temperature of the pressure gauge, resulting provision at its lowest point, whereas the line of a liquid
from the effects of pressure medium, ambient temperature medium should feature an air bleeding provision at its high-
and possibly heat radiation must not exceed the tempe- est point. A filter or separator that enables cleaning without
rature span the pressure gauge is intended for. Suitably being removed should be provided where the pressure
shaped tailpipes or syphons with water filling may be used medium contains suspended matter.
to separate the pressure gauge and its isolating device Generally, the line should be dimensioned and fastened
from hot pressure media. such as to with stand mechanical vibration or thermal ex-
pansion and provide safe operation under normal service
Diaphragm seals conditions. If a static head of liquid is acting on the gauge,
then this causes a zero offset �p, where �p is the pressure
Diaphragm seals may be employed to separate the pressu- resulting from specific gravity and height of the liquid head.
re gauge from a pressure medium that must not enter the
elastic pressure element. ∆�p un bar = (�ρM - ρ
� �L) • g • ∆
� h • 10-5 (bar) =
Diaphragm seal and pressure element are filled with an where
inert liquid that acts as a pressure transmitting agent.
Once assembled and filled the pressure instrument must �ρM = S.G. of pressure medium in (kg/m3)
not be dismantled from the diaphragm seal.
ρ�L = S.G. of ambient air in (kg/m3)
Overload protection for pressure elements (standard value 1,205 kg/m3 at 20 °C)
Should the measuring media be subject to rapid fluctuati- ∆h = Level difference in metres (m)
ons in pressure, or pressure surges have to be taken into
account, these must not be allowed to act directly on the g = Gravity accerleration in (m/s2)
pressure element. (standard value = 9,81 m/s2)
The pressure surges must be restricted in their effect, for The corresponding indication will be lower by the value of
example, by fitting integral restrictor screws (to reduce the ∆p if the gauge is mounted above, but higher by the value
cross-section in the canal) or by using adjustable snubber of ∆p if the gauge is mounted below the pressure tapping
devices. point.
Normal gauge position will have the dial facia in its vertical
In cases where it is necessary to select a range less than plane. Calibration of the gauge in a position other than
the maximum pressure which could occur in the system, in vertical will be indicated by a corresponding symbol on the
order to obtain a high reading resolution, the pressure ele- dial.
ment must be protected against damage. Some pressure
gauges are provided with in-built over pressure safety to Installation and commissioning
high pressures.
Correct sealing of pressure gauge connections with parallel
If the pressure gauge does not have the capability to with- thread shall be means of a � suitable sealing ring, sealing
stand high overpressures a separate overpressure protec- washer or WIKA profile seals.
tion valve must be fitted. The sealing of tapered threads (e.g. NPT threads) is made by
providing the thread 
� with additional sealing material like, for
The valve will immediately isolate the system in the event example, PTFE tape (EN 837-2).
of sudden surges in pressure, or gradually close in the
event of slow pressure increases. The setting for the valve  Parallel and  tapered thread connection
must be adjusted according to its anticipated usage.
Pressure tapping points

wrench surface sealing of the
To ensure correct operation the gauge should be located at thread 
sealing area 
a point of undisturbed and continuous flow, and it should
be fitted via an isolating device.
The torque depends on the seal used. With standard
Tail pipes G-type pipe thread, gauge connection by means of a union
nut or a LH-RH adjusting nut is recommended to simplify
The tail pipe, that is the connecting line between pressure correct orientation of the gauge.
tapping point and pressure gauge, should be of sufficient- The tightening or loosening torque applied to the connec-
ly large diameter (≥ 6 mm) to avoid clogging by possibly tion should be by means of the spanner flats provided on
suspended matter. Horizontal lines of considerable length the stem and should not be by means of grasping the case
Page 2 of 4 WIKA Data Sheet IN 00.05 ∙� 10/2005

as this may damage the gauge.  Oxygen
 Acetylene
The connecting tail pipe should be thoroughly cleaned  Flammable gases or liquids
prior to fitting of the gauge.  Toxic gases or liquids
 Steam
For internal pressure compensation, some pressure  Ammonia and other refrigerants
gauges types are provided with lock-up pressure vent with
the inscription CLOSE and OPEN. This pressure vent is as well as portable or stationary pressure systems such as
closed at time of supply (lever in CLOSE position).
Prior to inspection and/or after installation and prior to  Air compressors
initial operation, the gauges have to be vented (lever in  Welding equipment
OPEN position).  Pressure vessels and boilers
 Life support equipment
No pressure higher than indicated by the working pressure
symbol  (final value) must be applied to the gauge during may require pressure gauges of a construction complying
hydrostatic pressure test of the system (EN 837-1 and with national standards and/or local safety codes. This
EN 837-3). Otherwise the gauge must be isolated or must be considered and clearly specified when placing an
removed during this operation. order for such gauges. Your WIKA contact will be pleased
to assist in selecting a suitable pressure gauge model.
In the case of diaphragm gauges, care should be taken not
to accidentally loosen the bolts that retain upper and lower Storage
diaphragm housing.
The pressure gauge should remain in its original packing
No attempts should be made to remove a pressurised
until installation. The gauge should be protected from
gauge. The pressure system must be totally vented if the
external damage during storage.
gauge can not be otherwise isolated.
Storage temperature should not exceed - 40 °C or + 60 °C
unless specified otherwise. Consult the data sheet pertai-
Process medium remaining in the pressure element may be
ning to the pressure gauge model.
hazardous or toxic. This must be considered when hand-
Pressure gauges removed from service should be protected
ling or storing a gauge which has been removed from the
from dust and humidity, preferably by using the original
process.
packing material. Remainder of the pressure medium
Pressure gauges in service contained in the pressure element may be susceptible to
frost. This should be considered when storing the removed
Always open isolating devices gently, never abruptly, since pressure gauge.
this may generate sudden pressure surges that may damage
the gauge. Reference documents
The maximum working pressure for which the pressure DIN and EN Standards
gauge is suitable, or also the minimum working pressure
in the case of vacuum or compound gauges, is indicated EN 837-1
on the dial by corresponding symbols (EN 837-1 and EN Pressure gauges; part 1: Bourdon tube pressure gauges;
837-3). Fluctuating pressure always reduces the maximum Dimensions, metrology, requirements and testing
working pressure of the gauge. Consult the data sheet EN 837-2
pertaining to the pressure gauge model. Pressure gauges; part 2: Selection and installation recom-
mendation for pressure gauges
Correct zeroing may be checked by closing the isolating
device and relieving the gauge from pressure. The pointer EN 837-3
must fall within the thickened portion of the zero mark h . Pressure gauges; part 3: Diaphragm and capsule pressure
Unless the gauge temperature is considerably higher or lo- gauges; Dimensions, metrology, requirements and testing
wer than 20 °C, a pointer not returning to zero may indicate DIN 16 270
serious damage of the gauge. PN 250 and PN 400 valves without test connection for
pressure gauges
On-site testing of the pressure gauge is feasible by means
of special isolating devices enabling connection of a test
DIN 16 271
gauge together with a suitable pressure source.
PN 250 and PN 400 valves with test connection for pressure
gauges
Pressure gauge safety
DIN 16 272
Pressure media such as,
PN 250 and PN 400 valves with blocking test connection
for pressure gauges
WIKA Data Sheet IN 00.05 ∙� 10/2005 Page 3 of 4

Accessories for pressure gauges
Pressure gauge
Adjustable snubber
cock Adaptor for surface LH-RH adjusting
Trumpet-form mounting bracket nut
Overpressure protector syphon
Pressure gauge valve U-form syphon Pressure gauge valve with extra Surface mounting
valve for test connector bracket
Arrangements for pressure measurement
Recommended measuring arrangements for various types of process fluid
Liquid media Gaseous media

Contents of Liquid Liquid with Vapour only Gas only Wet gas Liquid gas
tail pipe vapour condensate
Typically Condensate Boiling liquid LPG Dry air Moist air Steam
Flue gas
Pressure
instrument
higher than
tapping point
Pressure
instrument
lower than
tapping point
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.
9099964 10/2005 GB
Page 4 of 4 WIKA Data Sheet IN 00.05 ∙� 10/2005
WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Phone (+49) 93 72/132-0
Fax (+49) 93 72/132-406
E-Mail info@wika.de
www.wika.de
1. Safety instructions nut is recommended to simplify correct orienta-
Operating tion of the gauge. When a blow-out device is
Instructions The user must ensure that the fitted to a pressure gauge it shall be resistant to
Pressure Gauges
! appropriate pressure gauge with
regard to scale range and performance
and the appropriate wetted material
blocking by debris and dirt.
With safety pattern gauges (see dial symbol k )
you need to pay attention to the fact that the
(corrosion) for the specific measuring free space behind the blow-out back will be at
conditions of the respective application is selec- least 15 mm.
ted. In order to guarantee the accuracy and
Examples: long-term stability specified, the corresponding 2.1 Requirements for the installation point
load limits are to be observed. Specifications:
If the measuring point is not adequately stable a
see data sheet under www.wika.de
measuring instrument support such as a bracket
Only qualified persons authorised by the plant or flange should be used for fastening (and
manager are permitted to install, maintain and possibly via a flexible capillary line). If the
Model 732.14,
service the pressure gauges. pressure gauge is exposed to vibration or
Overpressure safety pulsating pressure or both, then a liquid filled
Dangerous pressure media such as Oxygen,
up to 400 bar pressure gauge may provide considerably better
Acetylene, flammable gases or liquids, toxic
Model 432.36, performance and readability. Instruments should
gases or liquids as well as for refrigeration
Overpressure safety be protected against coarse dirt and wide
plants or compressors requires attention above
up to 400 bar fluctuations in ambient temperature. EN 837-2
the standard regulations. Here the specific
"Selection and installation recommendations for
Model 213.40 safety codes or regulations must be considered.
pressure gauges" should be complied with.
After an external fire pressure media can leak
out particularly at soft solder joints. All gauges 3. Admissible ambient and working
have to be checked and, if necessary, replaced temperatures
before recommissioning the plant. When installing the pressure gauge it has to be
Serious injuries and/or damage can occur ensured that, taking the influence of convection
should the appropriate regulations not be and heat radiation into consideration, no upper
observed. or lower deviation from the permissible ambient
Notes according to and medium temperatures can occur. The
Pressure Equipment Directive 97/23/EC influence of temperature on the class accuracy
2. Mechanical connection
T The pressure gauges are "pressure accessories" is to be observed.
According to the general technical regulations
in accordance with article 1, paragraph 2.1.4 for pressure gauges, respectively (i.e. EN 837-2). 4. Storage
T The volume of the pressure bearing housings of When screw-fitting the gauges the force The pressure gauge should remain in its original
WIKA pressure gauges is < 0.1 L required for this must not be applied through the packing until installation. The gauge should be
case or terminal box but just through the
T The pressure gauges carry the CE marking for protected from external damage during storage.
spanner flats (with suitable tool) provided for this Storage temperature: -40 °C ... +70 °C.
fluid group 1G in accordance with annex 2,
purpose. Pressure gauges removed from service should
table 1 when their permissible working pressure
exceeds 200 bar be protected from dust and humidity.
Pressure gauges that do not carry the CE marking Installation with
are manufactured in accordance with article 3, open-ended spanner 5. Maintenance and servicing / Repairs
paragraph 3 "sound engineering practice". The instruments require no maintenance or ser-
vicing. Tests should be carried out on a regular
Applied standard Correct sealing of pressure gauge connections
basis to guarantee the measuring accuracy of
with parallel thread ? shall be means of a
EN 837-1 Bourdon tube pressure gauges, Dimensions, the pressure gauge. The tests or recalibrations
suitable sealing ring, sealing washer or WIKA
metrology, requirements and testing have to be carried out by qualified persons with
EN 837-2 Selection and installation recommen- profile seals. The sealing of tapered threads (e.g.
the appropriate equipment.
dations for pressure gauges NPT threads) is made by providing the thread
EN 837-3 Diaphragm and capsule pressure gauges, @‚ with additional sealing material like, for
Remainder of the pressure medium
Dimensions, metrology, requirements and example, PTFE tape (EN 837-2).
testing
contained in the pressure element
may be hazardous or toxic. This
WIKA Alexander Wiegand GmbH & Co. KG Wrench surface Sealing of ! should be considered when handling
2408976 09/2006
Alexander-Wiegand-Straße 30 and storing the removed pressure

the thread @
63911 Klingenberg • Germany Sealing area ? gauge.
Phone (+49) 93 72/132-0
Fax (+49) 93 72/132-406 The torque depends on the seal used. With
E-Mail info@wika.de standard G-type pipe thread, gauge connection
www.wika.de by means of a union nut or a LH-RH adjusting Technical alteration rights reserved.
Customer: DESCON Pump type: HGM 2/9
Plant: ENGRO KSB serial No.: 9973105255 000100/1 & 000300/1
KKS No.: PI 101
Measured variable Suction pressure

Instrument type Bourdon tube pressure gauge
Manufacturer WIKA
Type 233.50.100
Measurement Local
Nominal size 100
Accuracy class 1.0
Scale range 0-6 bar
Damping Glycerine fill
Permissible Ambient: TMIN – 20 °C, TMAX + 60 °C
temperatures Measured medium: TMAX + 100 °C
Temperature error Indication error when temperature at pressure
element deviates from reference temp. of +20°C
Rising temperature: approx. + 0.4 %/10K
Falling temperature: approx. - 0.4 %/10K
Percentage of the true scale value
Pressure connection Radially at bottom, EN 837-1
Degree of protection IP65
Design EN 837-1
Pressure element Stainless steel
< 100 bar C-type
≥ 100 bar helical type
Working pressure Static load: Full scale value
Dynamic load: 0.9 x full scale value
Short time (≤ 1h): 1.3 x full scale value
Movement Stainless steel
Dial Aluminium, white, with black lettering
Pointer Aluminium, black
Case Natural finish stainless steel
Window Laminated safety glass
Bezel ring Cam ring (bayonet type)
Natural finish stainless steel
Weight Approx. 0.9 kg
Pressure Equipment 97/23/EC
Directive (PED)
Dimensions in mm
a b D1 D2 e f G h SW
15.5 52.5 101 99 21 30 G1/2A 87 22
BENENNUNG / DENOMINATION
Data sheet
INDEX ÄNDERUNG DATUM/DATE NAME

ALTERATION
STELLE/DEPARTMENT NR. / NO. BLATT-NR.

SHEET-NO
NORM/STANDARD
01 E
GEPR/APPROVED SCHUTZVERMERK DIN 34-1-D COPYRIGHT DIN 34-1-E 1
BEARB/PREPARED ERS. FÜR / REPLACES ENTST. AUS / ORIGINAL FROM von / of
DATUM/DATE NAME 1
Plant: ENGRO KSB serial No.: 9973105255 000100/1 & 000300/1
KKS No.: PI 102
Measured variable Discharge pressure

Instrument type Bourdon tube pressure gauge
Manufacturer WIKA
Type 233.50.100
Measurement Local
Nominal size 100
Accuracy class 1.0
Scale range 0-100 bar
Damping Glycerine fill
Permissible Ambient: TMIN – 20 °C, TMAX + 60 °C
temperatures Measured medium: TMAX + 100 °C
Temperature error Indication error when temperature at pressure
element deviates from reference temp. of +20°C
Rising temperature: approx. + 0.4 %/10K
Falling temperature: approx. - 0.4 %/10K
Percentage of the true scale value
Pressure connection Radially at bottom, EN 837-1
Degree of protection IP65
Design EN 837-1
Pressure element Stainless steel
< 100 bar C-type
≥ 100 bar helical type
Working pressure Static load: Full scale value
Dynamic load: 0.9 x full scale value
Short time (≤ 1h): 1.3 x full scale value
Movement Stainless steel
Dial Aluminium, white, with black lettering
Pointer Aluminium, black
Case Natural finish stainless steel
Window Laminated safety glass
Bezel ring Cam ring (bayonet type)
Natural finish stainless steel
Weight Approx. 0.9 kg
Pressure Equipment 97/23/EC
Directive (PED)
Dimensions in mm
a b D1 D2 e f G h SW
15.5 52.5 101 99 21 30 G1/2A 87 22
Data sheet

ALTERATION

SHEET-NO
NORM/STANDARD
01 E
DATUM/DATE NAME 1
Plant: ENGRO KSB works No. 9973105255 000100/1 & 000300/1
KKS No.: YE 103 & YE 104
Measured variable Suction and discharge casing vibrations
Instrument type Measuring nipple (SPM)
Manufacturer KSB standard
Type Manufacturer's standard
Regulation Local
Form SPM
Sensor 1 (for each measuring point)
Thread connection M8
Length (l) 24 mm
Material St gal Zn
Measuring nipple with protecting cap
Datenblatt
Data sheet
ALTERATION

SHEET-NO
NORM/STANDARD
01
DATUM/DATE NAME 1
C:\Users\raulud\Documents\BV_Temp\BV_9973105255 Descon-Engro\Dokumente\YE103.docx
9.8 Gear/Variable Speed Coupling not in scope

Baureihe_HG Datum_
Werk-Nr._
9.9 Safety Features not in scope

Baureihe_HG Datum_
Werk-Nr._

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Instruction Manual

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Instruction Manual

Boiler Feed Water Pump Driven By Electric Motor / Turbine

Works serial No. 9973105255 000100/1 & 9973105255 000300/1

Service adress Germany

 KSB Service GmbH Michael Matthes

Tel. +49 6233 86 3100

Round-the-clock phone number in case of necessity:

Tel. +49 6233 86-0

Legal information / Copyright

Installation/Operating Manual HGM

Subject to technical modification without prior notice.

E KSB Aktiengesellschaft Frankenthal 21.10.2009

Chapter 3 Transport / Temporary Storage / Disposal

Chapter 5 Installation at Site

5.5 Drilling the Holes for Fastening the Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chapter 6 Commissioning, Start--up / Operation / Shutdown

Chapter 7 Supervision / Servicing / Maintenance

7.3.6 Dismantling the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 9 Relevant Documentation

Non--compliance with the regulations laid down in the in-

1.1 General Information

1.2 Information on the Instruction Manual

1.3 Relevant Documentation

1.4 Declaration of Conformity

2.1 General Information

2.1.1 Key to safety Symbols/Markings

2.1.1.1 Personal injury:

General hazard symbol

Electrical hazard symbol

Hot surface hazard

Use ear protection!

2.1.1.2 Damage to property:

2.2 General Safety Instructions

2.2.1 Intended Use

2.2.2 Prevention of Foreseeable Misuse

2.2.3 Personnel Qualification and Training

2.2.4 Non--compliance with Safety Instructions

2.2.5 Safety Awareness

2.2.6 Safety Instructions for the Operator/User

2.2.7 Safety Instructions for Work on the Pump (Set)

2.2.8 Unauthorised Modification and Manufacture of Spare Parts

2.3 Pump Signage

2.3.1 Temperature >80_C/176_F:

Temperature hazard warning sign

2.3.2 Instruction manual

Instruction manual warning sign

2.3.3 Name plate

3. Transport / Temporary Storage / Disposal

3.1.2 Lifting Accessories (e.g. eyebolt, ropes, lifting gear)

3.1.3 Signals During Transport

3.1.4 Transport Symbols

3.2 Transport of the Packaged Components of the Pump Set

Transport of the packaged components of the pump set

For weights, please refer the packing list.

3.3 Transport of the Partly--packaged or Unpackaged Components of

Weights, see Table of Weights in chapter 9.1.

3.3.1 Transport of the Pump Set

Transport of pump sets mounted on baseplates (examples)

Transport of pump sets mounted on baseplates (examples)

3.3.2 Transport of the pump

1 Transport of a pump without transport frame

3.3.3 Transport of the Other Pump Set Components

3.3.4 Transport of the Pump Rotor

Transport of the pump rotor

Chapter 9.1: Installation Plan