9750 KSB Rot Man 0001 - B - Installation and Operating Manual

COMMENT RESPONSE SHEET
9750-KSB-ROT-MAN-0001 INSTALLATION AND OPERATING MANUAL
Date: 11-12-19
Queries by EMPLOYER Clarifications by KSB

Document Reference /
Remarks
No.: Reference section
Date Comment Date Response
/ page
9750-KSB-ROT-MAN- Delete page 2 -3 (based on agreement with TPEC, page 2 and 3 for table of
05-Jul-19 1 11/12/2019 Revised
0001 content to be deleted)
9750-KSB-ROT-MAN- Add devider "PART 1 INSTALLATION AND OPERATING MANUAL OF

05-Jul-19 2 11/12/2019 Revised
0001 JOCKEY PUMP (MOVITEC)"
9750-KSB-ROT-MAN- Add devider " PART 2 INSTALLATION AND OPERATING MANUAL OF

05-Jul-19 3 11/12/2019 Revised
0001 FIRE WATER PUMP (OMEGA)"
9750-KSB-ROT-MAN-
05-Jul-19 3 Add IOM engine, PRV, Flowmeter, control panel 11/12/2019 Revised
0001
CONTRACTOR INFORMATION EMPLOYER'S INFORMATION
Company : KSB Department :

Name : Dhien Kusuma Wardani Name :
Designation : General doc Designation :
Date : Date: 11-12-19 Date :
EMILY 1 PROJECT
FUEL TERMINAL AND JETTY
TITLE OF DOCUMENT:
INSTALLATION AND OPERATING MANUAL
DOCUMENT NO. : 9750-KSB-ROT-MAN-0001

PO / SCA NO. : 9750-ROT-3210003894
COMPANY NAME : PT. KSB INDONESIA
SERVICE DESCRIPTION : FIRE WATER PUMP
PT. TRIPATRA ENGINEERS AND CONSTRUCTORS

1 - APPROVED DATE:
2 - APPROVED WITH COMMENT
3 - COMMENTED
4 - REJECTED SIGN:
REV. ISSUED DATE STATUS PREPARED BY REVIEWED BY APPROVED BY
A 16-Apr-19 Issued for Review IL DK RM

B 11-Dec-19 Issued for Approval IL DK RM
PART 1
INSTALLATION AND OPERATING MANUAL OF
JOCKEY PUMP (MOVITEC)
High-pressure In-line Pump
Movitec
Installation/Operating Manual
Mat. No.: 01424629

Legal information/Copyright
Installation/Operating Manual Movitec
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or
processed for any other purpose, nor otherwise transmitted, published or made available to a third party without
the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft, Frankenthal 20.05.2014

Contents
Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ...........................................................................................................6
1.2 Installation of partly completed machinery .................................................... 6
1.3 Target group ..................................................................................................... 6
1.4 Other applicable documents ............................................................................ 6
1.5 Symbols .............................................................................................................6
2 Safety .....................................................................................................8
2.1 Key to safety symbols/markings ....................................................................... 8
2.2 General .............................................................................................................. 8
2.3 Intended use .....................................................................................................8
2.4 Personnel qualification and training ............................................................... 9
2.5 Consequences and risks caused by non-compliance with this manual ......... 9
2.6 Safety awareness ..............................................................................................9
2.7 Safety information for the operator/user ....................................................... 9
2.8 Safety information for maintenance, inspection and installation work ..... 10
2.9 Unauthorised modes of operation ................................................................ 10
3 Transport/Temporary Storage/Disposal .............................................11

3.1 Checking the condition upon delivery .......................................................... 11
3.2 Transport ......................................................................................................... 11
3.3 Storage/preservation ...................................................................................... 12
3.4 Disposal ...........................................................................................................13
3.5 Return to supplier ........................................................................................... 13
4 Description of the Pump (Set) ............................................................14

4.1 General description ........................................................................................ 14
4.2 Product Information as per Regulation No. 547/2012 (for water pumps with
a maximum shaft power of 150 kW) implementing "Ecodesign" Directive
2009/125/EC ..................................................................................................... 14
4.3 Designation ..................................................................................................... 14
4.4 Name plate ...................................................................................................... 15
4.5 Design details .................................................................................................. 16
4.6 Configuration and function ........................................................................... 17
4.7 Noise characteristics .......................................................................................17
4.8 Scope of supply ............................................................................................... 17
4.9 Dimensions and weights ................................................................................18
5 Installation at Site ...............................................................................19

5.1 Safety regulations ........................................................................................... 19
5.2 Checks to be carried out prior to installation ............................................... 19
5.3 Installing the pump set .................................................................................. 19
Movitec 3 of 62
Contents
5.4 Piping .............................................................................................................. 20

5.5 Fitting a by-pass ............................................................................................. 22
5.6 Electrical connection ...................................................................................... 22
5.7 Checking the direction of rotation ................................................................ 24
6 Commissioning/Start-up/Shutdown ...................................................26
6.1 Commissioning/start-up ................................................................................. 26
6.2 Operating limits .............................................................................................. 28
6.3 Shutdown/storage/preservation .................................................................... 31
6.4 Returning to service .......................................................................................31
7 Servicing/Maintenance .......................................................................33
7.1 Safety regulations ........................................................................................... 33
7.2 Maintenance/inspection ................................................................................. 34
7.3 Drainage/cleaning ..........................................................................................36
7.4 Dismantling the pump set .............................................................................. 36
7.5 Reassembling the pump set ........................................................................... 41
7.6 Tightening torques ......................................................................................... 47
7.7 Spare parts stock ............................................................................................. 48
8 Trouble-shooting ................................................................................49
9 Related Documents ............................................................................51

9.1 General assembly drawings/exploded views with list of components ........ 51
9.2 Wiring diagram ............................................................................................... 57
10 EC Declaration of Conformity ............................................................58
11 Certificate of Decontamination .........................................................59
Index ....................................................................................................60
4 of 62 Movitec
Glossary
Glossary
Certificate of decontamination Pump

A certificate of decontamination is enclosed by Machine without drive, additional components
the customer when returning the product to or accessories
the manufacturer to certify that the product
has been properly drained to eliminate any
Pump set
environmental and health hazards arising from
components in contact with the fluid handled. Complete pump set consisting of pump, drive,
additional components and accessories
Discharge line
Suction lift line/suction head line
The line which is connected to the discharge
nozzle The line which is connected to the suction
nozzle
Hydraulic system
The part of the pump in which the kinetic
energy is converted into pressure energy
Noise characteristics
The noise emission to be expected, indicated as
sound pressure level LpA in dB(A)
Movitec 5 of 62
1 General
1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series/size, the main operating data and the order
number. The serial/series number uniquely identify the system and serve as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics: (⇨ Section 4.7 Page 17)
1.2 Installation of partly completed machinery

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

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (⇨ Section 2.4 Page 9)
1.4 Other applicable documents

Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
General arrangement drawing/ Description of mating and installation dimensions
outline drawing for the pump (set), weights
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components1) Description of all pump components
Drawing for assembly Sectional drawing of the installed shaft seal
For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1) If agreed upon in scope of supply
6 of 62 Movitec
1 General
Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
Movitec 7 of 62
2 Safety
2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
! DANGER DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
! WARNING WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this manual.
2.3 Intended use

The pump (set) must only be operated within the operating limits described in the
other applicable documents. (⇨ Section 1.4 Page 6)
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate the pump (set) in partially assembled condition.
▪ Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model.
▪ Never operate the pump without the fluid handled.
▪ Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
8 of 62 Movitec
2 Safety
▪ Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪ Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪ Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪ Never open discharge-side shut-off elements further than permitted.
– The maximum flow rate specified in the data sheet or product literature
would be exceeded.
– Risk of cavitation damage
▪ Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪ Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪ Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards and laws
2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any contact guards during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
Movitec 9 of 62
2 Safety
▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪ If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation work

▪ Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪ Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪ The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪ Only carry out work on the pump (set) during standstill of the pump.
▪ The pump casing must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pump set out of service always adhere to the procedure
described in the manual. (⇨ Section 6.3 Page 31)
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning. (⇨ Section 6.1 Page 26)
2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
(⇨ Section 2.3 Page 8)
10 of 62 Movitec
3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
Transporting the pump set
DANGER
Improper transport
Danger to life from falling parts!
Damage to the pump set!
▷ Use the attachment point provided (pump handle) for attaching lifting
accessories.
▷ Never suspend the pump set by its power cable.
▷ Use the lifting chain/rope included in the scope of supply exclusively for
lowering/lifting the pump set into/out of the pump sump.
▷ Securely attach the lifting chain/rope to the pump and crane.
▷ Use tested, marked and approved lifting accessories only.
▷ Observe any regional transport regulations.
▷ Observe the product literature supplied by the lifting accessory manufacturer.
▷ The load-carrying capacity of the lifting accessory must be higher than the
weight indicated on the name plate of the pump set to be lifted. Take into
account any additional system components to be lifted.
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
To transport the pump/pump set suspend it from the lifting tackle as shown below.
Movitec 11 of 62
Fig. 1: Transporting the pump set
Setting down the pump set
WARNING
Incorrect positioning
▷ Set the pump set down in a vertical position with the motor on top.
▷ Use appropriate means to secure the pump set against overturning and tipping
over.
▷ Refer to the weights given in the data sheet/on the name plate.
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
▪ Store the pump set under dry and vibration-free conditions, if possible in its
original packaging.
▪ Fill some antifreeze (e.g. glycol) into the pump to protect it from frost/freezing.
▪ Manually rotate the shaft once every three months as well as shortly before start-
up.
▪ Spray the inside of the mechanical seal chamber with a preservative to prevent
seizure of the mechanical seal.
12 of 62 Movitec
Table 4: Ambient conditions for storage

Ambient condition Value
Relative humidity 5 % to 80 %2)
(non-condensing)
Ambient temperature -10°C to +40°C
3.4 Disposal
WARNING
Fluids, consumables and supplies which are hot and/or pose a health hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set).
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.
3.5 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 36)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the pump set has handled fluids whose residues could lead to corrosion in the
presence of atmospheric humidity or could ignite upon contact with oxygen,
the pump set must also be neutralised, and anhydrous inert gas must be blown
through the pump to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump (set).
Always indicate any safety and decontamination measures taken. (⇨ Section 11
Page 59)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
KSB web site at: www.ksb.com/certificate_of_decontamination
2) At 20°C
Movitec 13 of 62
4 Description of the Pump (Set)
4.1 General description

▪ High-pressure in-line pump
Pump for handling clean or slightly aggressive aqueous fluids.
4.2 Product Information as per Regulation No. 547/2012 (for water pumps
with a maximum shaft power of 150 kW) implementing "Ecodesign"
Directive 2009/125/EC
▪ Minimum efficiency index: see name plate, key to name plate (⇨ Section 4.4 Page
15)
▪ The benchmark for the most efficient water pumps is the MEI ≥ 0.70.
▪ Year of construction: see name plate, key to name plate (⇨ Section 4.4 Page 15)
▪ Manufacturer’s name or trade mark, commercial registration number and place
of manufacture: see data sheet or order documentation
▪ Product’s type and size identificator: see name plate, key to name plate (⇨
Section 4.4 Page 15)
▪ Hydraulic pump efficiency (%) with trimmed impeller: see data sheet
▪ Pump performance curves, including efficiency characteristics: see documented
characteristic curve
▪ The efficiency of a pump with a trimmed impeller is usually lower than that of a
pump with full impeller diameter. Trimming of the impeller will adapt the pump
to a fixed duty point, leading to reduced energy consumption. The minimum
efficiency index (MEI) is based on the full impeller diameter.
▪ Operation of this water pump with variable duty points may be more efficient
and economic when controlled, for example, by the use of a variable speed drive
that matches the pump duty to the system.
▪ Information on dismantling, recycling and disposal after decommissioning: (⇨
▪ Information on benchmark efficiency or benchmark efficiency graph for
MEI = 0.7 (0.4) for the pump based on the model shown in the Figure are
available at: http://www.europump.org/efficiencycharts
4.3 Designation
Example: Movitec VCF 90/2-1 B
Table 5: Key to the designation
Code Description
Movitec Type series
VC Design
LHS Stainless steel (pump casing)
Stainless steel (hydraulic system of the pump)
V Stainless steel/grey cast iron (pump casing)
VS Stainless steel/grey cast iron (pump casing)
VC Grey cast iron (pump casing)
VM Version with close-coupled motor
F Type of connection
- Oval flange
E External thread
F Round flange
T Tri-clamp coupling
V Victaulic coupling
14 of 62 Movitec
Code Description
90 Size, flow rate [m³/h] at Qopt
2, 4, 6, 10, 15, 25, 40, 60, 90
2 Number of stages
-1 Number of reduced stages
B Generation
3) Generation A
B Generation B
4.4 Name plate
NOTE
If pumps with VdS certification are supplied, the details on the Movitec – VdS
design name plate must be observed.
a)
1
2
Movitec VCF 90/2-1 B KSB B.V.
3
4 Frame 160 (12,2kW) 50 Hz AT 11
Made in NL
5 ID 9972040368 Seal. SiC/Ca/EPDM 12

6 Q 85 m³/h PN25 -20 / +100 °C 13
H 38.1m Easy Access Code 23
7 n fix. 2900 rpm Hydr. PN40 + 80 °C
14
8 PO 700041712 140°C+PN25 15
9 Prod. 45/2011 979441-0123 Conn. PN16 MEI ≥ 0,70
10 16
17
c)
KSB B.V.
b) 19 NL-2401 LJ Alphen a/d Rijn
20 KSB Code
18 21 Sprinklerpumpe Typ Movitec V 40/3-2 B 28
Movitec VCF 90/2-1 B KSB B.V.
22 Fabr.-Nr. 997212345 000100 Jahr 2014 29
15 kW (12,2kW) 50 Hz AT 23 Q zul. 716,6 l/min Laufraddurchmesser 133,8 mm 30
24 31
Made in NL
H 46,3 m max. IA Direkt A

ID 9972040368 Seal. SiC/Ca/EPDM 25 PM 11,0 kW Umschaltstrom Y A 32
Q 85 m³/h PN25 -20 / +100 °C 26
H 38.1 m Easy Access Code 23 nN 2940 1/min VdS-Anerk.-Nr. P4050078
n fix. 2900 rpm Hydr. PN40 + 80 °C 27 PN 40 bar
PO 700041712 140°C+PN25 1.4308
Prod. 45/2011 979441-0123 Conn. PN16 MEI ≥ 0,70 Mat. No. 01573616 ZN 3814 - 39 DE
Fig. 2: Name plate (example) a) Pump without motor b) Pump with motor c) VdS design
1 Designation 2 Frame size
3 Power required 4 Rated frequency
5 KSB order number 6 Flow rate
7 Head 8 Rated speed
9 KSB purchase order number 10 Week/year of production; serial number
11 Seal code, pump elastomers 12 Maximum pressure at specified temperature
13 Mechanical seal type 14 Maximum temperature at specified pressure
15 Maximum temperature at specified pressure 16 Minimum efficiency index
17 Pressure class 18 Motor rating
19 KSB Code 20 Type series, design, size, number of stages,
number of reduced stages, and generation
21 KSB order and order item number 22 VdS-approved flow rate
23 VdS-approved head 24 Required motor rating at 15 m NPSH
25 Rated speed 26 Permissible nominal pressure
27 Pump casing material 28 Year of construction
3) Blank
Movitec 15 of 62
29 Impeller diameter [mm] 30 Maximum starting current (only relevant for

submersible pumps)
31 Switching current (only relevant for submersible 32 VdS approval number
pumps)
4.5 Design details

Design
▪ High-pressure in-line pump
▪ Maximum pressure class PN 40
▪ Centrifugal pump
▪ Single-stage or multi-stage
Installation types
Standard:
▪ Vertical installation
Optional:
▪ Horizontal installation
Drive
▪ Surface-cooled KSB squirrel-cage motor
▪ 3~230/400 V up to 2.2 kW
▪ 3~400/690 V from 3 kW
▪ Thermal class F to IEC34-1
▪ Efficiency class IE2 (from 0.75 kW)
▪ IP55 enclosure
▪ Frequency 50 Hz
▪ Thermal class F
Optional:
▪ Efficiency class IE3
Shaft seal
The shaft seal is an uncooled, maintenance-free mechanical seal to EN 12756.
▪ "Fixed" design
– Mechanical seal in standard design
– Unbalanced bellows-type seal
– ≤ 25 bar
– Fitted as standard for Movitec 2B, 4B, 6B, 10B, 15B
▪ "Easy access" design
– Easy to replace
– Unbalanced bellows-type seal
– ≤ 25 bar
– Drive lantern need not be removed to replace the seal.
– Motor rating 5.5 kW and above: Motor need not be removed.
– Fitted as standard for Movitec 25B, 40B, 60B, 90B
▪ Cartridge design
Cartridge-type seal, available in unbalanced bellows-type design (PN 25) or
special balanced design (PN 40). Drive lantern need not be removed to replace
the seal.
Motor rating 5.5 kW and above: Motor need not be removed.
– Cartridge seal
– Unbalanced bellows-type design (PN 25) or special balanced design (PN 40)
– Drive lantern need not be removed to replace the seal.
16 of 62 Movitec
– Motor rating 5.5 kW and above: Motor need not be removed.

– Optionally available for all sizes except Movitec LHS 6
Bearings
▪ Tungsten carbide plain bearings at the hydraulic rotor
4.6 Configuration and function
4
2
Fig. 3: Sectional drawing

1 Impeller 2 Suction nozzle
3 Pump shroud 4 Discharge nozzle
Design The pump is designed with a radial fluid inlet (suction nozzle) and a radial outlet
(discharge nozzle) arranged on the same axis. The hydraulic system is rigidly
connected to the motor by a shaft coupling.
Function During pump operation, a lower pressure forms at the impeller inlet. This lower
pressure makes the fluid enter the pump via the suction nozzle (2). Each stage
consists of one impeller (1) and one diffuser. The flow through a stage equals the
flow rate of the pump. The stage diameter is related to the centrifugal forces and the
"stage pressure". The more stages, the higher the pressure. The fluid is guided
outwards to the area between the pump stages and the stage casing (3), from where
it leaves the pump via the discharge nozzle (4).
Sealing The pump is sealed by a standardised mechanical seal.
4.7 Noise characteristics

The noise characteristics given refer to the motor. See motor literature supplied.
4.8 Scope of supply

Depending on the model, the following items are included in the scope of supply:
▪ Pump
▪ Electric motor
Movitec 17 of 62
4.9 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outline
drawing or data sheet of the pump set.
18 of 62 Movitec
5 Installation at Site
5.1 Safety regulations
DANGER
Installation in potentially explosive atmospheres
Explosion hazard!
▷ Never install the pump in potentially explosive atmospheres.
▷ Observe the information given in the data sheet and on the name plates of the
pump system.
WARNING
Pump with long-term preservation: Harmful preservatives in drinking water systems
Danger of poisoning!
▷ Flush the system prior to commissioning.
▷ If necessary, dismantle the pump and thoroughly remove the preservative from
all wetted components.
▷ Observe the data given in the order confirmation.
5.2 Checks to be carried out prior to installation

Place of installation
WARNING
Installation on mounting surface which is unsecured and cannot support the load
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN 206-1.
▷ The mounting surface must have set and must be completely horizontal and
even.
▷ Observe the weights indicated.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.3 Installing the pump set
CAUTION
Ingress of leakage into the motor
Damage to the pump!
▷ Never install the pump set with the "motor below".
1. Install and fasten the pump set on a sturdy and level foundation in a dry, frost-
proof room.
2. Make sure that sufficient air can reach the fan opening of the motor.
(The clearance above the fan opening must measure at least 1/4 of the diameter
of the fan cover air intake.)
3. Place a spirit level on the discharge nozzle to align the pump set.
Movitec 19 of 62
5.4 Piping
5.4.1 Connecting the piping
DANGER
Excessive loads acting on the pump nozzles
Danger to life from leakage of hot, toxic, corrosive or flammable fluids!
▷ Do not use the pump as an anchorage point for the piping.
▷ Anchor the pipelines in close proximity to the pump and connect them without
transmitting any stresses or strains.
▷ Take appropriate measures to compensate thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.
NOTE
It is recommended to install check and shut-off elements in the system, depending
on the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
NOTE
VdS-certified pumps must be connected in compliance with current information
from VdS CEA 4001.
✓ The suction lift line has been laid with a rising slope, the suction head line with
a downward slope towards the pump.
✓ A flow stabilisation section having a length equivalent to at least twice the
diameter of the suction flange has been provided upstream of the suction
flange.
✓ The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
As far as the nominal diameters in the suction and discharge line, and
installation of check valves and shut-off elements in a fire protection system are
concerned, observe the sizing specifications in the relevant directives.
✓ Adapters to larger nominal diameters are designed with a diffuser angle of
approx. 8° to avoid excessive pressure losses.
✓ The pipelines have been anchored in close proximity to the pump and
connected without transmitting any stresses or strains.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the
suction and discharge nozzles of the pump.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Remove any impurities from the piping.
▷ If necessary, install a filter.
3. If required, install a filter in the piping (see figure: Filter in the piping).
20 of 62 Movitec
2
Fig. 4: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter)
made of corrosion-resistant material.
Use a filter with a filter area three times the cross-section of the piping.
Conical filters have proved suitable.
4. Connect the pump nozzles to the piping.
CAUTION
Aggressive flushing and pickling agents
Damage to the pump!
▷ Match the cleaning operation mode and duration for flushing and pickling
service to the casing and seal materials used.
5.4.2 Permissible forces and moments at the pump nozzles
Fig. 5: Forces and moments at the pump nozzles

Direction of forces
FX Horizontal, parallel to the pump axis
FY Vertical to the pump axis
FZ Horizontal, at a right angle to the pump axis
Direction of moments
MX Around the horizontal axis, parallel to the pump axis
MY Around the vertical nozzle axis
MZ Around the horizontal axis, at a right angle to the pump axis
Movitec 21 of 62
Forces and moments at the pump nozzles

Table 6: Forces and moments at the pump nozzles of Movitec V(S)F
Movitec DN Fx Fy Fz ∑F Mx My Mz ∑M
[mm] [N] [N] [N] [N] [Nm] [Nm] [Nm] [Nm]
V(S)F 2B 25 3300 -2400 1700 4400 280 95 -210 400
V(S)F 4B 25 3300 -2400 1700 4400 280 95 -210 400
V(S)F 6B 32 3300 -2400 1700 4400 280 95 -210 400
V(S)F 10B 40 4000 -3100 3100 5900 440 180 -200 500
V(S)F 15 B 50 4000 -3100 3100 5900 440 180 -200 500
V(S)F 25B 65 3200 -3500 3500 5890 1000 230 -400 1100
V(S)F 40B 80 4000 -1800 2000 4820 400 200 -300 540
PN 16/25
V(S)F 40B 80 3700 -3300 3700 6190 975 240 -450 1100
PN 40
V(S)F 60B 80 4000 -1800 2000 4820 400 200 -300 540
PN 16/25
V(S)F 60B 80 3700 -3300 3700 6190 975 240 -450 1100
PN 40
V(S)F 90B 100 3500 -2500 1000 4420 750 500 -625 1100
LHS 6 32 8000 -2000 3200 8800 460 460 -500 800
Table 7: Forces and moments at the pump nozzles of Movitec VCF
Movitec DN Fx Fy Fz ∑F Mx My Mz ∑M
[mm] [N] [N] [N] [N] [Nm] [Nm] [Nm] [Nm]
VCF 2B 25 9400 -3200 3200 10430 600 300 360 760
VCF 4B 25 9400 -3200 3200 10430 600 300 360 760
VCF 6B 32 9400 -3200 3200 10430 600 300 360 760
VCF 10B 40 8000 -2000 3200 8850 460 460 -500 820
VCF 15B 50 8000 -2000 3200 8850 460 460 -500 820
VCF 25B 65 5000 -2000 2500 5940 1000 300 -300 1090
VCF 40B 80 6000 -3000 3000 7350 1800 1000 -1000 2290
VCF 60B 100 6000 -3000 3000 7350 1800 1000 -1000 2290
VCF 90B 100 6200 -4100 4100 8490 2000 1200 -1200 2620
5.5 Fitting a by-pass
NOTE
If the pump is operated against a closed valve, it is recommended to install a by-
pass.
The by-pass capacity must correspond to at least 10 % of the optimum volume flow
rate.
5.6 Electrical connection
DANGER
Incorrect connection
Explosion hazard!
▷ The connection point of the cable ends must be located outside hazardous
areas or in an area approved for electrical equipment.
22 of 62 Movitec
DANGER
Operating a pump set that has not been fully connected
Explosion hazard!
▷ Never start up a pump set with power cables that have not been fully
connected or non-operational monitoring devices.
DANGER
Connection of damaged power cables
Danger of death from electric shock!
▷ Check the power cables for damage before connecting them to the power
supply.
▷ Never connect damaged power cables.
DANGER
Work on the pump set by unqualified personnel
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
CAUTION
Improper routing of power cable
Damage to the power cables!
▷ Never move the power cables at temperatures below - 25 ℃.
▷ Never kink or crush the power cables.
▷ Never lift the pump set by the power cables.
▷ Adjust the length of the power cables to the site requirements.
CAUTION
Pump (set) overload
Damage to the machinery!
▷ Install a monitoring system that complies with the requirements of EN 13463-6.
▷ Protect the motor by a thermal time-lag overload protection device in
accordance with IEC 947 and local regulations.
(If the pump is used in a fire protection system as the main fire-fighting pump,
the pump must not be tripped automatically by motor protection devices!)
▷ Make sure that the motor's specifications match those of the power supply it
will be connected to.
NOTE
Sprinkler pumps with VdS certification must not be able to be tripped automatically
by measures of any kind.
For electrical connection observe the wiring diagrams in the Annex and the
information for planning the control system.
Movitec 23 of 62
If a motor of a different make is used, observe the relevant operating instructions.

The pump set is supplied with power cables as standard. Always use all cables
provided and connect all marked cores of the control cable.
Movitec B
The permissible rated current of the motor supplied is shown on the motor name
plate.
It describes the permissible operating range of the motor and can be used for setting
the overload protection device. If the actual power input is measured during
operation, the motor protection switch can be pre-set to a lower value to protect the
pump set.
This current value can also be used to select appropriate electrical equipment such as
frequency inverter, master switch, conductor diameter, etc.
Movitec A
The permissible rated current of the motor supplied is indicated on the motor name
plate as Imax.
This maximum permissible current indicates the motor's maximum operating range
and can be used for setting the overload protection device. The actual input power
at 400 V is shown on the pump name plate as Inom. It can be used to pre-set the motor
protection switch in order to protect the pump set.
5.6.1 Overload protection

Standard motors ≥ 3 kW are equipped with three PTC thermistors.
Table 8: Technical data of the PTC thermistors
Size Value
tn [°C] 140
R20°C [Ω] ~ 20
Rtn-20°C [Ω] ~ 250
Rtn-5°C [Ω] < 550
Rtn+5°C [Ω] > 1330
Rtn+15°C [Ω] > 4000
Un [V DC] 2.5 < U < 30
NOTE
Sprinkler pumps with VdS certification must not be able to be tripped automatically
by measures of any kind.
1. Protect the pump set against overloading by a thermal time-lag overload

protection device in accordance with IEC 947 and local regulations.
2. Connect the PTC to a thermistor relay.
5.7 Checking the direction of rotation
DANGER
Temperature increase resulting from contact between rotating and stationary
components
▷ Never check the direction of rotation by starting up the unfilled pump set.
▷ Separate the pump from the motor to check the direction of rotation.
24 of 62 Movitec
WARNING
Hands inside the pump casing
Risk of injuries, damage to the pump!
▷ Always disconnect the pump set from the power supply and secure it against
unintentional start-up before inserting your hands or other objects into the
pump.
CAUTION
Drive and pump running in the wrong direction of rotation
Damage to the pump!
▷ Refer to the arrow indicating the direction of rotation on the pump.
▷ Check the direction of rotation. If required, check the electrical connection and
correct the direction of rotation.
The correct direction of rotation of the motor and pump is clockwise (seen from the
drive end).
1. Start the motor and stop it again immediately to determine the motor's
direction of rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction
of rotation on the pump.
3. If the motor runs in the wrong direction of rotation, check the electrical
connection of the motor and the control system, if applicable.
Fig. 6: Direction of fluid flow and arrow indicating the direction of rotation
1 Direction of rotation of the motor 2 Direction of fluid flow
Movitec 25 of 62
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/start-up
6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the following
conditions are met:
▪ The pump set has been installed correctly.
▪ The pump set has been properly connected to the electric power supply and is
equipped with all protection devices.
▪ The pump has been primed with the fluid to be pumped.
▪ The direction of rotation has been checked.
▪ All auxiliary connections required are connected and operational.
▪ The pump and motor shafts are running smoothly and with no excessive noise.
▪ After prolonged shutdown of the pump (set), the required activities have been
carried out. (⇨ Section 6.4 Page 31)
The following must be ensured for a pump with a thrust bearing housing:
▪ The axial clearance between the thrust bearing housing and the motor shaft is
set correctly.
▪ The thrust bearing housing is lubricated if it is equipped with a lubricating
nipple.
6.1.2 Priming and venting the pump
DANGER
Formation of a potentially explosive atmosphere inside the pump
Explosion hazard!
▷ Before starting up the pump set, vent the pump and suction line and prime
both with the fluid to be handled.
CAUTION
Increased wear due to dry running
▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during
pump operation.
26 of 62 Movitec
Priming in an open or closed circuit with sufficient supply pressure
C
A
B
Fig. 7: Pump with open or closed circuit

A Shut-off valve in suction line B Shut-off valve in discharge line
C Filler opening
1. Close the shut-off valve in suction line A and the shut-off valve in discharge line
B.
2. Open filler opening C.
3. Open the shut-off valve in suction line A gradually until fluid escapes from filler
opening C.
4. Close filler opening C.
5. Fully open the shut-off valve in suction line A.
6. Fully open the shut-off valve in discharge line B.
Priming in open circuit with fluid level below the pump
Fig. 8: Pump with open circuit and fluid level below the pump
A Shut-off valve in discharge line B Filler opening
1. Remove the plug of filler opening B from the upper pump bracket.
2. Close the shut-off valve in discharge line A.
3. Fill fluid into the pump casing through filler opening B until the fluid reaches
the maximum fill level.
Movitec 27 of 62
4. Close filler opening B.

5. Fully open the shut-off valve in discharge line A.
Venting
The pump can be vented via the corresponding connections when it is not in
operation.
1 1
Fig. 9: Vent connections

1 Vent connections
6.2 Operating limits
DANGER
Non-compliance with operating limits
▷ Comply with the operating data indicated in the data sheet.
▷ Avoid operation against a closed shut-off element.
▷ Never operate the pump set outside the limits specified below.
DANGER
Non-compliance with operating limits for the fluid handled
Explosion hazard!
▷ Never use the pump to handle different fluids which might react chemically
with each other.
▷ Never use the pump to handle a flammable fluid with a fluid temperature
above the ignition temperature.
CAUTION
Excessive temperature difference between the fluid handled and the pump
▷ The temperature difference between the fluid handled and the pump must
never exceed 60 °C.
▷ If the temperature difference between the pump and the fluid handled exceeds
30 °C, prime/heat up the pump slowly to avoid any risk of thermal shock.
The operating range depends on the application as well as on the combination of
pressure and temperature.
28 of 62 Movitec
Table 9: Specified operating range

Characteristic Operating range
Ambient temperature [°C]4) -20 to 40
Minimum inlet pressure NPSHreq + 1 m
Viscosity [cSt]5) 1 - 100
Density [kg/m³]5) 1000 - 2500
Frequency [Hz]6) 30 - 60
Maximum number of start-ups per hour7) See motor data sheet
Permissible particle size [mm] 0,005 - 1
Cooling8) Forced cooling
6.2.1 Minimum/maximum flow rate

Table 10: Minimum/maximum flow rate (Q) at a fluid temperature ≤ 20 °C
Movitec Q [m³/h]
50 Hz 60 Hz
2-pole 4-pole 2-pole 4-pole
min. max. min. max. min. max. min. max.
2B 0,2 3,3 - - 0,2 4,0 - -
4B 0,4 6,5 - - 0,5 7,8 - -
6B 0,6 9,0 - - 0,8 8,6 - -
10B 1,19) 13,2 0,5 6,6 1,3 15,8 0,6 7,9
15B 1,6 9) 22,5 0,8 11,3 2,0 27,0 1,0 13,5
25B 2,8 35,0 1,4 17,5 3,1 42,0 1,6 21,0
40B 4,0 54,0 2,0 27 5,1 65,0 - -
60B 6,0 76,0 3,0 38 6,1 90,0 - -
90B 8,5 110,0 4,3 53,9 10,2 132,0 5,0 65,1
LHS 6 0,8 8,6 - - 0,7 8,6 - -
40
Q [%]
35
30
25
20
15
10
5
0
40 50 60 70 80 90 100 110 120 130 140
t [°C]
Fig. 10: Minimum flow rate required as a function of fluid temperature at a fluid
temperature > 20 °C
4) If the ambient temperature exceeds the permissible maximum or if the motor is located more than 1000 metres above sea
level, the motor cooling is less effective and the motor might have to be de-rated. The motor load depends on the
installation altitude above sea level or on the ambient temperature. For detailed recommendations contact your sales
house.
5) Fluctuations could require de-rating of the motor. For more detailed recommendations contact your sales house.
6) Pumps which are selected for 50 Hz must not be connected to a 60 Hz mains.
7) Excessive starting/stopping, particularly in combination with high pressure differences (Δp) may reduce the service life of
the product.
8) The clearance above the fan openings of the motor must measure at least 1/4 of the diameter of the fan openings to allow
the (cooling) air to circulate properly.
9) For pumps with VdS certification, the minimum flow rate Q min is 5 % of the permissible flow rate.
Movitec 29 of 62
6.2.2 Pressure and temperature limits
6.2.2.1 Movitec A, B
Movitec A
Table 11: Pressure and temperature limits
Size Pressure Temperature
[bar] [°C]
LHS6 40 120
Movitec B
The pump's pressure and temperature limits are indicated on the name plate. (⇨
6.2.2.2 Shaft seal

Table 12: Available mechanical seals
Mechanical seal Temperature Pressure
Code Type Code Elastomer Design min. max. [bar]
to EN 12756 C E F [°C] [°C]
11 MG-G60 B Q1 E G G EPDM ✘ ✘ ✘ -20 +100 10
12 MG-G60 B Q1 V G G FPM ✘ ✘ ✘ -20 +120 10
13 RMG-G606 Q1 B E G G EPDM WRAS / ✘ ✘ ✘ -20 +100 25
ACS
14 RMG-G606 Q1 B V G G FPM ✘ ✘ ✘ -20 +120 25
15 RMG-G606 U3 U3 X4 G G HNBR ✘ ✘ ✘ -20 +12010) 25
16 RMG-G606 U3 U3 V GG FPM ✘ ✘ ✘ -20 +12010) 25
18 RMG-G606 U3 B E G G EPDM 559236 ✘ ✘ ✘ -20 +12010) 25
20 H7N Q1 A E G G EPDM 559236 ✘ - - -20 +12011) 40
21 H7N Q1 A V G G FPM ✘ - - -20 +12011) 40
22 H7N Q1 A X4 G G HNBR ✘ - - -20 +12011) 40
23 RMG-G606 Q1 B E G G EPDM ✘ ✘ ✘ -20 +100 25
24 MG-G606 Q1 Q1 V G G FPM ✘ ✘ ✘ -20 +120 10
28 MG-G606 Q1 Q1 X4 G G HNBR ✘ ✘ ✘ -20 +120 10
29 MG-G606 Q1 Q1 E G G EPDM ✘ ✘ ✘ -20 +100 10
Table 13: Key to mechanical seal materials
Description Code Contact face materials / secondary seals
to EN 12756
Primary ring B Hard carbon, resin-impregnated
U3 Tungsten carbide (CrNiMo binder)
Q1 Silicon carbide (sintered without pressure)
Mating ring A Carbon graphite, antimony-impregnated
B Hard carbon, resin-impregnated
U3 Tungsten carbide (CrNiMo binder)
Q1 Silicon carbide (sintered without pressure)
Elastomer E EPDM (ethylene propylene rubber)
V Fluoroelastomer (Viton)
X4 HNBR
Spring G CrNiMo steel
Other metal parts G CrNiMo steel
10) Up to 140 °C if the pressure does not exceed 16 bar

11) Up to 140 °C if the pressure does not exceed 25 bar
30 of 62 Movitec
6.2.3 Rated/maximum current

Movitec B
The permissible rated current of the motor supplied is shown on the motor name
plate.
It describes the permissible operating range of the motor and can be used for setting
the overload protection device. If the actual power input is measured during
operation, the motor protection switch can be pre-set to a lower value to protect the
pump set.
Movitec A
The permissible rated current of the motor supplied is indicated on the motor name
plate as Imax.
This maximum permissible current indicates the motor's maximum operating range
and can be used for setting the overload protection device. The actual input power
at 400 V is shown on the pump name plate as Inom. It can be used to pre-set the motor
protection switch in order to protect the pump set.
6.3 Shutdown/storage/preservation
6.3.1 Measures to be taken for shutdown

The pump set remains installed
✓ Sufficient fluid is supplied for the operation check run of the pump.
1. Start up the pump regularly once a month or once every three months for
approximately five minutes during prolonged shutdown periods.
This will prevent the formation of deposits within the pump and the pump
intake area.
CAUTION
Danger of freezing during prolonged pump shutdown periods
Damage to the pump!
▷ The temperature maintenance equipment must remain in operation also during
pump shutdown periods.
The pump set is removed from the piping and stored

✓ The checks and maintenance operations have been performed.
1. Spray-coat the inside wall of the pump casing with a preservative.
2. Spray the preservative through the inlet and outlet nozzles of the fluid
handled.
It is advisable to close the fluid inlet and outlet nozzles afterwards (e.g. with
plastic caps or similar).
Observe any additional instructions and information provided. (⇨ Section 3 Page 11)
6.4 Returning to service

For returning the pump to service observe the sections on commissioning/start-up
(⇨ Section 6.1 Page 26) and the operating limits.
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (⇨ Section 7 Page 33)
Movitec 31 of 62
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant
and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer
seals.
32 of 62 Movitec
7 Servicing/Maintenance
DANGER
Sparks produced during servicing work
Explosion hazard!
▷ Observe the safety regulations in force at the place of installation!
▷ Never open an energised pump set.
▷ Always perform maintenance work on pump sets outside potentially explosive
atmospheres only.
DANGER
Improperly serviced pump set
Explosion hazard!
▷ Service the pump set regularly.
▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.
The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly familiar
with the manual.
WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
▷ Make sure that the pump set cannot be started up unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
WARNING
Fluids and supplies posing a health hazard and/or hot fluids or supplies
Risk of injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps which handle fluids posing a health hazard.
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tipping or falling over.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump, pump set and pump parts with a
minimum of servicing/maintenance expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".
Movitec 33 of 62
Never use force when dismantling and reassembling the pump set.
7.2 Maintenance/inspection
7.2.1 Supervision of operation
DANGER
Explosion hazard!
DANGER
Incorrectly serviced shaft seal
Fire hazard!
Leakage of hot fluids!
▷ Regularly service the shaft seal.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Fire hazard!
▷ Regularly check the condition of the lubricant.
▷ Regularly check the rolling element bearings for running noises.
CAUTION
Increased wear due to dry running
pump operation.
CAUTION
Impermissibly high temperature of fluid handled
Damage to the pump!
▷ Prolonged operation against a closed shut-off element is not permitted
(heating up of the fluid).
▷ Observe the temperature limits in the data sheet and in the section on
operating limits.
While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.
▪ Check the shaft seal.
Visual inspection while rotating the shaft once by hand.
▪ Check the static seals for leakage.
No leakage from the seals is allowed.
▪ Check the rolling element bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
▪ Monitor the correct functioning of any auxiliary connections.
34 of 62 Movitec
7.2.2 Lubrication and lubricant change
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing seals
Fire hazard!
▷ Regularly check the condition of the lubricant.
7.2.2.1 Grease lubrication

The bearings are supplied packed with high-quality lithium-soap grease.
7.2.2.1.1 Intervals
Depending on the pump size and rotational speed, re-lubricate the rolling element
bearings at regular intervals or replace the grease in the rolling element bearings.
NOTE
On some pump designs the rolling element bearings are lubricated for life. These
pumps are not provided with a lubricating nipple on the bearing bracket.
NOTE
If re-lubrication intervals are short, we recommend that the grease be completely
replaced once a year.
Otherwise, the grease fill must be replaced completely every two years. To do so,
remove the rolling element bearings, clean and pack with new grease.
Motors with lubricating nipple must be re-lubricated every 2000 hours.
If the pump is operated under extreme conditions, such as vibrations or high
temperatures, the motors must be re-lubricated more frequently.
7.2.2.1.2 Grease quality

Optimum grease properties for rolling element bearings
▪ High melting point lithium soap base grease
▪ Free of resin and acid
▪ Not liable to crumble
▪ Rust-preventive characteristics
7.2.2.1.3 Grease quantity

Use 15 grams of grease per bearing.
7.2.2.1.4 Re-lubricating with grease
WARNING
Work in the immediate vicinity of rotating parts
Risk of hand injuries!
▷ Always have this work performed by trained personnel.
▷ Take particular caution when performing this work.
Movitec 35 of 62
CAUTION
Contaminated lubricating nipples
Contamination of the lubricating grease!
▷ Clean the grease lubricating nipples before re-lubricating them.
1. Clean the lubricating nipples, if contaminated.
2. Position the grease press on the lubricating nipple.
3. Press in the grease.
7.3 Drainage/cleaning
WARNING
Fluids, consumables and supplies which are hot and/or pose a health hazard
▷ Collect and properly dispose of flushing fluid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
If the pump set has handled fluids whose residues could lead to corrosion in the
presence of atmospheric humidity or could ignite upon contact with oxygen, the
pump set must be neutralised, and anhydrous inert gas must be blown through the
pump to ensure drying.
The pump is fitted with nozzles for draining.
The pump must not be drained while it is in operation!
1 2
Fig. 11: Connections for draining the pump

1 Connection for draining the 2 Connection for draining the
suction section discharge section
7.4 Dismantling the pump set
7.4.1 General information/Safety regulations
WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
36 of 62 Movitec
WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
WARNING
Observe the general safety instructions and information. (⇨ Section 7.1 Page 33)
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly observe the exploded views and the general
assembly drawing.
In case of damage you can always contact our service staff.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. Find your contact in the attached "Addresses" booklet or on
the Internet at "www.ksb.com/contact".
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set.
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure.
▷ Close any auxiliary connections.
NOTE
After a prolonged period of operation the individual components may be hard to
pull off the shaft. If this is the case, use a brand name penetrating agent and/or - if
possible - an appropriate puller.
7.4.2 Preparing the pump set
DANGER
Power supply not disconnected
Danger to life!
▷ Disconnect all electrical connections from the power supply and secure against
unintentional start-up.
1. De-energise the pump set and secure it against unintentional start-up.
Movitec 37 of 62
7.4.3 Removing the motor
WARNING
Motor tipping over
▷ Suspend or support the motor to prevent it from tipping over.
✓ Energy supply is disconnected.
862
914.01 550
681
914.05 554.02
901.02
901.04
554.04
Fig. 12: Removing the motor

1. Undo hexagon socket head cap screws 914.01.
2. Remove coupling guard 681.
4. Take off coupling 862 with pin 560.
5. Unscrew and remove hexagon head bolts 901.02 or 901.04 and washer 554.02
or 554.04.
6. Lift the motor off the pump.
7.4.4 Removing the retaining bracket (optional)

✓ The motor has been removed. (⇨ Section 7.4.3 Page 38)
1. Remove retaining bracket 89-11.03
38 of 62 Movitec
89-11.03
862 560
914.01
681 862
914.05 920.01
341
554.02
901.02
210
Fig. 13: Removing retaining bracket 89-11.03
7.4.5 Removing the mechanical seal
7.4.5.1 Fixed seal
920.03
433
412.01
Fig. 14: Removing the mechanical seal

1. Undo nuts 920.03 and lift off the drive lantern.
2. Remove mechanical seal 433 and O-rings 412.01.
Movitec 39 of 62
7.4.5.2 Easy access seal
914.03
969
412.06
433

2. Remove O-ring 412.06.
3. Remove the mechanical seal 433 using tool 969.
7.4.5.3 Cartridge seal
914.03
433
412.06

2. Remove mechanical seal 433.
3. Remove O-ring 412.06.
40 of 62 Movitec
7.5 Reassembling the pump set
WARNING
CAUTION
Improper reassembly
Damage to the pump!
▷ Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
▷ Use original spare parts only.
NOTE
Use suitable tools for setting the pump shaft!
Consult KSB if necessary.
Sequence Always reassemble the pump set in accordance with the corresponding general
assembly drawing.
Sealing elements ▪ O-rings
– Check O-rings for any damage and replace by new O-rings, if required.
▪ Assembly adhesives
– Avoid the use of assembly adhesives, if possible.
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.
7.5.2 Installing the mechanical seal
CAUTION
Incorrect installation of mechanical seal
▷ Assembly/installation should only be carried out by qualified specialist
personnel.
Installing the The following rules must be observed when installing the mechanical seal:
mechanical seal ▪ Work cleanly and accurately.
▪ Only remove the protective wrapping of the contact faces immediately before
installation takes place.
▪ Prevent any damage to the sealing surfaces or O-rings.
Movitec 41 of 62
7.5.2.1 Fixed seal
920.03
433
412.01
Fig. 17: Fitting the mechanical seal

1. Insert mechanical seal 433 and O-rings 412.01.
2. Fit the drive lantern. Screw on nuts 920.03.
3. Adjust mechanical seal 433.
7.5.2.2 Easy access seal
914.03
969
412.06
433

1. Insert the mechanical seal 433 using tool 969.
2. Insert O-ring 412.06.
3. Screw in hexagon socket head cap screws 914.03.
42 of 62 Movitec
7.5.2.3 Cartridge seal
914.03
433
412.06

1. Insert O-ring 412.16.
2. Insert mechanical seal 433.
7.5.3 Mounting the motor
WARNING
Motor tipping over
▷ Suspend or support the motor to prevent it from tipping over.
NOTE
It is recommended to use a specially designed KSB motor.
The motor must meet the following conditions:

▪ Reinforced bearing at the driven end
(absorbing the axial forces)
▪ Motor fastened axially
(minimising the axial clearance of the hydraulic system of the pump)
▪ Non-keywayed shaft
(improving the coupling connection and smooth running of the motor)
▪ The rated power must be suitable for the relevant operating frequency.
▪ The effective speed must always be complied with for pumps with VdS
certification.
▪ The frame size must be suitable for connecting the motor to the drive lantern.
Table 14: Recommended motor bearing at the drive end
Motor rating 1-phase 3-phase
[kW] 50 Hz 50/60 Hz
2-pole 4-pole
0,25 - - 6202-2Z-C3
0,37 6202-2Z-C3 6203-2Z-C3 6202-2Z-C3
Movitec 43 of 62
Motor rating 1-phase 3-phase

[kW] 50 Hz 50/60 Hz
2-pole 4-pole
0,55 6202-2Z-C3 6203-2Z-C3 6202-2Z-C3
0,75 6204-2Z-C3 6204-2Z-C3 6202-2Z-C3
1,1 6204-2Z-C3 6204-2Z-C3 6205-2Z-C3
1,5 6305-2Z-C3 6305-2Z-C3 6205-2Z-C3
2,2 6305-2Z-C3 6305-2Z-C3 6206-2Z-C3
3,0 - 6306-2Z-C3 6206-2Z-C3
4,0 - 6306-2Z-C3 6208-2Z-C3
5,5 - 6308-2Z-C3 6208-2Z-C3
7,5 - 6308-2Z-C3 6208-2Z-C3
11,0 - 7309-BEP -
15,0 - 7309-BEP -
18,5 - 7309-BEP -
22,0 - 7311-BEP -
30,0 - 7312-BEP -
37,0 - 7312-BEP -
45,0 - 7313-BEP -
862
914.01 550
681
914.05 554.02
901.02
901.04
554.04
Fig. 20: Mounting the motor

✓ Retaining bracket 89-11.03 (if applicable) has been removed. (⇨ Section 7.4.4
Page 38)
1. Align the motor on the drive lantern.
44 of 62 Movitec
2. Screw in hexagon head bolts 901.02 or 901.04 and washer 554.02 or 554.04.
CAUTION
Incorrect installation of coupling
▷ The coupling must be installed by qualified specialist personnel.
3. Insert coupling 862 with pin 560.
5. Fit coupling guard 681.
7.5.4 Adjusting the mechanical seal, coupling and pump shaft
NOTE
Use suitable tools for setting the pump shaft!
Consult KSB if necessary.
NOTE
Motors ≥ 11 kW: lock rotor before adjusting the coupling. This will prevent the
rotor from being lifted out of the bearings.
Movitec B
✓ The motor has been mounted on the pump. (⇨ Section 7.5.3 Page 43)
✓ Coupling 862 has been fastened with pin 560 and screws 914.01.
Movitec 45 of 62
1. Lower the coupling 862 to its lowest position, then raise it again by 1.5 mm.
Fixed seal / Easy access seal
Cartridge seal
A
A
2. Verify that no clearances remain between the coupling halves, and fasten the
coupling in this position.
Movitec A
✓ The motor has been mounted on the pump.
✓ Coupling 862 has been fastened with pin 560 and screws 914.01.
46 of 62 Movitec
1. Raise coupling 862 to its highest position, then lower it again by 1 mm.
1
2. Verify that no clearances remain between the coupling halves, and fasten the
coupling in this position.
7.6 Tightening torques

Table 15: Tightening torques
Part No. Thread Torque
[Nm]
801 M6 10
801 M12 70
801 M16 70
903.01 G 3/8 15
903.02 G 1/4 1512)
914.01 M6 steel 16
914.01 M8 steel / grey cast iron 30
914.01 M8 aluminium 22
914.01 M10 70
914.02 M6 10
914.02 M8 10
914.02 M10 50
914.02 M12 70
914.02 M16 70
914.03 M5 4+2
914.03 M6 10
914.03 M8 10
920.02 M10 28
920.02 M12 50
920.03 M8 12
920.03 M10 20
920.03 M12 25
920.03 M16 50
12) For Movitec 45, 65 and LHS 6 = 10 Nm
Movitec 47 of 62
7.7 Spare parts stock
7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:
▪ Type series
▪ Size
▪ Material variant
▪ Seal code
▪ Order number
▪ Order item number
▪ Consecutive number
▪ Year of construction
Refer to the name plate for all data.
Also specify the following data:
▪ Part No. and description
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)
48 of 62 Movitec
8 Trouble-shooting
8 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work to remedy faults observe the relevant information in this manual
or in the relevant accessory manufacturer's documentation.
If problems occur that are not described in the following table, consultation with
KSB’s customer service is required.
Table 16: Trouble-shooting
Fault/malfunction Causes Remedy
Leakage along the shaft Contact surface of the primary rings of ▪ Replace the shaft seal.
the mechanical seal worn or damaged ▪ Check pump for impurities.
Axial movement of the mechanical seal ▪ Quickly open and close the
is restricted because it is stuck. discharge-side valve during
operation.
Shaft seal fitted incorrectly ▪ Re-install shaft seal correctly (use
water and soap as a lubricant).
Elastomers damaged by the fluid ▪ Use a suitable elastomer for the
handled shaft seal.
Total operating pressure too high ▪ Use a shaft seal with suitable
pressure class.
Shaft is damaged. ▪ Replace the shaft.
Pump running dry ▪ Replace the shaft seal.
Leakage at the casing cover and O-ring worn ▪ Replace the O-ring.
the lower section of the pump O-ring not resistant to fluid handled ▪ Replace O-ring with O-ring made of
casing suitable material.
Pump not installed free from stresses ▪ Connect the piping properly.
and strains
Pump vibrates and causes Coupling fitted incorrectly ▪ Make sure the coupling halves are
running noises. parallel.
Rotor adjusted incorrectly ▪ Re-adjust rotor.
Pump not primed ▪ Prime and vent the pump.
No or insufficient inflow ▪ Provide sufficient supply.
▪ Check inlet line for clogging.
Bearings of pump and/or motor ▪ Replace bearings.
defective
NPSH available too low (cavitation) ▪ Improve suction conditions.
Pump not working in its operating ▪ Adjust system to operation within
range. operating range or select different
pump.
Pump clogged ▪ Clean pump.
Pump positioned on an uneven surface ▪ Level the surface or rigidly fasten
pump to installation surface.
Pump does not start. No voltage at the terminals ▪ Check power supply (circuit, master
switch, fuses).
Thermal motor protection device has ▪ Re-set thermal motor protection
tripped. (Inom see name plate).
Motor running but pump does Motor shaft defective ▪ Contact supplier.
not start. Pump shaft defective ▪ Contact supplier.
Shaft coupling has become loose. ▪ Tighten the fastening screws.
Insufficient/excessive delivery Valves in suction and discharge lines ▪ Open shut-off valves.
and/or insufficient pressure closed
Air in the pump ▪ Vent pump.
Insufficient inlet pressure ▪ Increase inlet pressure.
Wrong direction of rotation ▪ Check electrical connection.
Suction line not vented. ▪ Vent suction line.
Air pocket in suction line ▪ Lay suction line with a rising slope
towards the pump.
Movitec 49 of 62
8 Trouble-shooting
Fault/malfunction Causes Remedy

Pump takes in air due to leakage in ▪ Repair.
suction line.
Insufficient flow rate leads to air ▪ Use smaller pump.
remaining in the pump. ▪ Increase the (volume) flow rate.
Diameter of suction line too small ▪ Increase diameter of suction line.
Foot valve clogged. ▪ Clean foot valve.
Impeller or diffuser clogged ▪ Clean pump.
O-ring not resistant to fluid handled ▪ Replace O-ring with O-ring made of
suitable material.
50 of 62 Movitec
9 Related Documents
9 Related Documents
9.1 General assembly drawings/exploded views with list of components
9.1.1 Movitec 2B, 4B, 6B
800
341 554.02
920.01 901.02
914.01 681
862 914.05
560
914.03 903.01
471 412.07
412.06 920.03
554.01
950 433
108.05 525.06
412.01 905
932 160
10-6 210
108.01 525.05
108.02 525.03
230 525.01
412.03 529
108.04 525.04
101 930
400 920.02
903.02
412.04
723
554.03
901.03
890
Fig. 21: General assembly drawing of Movitec 2B, 4B, 6B

Table 17: List of components
Part No. Description Part No. Description
10-6 Pump shroud 560 Pin
101 Pump casing 681 Coupling guard
108 Stage casing 723 Flange
160 Cover 800 Motor
210 Shaft 862 Coupling
230 Impeller 890 Baseplate
341 Drive lantern 901 Hexagon head bolt
400 Gasket 903 Vent plug
412 O-ring 905 Tie bolt
433 Mechanical seal 914 Hexagon socket head cap screw
471 Seal cover 920 Nut
525 Spacer sleeve 930 Safety device
529 Bearing sleeve 932 Circlip
554 Washer 950 Spring
Movitec 51 of 62
9 Related Documents
9.1.2 Movitec 10B, 15B
800
341
920.01
914.01
862 554.02
560 901.02
914.03 681
471 914.05
903.01
412.06
950 412.07
920.03
108.05 554.01
412.01 433
932 525.06
10-6 160
108.01 525.05
230 905
108.02 210
412.03 525.03
525.01
108.04
529
525.01
101 525.04
131 930
400 920.02
723
544.03 903.02
901.03 412.04
890
Fig. 22: General assembly drawing of Movitec 10B, 15B

10-6 Pump shroud 554 Washer
101 Pump casing 560 Pin
108 Stage casing 681 Coupling guard
131 Inlet ring 723 Flange
160 Cover 800 Motor
210 Shaft 862 Coupling
230 Impeller 890 Baseplate
400 Gasket 903 Vent plug
471 Seal cover 920 Nut
544 Threaded bush 950 Spring
52 of 62 Movitec
9 Related Documents
9.1.3 Movitec 25B, 40B, 60B
800
341
920.01 554.02
914.01 901.02
862 681
560
914.03
903.01
433.02 412.07
412.06 920.03
554.01
412.01
932 433
160
525.06
108.05 525.05
230 905
412.03 525.02
108.01 210
525.03
525.02
10-6
108.02 529
509.03 525.01
0.8
131 525.04
930
101
920.02
903.02
412.04
890
Fig. 23: General assembly drawing of Movitec 25B, 40B, 60B

10-6 Pump shroud 554 Washer
101 Pump casing 560 Pin
108 Stage casing 681 Coupling guard
131 Inlet ring 800 Motor
160 Cover 862 Coupling
210 Shaft 890 Baseplate
230 Impeller 901 Hexagon head bolt
341 Drive lantern 903 Vent plug
509 Intermediate ring 920 Nut
544 Threaded bush
Movitec 53 of 62
9 Related Documents
9.1.4 Movitec 90B
901.04
554.04
801
722 914.02
890
341.01
914.05
914.01 681
862
580
500
904
914.03
471
412.06
525.07 903.01
433 412.07
920.03
412.06
554.01
160
341.02
932
525.05 10-6
905
525.03
210
108.01
230.01
230.02
412.03
525.02
529
108.02
525.01
230.01
525.02
108.01
525.03
230.01
412.01
503
525.04
930
920.02
101
903.02
412.04
890
Fig. 24: General assembly drawing of Movitec 90B

108 Stage casing 580 Cap
160 Cover 681 Coupling guard
230 Impeller 722 Double-flanged adapter
341 Drive lantern 801 Flanged motor
412 O-ring 862 Coupling
433 Mechanical seal 890 Baseplate
471 Seal cover 901 Hexagon head bolt
500 Ring 904 Grub screw
503 Impeller wear ring 914 Hexagon socket head cap screw
525 Spacer sleeve 920 Nut
529 Bearing sleeve 930 Safety device
554 Washer 932 Circlip
54 of 62 Movitec
9 Related Documents
9.1.5 Movitec LHS 6
901.04
554.04
801
722
920.05
341
554.02
862
901.02
560
914.01
903.01 920.01
411.01 901.01
433 681
920.03
412.01
554.01
108.05
932
10-6
525.05
230
412.03 905
108.01 210
525.03
108.02
525.02
108.04
529
525.01
412.01
930
101
920.02
525.04
920.02 411.04
Fig. 25: General assembly drawing of Movitec LHS 6

10-6 Pump shroud 560 Pin
101 Pump casing 681 Coupling guard
108 Stage casing 722 Double-flanged adapter
210 Shaft 801 Flanged motor
230 Impeller 862 Coupling
411 Joint ring 903 Vent plug
525 Spacer sleeve 920 Nut
529 Bearing sleeve 930 Safety device
554 Washer 932 Circlip
Movitec 55 of 62
9 Related Documents
9.1.6 Movitec motor
1~
837
832
832
831
400.02
833
835
400.03 833
81-37
800/801 900.01
412.01
82-5
900.02
400.03
1,5 - 7,5 kW
0,37 - 1,1 kW 400.02

903
81-55
900.03
Fig. 26: Exploded view of Movitec motor

400 Gasket 831 Fan impeller
800 Motor 832 Fan hood
801 Flanged motor 833 Terminal box
81-37 Terminal box cover 835 Terminal board
81-55 Socket 837 Capacitor
82-5 Adapter 900 Screw
56 of 62 Movitec
9 Related Documents
9.2 Wiring diagram
Fig. 27: Wiring diagram, depending on selected motor
Movitec 57 of 62
10 EC Declaration of Conformity
10 EC Declaration of Conformity
Manufacturer: KSB B.V.

Kalkovenweg 13
2401 LJ Alphen aan den Rijn (The Netherlands)
The manufacturer herewith declares that the product:
Movitec
Serial number: 18/2012 1000000-0001 - 52/2016 9999999-9999
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): EC Machinery Directive 2006/42/EC
– Pump (set): Ecodesign Directive 2009/125/EC, Regulation 547/2012
(for water pumps with a maximum shaft power of 150kW)
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
Person authorised to compile the technical file:
Wil Ouwehand
Technical Director
KSB B.V.
(subsidiary DP Industries B.V.)
Kalkovenweg 13
2401 LJ Alphen aan den Rijn (The Netherlands)
The EC Declaration of Conformity was issued in/on:
Alphen aan den Rijn, 1 February 2014
Wil Ouwehand
Technical Director
KSB B.V.
Kalkovenweg 13
2401 LJ Alphen aan den Rijn
58 of 62 Movitec
11 Certificate of Decontamination
Type: ................................................................................................................................
Order number/
Order item number13): ................................................................................................................................
Delivery date: ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled13): ................................................................................................................................
Please tick where applicable13):
⃞ ⃞ ⃞ ⃞
Radioactive Explosive Corrosive Toxic
⃞ ⃞ ⃞ ⃞
Harmful Bio-hazardous Highly flammable Safe
Reason for return13): ................................................................................................................................
Comments: ................................................................................................................................
................................................................................................................................
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.
On seal-less pumps, the rotor has been removed from the pump for cleaning.
⃞ No special safety precautions are required for further handling.

⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:
...............................................................................................................................................................
...............................................................................................................................................................
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with
the relevant legal provisions.
.................................................................... ....................................................... .......................................................

Place, date and signature Address Company stamp
13) Required fields
Movitec 59 of 62
Index
Index
B Installation types 16
Intended use 8
Bearings 17
M
C Misuse 9
Certificate of decontamination 59
Commissioning 26
Configuration 17 N
Name plate 15
D
Design 16 O
Direction of rotation 25 Operating limits 8
Dismantling 37 Other applicable documents 6
Disposal 13
Drive 16
P
E Partly completed machinery 6
Permissible forces at the pump nozzles 22
Electrical connection 23 Piping 20
Event of damage Preservation 12, 31
Ordering spare parts 48 Product description 14
Explosion protection 22, 23, 33, 34
F R
Reassembly 37
Fault/malfunction 49 Return to supplier 13
Function 17 Returning to service 31
G S
Grease lubrication Safety 8
Grease quality 35 Safety awareness 9
Intervals 35 Scope of supply 17
Servicing/Maintenance 34
I Shaft seal 16
Shutdown 31
Installation Spare part
Installation on a foundation 19 Ordering spare parts 48
Installation at site 19 Storage 12, 31
60 of 62 Movitec
1798.82/07-EN (01424629)
KSB Aktiengesellschaft
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0 • Fax +49 6233 86-3401
www.ksb.com
PART 2
FIRE WATER PUMP SET (OMEGA)
Operating Manual
Diesel Pump Set With Sprinkler Pump
For Fire-Fighting Application According To FM
KAGEMA Industrieausrüstungen GmbH

Adenser Str.1
30982 Pattensen
GERMANY
Tel: +49 5069 9093 - 0
Fax: +49 5069 9093 - 90
www.kagema.com
Operating Manual
The documentation and wiring diagrams must be available at the diesel pump set at all times. The
pump set must not be installed and be operated without the documentation and wiring diagrams.
All rights reserved.
Use only for intended purpose. It may not be translated into other languages either fully or partially
without prior written permission.
Technical changes reserved.

© 2019 KAGEMA Industrieausrüstungen GmbH / A KSB Company
Version 2019/1
KAGEMA Industrieausrüstungen GmbH 2
Contents
1 Notes on using the operating manual ............................................................................................ 5

1.1 Validity of the operating manual .............................................................................................. 5
1.2 Nameplates.............................................................................................................................. 5
1.2.1 Nameplate of the pump unit ..................................................................................................... 5
1.2.2 Nameplate of fuel tank ............................................................................................................. 6
1.3 Symbols ................................................................................................................................... 6
1.3.1 Hazard symbols ....................................................................................................................... 6
1.3.2 Prohibitive symbols .................................................................................................................. 8
1.3.3 Symbols for personal protective equipment ............................................................................. 8
1.3.4 Note symbols ........................................................................................................................... 9
2 Technical informationen .................................................................................................................. 9
2.1 Parts of the diesel pump set .................................................................................................... 9
2.2 Technical data ......................................................................................................................... 9
3 Safety ............................................................................................................................................... 10
3.1 General safety instructions .................................................................................................... 10
3.2 Safety notes for service and maintenance ............................................................................ 11
3.3 Safety notes for electrical work.............................................................................................. 12
3.4 Behavior in accidants with damage to persons ..................................................................... 12
3.5 Personnel qualifications ......................................................................................................... 12
3.6 Obligations of the operating company ................................................................................... 13
3.7 Intended use .......................................................................................................................... 14
3.8 Improper use.......................................................................................................................... 14
3.9 Safety and protective equipment ........................................................................................... 14
3.10 Safety signs and labels at diesel pump unit .......................................................................... 15
3.11 Residual risk .......................................................................................................................... 16
4 Scope of supply and transport ..................................................................................................... 18
4.1 Scope of supply ..................................................................................................................... 18
4.2 Transport ............................................................................................................................... 18
5 Assembly, installation and initial start-up ................................................................................... 19
5.1 Safety instructions for assembly ............................................................................................ 19
5.2 Electrical installation .............................................................................................................. 20
5.3 Assembly and installation ...................................................................................................... 21
5.4 Initial start-up ......................................................................................................................... 25
6 Operation ......................................................................................................................................... 25
6.1 Operating elements and displays at the control unit ............................................................. 26
6.2 Start-up .................................................................................................................................. 27
6.3 Automatic operation of the diesel pump set .......................................................................... 27
6.3.1 Starting the engine automatically ........................................................................................... 27
6.3.2 Stopping the engine ............................................................................................................... 28
Version 2019/1
6.4 Manual operation ................................................................................................................... 28

6.5 Test, Trial operation ............................................................................................................... 28
6.5.1 Cooling procedure for engine ................................................................................................. 30
6.6 Shutdown ............................................................................................................................... 30
7 Faults and troubleshooting ........................................................................................................... 31
7.1 Safety instructions for troubleshooting .................................................................................. 31
7.2 Shutdown for troubleshooting ................................................................................................ 32
7.3 Restart after troubleshooting ................................................................................................. 32
8 Maintenance .................................................................................................................................... 32
8.1 Safety notes for service and maintenance ............................................................................ 33
8.2 Maintenance intervals ............................................................................................................ 34
8.3 Maintenance activities ............................................................................................................ 34
8.3.1 Securing against automatic start-up ....................................................................................... 34
8.3.2 Visual inspection of the diesel pump set ................................................................................ 34
8.3.3 Checking safety signs and labels ........................................................................................... 34
8.3.4 Cleaning ................................................................................................................................. 34
8.3.5 Checking the fuel level ........................................................................................................... 35
8.3.6 Checking operating fluid levels of diesel engine .................................................................... 35
8.4 Restart after maintenance ..................................................................................................... 35
9 Storage ............................................................................................................................................ 36
10 Disassembly and disposal ............................................................................................................ 36
11 Spare parts ...................................................................................................................................... 36
12 Maintenance log ............................................................................................................................. 37
Appendix .............................................................................................................................................. 38
Version 2019/1
1 Notes on using the operating manual

This operating manual is an integral part of the diesel pump set.
As a central part of the user documentation the operating manual has a special significance.
Observing the contained instructions, data and regulations helps you to operate and install the diesel
pump set safely and with a minor failure probability.
We reserve the right to make technical changes.
1.1 Validity of the operating manual
This manual is valid for the diesel pump set.

The project-no. can be found in the corresponding product data sheet.
1.2 Nameplates
1.2.1 Nameplate of the pump unit
The nameplate is attached to the side of the pump unit.
Figure 1: Nameplate of the pump unit (example)
Version 2019/1
1.2.2 Nameplate of fuel tank
The nameplate is attached to the fuel tank.
Figure 2: Nameplate of the fuel tank (example)
1.3 Symbols
The following symbols represent very important information in the operating manual:
1.3.1 Hazard symbols
Danger!
This sign indicates an immediate danger to the life and health of persons, up to
perilous injuries or death.
Danger!
Danger due to electrical power!
This sign indicates dangers due to electrical power.
Danger!
Crush hazard!
The texts marked with this sign inform about dangerous situations with crush
hazard for the entire body.
Warning!
Warning of hand injuries!
This sign indicates dangerous situations with limb crush hazard.
Version 2019/1
Danger!
Draw-in hazard!
The texts marked with this sign inform about dangerous situations with draw-in
hazard for clothes and limbs.
Danger!
Fire hazard!
The texts marked with this sign inform about dangerous situations with fire
hazard.
Danger!
Danger due to suspended loads!
The texts marked with this sign inform about dangerous situations with dangers
due to suspended loads.
Danger!
Danger of tipping over!
The texts marked with this sign inform about dangerous situations where there is
a danger of the machine tipping over.
Warning!
Trip hazard!
The texts marked with this sign inform about dangerous situations with trip
hazard.
Danger!
Fall hazard!
The texts marked with this sign inform about dangerous situations with fall
hazard.
Danger!
Danger due to automatic start-up!
The texts marked with this sign inform about dangerous situations due to
automatic start-up of the diesel pump set.
Danger!
Danger due to hot surfaces!
The texts marked with this sign inform about dangerous situations due to hot
surfaces.
Dangerous for the environment!

This sign indicates that the used substances are environmentally hazardous.
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1.3.2 Prohibitive symbols
Access for unauthorized persons prohibited!

The texts marked with this sign inform that the indicated place must not be
entered by unauthorized people.
Fire and open flames are prohibited!

This symbol informs you that fire and open flames are prohibited in this area.
Smoking is prohibited!
This symbol informs you that smoking is prohibited in this area.
.
1.3.3 Symbols for personal protective equipment
Wear a safety helmet.
Wear ear protection.
Wear safety glasses.
Wear protective clothing.
Wear safety gloves.

It will be expressly pointed out when insulating protective gloves are to be worn.
Wear safety boots.
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1.3.4 Note symbols
Note!
This symbol indicates general notes. It is accompanied by this pictogram and the
word Note in bold print.
2 Technical informationen
2.1 Parts of the diesel pump set
The diesel pump set with sprinkler pump consists of

 drive unit
 pump unit
 coupling unit
 fuel tank unit
 control panel unit
 base frame
 battery set
 exhaust gas noise muffler (loose delivery)
2.2 Technical data
You can find the technical data in the product data sheet.
Irrespective of the data given in the product data sheet note following operation conditions:
 min. +5°C ambient temperature in the pump room for diesel driven pump sets
Note!
Also note the instructions in the corresponding regulations.
The operator must ensure a sufficient ventilation in the pump room.
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3 Safety
3.1 General safety instructions
The diesel pump set is designed and built according to the current state of the art and recognised
safety regulations. However, operating the diesel pump set can lead to dangers for the user's or third
party's life and limb. Damages to the diesel pump set and other material assets are also feasible.
Observe the following safety instructions:
Danger!
Danger due to automatic start-up.
When ready for operation the diesel pump set might start automatically at any
time. Stay away from rotating and moving parts.
Danger!
Danger due to running system.
After automatic start-up the system must not stop and even in the case of an error
should be kept running for as long as possible. Stopping of the diesel pump set
would be in violation of the superordinate admission rule.
It is imperative to observe the superordinate admission rule of the plant.
 Wear safety shoes and suitable gloves during all work at the diesel pump
set.
 Note all safety and hazard notes at the diesel pump set.
 Keep all safety and hazard notes at the diesel pump set readable.
 Note all national health, safety at work, accident prevention, fire protection
and environment protection regulations. The personnel working with the
diesel pump set must be familiar with these regulations.
 The manual instruction must be available all the time for the personnel
working with the diesel pump set.
 The work at the diesel pump set and components must always be done
carefully.
 Nobody is allowed in the direct danger zone of the diesel pump set.
 For potential emergencies ensure that the location and handling of first-
aid equipment are made known. Also instruct the operating personnel
regarding medical care in case of accidents.
 Assign the responsibilities before work begins.
 Changes at the diesel pump set and the components without compliance
of the manufacturer are not allowed.
 Do not remove protection devices.
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3.2 Safety notes for service and maintenance
Note following safety notes before service and maintenance:

 Have maintenance and repair work carried out by qualified and authorized personnel only.
 Ensure before maintenance and repair work that the diesel pump set cannot start
automatically. Turn off the main fuse before.
 Note all the safety instructions given in the operating manuals of the single components of the
diesel pump set.
 Inform the operating company before special work or maintenance work is carried out. Appoint
a supervisor.
 For the execution of maintenance work please contact the customer service of KAGEMA
Industrieausrüstungen GmbH. If a customer makes improper changes to the diesel pump set
the warranty becomes void.
 Largely cordon off the maintenance area, as required.
 Observe the maintenance, inspection and lubrication intervals specified in the operating
manual (also see appendix).
 Always wear safety boots and protective clothing.

 When working near engines or moving parts only wear close-fitting
clothing, no pendants (or other dangling jewellery) and keep your hair
tied up.
 Protect your hands by use of hand cream.
 Principally wear protective gloves and safety glasses during the following
tasks:
- Filling in inhibitors or antifreeze mixture.
- Changing or refilling fuel and lube oil (hot engine oil may cause burns.
Only carry out the task when the oil has cooled down to below 50 °C).
 Wear safety glasses when working with compressed air (max. air
pressure for engine cleaning less than 200 kPa (2 bar, 30 psi, 2 kg/cm²).
 For all work taking place inside the pump room, avoid contact with
rotating or intensely heated components. Proceed carefully.
 When working near suspended loads or technical installations at face
value always wear a hard hat.
 When performing maintenance work above head height use a stable
ladder or other safe climbing aids.
 Only use suitable tools when carrying out maintenance measures.
 Spare parts must correspond to the technical requirements specified by
KAGEMA Industrieausrüstungen GmbH. This is always ensured when
using original spare parts.
 Do not leave objects on the unit.
 Upon completion of maintenance, inspection and repair work reattach any
disconnected safety devices and check them for proper function.
 Cover any opened ducts when the work is completed.
 Immediately take off work clothing soaked with lubricant.
 Keep the engine clean. Immediately eliminate splashes of oil, diesel fuel
and coolant.
 Store cleaning rags soaked with lubricant in flame-retardant containers.
 Keep sufficiently dimensioned and safe waste oil containers available.
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3.3 Safety notes for electrical work
Danger!
Hazardous electric voltage!
Observe the following safety instructions for working on the electrical system of
the diesel pump set:
When working on the electrical equipment adhere to the following safety
regulations:
1. Disconnect from the main net voltage.
2. Secure against restart.
3. Check for de-energized status.
4. Earth and short circuit.
5. Cover live parts.
 Work on the electrical system may only be carried out by skilled electricians
or instructed persons supervised by a skilled electrician according to
electrical engineering rules and regulations.
 The electrical equipment must be regularly inspected / checked by trained
electricians.
 Defects such as loose connections or scorched cables must be remedied
immediately.
 Do not work on live parts of the electrical system.
 If a short circuit occurs there is a risk of sparking and fire. Only use original
fuses with the specified current intensity and tripping characteristic. Before
replacing a blown fuse find the cause and rectify the fault.
 If it is necessary to work on live parts only use insulated tools. Call in another
person which can disconnect the main fuse in case of an emergency.
 Cordon off the working area with a red and white safety chain and a warning
sign.
3.4 Behavior in accidants with damage to persons
 Shut down the diesel pump set.

 Render first aid.
 Inform the fire service, the rescue service and the company management about the accident.
 Secure the scene of accident.
3.5 Personnel qualifications
 Secure that only instructed personnel works at the diesel pump set and the components.
 It is only allowed to personnel which knows the operating manual to work at the diesel pump
set.
 Trainees working with the diesel pump set or components must always be under supervision.
 The individual work on the pump set requires varies personnel qualification listed in table 1.
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The various qualifications comprise the following skills and knowledge:

 Instructed persons who operate the plant must be able to recognise potential damages and
dangers at the installation.
 Electrically qualified personnel must be able to read and understand electric circuit diagrams,
commission and maintain electrical systems to wire switch and control cabinets, to install
controlling software, to ensure proper functioning of electrical components and to identify
possible hazards in the work with electric and electronic systems.
 Trained industrial mechanics must be able to read and understand machine drawings, to carry
out mechanical maintenance work, to ensure the functionality of mechanical components and
to identify possible hazards in the work with mechanical components.
Table 1 : Overview of the minimum required personnel qualification
3.6 Obligations of the operating company
The operator must check on the staff to make sure that they are aware of dangers and to ensure safe
working in accordance with the plant´s directives and train the personnel at regular intervals, if
required.
The installation supplied by KAGEMA Industrieausrüstungen GmbH is part of a sprinkler system and
must be integrated in the entire system by the operator in terms of control circuits as well as related to
safety.
Before start-up the operator must ensure that
 the pump room meets the given requirements.
 only authorized personnel can access the pump room.
 the diesel pump unit is integrated in the entire system according to the specifications in the
electrical documentation.
 all operating and display elements are connected according to the electrical documentation.
 a sufficient water supply is available for the system.
 safety and protective installations function properly.
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 during operation there is sufficient ventilation and an exhaust gas pipeline available for the
diesel pump set.
 supply lines and cables are installed in ducts in a way to avoid trip hazards.
3.7 Intended use
The diesel pump set is only intended to be used for fire-fighting application according to FM regulations.
The diesel pump set may only be operated in rooms with locked access doors.
The diesel pump set must only be started manually in trial and emergency operation if it is in a
technically perfect condition and when the operator is aware of safety and dangers.
Intended use also includes
 observing this operating manual
 observing the corresponding operating instructions of the control unit
 observing the project data sheet
 observing the directives of the plant
 observing the maintenance and service intervals
3.8 Improper use
Using the diesel pump set for any other pupose than described in chapter 3.7 is regarded as improper
use.
Pumping any other medium than described in chapter 3.7 is regarded as improper use.
Operation by insufficiently qualified personnel is considered as improper use.
KAGEMA Industrieausrüstungen GmbH is not liable for any damages resulting from improper use.
3.9 Safety and protective equipment
Danger!
Risk of death due to protective equipment that is either not in use or inoperative.
The plant's operating company must ensure that the safety and protective
equipment is functioning properly and in use.
The protective devices listed below are installed on the diesel pump set. If the
protective equipment is inoperative the diesel pump set must not be put into
operation under any circumstances. The protective installations must be
repaired first or replaced by functioning ones.
 protective cover for the fan belt and alternator
 protective cover for coupling
 high-temperature mats or covers around the exhaust manifold to avoid
direct contact with the hot surface
 terminal covers at batteries
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3.10 Safety signs and labels at diesel pump unit
The following safety signs and labels are attached to the diesel pump s e t. Check them regularly. If the
safety signs are illegible, they need to be replaced.
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Table 2 : Safety signs and labels at the diesel pump set
3.11 Residual risk
Warning!
Crush hazard when setting up the diesel pump set.
When setting up and aligning the diesel pump set make sure nobody reaches or
steps underneath.
Danger!
Danger of respiratory problems and suffication due to exhaust gases.
The carbon monoxide contained in the engine exhaust gas is odourless and
dangerous because it is toxic and an explosive mixture in combination with air
forms. Carbon monoxide is extremely dangerous in closed rooms because a
short period of time suffices for accumulating a critical concentration. The
operator has to ensure a sufficient ventilation and extraction of exhaust gas in
the pump room.
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Warning!
Trip hazard.
During assembly and maintenance work in the pump room there may be a trip
hazard over lines and cables. Watch your step.
Danger!
Fall hazard during assembly and maintenance work in the pump room above
head height.
Use safe climbing aids.
Warning!
Danger due to flying objects during trial operation.
Before trial operation remove any tools or foreign material and loose objects.
Danger!
Danger due to parts tipping over.
After set-up and levelling the operator must fix the diesel pump set firmly to the
foundation. The foundation bolts must be designed for the loads.
Danger!
Danger due to automatic start-up.
When ready for operation the diesel pump set might start automatically at any
Wear close-fitting clothing.
Danger!
Danger due to running system.
After automatic start-up the system must not stop and even in the case of an error
should be kept running for as long as possible. Stopping of the diesel pump set
would be in violation of the superordinate admission rule.
It is imperative to observe the superordinate admission rule of the plant.
Danger!
Slip hazard on grease and oil.
Keep the immediate surroundings of the engine as well as of ladders and steps
at the plant free from grease and oil. Ensure regular cleaning of the diesel pump
set.
Danger!
Burn hazard due to hot surfaces.
During operation there is a burn hazard at the motor block, the exhaust system
and the engine's cooling water pipes. Do not touch the engine with bare hands.
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Danger!
Fire hazard due to combustible materials.
There must be no combustible materials located near the exhaust gas pipeline.
Danger!
Fire hazard due to combustible fuel.
Smoking and open flames are prohibited in the pump room.
Check the filling level and refill the fuel tank only with a switched off engine.
Danger!
Danger from caustic battery fluid.
During normal operation contact with the battery fluid is next to impossible.
Battery fluid can only leak out due to inappropriate handling e.g. excess load at
valves or housing in the wake of mechanical damage.
Always wear protective gloves, protective clothing and safety glasses for works
involving the contact with battery fluid.
Explosion and fire hazard!

The metal parts of the batteries are always live.
Do not place any foreign objects or tools on the battery. Avoid short circuits.
4 Scope of supply and transport
4.1 Scope of supply
The diesel pump set is delivered not mounted completely. For assembly and installation see
chapter 5.
Please check all components of the diesel pump set on visible transport damages and inform
KAGEMA Industrieausrüstungen GmbH immediately if there are damages.
4.2 Transport
Dangerous for the environment!

Transport the diesel pump set in horizontal positions to avoid leaking of the filled
in operating fluids.
For additional information of transport and hazardous goods also observe the transport advices.
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Danger!
Danger due to suspended loads! The load may fall down.
 Do not stand below lifted components or in their vicinity.
 Keep third parties out of the danger zone. Use appropriate barriers or
assign a supervisor.
 Transport all components with a forklift or crane.
 Never exceed the permissible load of the used lifting tool.
 All lifting tools used for transportation or loading and unloading must have
a minimum load carrying capacity corresponding to the weight of the
machine parts. Information regarding the weight of the machine parts can
be found in the product data sheet.
 For transportation with a crane use the lifting eyes at the diesel pump set
to attach the crane hook.
 Always position the forks underneath the base frame when transporting
with a forklift. Secure the diesel pump set additionally against sliding off
the forks.
 Marshallers must be located within sight and earshot of the operator of
the means of transport.
 Only transport the diesel pump set in dry and frost-free conditions.
5 Assembly, installation and initial start-up
Note!
The installation must only be carried out by specialists. Start-up and test run are
effected by the manufacturer's employees or authorized personnel. It will only be
handed over when all checks are completed successfully.
5.1 Safety instructions for assembly
For assembly observe the following:

 KAGEMA Industrieausrüstungen GmbH always recommends to have the assembly and initial
start-up carried out by KAGEMA Industrieausrüstungen GmbH personnel.
 Before assembly observe the supplied dimensional drawings.
 The operator of the diesel pump set must provide sufficient lighting at the installation site.
 Work equipment required for assembly (e.g. lifting platforms, cranes etc.) must be provided by
the company commissioned to perform the assembly task.
Danger!
Danger due to suspended loads! The load may fall down.
Do not stand below lifted components or in their vicinity.
The applied lifting gear must be designed for the weight of the installation.
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Danger!
Fall hazard when working above head height.
For assembling the diesel pump set use stable scaffolding and other safe climbing
aids.
Warning!
Hand crush hazard when putting up the diesel pump set.
When setting up and aligning the diesel pump set make sure nobody reaches or
steps underneath.
Have the diesel pump set assembled by expert personnel.
5.2 Electrical installation
The electrical installation is performed either by KAGEMA Industrieausrüstungen GmbH or by

authorized personnel after assembly.
 For the electrical installation observe all safety instructions in chapter 3.3.
 Before start-up check the protective bonding circuit at the entire installation for continuous
connection.
 Create test reports for all checks at the diesel pump set.
Danger!
The diesel pump set may only be connected by qualified electricians adhering to
the applicable regulations for accident prevention and installation.
Safety measures and protective devices must be provided in order to connect the
entire diesel pump set to the control system. For example:
 earthing
 overcurrent protection devices
 cable conduits to avoid damage to the electric supply cables
A wiring diagram from which you can see how the electric components of the
diesel pump set must be connected is provided with the set. During connection
make sure that the main voltage corresponds to the voltage given on the
nameplate.
Earthing or protective conductors must be connected with the given earthing
terminal.
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5.3 Assembly and installation
Note!
Assembly and installation of the diesel pump set are performed either by
KAGEMA employees or by authorized personnel.
The integration of backflow preventers and shut-off devices is recommended
depending on the type of installation and pump. These however have to be
incorporated in a way that draining or dismantling the pump is not impeded.
Hinweis!
KAGEMA Industrieausrüstungen recommends to realize the entire machine room – or
at least the immediate sourroundings of the pump set – as oil-proofed pan on site. Please
also note the corresponding regulations.
Danger!
Danger due to parts tipping over!
After set-up and levelling the operator must fix the diesel pump set firmly to the
foundation. The foundation bolts must be designed for the loads.
Note!
The foundation must be suitable for the loads.
Note!
The bore holes for the foundation bolts must be square or round. The
dimensions and arrangement of the bore holes in the diesel pump set base
frame can be found in the diesel pump set drawing.
Note!
Note following instructions:
 The foundation bolts must be cleaned and degreased before
assembling. Also note the manufacturer´s instructions.
 Observe the instructions of the manufacturer of the concrete mixture.
 The bore holes must be protected against dirt before filling in the
concrete mixture.
 Directly before setting in the foundation bolts in the bore hole clean the
hole if necessary, e. g. with compressed air.
 Place the base frame with the inserted foundation bolts on the
foundation and align it. If required also use shims underneath the
fastening angles.
 Observe the tolerances of the coupling given in the installation instructions
of the coupling (also see appendix C of this manual).
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 Grout the holes for the foundation bolts with a quick-setting, low-
shrinkage concete mixture. Produce flowability with the help of a
solvent.
 When the concrete has set tighten the foundation bolts evenly until
there is no clearance between the nuts and the base frame.
 If the base frame is not seated completely flush on the foundation after
levelling grout the gap between the base frame and foundation with a
quick-setting, low-shrinkage concete. The base frame must rest on the
foundation in its full length.
 When the concrete has set tighten the foundation bolts evenly to
the required tightening.
Use the specified number of foundation bolts.
 Connect the piping to the pump without any stresses or strains.
 Check the alignment of the coupling and realign if required.
Danger from exceeding the permissible load at the pump connections!

Risk of death from escaping hot, toxic, caustic or combustible medium to be
pumped at leaks.
 Do not use the pump as fixed point for the pipelines.
 Intercept the pipelines directly in front of the pump and connect them free
of tension.
 Take appropriate measures to compensate for the pipe´s expansion due
to temperature rises.
Note!
In case of incorrect grounding during electric welding on the piping there is a
danger of the pump's roller bearing being wrecked.
 Never use the pump or baseplate for grounding.
 Avoid current flow through roller bearings.
 Clean, blow out and purge the containers, pipelines and connections
thoroughly before connecting them to the pump (especially in case of new
installations).
 Before integration in the piping remove the pump´s flange covers.
 Examine the pump interior for foreign objects and remove these, if required.
 If required deploy filters in the pipe.
 Connect the suction and discharge pipe to the pump.
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Note!
 Only in case of water-cooled engines:
If the cooling water supply pipe from the pump to the heat exchanger of the
diesel engine is not already installed by KAGEMA Industrieausrüstungen
GmbH the pipe must be connected flexible to the heat exchanger by client.
 Only in case of water-cooled engines:
Install the cooling water return from the heat exchanger with at least DN50
(2”). The cooling water return pipe must be connected flexible at the heat
exchanger by client. The water outlet must be visible. If it is not possible to
install the return visibly a fitting needs to be assembled in order to render the
cooling water flow visible. If the water level of the storage tank is lower than
the level of the fill-up tank, then install the return line above the level of the
fill-up container. Only after that you may lower the return line to the storage
tank. Install a vent valve at the highest point of the cooling water pipe.
 Only in case of radiator-cooled engines:
Lead the exhaust air from the radiator cooler outside via ducts on the shortest
way possible. The radiator cooler must be connected flexible to the further
exhaust air system.
 Ensure a sufficient ventilation of the pump room according to the related
regulations. Ensure that no thermic short circuit can occur.
 Install the exhaust gas pipe observing the minimum dimensions given in the
product data sheet, the dimensional drawing and calculation.
 Lead the exhaust pipe outside along the shortest route possible.
 Design the outlet in the outside in a way that no water or snow can enter.
 Install the exhaust gas pipe in a way to prevent condensate from reaching
the engine.
 Affix a coarse-meshed protective grid to prevent the nesting of birds.
 To prevent the compensator from being distorted by improper fastening a
supporting point has to be provided for the exhaust gas pipe directly behind
the compensator. Check the mounting direction of the compensator.
 Use the supplied compensator to connect the exhaust gas pipe flexibly to the
engine.
 When installing the exhaust gas pipe note that the pipe warms up to
400 - 600°C at full engine load. Thus the pipe expands up to 6 mm per
metre. The pipe suspension is to be designed accordingly.
 The exhaust gas noise muffler can be assembled in any position. The
exhaust gas noise muffler should be installed at a distance of 2-5 m behind
the engine´s exhaust gas outlet.
 If the exhaust gas noise muffler is mounted in vertical position a condensate
drain must be provided so that no condensate can get into the exhaust gas
outlet of the engine.
 The exhaust gas noise muffler is equipped with a flange and counterflange
at both end sides. For connecting the exhaust gas noise muffler to the
exhaust gas pipe unscrew the counterflange, connect the exhaust gas pipe
with the flanges by welding and screw the flanges at the muffler again.
 The entire length of the exhaust pipe must not exceed 10 m.
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Note!
If the fuel tank is delivered loose for transport the fuel tank must be installed on
the support construction before initial start-up. Install it nearby the diesel pump
set to avoid long diesel fuel pipes. The fuel supply line with the ball valve must
be connected to the fuel inlet of the diesel engine and the fuel return line must be
connected to the fuel outlet of the engine.
Note!
If the batteries are delivered on a battery rack this rack must be installed nearby
the starter of the engine. The batteries must be connected to the starter
according to the wiring diagram.
Note!
All sensors, switches and cables at the electric pump set must be connected to
the control panel according to the electrical documentation and to FM
regulations.
Note!
Voltage must only be switched on after the starter batteries have been connected
and the wiring has been checked.
 Connect the control box of the diesel pump control unit according to the
operating instructions for the control box.
 Connect the power supply for the control box according to the
specifications in the wiring diagram.
 Only connect the starter batteries upon start-up and after the installation
has been inspected.
Note!
Also note all instructions in the appendix.
Note!
Also note all instructions given in the FM regulations.
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5.4 Initial start-up
Requirements Assembly, installation of the diesel pump set has been carried out as described in
chapter 5.2 and 5.3.
Note!
Before start-up the operator has to ensure that all displays and operating
elements are connected according to the electrical documentation.
Note!
Initial start-up and test run of the diesel pump set are to be performed by
KAGEMA Industrieausrüstungen GmbH personnel or authorized personnel.
The diesel pump set must not be operated without prior initial start-up effected by
KAGEMA Industrieausrüstungen GmbH.
Note!
Do not leave the control panel or control center during the operation of the diesel
pump set. For stopping the diesel engine also note the instructions given in the
operating manual of the diesel engine (alsoo see appendix A) and in the
Note!
The water reservoir must be filled minimum 24h before initial start-up.
6 Operation
For operation of the diesel engine and the pump also see the appendix A and B of this manual.
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6.1 Operating elements and displays at the control unit
The following operating elements are provided at the diesel fuel tank:
Figure 3: Mechanical fuel level indicator
Figure 5: ball valve fuel supply line (example)
Figure 4: Hand pump for manual tank refilling (example)
Figure 6: Condensate drain at fuel tank (example)
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For more information regarding the operating elements at the diesel engine also see operating manual
of the diesel engine (appendix A).
Information regarding the operating elements and displays at the diesel pump control box is provided in
the operating manual of the control unit.
Note!
For the operating elements of the control unit also observe the electrical
documentation inside the control cabinet.
6.2 Start-up
Note!
Prior to start-up, make sure that all components are connected according to the
Requirements Assembly, installation, initial start-up and setting of the installation's motor current
protective devices have been effected as described in chapter 5.
The diesel pump set is ready for operation as soon as the voltage supply is connected to the control box
and all automatic circuit breakers have been switched on. As of this moment all important functions of
the pump unit are monitored.
6.3 Automatic operation of the diesel pump set
Danger!
Danger due to automatic start-up!
When ready for operation, the diesel pump set might start automatically at any
Warning!
Danger of respiratory problems and suffication due to exhaust gases. The
operator must ensure sufficient ventilation inside the pump room.
The diesel pump set starts automatically.
6.3.1 Starting the engine automatically
Start-up of the diesel pump set is triggered when the unit gets an external start command, e.g. remote
signal or signal from a pressure switch.
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Note!
For automatic operation also note the electrical documentation.
Note!
Not all engine failures do lead to an automatic stopping of the engine.
Information on the individual monitoring processes and fault messages can be
found in the documentation of the control unit.
6.3.2 Stopping the engine
Note!
Unless it is an emergency only the operator may grant the permission to switch
off the diesel pump set.
Before an installation is switched off completely or partially, the premises have to
be inspected thoroughly to ensure that there exists no danger.
The engine of the diesel pump set keeps running

 until the fuel supply is interrupted (e.g. fuel tank empty, close fuel tap)
 until the engine is stopped manually
 until the engine is ruined
 because the switch-off function is not working due to a fault in the control
system.
Note!
For stopping the diesel engine also note the electrical documentation.
6.4 Manual operation
Note!
For manual operation also note the electrical documentation.
6.5 Test, Trial operation
Note!
Test of the diesel pump set must be carried out to the corresponding regulations.
For test operation also note the electrical documentation.
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During the required tests there must be no unauthorized persons located in the
pump room.
Note!
Do not leave the control panel or control center during the operation of the diesel
pump set.
Warning!
Danger due to flying objects during trial operation.
Before trial operation remove any tools or foreign material and loose objects.
Always wear ear protection during trial operation.
Note!
The required trial operation has to be carried out by authorized expert personnel
or employees of KAGEMA Industrieausrüstungen GmbH.
Weekly trial operation also comprises the following tasks:

 Carrying out all inspections according to the manuals of the single
components of the diesel pump set (also see appendix of this manual).
 Check all main shut-off valves at the entire installation for their correct
position ready for operation.
 Check all water levels relevant for the water supply of the installation.
 Drain the condensate in the diesel fuel tank.
 Check the diesel fuel level in the tank.
 Check the oil and cooling water level of the diesel engine.
 Check the cooling water flow at the cooling water outlet (only at heat
exchanger cooled engines).
 Check the operating data of the diesel engine, e.g. oil and cooling water
temperature, engine speed, during the test.
Note!
During test of automatic start the diesel pump set has to be operated till the
normal operating data of the engine, e.g. oil and cooling water temperature, are
reached. If failures occur during the test of the diesel pump set stop the engine
according to the electrical documentation. After the test of the diesel pump set
check all levels of the operating fluids and refuel them if required.
Version 2019/1
Note!
During entire inspection monitor the oil pressure, engine temperature and
cooling water flow (only applies for water-cooled engines).
6.5.1 Cooling procedure for engine
1. Before completion of the test run, allow the unit to cool down for 5 minutes whilst the testing valve
is closed. This applies particularly when checking the flow rate.
2. If after switch-off the engine temperature increases to more than 100 °C, start the unit again by
hand.
3. Stop the unit if the indicator light "monitoring ON" lights up. It may be necessary to repeat this
procedure 2 to 3 times.
6.6 Shutdown
Danger!
Work on the electrical system may only be carried out by skilled electricians or
instructed persons supervised by a skilled electrician, according to electrical
engineering rules and regulations.
To take the diesel pump set out of operation for an extended period of time
please proceed as follows:
1. Disconnect the voltage supply for the control box.

2. Disconnect the batteries.
3. Close the fuel tap at the diesel engine.
4. Close the plant's shut-off valve.
5. De-register the diesel pump set according to the plant’s rules.
Note!
Also note the operating manuals of the single components.
Note!
When decommissioning for more than three months please contact Kagema
Industrieausrüstungen GmbH.
Version 2019/1
7 Faults and troubleshooting
Anybody charged with the rectification of faults must have read this operating manual and understand
the special dangers presented by this installation.
Immediately rectify any faults that arise, so as to avoid greater damage. Information on how to locate
and rectify faults can be found in the supplied external device descriptions or operating manuals (also
see appendix). Missing documents can be requested from the customer service.
If questions arise during troubleshooting please contact our customer service:
Phone: +49 (0)5069 / 90 93 - 39

Fax: +49 (0)5069 / 90 93 - 19
For faults in the control equipment and the electrical system consult a skilled electrician.
7.1 Safety instructions for troubleshooting
Whenever repairs are carried out, there is an increased risk of accidents.

Before starting any maintenance, repair and inspection work observe the
applicable regulations as well as the following safety instructions:
 Maintenance, inspection and repair work must only be carried out by
personnel with the appropriate qualifications.
 Before starting maintenance de-register the diesel pump set according to
the applicable instructions.
 Prior to maintenance work disconnect the electrical energy supply for the
control panel or secure diesel pump set against inadvertent start-up. Attach
a sign reading "Maintenance work in progress".
 Only carry out troubleshooting tasks when the diesel pump set is shut
down.
 During work affecting the operation, conversion or the settings of the
installation, or the inspection, maintenance and repair, make sure that the
processes for switching on or off take place according to the operating
manual and the information regarding maintenance.
 After troubleshooting reinstall all safety equipment and check them for
proper functioning.
 In case of servicing or maintenance work retighten loosened screwed
connections.
 Do not leave any tools or maintenance materials.
Version 2019/1
7.2 Shutdown for troubleshooting
Danger!
Danger due to starting system!
Prior to any maintenance work secure the diesel pump set against inadvertent start-
up.
1. Switch off fuse in the control panel.
3. Attach a sign reading "Maintenance work in progress".
Danger!
instructed persons supervised by a skilled electrician according to electrical
1. Switch off the main fuses in the control panel.
7.3 Restart after troubleshooting
After troubleshooting reinstall all safety equipment and check them for proper functioning.
In case of servicing or maintenance work retighten loosened screwed connections.
Do not leave any tools or maintenance materials.
Danger!
1. For restarting after troubleshooting switch all fuses in the control panel of the
control back on.
2. Reconnect the batteries.
3. Register the diesel pump set again.
8 Maintenance
Inspection and maintenance work includes measures to assess the actual condition as well as
measures to maintain the desired condition of the installation. Carry out these measures carefully and in
due time. Only by doing so a long lifetime for the diesel pump set can be ensured. Perform
maintenance tasks according to the maintenance intervals and operating instructions and record the
activities in the maintenance log (chapter 12).
Version 2019/1
8.1 Safety notes for service and maintenance
Note following safety notes before service and maintenance:

 Have maintenance and repair work carried out by qualified and authorized personnel only.
 Ensure before maintenance and repair work that the diesel pump set cannot start
automatically. Turn off the main fuse before.
 Note all the safety instructions given in the operating manuals of the single components of the
diesel pump set.
 Inform the operating company before special work or maintenance work is carried out. Appoint
a supervisor.
 For the execution of maintenance work please contact the customer service of KAGEMA
Industrieausrüstungen GmbH. If a customer makes improper changes to the diesel pump set
the warranty becomes void.
 Largely cordon off the maintenance area, as required.
 Observe the maintenance, inspection and lubrication intervals specified in the operating
manuals of the single components (also see appendix).
 Always wear safety boots and protective clothing.

 When working near engines or moving parts only wear close-fitting
clothing, no pendants (or other dangling jewellery) and keep your hair
tied up.
 Protect your hands by use of hand cream.
 Principally wear protective gloves and safety glasses during the following
tasks:
- Filling in inhibitors or antifreeze mixture.
- Changing or refilling fuel and lube oil (hot engine oil may cause burns.
Only carry out the task when the oil has cooled down to below 50 °C).
 Wear safety glasses when working with compressed air (max. air
pressure for engine cleaning less than 200 kPa (2 bar, 30 psi, 2 kg/cm²).
 For all work taking place inside the pump room, avoid contact with
rotating or intensely heated components. Proceed carefully.
 When working near suspended loads or technical installations at face
value always wear a hard hat.
 When performing maintenance work above head height use a stable
ladder or other safe climbing aids.
 Only use suitable tools when carrying out maintenance measures.
 Spare parts must correspond to the technical requirements specified by
KAGEMA Industrieausrüstungen GmbH. This is always ensured when
using original spare parts.
 Do not leave objects on the unit.
 Upon completion of maintenance, inspection and repair work reattach any
disconnected safety devices and check them for proper function.
 Cover any opened ducts when the work is completed.
 Immediately take off work clothing soaked with lubricant.
 Keep the engine clean. Immediately eliminate splashes of oil, diesel fuel
and coolant.
 Store cleaning rags soaked with lubricant in flame-retardant containers.
 Keep sufficiently dimensioned and safe waste oil containers available.
Version 2019/1
8.2 Maintenance intervals
Observe the maintenance intervals given in the operating manuals of the single components (also see
appendix).
8.3 Maintenance activities
8.3.1 Securing against automatic start-up
Danger!
Danger due to starting system!
Prior to any maintenance work secure the diesel pump set against inadvertent start-
up.
1. Switch off fuse in the control panel.
Danger!
1. Switch off the main fuses in the control panel.
8.3.2 Visual inspection of the diesel pump set
Check the diesel pump set for externally visible damages and defects as well as for leaks.
Notify the responsible position or person immediately of any changes that have occurred (including
those of the operating behaviour).
If required shut down the diesel pump set immediately secure it.
8.3.3 Checking safety signs and labels
Check the safety signs and labels at the diesel pump set regarding legibility and completeness.
If the safety signs and labels are illegible or missing they need to be replaced
8.3.4 Cleaning
Secure the diesel pump set.

Clean the exterior of the diesel pump set with a clean hand brush or a dry cloth. Do not use steam or
water jet cleaners.
Version 2019/1
8.3.5 Checking the fuel level
Note!
The fuel tank is to be refilled after every operation of the diesel pump set.
Danger!
Fire hazard due to combustible fuel.
Smoking and open flames are prohibited. Only fill the fuel tank when the
engine is switched off.
1. Check the fuel tank filling level at the tank's indication.

2. If the filling is too low refill the fuel tank. Secure the diesel pump set
before.
8.3.6 Checking operating fluid levels of diesel engine
Check the operating fluid levels of the diesel engine (lubricating oil, cooling water) according to the
operating manual of the diesel engine (also see appendix A).
8.4 Restart after maintenance
After maintenance and servicing reinstall all safety equipment and check them for proper functioning.
In case of servicing or maintenance work retighten loosened screwed connections.
Do not leave any tools or maintenance materials.
Danger!
1. For restarting after troubleshooting switch all fuses in the control panel of the
control back on.
2. Reconnect the batteries.
3. Register the diesel pump set again.
Version 2019/1
9 Storage
Store the diesel pump set under the following storage conditions:
 dry
 with a roof overhead
 storage temperature: frostfree and up to +40 °C
Note!
Also note the instructions in the corresponding regulations.
For more information also see the operating manuals of the single components in the appendix.
10 Disassembly and disposal
After its final use, the operator is responsible for disposal of the installation at his own expense and
according to the applicable regulations. He is also required to release KAGEMA Industrieausrüstungen
GmbH of any return obligations and any claims by third parties.
Disassemble the diesel pump set for disposal and separate it into the individual material groups:
 plastics
 non-ferrous metals (e. g. copper scrap)
 aluminium
 electronic scrap
 steel
Dispose of the materials and auxiliary supplies in accordance with national legislation.
Batteries
Return them to the manufacturer!

Used batteries with this symbol are recyclable goods must be fed to the
recycling process. Used batteries not returned to the recycling process must
be disposed of as hazardous waste whilst observing all applicable regulations.
11 Spare parts
Only use original spare parts. For this contact our customer service.
Phone: +49 (0)5069 / 90 93 - 39
Fax: +49 (0)5069 / 90 93 - 19
Version 2019/1
12 Maintenance log
Maintenance log – pump unit
During any maintenance work on a running installation, it must be ensured that nobody is situated in the
danger zone!
Customer: Order no.:

Start-up date:
Put down all deficiencies or touched up points in the comments column (short description). If the
text field is insufficient, add another page to the maintenance protocol as an appendix.
Date Operating Performed maintenance tasks Comment: Signature

hours
Version 2019/1
Appendix
Appendix A Operating manual diesel engine
Appendix B Operating manual pump
Appendix C Operating manual coupling
Appendix D Starter batteries
Version 2019/1
Appendix A
Operating manual diesel engine
Operation and Maintenance
Instructions Manual
DP/DQ/DR/DS/DT MODEL ENGINES
FOR
FIRE PUMP APPLICATIONS
Clarke UK, Ltd. Clarke Fire Protection Products, Inc.

Unit 1, Grange Works 100 Progress Place
Lomond Road Cincinnati, OH 45246
Coatbridge U.S.A.
ML5 2NN
United Kingdom
TELE: +44(0)1236 429946 TELE: +1.513.771.2200 Ext. 427
FAX: +44(0)1236 427274 FAX: +1.513.771.5375
www.clarkefire.com
C133292 rev AB
3/17
CONTENTS
SUBJECT PAGE
1.0 INTRODUCTION 6
1.1 IDENTIFICATION/NAMEPLATE 6
1.2 SAFETY/CAUTION/WARNINGS 7
2.0 INSTALLATION/OPERATION 11
2.1 TYPICAL INSTALLATION 11
2.2 ENGINE STORAGE 12
2.2.1 Storage Less than 1 year 12
2.2.2 Extended Storage Maintenance Procedure 12
2.3 INSTALLATION INSTRUCTIONS 12
2.4 SPECIFIC FLYWHEEL COUPLING ALIGNMENT INSTRUCTIONS 14
2.4.1 Listed Driveshaft 14
2.4.2 Driveshaft 14
2.4.3 Other Coupling Types 16
2.5 STARTING/STOPPING THE ENGINE 16
2.5.1 To Start Engine 16
2.5.1.1 Optional Pneumatic Starting System 18
2.5.2 To Stop Engine 19
2.5.3 Emergency Stop Instructions 19
2.6 WEEKLY TEST 19
3.0 ENGINE SYSTEMS 20
3.1 FUEL SYSTEM 20
3.1.1 Diesel Fuel Specification 20
3.1.2 Bleeding the Fuel System 21
3.1.3 Changing Fuel Filter Cartridge 22
3.1.3.1 Fuel Filters 22
3.1.4 Fuel Tanks 23
3.1.5 Fuel Injection Pump Components 23
3.1.6 Priming Pump Strainer Cleaning 23
3.2 AIR/EXHAUST SYSTEM 23
3.2.1 Ambient Conditions 23
3.2.2 Ventilation 23
3.2.3 Standard Air Cleaner 23
3.2.4 Crankcase Ventilation 25
3.2.4.1 Open Crankcase Ventilation 25
3.2.4.2 Crankcase Ventilation System 25
3.2.5 Exhaust System 26
3.3 LUBRICATION SYSTEM 26
3.3.1 Checking Sump Oil 26
3.3.2 Changing Engine Oil 27
Page 2 of 50
3.3.3 Changing Oil Filter Cartridge 27
3.3.4 Oil Specification 28
3.3.5 Oil Capacities 28
3.4 COOLING SYSTEM 28
3.4.1 Intended Engine Operating Temperature 28
3.4.2 Engine Coolant 28
3.4.3 Water 29
3.4.4 Coolant Capacities 29
3.4.5 Coolant Inhibitors 29
3.4.6 Procedure for Filling Engine 30
3.4.6.1 Partial Fill 30
3.4.7 Providing Adequate Raw Water Supply to the Engine Heat Exchanger 30
3.4.7.1 Raw Water Supply 30
3.4.7.2 Cooling Loop 30
3.4.7.3 Setting Raw Water Flow Rate 32
3.4.7.4 Raw Water Outlet 32
3.4.7.5 Raw Water Quality, Strainers and Deterioration of Heat Exchanger (or CAC) 33
3.4.7.6 Backflow Preventers 33
3.4.7.7 Raw Water Outlet Temperature 33
3.4.8 Flow Paths of Engine Cooling System 33
3.4.9 Important Service Notice 35
3.4.9.1 Water Pump Cavitation 35
3.5 ELECTRICAL SYSTEM 35
3.5.1 Wiring Diagrams 35
3.5.2 Checking Drive Belt Tension and Adjustment 36
3.5.3 Speed Switch 36
3.5.4 Magnetic Pick-Up 37
3.5.5 Mechanical Engine Control and Alarm Board (MECAB) Speed Switch Troubleshooting 37
3.5.6 Field Simulation of Pump Controller Alarms 39
3.5.7 Battery Requirements 40
3.6 ENGINE SPEED ADJUSTMENT 40
4.0 MAINTENANCE SCHEDULE 41
4.1 ROUTINE MAINTENANCE 41
5.0 TROUBLE SHOOTING 42
6.0 PARTS INFORMATION 42
6.1 SPARES 42
6.2 ENGINE MAINTENANCE PARTS LIST 42
7.0 OWNER ASSISTANCE 42
8.0 WARRANTY 42
8.1 GENERAL WARRANTY STATEMENT 42
Page 3 of 50
8.2 CLARKE WARRANTY 42
8.3 DOOSAN WARRANTY 42
9.0 INSTALLATION & OPERATION DATA (See Page 5) 46
10.0 WIRING DIAGRAMS (See Page 5) 46
11.0 PARTS ILLLUSTRATION (See Page 5) 46
12.0 APPENDIX (Alpha Index) 47
Check factory availability for a manual in one of the following languages:
Spanish
French
German
Italian
NOTE
The information contained in this book is intended to assist operating personnel by providing
information on the characteristics of the purchased equipment.
It does not relieve the user of their responsibility of using accepted practices in the installation,
operation, and maintenance of the equipment.
NOTE: CLARKE FPPG Reserves the right to update the contents of this publication without
notice.
Page 4 of 50
Technical Catalog Discontinuation Notice
Effective January 2015,
Clarke has done away with the Technical Catalogs. The Technical Catalogs consisted of the following
technical documents:
o Model Specific Installation and Operations Data (I&O)
o NFPA20 Cooling Loop C131977
o NFPA20 Lead Acid Battery Specifications C131885
o NFPA20 Exhaust Piping C06918
o NFPA20 Fuel Line Plumbing C132026
o DC Jacket Water Heater Wiring Diagrams
o AC Wiring Diagrams
o Parts Illustration
o Language Translation Pages
All the above can be located on www.clarkefire.com as follows:
 For all documents listed above, use the following steps to get to the document pages that you are
looking for:
Page 5 of 50
1.0 INTRODUCTION MODEL NUMBERING & IDENTIFICATION
The following paragraphs summarize the “Scope of There are two identification plates attached to each
Supply” of the Engine: engine. Clarke Identification Plate: Engine Model,
Serial Number, Rating and Date of Manufacture are
 The CLARKE Engine supplied has been shown on this identification plate.
designed for the sole purpose of driving a Note that there are five types of identification plates,
stationary Emergency Fire Pump. It must not dependent on whether the engine is a “Non-Listed”
be used for any other purpose. or “Listed/Approved” Model. These are typical
examples. (See Figure #1).
 Shall not be subjected to Horsepower
requirements greater than the certified Clarke Identification Plates
nameplate rating (for UL/cUL/FM/LPCB USA Non Listed USA Listed/Approved
only).
 Engines must be sized to cover fully the

maximum power absorbed by any particular
driven equipment together with a safety
factor on no less than 10%. (For Non-listed
only).
 Derates for elevation and temperature need to

be considered for maximum pump power.
 Fuel delivery settings are factory set with-in

the injection pump and must not be tampered
UK Non-Listed UK Listed/Approved
with or adjusted. Minor RPM adjustments to
meet pump requirements are permissible.
 The engine shall be installed and maintained

in accordance with the guidelines stated in
this manual.
 Periodic running checks to ensure

functionality should be kept to a maximum of
½ hour per week.
1.1 IDENTIFICATION/NAMEPLATE
 Throughout this manual, the terms “Engine” USA Listed FM Approved UK Listed – FM Approved
and “Machine” are used.
 The term “Engine” refers solely to the diesel

engine driver as supplied by CLARKE.
 The term “Machine” refers to any piece of

equipment with which the engine might
interface.
This manual provides all the information necessary to

operate your newly acquired engine safely and
efficiently, and perform routine servicing correctly.
Please read it carefully.
Figure 1
Page 6 of 50
The Clarke 10 digit model numbers reflects the base ENGINE MODEL WEIGHT lbs (kg)
engine type, number of cylinders, cooling system, DP6H-UFAA50, DP6H-UFAA62,
DP6H-UFKA50, DP6H-UFKA62,
approval listing, manufacturing location, emissions DP6H-UFAAX8, DP6H-UFKAX8,
code and a power rating code. DP6H-UFAA70, DP6H-UFKA70,
DP6H-APKA60, DP6H-APKA70,
Example: DT2H-UFAA90 DP6H-NLKA50, DP6H-NLKA62, 2250 (1020)
 D = Doosan base engine prepared by DP6H-NLKAX8, DP6H-NLKA70,
CLARKE DP6H-NLKA88, DP6H-FMKA50,
DP6H-UFAA88, DP6H-UFKA88,
 T = base engine series DP6H-FMKA88, DP6H-FMKA62,
 2 = 12 cylinders DP6R-NLKA49, DP6R-NLKA61
DQ6H-UFAA4G, DQ6H-UFAA48,
 H = Heat Exchanger cooled (R = Radiator) DQ6H-UFAA50, DQ6H-UFAA58,
 UF = Underwriters Laboratories Listed/ DQ6H-UFAA60, DQ6H-UFAA88,
DQ6H-UFAA98, DQ6H-UFKA4G,
Factory Mutual Approved, (LP = LPCB Loss DQ6H-UFKA48, DQ6H-UFKA50,
Prevention Council Board Approved, NL = DQ6H-UFKA60, DQ6H-UFKA88,
Non-Listed, AP = APSAD DQ6H-UFKA98
DQ6H-APKA60, DP6H-APKA90
 A=Manufacturing Location (A= Cincinnati, DQ6H-NLKA48, DQ6H-NLKA4G
K= Coatbridge) DQ6H-NLKA50, DQ6H-NLKA60
 A= Non-Emissioned DQ6H-NLKA88, DQ6H-NLKA98,
DQ6H-UFAA40, DQ6H-UFAAX8,
 90 = A power rating code DQ6R-NLAA47, DQ6R-NLAA4F, 2500 (1134)
DQ6R-NLAA49, DQ6R-NLAA59,
DQ6R-NLAA87, DQ6R-NLAA97,
Doosan Identification Plate: The second DQ6H-NLKA40, DQ6H-NLKAX8,
identification plate contains the Doosan Model DQ6H-UFKA40, DQ6H-UFKAX8,
DQ6H-FMKA48, DQ6H-FMKA4G,
Number and Serial Number. On the DT Series, the DQ6H-FMKA40, DQ6H-FMKA50,
Doosan Serial identification plate is located on the DQ6H-FMKA60, DQ6H-FMKA88,
left-hand side of the engine near the front mount just DQ6H-FMKA98, DQ6H-FMKAX8,
DQ6R-NLKA47, DQ6R-NLKA4F,
above the oil pan rail. DQ6R-NLKA49, DQ6R-NLKA59,
DQ6R-NLKA87, DQ6R-NLKA97
1.2 SAFETY/CAUTION/WARNINGS DR8H-UFAA40, DR8H-UFAA5G,
DR8H-UFAA68, DR8H-UFAA62,
DR8H-FMAA40,
ATTENTION: This engine has components and DR8H-FMKA5G, DR8H-FMKA62,
fluids that reach very high operating temperatures DR8H-FMKA68, DR8H-UFKA40,
DR8H-UFKA5G, DR8H-UFKA62,
and is provided with moving pulleys and belts. DR8H-UFKA68, DR8H-APKA60
Approach with caution. It is the responsibility of the DR8H-NLAA40, DR8H-NLAA5G,
2700 (1225)
DR8H-NLAA62, DR8H-NLAA68,
builder of the machine using a Clarke engine to DR8H-UFAA98, DR8H-UFAA92,
optimize the application in terms of maximum end DR8H-UFKA98, DR8H-UFKA92
user safety. DR8H-NLKA40, DR8H-NLKA5G,
DR8H-NLKA62, DR8H-NLKA68
BASIC RULES DS0H-FMKA60, DS0H-FMKA68,
DS0H-FMKAN0, DS0H-UFAA68,
The following recommendations are given to reduce DS0H-UFAA60, DS0H-UFAAM0,
DS0H-UFKAM0, DS0H-UFAAN0, 3200 (1450)
the risk to persons and property when an engine is in DS0H-UFKA60, DS0H-UFKA68,
service or out of service. DS0H-UFKAN0, DS0H-APKA60,
DS0H-NLAA60, DS0H-NLAA68,
Engines must not be used for applications other than DS0H-NLAAN0, DS0H-NLAA70,
those declared under “Scope of Supply”. DS0H-UFAA98, DS0H-UFAA92,
DS0H-UFKA98, DS0H-UFKA92
DS0H-NLKA60, DS0H-NLKA68,
Incorrect handling, modifications and use of non- DS0H-NLKAN0, DS0R-NLAAL1,
original parts may affect safety. When lifting the DS0R-UFAA67, DS0R-UFAA59,
engine, take care to use suitable equipment to be DS0R-UFKA67, DS0R-UFKA59
DT2H-UFAA20, DT2H-UFAA60,
applied to the points specially provided as shown on DT2H-UFAA98, DT2H-UFAA92,
the appropriate Engine Installation Drawing. Engine DT2H-FMAA40, DT2H-FMAAX8,
weights are shown in Figure #2 DT2H-FMAAX2, DT2H-APKA90,
DT2H-FMKA40, DT2H-NLAA20,
DT2H-NLAA58, DT2H-NLAA50, DT2H-
4500 (2040)
NLAA60, DT2H-NLAA98, DT2H-
NLAA92, DT2H-UFAA48, DT2H-
UFAA40, DT2H-UFAA50, DT2H-
UFAA58,DT2H-UFAA88, DT2H-
UFAA68, DT2H-UFKA88, DT2H-
UFKA20, DT2H-UFKA50, DT2H-
Page 7 of 50
UFKA58, DT2H-FMKA40, DT2H- unit. Caution, when lifting, lift point should always
UFKA98, DT2H-UFKA92, DT2H-
UFKA60 be over the equipment Center of Gravity.
Figure #2
Note: The engine produces a noise level exceeding
Figure #3 shows the typical lifting arrangement of a 70 dB(a). When performing the weekly functional
bare engine. Note the lifting points on the engine are test, it is recommended that hearing protection be
for lifting the ENGINE only. Caution, when lifting, worn by operating personnel.
lift point should always be over the equipment Center
of Gravity. CLARKE UK provides the machine manufacturer
with a “Declaration of Incorporation”
for the Engine, when required, a copy of which is
enclosed in the manual. This document clearly states
the machine manufacturers’ duties and
responsibilities with respect to health and safety.
Refer to Figure #5.
Figure #3
Figure #4 shows the typical lifting arrangement of a

base mounted engine and pump set when the base (or
module) is furnished with lifting holes.
Figure #4
When Clarke furnishes the base (or module) for the

engine and pump set, the combined weight of the
engine and base (or module) will be indicated on the
Page 8 of 50
3133 East Kemper Road • Cincinnati, Ohio • 45241 • USA
Tel: +1 (513) 771-2200 • Fax: +1 (513) 771-0726
DECLARATION OF INCORPORATION
We hereby declare that the engine is intended to be incorporated into other machinery and
must not be put into service until the relevant machinery, into which the engine is to be
incorporated, has been declared in conformity with the essential health and safety
requirements of the machinery Directive 2006/42/EC and consequently the conditions required
for the CE Mark.
We declare that the engine is manufactured in accordance with the following Standards and
Directives:
Directive 2006/42/EC, 2004/108/EC, 2006/95/EC
Standards EN ISO 12100:2010, EN 60204-1:2006
1) Description – Diesel Engines

Manufacturer – Clarke Fire Protection Products, USA
Model Number –
Serial Number –
Year of Manufacture -
Contract Number –
Customer Order Number –
2) The engine has moving parts, areas of high temperatures and high temperature fluids under
pressure. In addition it has an electrical system, which may be under strong current.
3) The engine produces harmful gases, noise and vibration and it is necessary to take suitable
precautionary measures when moving, installing and operating the engine to reduce risk
associated with the characteristics stated above.
4) The engine must be installed in accordance with local laws and regulations. The engine must
not be started and operated before the machinery into which it is to be incorporated and/or its
overall installation has been made to comply with local laws and regulations. The engine must
only be used in accordance with the scope of supply and the intended applications.
Signed ___________________________________ Date: _______________

Ken Wauligman – Engineering Manager
C13944_rev. E 16July12
Figure #5
Page 9 of 50
WHAT TO DO IN AN EMERGENCY lights or activate electric bells or telephones so as to
avoid explosions.
Any user of the Engine who follows the instructions
set out in this manual, and complies with the Take the victim to a ventilated area or into the open
instructions on the labels affixed to the engine are air, placing him on his side if he is unconscious.
working in safe conditions.
CAUSTIC BURNS
If operating mistakes cause accidents call for help
If operating mistakes cause accidents call for help 1) Caustic burns to the skin are caused by acid
immediately from the EMERGENCY SERVICES. escaping from the batteries:
In the event of an emergency, and while awaiting the  remove the clothes
arrival of the EMERGENCY SERVICES, the  wash with running water, being
following general advice is given for the provision of careful not to affect injury-free areas
first aid. 2) Caustic burns to the eyes are caused by
battery acid, lubricating oil and diesel fuel.
FIRE  Wash the eye with running water for
at least 20 minutes, keeping the
Put out the fire using extinguishers recommended by eyelids open so that the water runs
the manufacturer of the machine or the installation. over the eyeball and moving the eye
in all directions.
BURNS
1) Put out the flames on the clothing of the ELECTROCUTION
burns victim by means of:
 drenching with water Electrocution can be caused by:
 use of powder extinguisher, making
sure not to direct the jets onto the 1) The engine’s electrical system (12/24
face VDC)
 blankets or rolling the victim on the 2) The electrical coolant pre-heating system
ground 115/230 Volt AC (if supplied) AC current.
2) Do not pull off strips of clothing that are
sticking to the skin. In the first case, the low voltage does not involve
3) In the case of scalding with liquids, remove high current flows through the human body;
the soaked clothing quickly but carefully. however, if there is a short circuit, caused by a metal
4) Cover the burn with a special anti-burn tool, sparks and burns may occur.
packet or with a sterile bandage. In the second case, the high voltage causes strong
currents, which can be dangerous.
CARBON MONOXIDE POISONING (CO) If this happens, break the current by operating the
switch before touching the injured person.
Carbon monoxide contained in engine exhaust gases
is odorless and dangerous because it is poisonous and If this is not possible, bear in mind that any other
with air, it forms an explosive mixture. attempt is highly dangerous also for the person
Carbon monoxide is very dangerous in enclosed assisting; therefore, any attempt to help the victim
premises because it can reach a critical concentration must be carried out without fail using means that are
in a short time. insulating.
When attending a person suffering from CO WOUNDS AND FRACTURES

poisoning in enclosed premises, ventilate the
premises immediately to reduce the gas The wide range of possible injuries and the specific
concentration. nature of the help needed means that the medical
services must be called.
When accessing the premises, the person providing If the person is bleeding, compress the wound
the aid must hold his breath, not light flames, turn on externally until help arrives.
Page 10 of 50
In the case of fracture do not move the part of the
body affected by the fracture. When moving an
injured person permission from that person must be
received until you can help him. Unless the injury is
life threatening, move the injured person with
extreme care and then only if strictly necessary.
WARNING LABELS Jacket Water Heater Voltage

Warning labels, in picture form, are applied to the
engine. Their meanings are given below.
Important Note: Labels that show an exclamation
mark indicate that there is a possibility of danger.
Heat Exchanger Maximum Working Pressure
Air Filter Installation
Coolant Mixture
2.0 INSTALLATION/OPERATION
2.1 TYPICAL INSTALLATION
A typical Fire Pump installation is shown in Figures

Lifting Point #6 & 6A.
1. Pump/Engine set
2. Main Pump Controller
3. Pump discharge
4. Air louver
5. Entrance door with air louver
6. Exhaust silencer
Automatic Start 7. Exhaust system supports
8. Exhaust outlet pipe
9. Concrete base
10. Exhaust flexible connection joint/pipe
11. Air Discharge Duct from Radiator
NOTE: For radiator cooled engines, the total air

supply path to the pump room, which includes any
louvers or dampers, shall not restrict the flow of the
Rotating Parts air more than 0.2” (5.1mm) water column. Likewise,
the air discharge path, which includes any louvers,
Page 11 of 50
dampers, or ducting, shall not restrict the flow of air 2) Refill the engine crankcase with MIL-L-
more than 0.3” (7.6mm) water column. 21260 preservative oil.
3) Change the fuel filters.
4) Install the coolant plugs and install coolant in
the normal mix percentage of 50% coolant,
50% water, premixed.
5) Remove the protection from the intake and
exhaust openings.
6) Prepare a preservative fuel container as a fuel
source using a fuel conditioner mixture of
C02686 or C02687 with ONLY Diesel #2
#6
fuel or “Red” diesel fuel (ASTM D-975) or
Typical Installation
BS2869 Class A2. (Refer to Section 3.1.1 for
Heat Exchanger Cooled Engine
Fuel Specification.)
7) Disconnect the coupling or drive shaft from
the pump.
11 8) Start and run the engine at a slow speed for
1-2 minutes being careful not to exceed the
normal operating temperature.
9) Drain the oil and coolant.
10) Replace the protective plugs that were used
for shipping and storage.
Figure #6A 11) Attach to the engine a visible card, specifying
Typical Installation “ENGINE WITHOUT OIL” DO NOT
Radiator Cooled Engine OPERATE”.
2.2 ENGINE STORAGE IMPORTANT: THIS TREATMENT MUST BE

REPEATED EVERY 6 MONTHS
2.2.1 Storage less than 1 year ************************
PUTTING ENGINE INTO SERVICE AFTER
Storing engines requires special attention. Clarke ADDITIONAL PRESERVATION SERVICE:
engines, as prepared for shipment, may be stored for To restore the normal operation running conditions of
a minimum of one year. During this period, they the engine, carry out the following:
should be stored indoors in a dry environment.
Protective coverings are recommended provided they 1) Fill the engine sump with the normal
are arranged to allow for air circulation. The stored recommended oil, to the required level.
engine should be inspected periodically for obvious 2) Remove the protective plugs used for
conditions such as standing water, part theft, excess shipping and storage.
dirt buildup or any other condition that may be 3) Refill cooling water to proper level.
detrimental to the engine or components. 4) Remove the card “ENGINE WITHOUT OIL,
Any such conditions found must be corrected DO NOT OPERATE”.
immediately. 5) Follow all steps of the Installation
Instructions when the engine will be put into
2.2.2 Extended Storage Maintenance Procedure service.
After a one year storage period or if the engine is 2.3 INSTALLATION INSTRUCTIONS
being taken out of service for more than 6 months,
additional preservation service must be performed as The correct installation of the engine is very
follows: important to achieving optimum performance and
extended engine life.
1) Drain the engine oil and change the oil filter.
Page 12 of 50
In this respect, the engine has certain installation 4) Engine is typically provided with premixed
requirements, which are critical to how it performs. coolant installed. If engine is not provided
These requirements are generally associated with the with coolant or there is a need to top off, fill
cooling, exhaust, induction air, and fuel systems. engine cooling system with premixed 50%
water / 50% coolant solution. Use only
This section of the manual should be read in coolants meeting ASTM-D6210
conjunction with the relevant Installation and specifications for heavy-duty diesel engines.
Operation Data Sheets. If there is any doubt about an Never use light-duty or automotive coolants
installation, contact should be made with Clarke in the engine that are stated as ASTM-D3306
Customer Support giving exact details of the only. Refer to Figure #23 in section 3.4.3
problem. for cooling system capacity. Refer to section
3.4.5 filling procedure.
All installations should be clean, free of any debris 5) Engine is shipped with oil installed. For
and dry. Care should be taken to ensure that there is make-up oil specifications refer to section
easy access to the engine for maintenance and repair. 3.3 Lubrication System.
The safety of personnel who may be in the area of the 6) Connect fuel supply and return line to fuel
engine when it is running is of paramount importance supply tank plumbing. Reference the Fuel
when designing the installation layout. System section of the Installation and
1) Secure pump set to foundation and complete Operation Data (see Page 5), for piping size,
installation in accordance with pump maximum allowable fuel pump suction, and
manufacturer’s instructions. Perform engine maximum allowable fuel head requirements.
to pump coupling alignment. Lubricate Falk Fill supply tank with ONLY #2 diesel fuel
coupling with supplied grease or driveshaft (ASTM D-975) or BS 2869 Class A2 “Red”
universal joints with NLGI grade #1 or #2 diesel fuel, bleed supply system of air and
grease at the (3) Zerk fittings. (Refer to check for leaks. CAUTION: Biodiesel fuel
section 2.4 for specific alignment is not recommended or stand-by equipment
instructions). that can have minimal fuel consumption
2) Engine with Heat Exchanger Cooling: Install (such as standby generators, fire protection,
the heat exchanger discharge pipe. The etc.) For standby applications use only
discharge pipe should be no smaller than the petroleum based diesel fuel with Doosan
outlet connection on the heat exchanger. approved conditioners/additives. For fuel
Discharge water piping should be installed in conditioners/additives check with your local
accordance with applicable codes. All Doosan dealer, or Clarke. Fuel supply level
plumbing connecting to the heat exchanger must meet applicable code requirements. Do
must be secured to minimize movement by not use a copper based or galvanized material
the engine. Cooling loop water pressure to for any component of a diesel fuel system.
the heat exchanger must not exceed the limit The fuel will chemically react with the zinc
that is stated on the heat exchanger supplied resulting in clogged fuel filters and injector
with the engine. systems.
3) Install all engine cooling system draincocks 7) Remove protective covering on air cleaner
and plugs. element.
8) Connect jacket water heater (if supplied) to
Qty Description Location AC power source. Connect the supplied
1 Plug Water Pump Inlet heater connection wire directly to a customer
RH Exhaust Manifold supplied electrical junction box. The
1 (DT2H Plug - Front electrical supply requirements are indicated
only) on the connection box. Connect to the heater
1 (DT2H Plug LH Exhaust Manifold directly to the junction box at the end of the
only) - Top heater only. Supply wiring should never be
1 Plug Water Pump Outlet routed through the engine gauge panel.
Tube Severe damage to critical engine control
1 ¼” Draincock Heater Inlet Tube
Page 13 of 50
components could result. Energize heater 2.4.2 Driveshaft
only after step #4 is completed.
9) Connect exhaust system to flexible To check the alignment of the pump shaft and engine
connection on the engine. The exhaust crankshaft centerlines for proper Parallel Offset and
system plumbing must be supported by the Angular tolerance, the driveshaft must be installed
building structure and not the engine. The between the flywheel drive disc and the flanged hub
exhaust flexible connection is provided only on the pump shaft.
for the purpose of thermal expansion and
vibration isolation, not for misalignment or Before removing the driveshaft guard, disconnect the
directional change. negative battery cable from both batteries.
10) Make electrical DC connections between the
engine gauge panel terminal strip (if Before beginning the alignment checks and making
supplied) and the controller per the controller any necessary corrections, install the driveshaft and
manufacturer’s instructions. Refer to the re-torque all driveshaft connection bolts to the values
wiring diagram sticker located on the inside given in the following table:
door of the engine gauge panel for proper
connection of the water solenoid. BOLT TIGHTENING
11) Fill batteries with electrolyte per battery DRIVE SIZE TORQUE
MODELS SHAFT /MATERIA ft-lbs
manufacturer’s instructions. Connect cables L GRADE (N-m)
between engine and batteries only after SC81A 7/16-20,
electrolyte is installed. Refer to the wiring or Grade 8 50-55
DP6H/R
diagram inside the engine gauge panel door CDS50-SC (Hi- (68-75)
(if supplied), or appropriate wiring diagram Tensile) (See Note #2)
(see Page 5), for correct positive and SC81A 7/16-20,
negative connections. or Grade 8 50-55
DQ6H/R
12) Connect negative cables directly to the CDS50-SC (Hi- (68-75)
ground stud. Connect each positive cable to Tensile) (See Note #2)
the large outer post of the manual starting
M16,
contactors. SC2160A
DR8H/R Class 10.9 100-105
13) Note: Clarke Operation and Maintenance
(Metric) (135-142)
Instructions Manual and Clarke parts
(Hi- (See Note #2)
illustration pages are located inside the
Tensile)
engine gauge panel.
M16,
14) IMPORTANT! In order to obtain prompt DS0H/R
SC2160A Class 10.9 100-105
Warranty Service and to comply with
(Metric) (135-142)
Emissions regulations, this engine must be
(Hi- (See Note #2)
registered to the final installation name and
Tensile)
address. To register this engine, go to DT2H-
www.clarkefire.com and select Warranty UFAA20
UFKA20, M16,Class 100-105
Registration. SC2160A
FMKA40 10.9 (135-142)
UFAA50,
(Metric) (See Note #2)
2.4 SPECIFIC FLYWHEEL COUPLING UFKA50,
ALIGNMENT INSTRUCTIONS UFAA58, (Hi-
UFKA58 Tensile)
UFAA30
2.4.1 Listed Driveshafts UFAA60
DT2H- M16,Class
UFAA98
Refer to Listed Driveshaft Installation, Operation and UFAA92 10.9 210-220
FMAAX8 SC2390 (Metric) (285-298)
Maintenance Manual C132355
FMAAX2
(Hi- (See Note
Tensile) #2,3)
Page 14 of 50
Note 1 – It is recommended that a medium strength B) With the driveshaft in the same orientation as
threadlocker (Loctite 243–blue) be used in the the previous step (Step A), check the
assembly and torquing of all hardware. This may be Horizontal Angular alignment of the shafts.
purchased as part number C126758, 50ml bottle. 1. Measure from the mating surface of the
companion hub to point G shown on
Note 2 – 4 of the hi-tensile bolts and/or nuts, that are figure #7b. (Point G is the furthermost
used to connect the driveshaft to the drive disc and point on the bearing bore). This
that connect the driveshaft to the pump companion measurement must be equal to the
flange, will require a “crow’s foot” wrench attached measurement at point E + 0.5 mm.
to a standard torque wrench in order to apply the
required tightening torque. A standard socket will
not work due to close proximity of the bolts and/or
nuts with the driveshaft yoke. The tightening torque
values listed for these bolts and/or nuts have been
corrected for using a “crow’s foot” adapter which
extends the standard torque wrench’s length.
Note 3 – For the high torque required for these nuts it

is recommended that a boxed end crows foot be used.
The following steps describe the proper way to check

alignment. A small pocket scale or ruler with
Figure #7b
millimeter markings is recommended to make all
measurements.
C) To check the Vertical Parallel Offset, the
A) To check the Horizontal Parallel Offset, the
driveshaft must be re-orientated.
driveshaft must be in the proper orientation.
1. Rotate the shaft 90○ so the reference
1. Rotate the shaft so the reference “AB” on the
“CD” on the flywheel adapter disc or the
flywheel adapter disc or the circumference of
circumference of the drive shaft flange
the drive shaft flange (against the flywheel
(against the flywheel) is in the position
adapter disc) is in the 12 o’clock position
shown on Figure#7c.
shown on figure #7a.
2. Measure from the face of the flywheel
2. Measure from the face of the flywheel
adapter disc to point H. (Point H is the
adapter disc to point E. (Point E is on the
furthermost point on the bearing bore
bearing bore as shown in Figure #7a). This
diameter). The measurement must be:
measurement must be:
Measurement Driveshaft
Measurement Driveshaft
112.5 + 1mm SC81A / CDS50-SC
109 + 2mm SC81A / CDS50-SC
126.5 + 1mm SC2160A
123.5 + 1.5mm SC2160A
145.5 + 1.5mm SC2390
142.5 +1.5mm SC2390
Figure #7a Figure #7c
Page 15 of 50
D) With the driveshaft in the same orientation as 2.4.3 Other Coupling Types
the previous step (Step C), check the Vertical
alignment of the shafts. Consult Factory or Clarke website at
1. Measure from the mating surface of the www.clarkefire.com for additional
pump companion hub of the drive shaft information.
to point J as shown in figure #7d. (Point J
is the same as point G, with the 2.5 STARTING/STOPPING THE ENGINE
driveshaft rotated 90o). This
measurement must be equal to the 2.5.1 To Start Engine
measurement at point H + 1 mm.
Before starting the engine for the first time review
Re-install all guards and grease fittings before section 3.4.6 to ensure there is an adequate Raw
reconnecting the battery cables. Water Supply to the Engine Heat Exchanger.
On UL/FM engines, use main pump controller for

starting and stopping the engine. Should the main
pump controller become inoperable, the engine can
be manually started and stopped from the engine
gauge panel. For manual starting and stopping of an
engine with a gauge panel:
IMPORTANT: Main pump controller selector

should be in the OFF position when starting from
engine gauge panel. Be sure to return selector on
main pump controller and engine gauge panel to
AUTOMATIC after completing manual run.
Figure #7d
 Position MAIN PUMP CONT ROLLER
DRIVESHAFT MAINTENANCE TO “OFF” POSITION . (Refer to Figure
#9).
1. To service the driveshaft disconnect the  Lift and hold MANUAL CRA NK #1, until
negative battery cables, remove the top of engine starts, or release after 15 seconds. If
guard and set aside. unit fails to start, wait for 15 seconds, use
2. Rotate engine shaft manually so the u-joint MANUAL CRANK #2 and repeat step.
grease fittings are accessible.  If COOLING WATE R is not flowing or
3. Using a hand held grease gun with N.L.G.I. engine TEMPERATURE is too HIGH,
grade 1 or 2 grease position on grease fitting. open cooling system manual by-pass valves
Pump with grease until grease is visible at all (applies to heat exchanger cooled engines
four cap seals. only).
4. Verify all driveshaft connecting bolts remain
tight. Re-torque per 2.4.1 if necessary. Note: You can also crank engines using manual
5. Reinstall top of guard and connect negative starting contactors.
battery cables.
Page 16 of 50
2 UL/FM Front Opening Instrument Panel
1
5
8 9 9 10
Figure #9
1 – Emergency Operating Instructions 6 – Overspeed Verification
2 – Automatic / Manual Mode Selector 7 – Overspeed Indication Light
3 – Manual Crank Controls 8 – Oil Pressure Gauge
4 – Overspeed Reset 9 – Voltmeters Battery 1 & 2
5 – Manual Mode Warning Light 10 – Coolant Temperature Gauge
Non-Listed Instrument Panel
1 – Emergency Operating Instructions 4 – Overspeed Reset

2 – Automatic-Manual Mode Selector 5 – Warning Light
3 – Manual Crank Controls 6 – Overspeed Verification
Page 17 of 50
IMPORTANT: Main pump controller selector 2.5.1.1 Optional Pneumatic Starting System
should be in the OFF position when starting from
engine gauge panel. Be sure to return selector on Some engines may be provided with an optional
main pump controller and engine gauge panel to pneumatic starting system to crank the engine from a
AUTOMATIC after completing manual run. pressurized receiver tank. See figure 9A for
schematic of the pneumatic starter system and wiring
diagram for field wiring.
Page 18 of 50
2.5.2 To Stop Engine
If engine is started from main pump controller use

main pump controller to stop the engine.
If engine is started from engine gauge panel: Return

MODE SELECT OR switch to
AUTOMATIC/MANUAL STOP position, engine
will stop. Close cooling system manual by-pass
valve if opened.
IMPORTANT: DO N OT leave the MODE

SELECTOR switch in the MANUAL RUN position
during AUTOMATIC operation. (The controller
will be unable to stop the engine and DAMAGE Figure #10A
MAY RESULT).
2.5.3 Emergency Stop Instructions
If energized to stop solenoid fails, you will NOT be

able to stop the engine from the instrument control
panel or fire pump controller. Use the emergency
stop lever to choke off fuel supply and shut the
engine down.
DP6H & DQ6H engine models: The emergency stop

lever is located on the right side (same side as
instrument panel) of the engine on the fuel injection
pump. To stop the engine, rotate the emergency stop
lever clockwise until it stops (see Figure #10A).
Figure #10B
Continue to hold lever in “STOP” position until
engine comes to a complete stop.
2.6 WEEKLY TEST
DR8H & DS0H engine models: The emergency stop
An experienced operator should always be present
lever is located near the front of the engine. To stop
during the weekly test.
the engine rotate the emergency stop lever until it
stops. Continue to hold lever in “STOP” position
NOTE: This engine is designed to operate at rated
until engine comes to a complete stop.
load conditions. For testing purposes the engine can
be run at lower load (lower flow) conditions.
DT2H engine models: If energized to stop solenoid
Running times in any one period should not exceed
fails, you will NOT be able to stop the engine from
30 minutes maximum.
the instrument control panel or fire pump controller.
This solenoid is located on the left side (opposite side
Before starting the engine make sure of the
of instrument panel) of the engine towards the front.
following:
To stop the engine, rotate the emergency stop lever
1) The operator has free access to stop the
counter-clockwise until the solenoid plunger is
engine in an emergency.
completely depressed (see Figure #10B). Continue
2) The plant room ventilation ducts are open
to hold lever in “STOP” position until engine comes
and the engine has good access for air.
to a complete stop.
3) All the guards are in position and, if not, for
whatever reason, any rotating parts will be
free and clear without restriction.
4) Battery covers are in place and there is
nothing on top of or touching the engine,
Page 19 of 50
which is not part of the original supply maintenance of Water-Based Fire Protection
specification. Systems,” Copyright © 2013 National Fire
5a) Heat Exchanger Cooling: The water supply Protection Association®. All Rights Reserved.
for coolant is available again without
restriction. 8.3.4 Diesel Fuel Testing and Maintenance
5b) Radiator Cooling: The air supply for cooling
is available again without restriction. 8.3.4.1 Diesel fuel shall be tested for
degradation no less than annually.
When engine is running make sure that the coolant
temperature and oil pressure raw cooling water flow 8.3.4.1.1* Fuel degradation testing shall
are within the limits specified on the relevant comply with ASTM D975-11b Standard
Installation & Operation Data (see Page 5). Specification for Diesel Fuel Oils, or ASTM
D6751 -11b Standard Specification for
If the coolant temperature is excessive, check: Biodiesel Fuel Blend Stock (B100) for
a. Cooling loop strainers Middle Distillate Fuels as approved by the
b. Proper functioning of thermostat engine manufacturer, using ASTM D 7462 -
c. Condition of heat exchanger tube 11 Standard Test Method for Oxidation
bundle Stability of Biodiesel (B100) and Blends of
Biodiesel with Middle Distillate Petroleum
3.0 ENGINE SYSTEMS Fuel (Accelerated Method).
3.1 FUEL SYSTEM 8.3.4.2* If diesel fuel is found to be deficient

in the testing required in 8.3.4.1.1, the fuel
3.1.1 Diesel Fuel Specification shall be reconditioned or replaced, the
supply tank shall be cleaned internally, and
All diesel fire pump drivers manufactured by Clarke the engine fuel filter(s) shall be changed.
are designed, tested and warranted for use only with
No. 2-D Diesel Fuel conforming to ASTM 8.3.4.2.1 After the restoration of the fuel and
International D-975-11b or British Standard tank in 8.3.4.2, the fuel shall be retested each
BS2869:2010+A1:2011 Fuels oils for agricultural, 6 months until experience indicates the fuel
domestic and industrial engines and boilers - can be stored for a minimum of one year
Specification. without degradation beyond that allowed in
8.3.4.1.1
Although the above referenced fuel specifications
allow limited amounts of Biodiesel, 100% petroleum 8.3.4.3 When provided, active fuel
fuel is preferred and should be used whenever maintenance systems shall be listed for fire
possible. Biodiesel in any amount greater than that pump service.
allowed by the above referenced specifications
should not be used. The use of fuels not referenced 8.3.4.3.1 Maintenance of active fuel
above, or Biodiesel in amounts greater than allowed maintenance systems shall be in accordance
in the above referenced specifications, may affect with the manufacturer’s recommendations.
performance and reliability, and may result in a non-
warrantable engine condition. 8.3.4.3.2 Maintenance of active fuel
maintenance systems shall be performed at a
To insure engine reliability and performance, the fuel minimum annual frequency for any portion of
provided for Clarke fire pump drivers must be the system that the manufacturer does not
maintained in a quality condition. Refer to NFPA 25 provide a recommended maintenance
2014, reprint provided below, for guidance to the frequency.
minimum requirements for fuel maintenance for all
Clarke fire pump engine installations. 8.3.4.3.3 Fuel additives shall be used and
maintained in accordance with the active fuel
The following is reprinted from the “NFPA 25 2014 maintenance system manufacturer’s
Standard for the Inspection, Testing, and recommendations.
Page 20 of 50
A.8.3.4.1.1 Commercial distillate fuel oils Tighten all connections before applying pressur e.
used in modern diesel engines are subject to Keep hands and body away from pinholes and
various detrimental effects from storage. The nozzles, which eject flui ds under high pressu re.
origin of the crude oil, refinement processing Use a piece of cardboar d or paper to search for
techniques, time of year, and geographical leaks. Do not use your hand.
consumption location all influence the
determination of fuel blend formulas. If ANY flui d is injected into the skin, it must be
Naturally occurring gums, waxes, soluble surgically removed within a few hour s by a doctor
metallic soaps, water, dirt, blends and familiar with this type injury or gangrene ma y
temperature all contribute to the degradation result. Ref Figure #11
of the fuel as it is handled and stored. These
effects begin at the time of fuel refinement
and continue until consumption. Proper
maintenance of stored distillate fuel is
critical for engine operation, efficiency, and
longevity.
Figure #11
Storage tanks should be kept water-free. Whenever the fuel system has been opened up for
Water contributes to steel tank corrosion and service (lines disconnected or filters removed), it will
the development of microbiological growth be necessary to bleed air from the system.
where fuel and water interface. This and the
metals of the system provide elements that DP6H, DQ6H, DR8H, DS0H, DT2H Engine Series:
react with fuel to form certain gels or
organic acids, resulting in clogging of filters 1) Loosen the air bleed valve (A) by hand on fuel
and system corrosion. Scheduled fuel filter head. Ref. Figure #12A and #12B.
maintenance helps to reduce fuel 2) Operate supply pump primer lever (B) until
degradation. Fuel maintenance filtration can fuel flow is free from air bubbles. On the DP6H,
remove contaminants and water and and DQ6H it will be necessary to rotate pump
maintain fuel conditions to provide reliability handle to release it and then to lock in place after
and efficiency for standby fire pump engines. fuel system is bled. Ref. Figure #13A and #13B.
Fuel maintenance and testing should begin 3) Tighten bleeding valve securely; continue
the day of installation and first fill. operating hand primer until pump action is not
felt.
A.8.3.4.2 Where environmental or fuel 4) Start engine and check for leaks.
quality conditions result in degradation of
the fuel while stored in the supply tank, from A
items such as water, micro-organisms and
particulates, or destabilization, active fuel
maintenance systems permanently installed
on the fuel storage tanks have proven to be
successful at maintaining fuel quality. An
active fuel maintenance system will maintain
the fuel quality in the tank, therefore
preventing the fuel from going through
possible cycles of degradation, risking
engine reliability, and then requiring
reconditioning. Figure #12A – DP6H, DQ6H, DR8H, & DS0H
models
3.1.2 Bleeding the Fuel System
CAUTION: Escaping fluid under pressu re can

penetrate th e skin causi ng serie s inj ury. Reliev e
pressure bef ore disconne cting fuel or other lines.
Page 21 of 50
A B
Figure #12B – DT2H-UFAA60,98,92,-FMAAX8,X2 models
Figure #13D- DT2H models

B
3.1.3 Changing the Fuel Filter Cartridges
Changing the cartridges and bleed any air from the

fuel system as per instructions given in section 3.1.1.
Fuel filter changes should take place as per
recommendations and only use approved filters. It
may also be necessary to change filters out with the
recommendations in the event of:
Figure #13A – DP6H & DQ6H models 1) The engine has had an overhaul.
2) The quality of the fuel is questionable.
3) The engine has been subjected to temporary
adverse conditions outwith it normal
operating parameters.
4) The fuel tank condensation trap has not been
drained in line with manufacturer’s
recommendations.
3.1.3.1 Fuel Filters
Note: DT2H-UFAA60,98,92,-FMAAX8,X2 (wet

exhaust manifold) engines are provided with parallel,
Figure #13B – DR8H models duplex fuel filters. Each filter is to be replaced by
utilizing the duplex valve to cut out that valve. Refer
to Figure 14.
Figure 14 – DT2H-UFAA60,98,92,-
Figure #13C – DS0H models
FMAAX8,X2 (wet exhaust manifold)
 Loosen the fuel filter by turning it

counterclockwise with the filter wrench.
Discard the used filter in a designated place.
Page 22 of 50
 Wipe the filter fitting face clean. 3.2.1 Ambient Conditions
 Apply a light coat of engine oil to the O-ring
and supply fuel to the new filters. Clarke engines are tested in accordance with SAE
 Turn the new filter until the filter O-ring is J1349 (Clarke USA) or ISO 3046 (Clarke UK). In
fitted against the sealing face. this capacity they may be derated to meet certain site
 And the turn the filter cartridge about ¾ ~ 1 conditions, failure to do so can seriously impede the
turn more with hands or filter wrench. performance of the engine and could lead to
premature failure.
CAUTION: DO NOT LEAV E SELECT OR
LEVER IN ANY IN TERMEDIATE POSITI ON 3.2.2 Ventilation
BECAUSE THIS WOULD INTE RFERE WITH
THE FUEL SUPPLY. See Figure #14. The engine must be provided with adequate
ventilation to satisfy the requirements of the
3.1.4 Fuel Tanks combustion system, radiator cooling systems where
fitted, and allow adequate dissipation of radiated heat
D and crankcase emissions. For all this data refer to
Keep the fuel tank filled to reduce condensation to a
minimum. Open drain at the bottom of the fuel tank Installation & Operation (see Page 5). This data can
onceCa week to drain off any possible water and/or be used for proper sizing of inlet and outlet louvers.
sediment. Fill tank after each test run.
Note: Per NFPA 25 standards, the fuel tank level 3.2.3 Standard Air Cleaner
must never be less than 67% of its capacity.
Maximum Allowable Fuel Head above Fuel pump, The standard air cleaner is a reusable type. Should a
Supply or Return. situation occur where the air cleaner becomes
Engine model feet meters plugged with dirt (starving the engine of air), loss of
B power and heavy black smoke will result; if equipped
DP, DQ 9.0 2.7 air filter restriction indicator (ref. Fig. #17A); the air
DR, DS, DT 10.7 3.3 cleaner should be serviced immediately. See Figure
#39 for air cleaner part numbers by Clarke Engine
3.1.5 Fuel Injection Pump Components Model.
Air filter
For Droop Spring and Run-Stop Solenoid (external to restriction
Injection Pump) part numbers consult factory. Base engine Speed (inches of water)
DP6H‐UFAAX8,
3.1.6 Priming Pump Strainer Cleaning
DP6H‐UFAA50,
DP6H‐UFAA88, 10
Clean the priming pump strainer on an annual basis.
The plastic strainer is incorporated in the priming DP6H‐UFAA62,
pump inlet side “banjo” bolt. Clean any debris from DP6H‐UFAA70
the strainer with compressed air and rinse it with fuel. DQ6H‐UFAA48,
DQ6H‐UFAA40,
DQ6H‐UFAA50,
14
DQ6H‐UFAA60,
DQ6H‐UFAA88,
DQ6H‐UFAA98
DR8H‐UFAA40,
DR8H‐UFAA5G,
DR8H‐UFAA68,
10
DR8H‐UFAA62,
DR8H‐UFAA98,
DR8H‐UFAA92
3.2 AIR/EXHAUST SYSTEM DS0H‐UFAAM0,
DS0H‐UFAAN0, 14

DS0H‐UFAA68,
Page 23 of 50
DS0H‐UFAA60,
DS0H‐UFAA98,
DS0H‐UFAA92
DT2H‐UFAA20,
DT2H‐UFAA58, 14

DT2H‐UFAA50
DT2H‐UFAA88 14
DT2H‐UFAA60,
DT2H‐UFAA98, 16

DT2H‐UFAA92
CAUTION: Do not attempt to remove the air

cleaner while an engine is running nor run the engine
while the air cleaner is off. Exposed components
could cause severe injury to personnel and major
internal engine damage could occur should any
foreign matter be drawn into the engine.
The air cleaner manufacturer recommends the

following:
1. The pre-oiled reusable elements are serviced
with a special oil. The elements can be
serviced or replaced.
2. Figure#15 shows the air filter service
instructions.
3. When servicing the element is not practical,
you can improve filter efficiency by re-
spraying with oil.
NOTE: Do not attempt this while engine is running
NOTE: Do not over oil the reusable element
Figure #15
Page 24 of 50
Note: Intake Air Shutoff Valve - Engine may
include an intake air shutoff valve as an optional
feature that is activated by an overspeed event
and provides a positive shutoff of combustion air
to the engine. The optional air intake shutoff
valve has not been evaluated by UL as part of a
UL Listed fire pump driver.
3.2.4 Crankcase Ventilation
3.2.4.1 DP6H, DQ6H – Open Crankcase Ventilation

(Refer to Figure #16) Figure #17A- DR8H / DS0H models
Vapors which may form within the engine are

removed from the crankcase and gear train
compartment by a continuous, pressurized ventilation
system.
A slight pressure is maintained within the engine

crankcase compartment. Vapors expelled through a
vent pipe attached to the rocker cover breather
element. Ref. Figure #16.
Figure #17B – DR8H / DS0H models
Figure # 16
3.2.4.2 DR8H, DS0H, & DT2H – Crankcase

Ventilation System
A crankcase ventilation system allows for the Figure #17C

recirculation of vapors (expelled through a vent pipe
attached to the rocker cover breather element) to the
combustion air inlet. Refer to Figures 17A, 17B,
17C, & 17D.
Figure #17D
Page 25 of 50
DT2H-UFAA20,
DT2H-UFAA58, 35
DT2H-UFAA50
DT2H-UFAA88 25
DT2H-UFAA60,
DT2H-UFAA98, 24
DT2H-UFAA92
The installation of the exhaust system should consist

of the following:
 Personnel protection from hot surfaces.
Figure #17E  Adequate supports to prevent strain on the
engine exhaust outlet and minimize
vibration.
 Protection against entry of water and other
foreign matter.
While the engine is running inspect exhaust pipe

outlet outside of the pump room itself for
environmental hazards such as excessive smoke
conditions. The following could be used as a guide
for general engine operating conditions.
1) Blue Smoke – Possible engine oil

Figure #17F consumption.
Engine Open Crankcase 2) White Smoke – Possibility of water in
Model Crankcase Ventilation cylinders, water in fuel or internal engine
Ventilation System problem.
DP6H–all models Standard
3.3 LUBRICATION SYSTEM
DQ6H–all models Standard
DR8H–all models Standard 3.3.1 Checking Sump Oil
DS0H–all models Standard Check the sump oil level using the dipstick on the
DT2H–all models Standard engine as shown in Figures #18A and 18B.
This level must always be between the dipstick marks
Min. and Max. with the engine not running. On
3.2.5 Exhaust System
DT2H engines the dipstick should be reinserted for
measurement very slowly so that the level on the
Excessive back pressures to the engine exhaust can
dipstick is accurate.
considerably reduce both engine performance and
life. It is therefore important that exhaust systems
should be the proper diameter and be as short as
possible within the minimum amount of bends. Refer
to Installation & Operating (see Page 5) for exhaust
data. Also refer to table below for maximum exhaust
restrictions.
Air filter restriction
Base engine
(inches of water)
DP 30
DQ 30
DR 30 Figure #18A – DT2H, DR8H, DS0H
DS 40
Page 26 of 50
Figure 14 – DT2H-UFAA60,98,92,-
FMAAX8,X2 (wet exhaust manifold)
Figure #18B - DP6H, DQ6H
3.3.2 Changing Engine Oil
1) Operate the engine until it is warm.

2) Stop the engine. Remove the sump drain
plug and drain the lubricating oil from the
sump. Fit the drain plug tighten the plug to
34 Nm (25.1lbf-ft) /3.5 kgf-m.
3) Fill engine with oil at the oil filler neck on
the valve cover. Check that the oil is at the
‘FULL” mark on the dipstick with new and
clean lubricating oil of an approved grade.
(see Figure 19D)
Figure 14 - DQ6H
Note: On DQ engines, drain oil from filter by

loosening drain plug on filter heard.
3. Remove the filter with a strap wrench or

similar tool. Then dispose of the filter
properly (Ref Figure #19A, #19B, and
Figure #19D #19C).
4. Clean the filter head.
4) Return the unit back into service by returning 5. Lubricate the top of the filter seal with clean
the main pump controller selector to engine lubricating oil.
“automatic” position and the manual 6. Fit the new filter and tighten it until sealing
operating lever to AUTO-OFF position. face is against the 0-ring. Turn 3/4 – 1 turns
5) Dispose used oil properly. further with the filter strap wrench.
7. Ensure that there is lubricating oil in the
3.3.3 Changing Oil Filter Cartridge sump. On turbocharged engines, ensure that
the engine will not start and operate the
1. Turn engine off. starter motor until oil pressure is obtained.
2. Put a tray under the filter to retain spilt 8. Refer to alarm 5 of section 3.5.5 for over
lubricating oil. crank/start disable instructions. Operate the
engine and check for leakage from the filter.
Note: DT2H-UFAA60,98,92,-FMAAX8,X2 (wet When the engine has cooled, check the oil
exhaust manifold)engines are provided with parallel, level on the dipstick and put more oil into the
duplex oil filters. Each filter is to be replaced by sump, if necessary.
utilizing the duplex valve to cut out that valve. Refer 9. Return the unit back into service by returning
to Figure 14. the main pump controller selector to
Page 27 of 50
“automatic” position and the manual 3.3.5 Oil Capacities (Including Filter)
operating lever to AUTO-OFF position. ENGINE OIL CAPACITY
MODEL QUARTS (LITERS)
DP6 – All Models 15 (14)
DQ6 – All Models 23 (22)
DR8 – All Models 21 (20)
DS0– All Models 35 (33)
DT2 – All Models 45 (43)
Figure #21
3.4 COOLING SYSTEM
Figure #19A – DP6H models 3.4.1 Intended Engine Operating Temperature
The DP, DQ, DR, DS & DT engines are provided

with either a heat exchanger or radiator to maintain
the engine coolant temperature within recommended
operating guidelines.
The DP, DQ, DR, DS, & DT engines have an

intended engine operating temperature of 160º F
(71ºC) to 185º F (85º C). A high coolant temperature
switch is provided to indicate a high coolant
Figure #19B – DQ6H models temperature alarm at 205º F (96º C).
3.4.2 Engine Coolant
The following information is provided as a guide for

Clarke Engine users in the selection of a suitable
coolant.
The water/ethylene glycol/inhibitor coolant mixture

Figure #19C – DR8H, DS0H, DT2H used in Clarke engines must meet the following basic
requirements:
3.3.4 Oil Specification  Provide for adequate heat transfer.
 Provide protection from cavitation damage.
This engine is factory-filled with oil.  Provide a corrosion/erosion-resistant
environment within the cooling system.
Important: Do not add makeup oil until the oil  Prevent formation of scale or sludge deposits
level is BELOW the add mark on the dispstick. in the cooling system.
 Be compatible with engine hose and seal
Oil spec to be used for all engine models: materials.
API Symbol:  Provide adequate freeze and boil over
protection.
WARNING
A water and anti-free ze solution is required for
pump installations. Premixing this solution prior
to installing is required. This prevents possible
pure anti-free ze che mical reactions to bloc k
heater el ements which can burnout the ele ment.
Note: CF-4, CG-4, CH-4 and CI-4 are also acceptable Please see the I&O section (see Page 5) for prope r
Figure #20 cooling system capacities of each model.
Page 28 of 50
3.4.3 Water Concentrations below 30% offer little freeze, boil
over or corrosion protection.
Water can produce a corrosive environment in the
cooling system, and the mineral content may permit IMPORTANT
scale deposits to form on internal cooling surfaces. Never use automotive-type coolants (such as those
Therefore, inhibitors must be added to control meeting only ASTM D3306 or ASTM D4656).
corrosion, cavitation, and scale deposits. These coolants do not contain the correct additives
to protect h eavy-duty di esel engines. They often
Chlorides, sulfates, magnesium and calcium are contain a high concentration of silicates and may
among the materials which make up dissolved solids damage the engine or cooling system.
that may cause scale deposits, sludge deposits, ENGINE COOLANT
corrosion or a combination of these. Chlorides MODEL CAPACITY
and/or sulfates tend to accelerate corrosion, while QUARTS (LITERS)
hardness (percentage of magnesium and calcium salts ALL DP6H 29 (28)
broadly classified as carbonates) causes deposits of ALL DQ6H 36 (34)
scale. Water within the limits specified in Figure ALL DR8H 30 (28)
#22 is satisfactory with an engine coolant when ALL DS0H 33 (31)
properly inhibited. Use of deionized or red distilled DT2H-UFAA20, 40, 38 (36)
water is preferred. 50, 58, 88
DT2H-UFAA60, 98, 109 (103) Max
Grains 92, -FMAAX8,X2 97 (92) Min.
Parts per per DS0R—UFAA67, 59 126 (119)
Materials Million Gallon Figure #23
Chloride (Max.) 40 2.5
Sulfates (Max.) 100 5.8 3.4.5 Coolant Inhibitor
Total Dissolves Solids
(Max.) 340 20 The importance of a properly inhibited coolant
Total Hardness (Max.) 170 10 cannot be over-emphasized. A coolant which has
Figure #22 insufficient or no inhibitors at all, invites the
formation of rust, scale, sludge and mineral deposits.
3.4.4 Coolant Capacities These deposits can greatly reduce the cooling
systems efficiency and protection capabilities.
Ethylene Glycol or Propylene Glycol are acceptable: Recommended supplemental coolant inhibitors are a
combination of chemical compounds which provide
IMPORTANT: corrosion protection, cavitation suppression, pH
Do not use cooling system sealing additives or controls and prevents scale. These inhibitors are
antifreeze that contains sealing additives. available in various forms, such as liquid packages or
integral parts of anti-freeze.
Do not mix ethylene glycol and propylene glycol
base coolants. It is imperative that supplemental inhibitors be added
to all Clarke engine systems. A pre-charge dosage
Do not use coolants that contain nitrites. must be used at the initial fill and the maintenance
dosage used at each service interval. Serious damage
Use an ethylene glycol coolant (low silicate will occur unless inhibitors are used. Some of the
formulation) that meets the standard of either the GM more common corrosion inhibitors are borates,
6038-N formulation (GM1899-M performance) or nitrates and silicates.
ASTM D6210 requirements. Inhibitors become depleted through normal
operation; additional inhibitors must be added to the
A 50% coolant water solution is recommended. A coolant as required to maintain original strength
concentration over 70% is not recommended because levels. Refer Figure #24 for proper concentrations of
of poor heat transfer capability, adverse freeze inhibitors.
protection and possible silicate dropout.
Page 29 of 50
Min. Max 3.4.6.1 Partial Fill
PPM PPM
Boron (B) 1000 1500 Install the pressure cap, start and run engine for
Nitrite (NO2) 800 2400 approximately 5 minutes in order to purge the air
Nitrates (NO3) 1000 2000 from the engine cavities.
Silicon (Si) 50 250
Phosphorous (P) 300 500 When verifying that the coolant is at a safe operating
PH 8.5 10.5 level, it is best to wait until the engine temperature
Figure #24 drops to approximately 120ºF (49ºC), or lower,
Do not use soluble oils or chromate inhibitors in before removing the pressure cap.
Clarke engines. Detrimental effects will occur.
Remove the pressure cap and refill to the proper fill
To properly check inhibitor concentrations it may be level. To continue the deaeration process start and
necessary to contact your local Service/Dealer for run engine until the temperature stabilizes at
assistance. Refer to Parts Information Section to approximately 160°-200° (71°-93° C) or run engine
obtain the part number for the factory Coolant for 25 minutes, whichever is longer. During this
Analysis Kit. This kit can be purchased for a warming process, you may see coolant coming from
nominal fee for analyzing the conditions of the the overflow tube attached at the pressure cap
engine’s coolant. location. Allow engine to cool, then remove the
pressure cap and refill to the proper fill level.
3.4.6 Procedure for Filling Engine
Caution: Do not remove pressure cap while coolant
During filling of the cooling system, air pockets may is at normal operating temperatures. Possible
form. The system must be purged of air prior to personal injury could result from the expulsion of hot
being put in service. This is best accomplished by coolant.
filling with a pre-mix solution.
3.4.7 Providing adequate Raw Water Supply to the
Note: On DT2H engines, it is important to loosen the Engine Heat Exchanger
bolts in the banjo connections at the top of each turbo
to provide a vent during the fill. Once the initial fill 3.4.7.1 Raw Water Supply
is complete, the bolts should be tightened and then
follow the partial fill instructions below. Most Clarke diesel engine fire pump drivers are heat
exchanger cooled and some engines also have a
charge air cooler (CAC) that uses raw water to cool
the air before entering the intake manifold. If you
have a radiator cooled Clarke engine, you can
disregard this section. Heat exchanger cooled diesel
engine drivers require a clean source of pressurized
water from the discharge side of the fire pump in
order to keep the engine from overheating by
providing a specified minimum amount of raw water
flow.
3.4.7.2 Cooling Loop
NOTE: Engine may include a cooling loop as an

Figure #25A
optional feature and has not been evaluated by UL as
part of a UL Listed fire pump driver.
Caution: Do not overfill cooling system. A
Clarke cooling loops are FM Approved to meet
pressurized system needs space for heat
standard sizing conditions of 50% blocked wye
expansion without overflowing.
strainers, 100degF (38degC) raw water inlet
temperature, 80 psi inlet pressure, and 10 psi
available at the engine outlet.
Page 30 of 50
Figure #26 shows the standard NFPA 20 cooling The shutoff valves are also used to isolate water
loop piping arrangement. The cooling loop consists pressure in the event of maintenance to pressure
of an Automatic flow line with a 12v or 24v solenoid regulators, strainers and solenoid valve. Shut off
valve (HSC and ES pump applications only) that is valves in the Automatic flow line are provided with
energized to open anytime the engine is called upon lockable handles for cooling loops that have been
to run from either the fire pump controller or from tested to FM requirements.
the engine instrument panel.
In each flow line there is also a pressure regulator.
NOTE: VT type pump applications do not require a Each pressure regulator protects the downstream
solenoid valve in the Automatic flow line. piping from over-pressurization which includes the
NOTE: With the Mechanical Engine and Alarm tube side of the engine shell & tube heat exchanger
Control Board, See section 3.5.5, the solenoid valve (and/or CAC) and to control raw water flow rate.
will open 15 seconds after engine shutdown and will The pressure regulators are set to limit downstream
stay open for 60 seconds. This allows for raw water pressure to 60 psi (4 bar). There is a 0-60 psi (0-4
to flow through the heat exchanger and reduce the bar) pressure gauge installed at the cooling loop
heat soak rise caused in the engine. outlet, and prior to the engine heat exchanger (or
CAC).
The second flow line is called the Manual by-pass
line and it can be opened at any time if for any reason Wye strainers are used to remove debris from the raw
the engine shows signs of overheating. Each line has water supply. One strainer is in the Automatic flow
two (quarter turn) shutoff values installed and the line and the other is in the Manual by-pass flow line.
normal position of the shutoff valve is to remain open
in the Automatic flow line and remain closed in the Note: See section 3.4.7.5 regarding strainer
Manual by-pass flow line. maintenance.
NOTE: Opening up both lines to flow is never a

problem should there be some concern of engine
overheat, especially if there is an emergency
situation. The Manual by-pass line can only be
opened by an operator in the pump room.
The shutoff valves are all identified to show which

are Normally Open (Automatic flow line) and which
are Normally Closed (Manual by-pass flow line).

Page 31 of 50

Figure #26
3.4.7.3 Setting Raw Water Flow Rate time required to fill the container and compare to the
gpm or L/min value provided on the I&O datasheet.
The proper amount of raw water flow thru the engine THIS IS CRITICAL FOR PROPER ENGINE
is of the utmost importance, and the pressure gauge COOLING AT MAXIMUM PUMP LOAD!!
value does little to indicate if there is sufficient flow. If proper cooling water flow rate is established then
When the engine is exercised weekly, the amount of no fire pump controller alarm will be triggered to
raw water flow exiting the engine should always be indicate clogged raw water strainer (low raw water
checked to verify it does not appear to have flow).
diminished. After verifying raw water flow rate in the Automatic
flowline, open the Manual by-pass line shut-off
During initial commissioning of the engine, it is valves, and then close the Automatic flowline shut-
important to correctly set the raw flow rate going thru off valves and repeat the above process in order to
the cooling loop. Each Clarke engine model has an verify the flowrate going thru the Manual by-pass
Installation and Operation (I&O) Datasheet that line. Note, with Automatic flowline closed the
provides basic operating conditions of the engine and controller low raw water flow alarm may be present ,
most values are given based upon engine speed. You this is normal. Once this is completed; close the
will find this datasheet in the documentation bag that Manual by-pass shut-off valves and open the
is shipped with the engine for your specific Clarke Automatic flowline shut-off valves to restore
model. This datasheet must be available during conditions back to normal.
commissioning in order to set the proper minimum
raw water flow. With the fire pump flowing 150% of 3.4.7.4 Raw Water Outlet
rated flow, and the Automatic flow line open; verify
sufficient raw water flow rate is achieved and that the NOTE: NFPA 20 does allow for the heat exchanger
reading of the cooling loop pressure gauge does not outlet flow to be returned to a suction reservoir. This
exceed 60 psi (4 bar). You will need to capture the makes it very difficult to measure the flowrate.
flow for a specific amount of time coming out of the When discharging to a suction reservoir, NFPA
heat exchanger and going to a floor drain in order to provides additional requirements:
establish a reasonably accurate flow rate value. Using
a container or bucket of known volume, record the
Page 32 of 50
1) A visual flow indicator and temperature Additionally, a raw water temperature switch will
indicator are installed in the discharge (waste send an alarm (terminal 310) when temperature of the
outlet) piping. water exceeds 105°F (41° C). Refer to Figures 26
2) When waste outlet piping is longer than 15ft and 26A1 for location of switch. If either of these
(4.6m) and / or the outlet discharges are more alarms are active, it indicates that the cooling
than 4ft (1.2M) higher than the heat system’s capability may be compromised.
exchanger, the pipe size increased by at least
one size.
3) Verify that when the correct flow rate is
achieved that the inlet pressure to the heat
exchanger (or CAC) does not exceed 60psi
(4bar)
If you have such an installation, it is recommended

that you run the engine for a period of time at
firepump 150% flow and confirm the visual flow
indicator is showing water flow, the temperature rise
is not excessive (usually no more than 40F (4.5C)
over ambient raw water temperature) and the engine
is showing no signs of overheating.

Figure #26A1
3.4.7.5 Raw Water Quality, Strainers and
Deterioration of Heat Exchanger (or CAC) 3.4.7.6 Backflow Preventers
Over time, as the heat exchanger (or CAC) begins to NFPA20 allows for the use of backflow preventers in
plug and foul, this pressure will rise and the flow will the Automatic and Manual flow line of the cooling
diminish which could mean that the heat exchanger loop as required by local code. For specific
(or CAC) may have to be replaced. application information contact factory.
It can be not stressed enough how important it is to
keep the wye strainers within the cooling loop clean: 3.4.7.7 Raw Water Outlet Temperature
Most engine failures occur due to plugged cooling
loop strainers! If the raw water supply has debris in Certain local codes may not allow you to discharge
it (leaves, stones, etc) as the strainer accumulates the waste water outlet from the engine heat
more debris (that will not pass thru it), the flowrate exchanger either due to its temperature or it now
will continue to diminish which will eventually starve being considered hazardous waste. It is
the engine of adequate cooling water flow which will recommended you always check local codes
lead to engine overheat and catastrophic engine regarding waste water discharge.
failure. When this occurs you have no fire
protection! Clarke recommends that after the initial 3.4.8 Flow Paths of Engine Cooling System
engine commissioning and also prior to each weekly
exercise of the engine / fire pump set, both strainers The engine coolant flows through the shell side of the
be removed and cleaned and then re-installed before heat exchanger (or radiator), engine coolant pump, oil
starting the engine. cooler, engine block and cylinder head, jacket water
heater, thermostat, and expansion tank. On DT2H
Clarke engines are equipped with an alarm that is engine models the flow also cools the turbocharger
meant to signal diminished raw water flow rate and the exhaust manifolds.
(terminal 311), possibly due to clogged raw water
strainers in the cooling loop. Refer to Figures 26 and On heat exchanger equipped engines raw cooling
26A1 for location of sensors. A circuit board located water flows through the tube side of the charge air
near the front of the cooling loop monitors cooler, if equipped, and the tube side of the heat
differential pressure between the two sensors and will exchanger.
send an alarm to the controller if a low water flow
condition exists.
Page 33 of 50
Refer to Figures #35E for DP6H and DQ6H engine
models and #35F for DT2H engine models for
cooling system flow path diagrams.
Figure #26A – DP6H & DQ6H engine models
Figure #26B – DR8H, DS0H, DT2H-UFAA40, 58 engine models
Page 34 of 50
Figure #26C – DT2H-UFAA60,98,92,-FMAAX8,X2 engine models only
3.4.9 IMPORTANT SERVICE NOTICE  Insufficient fluid level

 Failure to de-aerate
Any time an engine experiences a high coolant  Overheat
temperature alarm condition the primary cause of the
overheat must be determined and the cause corrected 3.5 ELECTRICAL SYSTEM
to prevent a recurring overheat event.. Additionally,
if an event of a restricted flow, collapsed hose, 3.5.1 Wiring Diagrams (Only with Engine Gauge
insufficient coolant level or failed pressure cap is Panel)
experienced, further investigation of the cooling Run/Stop Drawing Description Reference
system is required. Solenoid No. (DC Voltage) Document
1) The coolant shoud be drained (after de- Mechanical (Mechanical
energizing the coolant heater ETS = Engines Engines)
2) Replace the engine thermostat(s) Energized C071842 NFPA-20
3) Remove the engine water pump and to Stop and UL/FM
inspect the impeller and seal for damage, replace as engine
necessary. Reassemble and refill coolant according gauge panel
to the Installation and Operations Instruction Manual. (NL
4) Run the engine to verify normal operating Models -
temperature. Optional)
Drawing Description Reference
3.4.9.1 Cavitation No. (AC Voltage) Document
C07651 DP, DQ, DR, DS,
Cavitation is a condition that occurs when bubbles DT-UFAA20, 58,
form in the coolant flow in the low pressure areas of 50, 88 only – NFPA-
the cooling system and implode as they pass to the 20 and UL/FM
higher pressure areas of the system. This can result in Engine Jacket Water
damage to cooling system components, particularly Heater
the water pump impeller and cylinder liners.
DT2H-UFAA60,
Cavitation in an engine can be caused by:
C071613 98,92,-FMAAX8,X2
 Improper coolant only - NFPA-20 and
 Restricted coolant flow caused by collapsed UL/FM Engine
hose or plugged system Jacket Water Heater
 Coolant fill cap is loose or unable to retain Figure #27
the required pressure
Page 35 of 50
3.5.2 Checking Drive Belt Tension and To adjust Belt Tension:
Adjustment Check belt tension:
- Give at arrow must be 0.4” - 0.6” (10-15mm).
All drive belts must be adequately tightened to secure To increase tension of the water pump driving belts:
that both the engine water pump and battery charging - Loosen alternator or belt tensioner mounting
alternator (when fitted) are operating efficiently. bolts A and B.
Refer to Figures #28A,28B, 28C, 28D. - Adjust to proper belt tension.
B - Tighten mounting bolts A and B.
3.5.3 Speed Switch (when supplied)
Overspeed is defined as 120% of rated speed for

engines rated from 1470 through 2600 rpm. In the
event of an engine overspeed, the speed switch
signals the main pump controller and also affects an
engine shutdown. The OVERSPEED RESET
(Figure# 9) switch is included on the instrument
panel. Should an overspeed condition occur,
investigate the cause and make necessary corrections
Figure #28A – DP6H before placing engine back in service. The
OVERSPEED RESET must be manually lifted for
two (2) seconds to reset.
NOTE: This reset operation must be

completed to allow a restart. If not, the
engine will not start thru the main pump
controller or manually.
OVERSPEED VERIFICATION
Figure #28B – DQ6H B Hold the OVERSPEED VERIFICATION switch in
the “up” position. This will provide the main pump
controller with an overspeed signal and engine
shutdown at 67% of the set overspeed RPM. Start
the engine via the main pump controller; the speed
switch will generate an overspeed signal and
shutdown protecting both the engine and pump.
EXAMPLE
Rated Speed: 1760 RPM
Overspeed Shutdown: 2112 RPM (120% of
Figure #28C – DR8H / DS0H / DT2H 1760 RPM)
Verification Shutdown: 1410 RPM (67% of
2112 RPM)
CAUTION-after verification of overspeed, lift the

OVERSPEED RESET switch for two (2) seconds
and reset the main pump controller to re-instate
normal operation of the engine and speed switch.
Refer to Engineering Technical Bulletin – ETB003,

part number C133407, on the www.clarkefire.com
Figure #28D – DT2H B
Page 36 of 50
A
website for adjusting the overspeed setting for range
rated engines.
3.5.4 Magnetic Pick-Up (when supplied)
A magnetic pick-up, mounted in the flywheel

housing, provides the input signal for the tachometer
overspeed switch, and/or the main pump controller.
There should be approximately 0.03" air gap between
the top of the ring gear and the center of the magnetic
pick-up. With one tooth centered in the magnetic
pick-up hole, thread the pickup in until it touches the Figure #29
gear tooth and then back it out 1/2 turn. Tighten jam
nut while holding the pickup in position. Reconnect
to wiring harness. With the engine operating at rated
speed, the output voltage on the mag pickup should
be between 7 VAC(rms) – 14 VAC(rms).
3.5.5 Mechanical Engine Control and Alarm Board

(MECAB) Speed Switch Troubleshooting
This engine is equipped with a speed switch capable

of sensing engine sensor malfunctions and/or
electrical over-current(s) on engine alarm circuits
and alerting the user via flashing status lamps. This
flashing status indication is done so with the red
“OVERSPEED SHUTDOWN” lamp on the outside of Figure #30 – MECAB speed switch
the Clarke instrument panel (Figure #29) and a red
LED located on the middle of the speed switch inside List of Troubleshooting Malfunctions
of the Clarke instrument panel (Figure #30). In
addition to these flashing status lamps, a “Low Two (2) blinks – Electrical Current Exceeds 10
Engine Coolant Temperature Alarm” is sent via Amps on Alarm Circuits: Status lamps will flash
engine / fire pump controller inter-connect circuit two times continuously on the Clarke instrument
#312 as a means to alert the user outside of the panel and a “Low Engine Coolant Temperature”
engine room. alarm will be sent to the fire pump controller via
circuit #312.
NOTE: When first applying battery power to the
engine, or after activating the overspeed reset switch, Cause:
the OVERSPEED SHUTDOWN lamp and red LED
on the speed switch will flash several times. This is Electrical current exceeds 10 amps on one or more
an “INITIALIZATION PATTERN” and is normal. engine / fire pump controller inter-connect circuits
This will be referred to in the following
troubleshooting section.
Engine run alarm (#2)
Engine overspeed alarm (#3)
Engine low oil pressure alarm (#4)
Engine high coolant temperature alarm (#5)
Engine low coolant temperature alarm (#312)
Corrective actions:
Check each of the above circuits to determine which

contains the current overload.
Page 37 of 50
Once circuit(s) overload are corrected: On the Clarke
instrument panel, operate the “OVERSPEED
RESET” switch for two (2) seconds and release
(Figure #31).
Figure #32B – DR8H & DS0H models
Figure #31
The “INITIALIZATION PATTERN will flash. This is

normal. The continuous two (2) blink flash sequence
should turn off at this point.
Three (3) blinks – Engine Coolant Temperature Figure #32C – DT2H engine models
Sensor malfunction: Status lamps will flash three
times continuously on the Clarke instrument panel On the Clarke instrument panel, operate the
and a “Low Engine Coolant Temperature” alarm will
“OVERSPEED RESET” switch for four (4) seconds
be sent to the fire pump controller via circuit #312.
and release. (Refer to Figure #31).
Cause:
The “INITIALIZATION PATTERN” will flash. This
Engine coolant temperature sensor circuit is open or is normal. The continuous three (3) blink flash
shorted. sequence should turn off at this point.
Corrective Actions: If problem still exists, replace engine coolant
Verify wiring and connector plug at engine coolant temperature thermistor.
temperature sensor are secure. Sensor is located on
top of engine on DP6H and DQ6H engine models Five (5) blinks on instrument panel – Oil pressure
(Figure #32A), at the front of the engine near the switch or Engine speed sensor (magnetic pick-up)
cylinder head on DR8H and DS0H models, and malfunction: Status lamps will flash five times
behind engine heat exchanger as shown on DT2H continuously on the Clarke instrument panel and a
engine models (Figure #32B). “Low Engine Coolant Temperature” alarm will be
sent to the fire pump controller via circuit #312.
Cause:
Oil pressure switch failure or magnetic pick-up
failure.
Corrective Actions:
Oil Pressure switch check

Verify wiring and connector at engine oil pressure
switch are secure. Pressure switch is located on right
Figure #32A – DP6H & DQ6H engine models side of engine next to the flywheel housing on DP6H
Page 38 of 50
& DQ6H engine models (Figures #33A) and near the RESET” switch for two (2) seconds and release.
oil filters on DR8H, DS0H, and DT2H engine models (Refer to Figure #9)
as shown. (Figures #33B & #34).
The “INITIALIZATION PATTERN’ will flash. This
With engine off, check continuity between the two is normal. The continuous five (5) blink flash
terminals on the oil pressure switch. Note, do not sequence should turn off at this point.
disconnect wires when performing this task. If circuit is closed, the oil pressure switch is not
damaged and is working normally as expected.
Proceed to engine speed sensor check, below.
Engine speed sensor (magnetic pick-up) check
Verify wiring and connector at engine speed sensor
are secure. Magnetic pick-up is located on the right
side of the engine on the flywheel housing. (Figure
#35)
Figure #33A – DP6H & DQ6H engine models
Figure #35
With engine running, verify that the tachometer is

functioning normally.
Refer to section 3.5.4 of Engine Operator’s Manual

to properly reposition the magnetic pick-up if
tachometer is not functioning.
Figure #33B – DT2H engine models
Once magnetic pick-up is repositioned: On the
Clarke instrument panel, operate the “OVERSPEED
RESET” switch for two (2) seconds and release.
(Refer to Figure #9).
The “INITIALIZATION PATTERN” will flash. This

is normal. The continuous five (5) blink flash
sequence should turn off at this point. If problem still
exists, replace engine speed sensor (magnetic pick-
up).
3.5.6 FIELD SIMULATION OF PUMP

Figure #34- DT2H engine models
CONTROLLER ALARMS
If circuit is open, replace oil pressure switch. Field simulation of (5) pump controller alarms
After new switch is replaced: On the Clarke • Alarm 1: Over speed Shutdown: Follow
instrument panel, operate the “OVERSPEED over speed verification steps per section 3.5.3.
Page 39 of 50
• Alarm 2: Low Oil Pressure: DP, DQ, DR, DS: Refer to Clarke drawing (see Page 5) for
With the engine running, jumper the engine mounted additional information on Clarke supplied
low oil pressure switch at terminal “WK” to batteries.
“GROUND”. DT only: With the engine
running, jumper the engine mounted Low Oil 3.6 ENGINE SPEED ADJUSTMENT
Pressure switch (see Figures #33A, 33B, 34 for
location). A mechanical governor controls the engine speed.
Wait for 15 seconds and controller alarm will The governor is built into the fuel injection pump. All
activate. governors are adjusted to the rated speed at
nameplate power or maximum allowed pump load
• Alarm 3: High Engine Coolant Temperature: before leaving Clarke. During Start-Up Inspection or
With the engine running, set the High Engine Coolant when placing reconditioned units into service, some
Temperature DIP switch to “ON” (see Figure #36). minor speed adjustment may be required. It is
Use a fine pick or small screwdriver and slide the recommended that this adjustment be performed by
white slider to the left. Wait for 30 seconds and the authorized Service Dealer representative.
controller alarm will activate. Set white DIP switch
slider to “OFF” (right) when simulation is complete. To adjust the speed of the engine:
A. Start the engine by following the “To Start
• Alarm 4: Low Engine Coolant Temperature: With Engine” Procedure in this manual.
the engine not running, set the Low Engine Coolant B. Let the engine warm-up. Loosen the jam
Temperature DIP switch to “ON” (see Figure #36). nut(s) (Figure #37B, C, D).
Use a fine pick or small screwdriver and slide the C. While observing the instrument panel tach
white slider to the right. Controller alarm will rotate the long adjustor clockwise to lower
activate immediately. Set white DIP switch slider to the RPM and counter clockwise to raise the
“OFF” (left) when simulation is complete. RPM’s until desired speed is obtained. Ref.
Figure #37B, C, D.
• Alarm 5: Overcrank: Use manual stop override D. Holding secure the long adjustor with a
(ETS Governor Solenoid) to prevent the engine from wrench tighten the jam nut.
starting during the cycle-crank testing. NEVER shut E. Stop engine by following “To Stop Engine”
off the fuel supply to the engine to prevent it from Procedure in this manual.
starting. Shutting off the fuel supply will
cause an air lock condition in the fuel system If the engine has been designed and tested for range
and possibly cause fuel system component rating, stamp the metal tag titled “FIELD SETTING”
damage. with the final adjusted speed, horsepower, and 67%
overspeed verify shutdown setting and keep with the
engine. Refer to Figure #38A.
Figure #38A
Figure #36
3.5.7 BATTERY REQUIREMENTS
All Clarke engine models require 8D batteries, as

sized per SAE J537 and NFPA20. The battery
should meet the following criteria:
Cold Cranking Amps (CCA @ 0°F): 1400
Reserve Capacity (minutes): 430
Page 40 of 50
WEEKLY
 Air Cleaner
 Battery
 Belts
 Coolant Hoses
 Coolant Leaks
 Coolant Levels and Condition
 Cooling Loop Valves Position
 Cooling Water Solenoid Valve
 Cooling Water Discharge
 Exhaust System
 Fuel Tank
Figure #37B – DP6H models
 General Inspection
 Governor Run-Stop Control
 Jacket Water Heater
 Lubrication Oil Level
 Operating Gauges
 Remove Water from Fuel Filter
 Run Engine
 Warning Light
 Cooling Water Strainers
 Clean Radiator Core Debris (if equipped)
EVERY 6 MONTHS
 Batteries
Figure #37C – DQ6H models  Battery Charging Alternator
 Belt tension
 Coolant Protection Level
 Driveshaft U-Joints
 Fuel Lines
EVERY 1 YEAR
 Air Cleaner
 Fuel Priming Pump Strainer
 Coolant Inhibitor
 Crankcase Vent System
o Driveshaft U-Joints
Figure # - DT2H models  Fuel & Oil Filters
 Heat Exchanger Electrode
4.0 MAINTENANCE SCHEDULE  Lubricating Oil
 Mounting Isolators
4.1 ROUTINE MAINTENANCE  Wiring System
EVERY 2 YEARS
NOTE: The following Routine Maintenance schedule  Air Cleaner
is based on an engine usage rate not exceeding 2  Batteries
hours per month. For UL/FM engine models, also  Belts
refer to NFPA25.  Coolant Hoses
 Coolant
LEGEND:  Thermostat
 Check  Remove Water Pump to Inspect Impeller and
 Clean Seal
 Replace
o Lubricate IMPORTANT: Set main pump controller to “OFF”
while servicing engine. Before turning the main
pump controller to the "OFF" position, check with
Page 41 of 50
the maintenance and security supervisors to verify 7.0 OWNER ASSISTANCE
that all the departments concerned will be alerted of
the temporary interruption of their fire protection Consult Clarke Service Dealer or Factory. Service
equipment for normal maintenance or testing. Also, Dealers can be located by going to our website:
alert the local fire department in the event that the www.clarkefire.com.
main pump controller is connected by silent alarm to
headquarters. When servicing is complete, return 8.0 WARRANTY
main pump controller selector to "Automatic"
position and the mode selector on the engine to 8.1 GENERAL WARRANTY STATEMENT
“Automatic” position. Advise the appropriate
personnel the engine has been returned to the The satisfactory performance of Clarke engines and
“Automatic”. the goodwill of owners / operators of Clarke engines
are of primary concern to the Engine Manufacturer,
5.0 TROUBLE SHOOTING the Engine Service Dealer and Clarke. All provide
support of these products after final installation of the
Consult Clarke Service Dealer or Factory. Service complete fire pump and sprinkler system.
dealers can be located by going to our website: Warranty responsibility involves both Clarke and the
www.clarkefire.com. For trouble shooting pertaining Doosan service organizations worldwide.
to the flashing of the "OVERSPEED SHUTDOWN"
lamp, see section 3.5.5. The Engine Manufacturer (Doosan) provides
Warranty for the basic engine components and Clarke
6.0 PARTS INFORMATION provides warranty on the accessories added to meet
the NFPA-20 specifications and FM/UL certification
6.1 SPARE PARTS requirements.
To ensure best operation and efficiency of all engine 8.2 CLARKE WARRANTY
components, always use genuine Clarke spare parts.
All Clarke warranted components have warranty
Orders should specify: Duration of 24 months beginning at the Start-up date
 Engine Model Number - See Engine General of the fire pump system. The warranty coverage
 Engine Serial Number - Specification includes replacement of the part and reasonable cost
 Part Number(s) Refer to Engine Maintenance of labor for installation. Components failed due to
Parts List section 6.2 or Parts Illustration (see improper engine installation, transportation damage,
Page 5). or misuse is not covered under this warranty.
For additional warranty details, see the specific
Contact numbers for spare parts: warranty statement “Doosan New Engine Warranty”
• www.clarkefire.com on the following page. Also contact Clarke direct if
• Phone USA: (513) 771-2200 Ext. 427 (calling you have any questions or require additional
within USA) information.
• Phone UK: (44) 1236 429946 (calling outside USA)
• Fax USA: (513) 771-5375 (calling within USA) Clarke is not responsible for incidental or
• Fax UK: (44) 1236 427274 (calling outside USA) consequential costs, damage or expenses which the
• E-Mail USA: parts@clarkefire.com owner may incur as a result of a malfunction or
• E-Mail UK: dmurray@clarkefire.com failure covered by this warranty.
6.2 ENGINE MAINTENANCE PARTS LIST 8.3 DOOSAN WARRANTY
Refer to Appendix “A” at the end of this manual. WARRANTY POLICY
ENGINE Air Filter Service Air Filter Oil SUPPLIER’s liability under this warranty shall
MODEL Kit be IN LIEU OF ALL OTHER LIABILITIES OF
All 99-55050 C121157 SUPPLIER for defect in material or
Figure #39
Page 42 of 50
workmanship of Products or ANY OTHER of less than 30% of the Fire PUMP POWER shall be
WARRANTIES, EXPRESS OR IMPLIED, taken as 30% and time at standstill shall not be
statutory or at common law WHICH BUYER counted.
HEREBY WAIVES. In no event shall
SUPPLIER be liable for consequential or Fire Pump ratings should never be applied except is
indirect damages regarding Products or End- true emergency power outages. Negotiated power
outages contracted with a utility company are not
Products.
considered an emergency.
INDEMNIFICATION
NOTES:
Notwithstanding any other provisions in this
 Total running time must not exceed 200hours
Agreement, BUYER shall indemnify SUPPLIER and
per year.
its subsidiaries and hold them harmless against and
 There is no overload capability.
from any and all claims, damages, costs and expenses
with respect to any loss of or damage to property, and
any injury to or death of any person, arising out of or WARRANTY PERIOD
attributable to any use, application into other
machines/systems or sale of the Products. The warranty period begins both on the shipping date
of the Engine and on the first delivery date of the
3RD PARTY'S RIGHT Engine to the customer, whichever date occurs first,
and ends as shown in the APPENDIX-1 as attached.
SUPPLIER shall in no event warrant the any use,
application into other machines/ systems or sale of WARRANTY LIMITATIONS
Products is free from infringement of any 3rd party's
right. BUYER shall indemnify SUPPLIER and its What is covered:
subsidiaries and hold them harmless against from any
and all claims or actions against SUPPLIER or Any defect in Engines, arose only under normal
BUYER for infringement of any 3rd party's right in conditions of storage, use and service due to defect in
connection with BUYER's use, application into other workmanship or material with the exception of items
machines/ systems of the Products. list under “what is not covered”.
DEFINTION OF ENGINE RATING What is not covered:
It is important to choose the proper engine rating to With any of following conditions, Warranty is not
provide the optimum performance in a given covered.
application. Ratings in this Article show DOOSAN
Firepump engine guidelines on applications. (1) Any defect and / or functional difficulty of
Engines which are not operated according to
FIRE PUMP POWER RATING the rating specifications specified in Article
1 above.
Fire PUMP POWER Rating is applicable for (2) Any defect and / or functional difficulty of
supplying emergency power for the duration of the Engines resulting from any change,
utility power outage. NO OVERLOAD capability is modification or alteration of the Engine
available for this rating. Under no condition is an which result in any change in the
engine to operate in parallel with the public utility at specification of Engines without the prior
the Fire PUMP POWER rating. written consent or proper instruction of
SUPPLIER.
This rating should be applied where reliable utility (3) Any defect and / or functional difficulty of
power is available. A Fire Pump rated engine should Engines resulting from any incidental,
be sized for a maximum of 70% average load factor consequential or rated costs such as costs for
and 200 hours of operation per year. When traveling transport, communication expenses,
determining the actual average power output, power extra costs due to the installation in making
Page 43 of 50
the Engines accessible, docking and cranes, expenses involved in the same (at an hourly rate to be
loss of use, loss of income, loss of time, loss decided by SUPPLIER). SUPPLIER reserves the
of property, personal injury, or damages right to limit the number of repair service hours
other parts or goods than the indicated according to SUPPLIER’s repair labor time guide or
Engines delivered by SUPPLIER. the equivalent instruction.
(4) Any defect and / or functional Difficulty of
Engines caused by operation of Engines in With SUPPLIER’s option and provision of
disregard of SUPPLIER’s operation or replacement parts to BUYER to assist BUYER’s
service manual and / or any other instruction activities covered by the Warranty specified in the
by SUPPLIER. Article 2.3 above. In no event shall SUPPLIER be
(5) Any defect and / or functional Difficulty of liable for any expenses incurred in the replacement
Engines due to improper handling or parts supply other than net freight cost.
unsatisfactory repairing and maintenance of
Engines. Compensation of warranty claims shall be limited to
(6) Any defect and / or functional Difficulty of what is attributable to SUPPLIER’s responsibility
Engines due to the parts replacement with and the reimbursement rate for the warranty claims
non-genuine SUPPLIER service parts on follows APPENDIX-2 as attached.
non-equivalent in quality and design to
genuine SUPPLIER service parts. APPLICATION OF WARRANTY CLAIMS
Engines due to the parts replacement with The application of Warranty Claims by BUYER shall
non-genuine SUPPLIER service parts on be made in accordance with SUPPLIER’s designated
non-equivalent in quality and design to warranty claim application form he application.
genuine SUPPLIER service parts.
The following points must be included in any
Engines due to repair adjustment, service, or
warranty claim. If the claim does not provide all of
parts replacement by any personnel who are
this basic information, it will be incomplete and will
not authorized by SUPPLIER.
not be acceptable.
(9) Parts of Engines (Such as filter, belt, air
cleaner, gasket, packing, rubber, light bulb,
fuse, condenser, brush, electric wire (1) Engine Model & Engine Serial Number
harness and other similar wearing parts) to (2) The repair date or Engine operation hour up
be replaced in the course of or in connection to then
with the normal maintenance of Engines. (3) BUYER’s analysis of the cause of defect and
the details of the original customer complaint
with photographs of the defective parts as per
SUPPLIER and BUYER RESPONSIBLITIES
SUPPLIER’s requirement.
(4) Report and explanatory action of the repair or
SUPPLIER and BUYER respectively shall have the service.
following responsibilities in respect of defect in (5) Amount of claim for materials, labor and any
materials or workmanship covered by the warranty: other allowable expenses.
(6) Signature of service manager or equivalent
Warranty will be only applied for Engines for which authorized personnel of BUYER on each
SUPPLIER has received the warranty claim report or claim to confirm that the claim is complete
the equivalent written information when any Engines and accurate.
are delivered to the first customer.
The warranty claims must be received by SUPPLIER
SUPPLIER will compensate BUYER the genuine within forty-five (45) days from the date BUYER
parts expenses used for replacing the defective parts furnished and / or installed the new parts to replace
under Warranty. the defective parts (repair date). Warranty claims
received beyond the forty-five (45) day period will
BUYER shall carry out all repairs and the fitting of automatically be denied.
all replacement parts covered by the Warranty and
SUPPLIER will compensate BUYER the net labor
Page 44 of 50
If corrected or additional information is requested, occurring during such period will be the sole
the requested information shall be submitted by the responsibility of BUYER.
BUYER within thirty (30) days from the receipt of
the request to provide that information. Warranty PERFORMANCE OF SERVICES BY BUYER
claim returned beyond the thirty (30) day period will
automatically be denied. BUYER shall from time to time perform maintenance
and repair services in relation to Engines in
REMOVED PARTS accordance with the stipulation of “service
information” in effect at the time when Engines are
If BUYER makes any claim under this warranty that put into service and shall submit the required
any parts of Engines are defective, the removed part maintenance and service reports to SUPPLIER.
(s) must be kept by the BUYER for a period of six
(6) months from the date of warranty claim In the case of any functional difficulty and / or defect,
application unless otherwise instructed by BUYER shall immediately carry out any necessary
SUPPLIER for the disposal. repair or service and shall immediately notify
SUPPLIER of any major problem.
The removed parts must be kept in proper condition
to prevent additional damage or corrosion. Warranty BUYER s required to conform to all present and
compensation may be charged-back, if the removed future instruction from SUPPLIER concerning
parts are not properly kept, lost or not returned to maintenance and servicing of Engines in Territory.
SUPPLIER as per request.
SUPPLIER’s LIABILTY UNDER THIS
If requested by SUPPLIER, the removed parts shall WARRANTY
be shipped to SUPPLIER with charges borne by
SUPPLIER. SUPPLIER’s liability under this warranty shall be IN
LIEU OF ALL OTHER LIABILITIES OF
RECEIVING INSPECTION AND STORAGE OF SUPPLIER for defect in material or workmanship of
THE ENGINES Engines or ANY OTHER WARRANTIES,
EXPRESS OR IMPLIED, statutory or at common
BUYER shall inspect each shipment with respect to law WHICH BUYER HEREBY WAIVES. In no
the conformity with specifications, missing parts and event shall SUPPLIER be liable for consequential or
damage of Engines promptly upon receipt of indirect damages regarding Engines.
Engines. In the event that BUYER finds any
unsatisfactory condition through such inspection, SETTLEMENT OF DISPUTES
BUYER shall make a claim in writing respect thereto
within sixty (60) days after the shipping date of This agreement shall be construed in accordance with
Engines. the Korean laws. All disputes, controversies,
differences or claims arising out of or related to this
SUPPLIER will not be liable for any claim made by Agreement which cannot be settled amicably by
BUYER after such period and also shall not be liable negotiation between the parties hereto shall be
for damages of Engines where BUYER may make a referred to and settled by arbitration in Seoul, Korea
claim for such damages under an applicable policy of in accordance with the Arbitration Rules of the
insurance. In case the claims under this Article have International Chamber of Commerce.
been verified by SUPPLIER, upon request of APPENDIX – 1 WARRANTY PERIOD
BUYER, SUPPLIER will deliver free of charge such Rating ENGINE COVERAGE *
parts as are determined to be missing or damaged. MONTHS MONTHS Engine
(from (from Hours
BUYER shall be responsible for the proper storage Shipping Delivery
and maintenance not be decrease the performance of date) Date)
the Engines during the period of time from unloading Fire Pump 0 - 24 0 - 18 200
of Engines by the carrier of Port of Destination until
delivered to the first customer. Any damage * WHICHEVER OCCURS FIRST
Page 45 of 50
9.0 INSTALLATION & OPERATION DATA
(See Page 5)
10.0 WIRING DIAGRAMS
(See Page 5)
11.0 PARTS ILLUSTRATION DRAWING
(See Page 5)
Page 46 of 50
12.0 APPENDIX (Alpha Index)
Subject P age
Subject P age
I
A
Installation Data *
Air Cleaner 14,24,25,42,45
Installation Instructions 13
Alternator 37,42
L
B
Lube Oil Recommendations 28,29,42
Battery Cables 16,17
Lubricating Oil Volume 29
Battery Recommendations 15,37,41,42
Lubricating System 28
Belt Adjustment 37,42
M
C
Magnetic Pickup 38,39,40
Capacities 29,30
Maintenance Schedule 42
Coolant Recommendations 12
Manual Operation 16,17
Cooling System
Model Number Identification 6,7
Anti-Freeze Solutions 30
Cooling System Capacity 14,30,31
Cooling Water Supply (Loop) 14,32,33,34 N
Name Plate (Engine) 6
Cooling Water Flow Requirements *
Filling Procedure 14
Heat Exchanger 13,14,17,21,30,32,33,34,39 O
Oil Filter 13,28,40,42
Inhibitors 30,31
Oil Level Dipstick 28,29
Maintenance
Oil Pressure *
………... 13,14,15,16,21,22,31,32,42,43,45,46
Oil Specifications/Recommendations 14,29
Water …………………………11,12,13,14,15,17,21,
Operation Data *
……………22,24,27,28,30,32,33,34,36,37,42
Over speed Reset 18,37,38,39,40
Crankcase Ventilation 26,27
Over speed Verification 18,37
D
Dipstick, Oil Level 28,29 P
Parts Illustrations *
Driveshaft alignment 14,15,16
Parts Information 31,43
Driveshaft Maintenance 11,16
Pump, Fuel Injection 20,24,41
E
Electrical System 11,36 S
Serial Number 6,7,43,45
Engine Protective Systems (over speed)
Shutdown Systems 32,37,38,40,41
18,26,37,38,39,40,41,43
Specifications:
Engine Start-Up Service 41,43
Fuel 13,21
Exhaust System 15,24,27,42
Lubrication Oil 29
Speed Switch 37,38
F
Storage 13,22,44,46
Filters:
Air Cleaner 12,24,25,27,43
Fuel 13,14,21,22,23,42 T
Technical Data *
Lubricating Oil 11,28,29,42
Fuel Specifications 13,21
Fuel System Operation 14,21,22,23,41 W
Warranty 15,43,44,45,46
Bleeding 22
Wiring Diagram:
Pump, Injection 20,24,41
DC System *
Service 21,22
AC Heater Systems *
G
* See Page 5
Governor Speed Adjustment 41
Heaters, Engine 12,14,15,30,34,36,42
Page 47 of 50
Appendix “A”
DP6H & DQ6H ENGINE MODELS
Clarke Engine Models DP6H DQ6H
Part Description Part Number (standard items only, optional items not shown)
Oil Filter C04571 C04569
Fuel Filter (Primary) C02736
Fuel Filter (Secondary) N/A
Air Filter C03749 C03244
Alternator C072092 C072093
Fuel Injection Pump C02911 C02912
Heat Exchanger C051529
Starter Motor (12V) N/A
Starter Motor (24V) C072094
Switch, Oil Pressure C07645 or C071884
Switch, Speed C071571
Switch, Coolant Temperature INCLUDED IN C071571 SPEED SWITCH or C071881
Thermistor C071607 or C051749
Turbocharger C061646 C061647
Thermostat C051718 C051568
Nozzle, Injector C0275324 C02754
Page 48 of 50
Appendix “A” (continued)
DR8H, DS0H, & DT2H (DRY EXHAUST MANIFOLD) ENGINE MODELS
DT2H‐UFAA20,
DT2H‐UFKA20,
DT2H‐FMAA40,
DT2H‐FMKA40,
DT2H‐UFAA58,
Clarke Engine Models DR8H DS0H
DT2H‐UFKA58
DT2H‐UFAA50,
DT2H‐UFKA50,
DT2H‐UFAA88,
DT2H‐UFKA88 only
Part Description Part Number (standard items only, optional items not shown)
Oil Filter C04569 R. A
Fuel Filter (Primary) C02736 R. A
Air Filter C03749 R. A C03244 R. C
Alternator C072095
Fuel Injection Pump C02913 C02914 C02915
Heat Exchanger C051529 R. D C051389 R. B C051389 R. B
Starter Motor (12V) N/A
C07645 R. C OR C071273 R. A OR C071614 R. A OR C071884 R.A OR C072011 OR
Switch, Oil Pressure C072013
Switch, Speed C071963 R.A
Switch, Coolant Temperature INCLUDED IN C071963 R. A SPEED SWITCH OR C071881 R.A
Thermistor C071607 R. A OR C051749 R. B
C061648 C061650 C061652
(RIGHT) (RIGHT) (RIGHT)
C061649 C061651 C061653
Turbocharger (LEFT) (LEFT) (LEFT)
Thermostat C051568
Nozzle, Injector C02792
Page 49 of 50
Appendix “A” (continued)
DT2H (WET EXHAUST MANIFOLD) ENGINE MODELS
DT2H-UFAA60,98,92,-FMAAX8,X2,
Clarke Engine Models
UFKA60,98,92 only
Part Number (standard items only, optional items
Part Description not shown)
Oil Filter C04569 (4)
Fuel Filter (Primary) C02736 (4)
Fuel Filter (Secondary) N/A
Air Filter C03707 (2)
Alternator C072097
Fuel Injection Pump C02916
Heat Exchanger C052066
Switch, Oil Pressure C071614 or C071884
Switch, Speed C071273
Switch, Coolant Temperature INCLUDED IN C071571 SPEED SWITCH or C071881
Thermistor C071607 or C051749
Turbocharger C061654
Thermostat C051568
Nozzle, Injector C02716
Page 50 of 50
Appendix B
Operating manual pump
Axially Split Volute Casing Pump
Omega / Omega V
Horizontal Installation Type 3E
Vertical Installation Types DB, DK, DP, DJ
Installation/Operating Manual
Mat. No.: 01059616

Legal information/Copyright
Installation/Operating Manual Omega / Omega V
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 12/02/2018

Contents
Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ........................................................................................................................................................... 6
1.2 Installation of partly completed machinery.................................................................................................... 6
1.3 Target group..................................................................................................................................................... 6
1.4 Other applicable documents............................................................................................................................ 6
1.5 Symbols ............................................................................................................................................................. 6
2 Safety ...................................................................................................................................................... 8
2.1 Key to safety symbols/markings....................................................................................................................... 8
2.2 General.............................................................................................................................................................. 8
2.3 Intended use ..................................................................................................................................................... 9
2.4 Personnel qualification and training............................................................................................................... 9
2.5 Consequences and risks caused by non-compliance with this manual ......................................................... 9
2.6 Safety awareness .............................................................................................................................................. 9
2.7 Safety information for the operator/user ..................................................................................................... 10
2.8 Safety information for maintenance, inspection and installation .............................................................. 10
2.9 Unauthorised modes of operation ................................................................................................................ 10
2.10 Explosion protection ...................................................................................................................................... 10
2.10.1 Marking .............................................................................................................................................. 11
2.10.2 Temperature limits............................................................................................................................. 11
2.10.3 Repair.................................................................................................................................................. 11
3 Transport/Temporary Storage/Disposal............................................................................................. 12
3.1 Checking the condition upon delivery .......................................................................................................... 12
3.2 Transport......................................................................................................................................................... 12
3.3 Storage/preservation ...................................................................................................................................... 14
3.4 Return to supplier........................................................................................................................................... 15
3.5 Disposal ........................................................................................................................................................... 16
4 Description of the Pump (Set) ............................................................................................................. 17
4.1 General description ........................................................................................................................................ 17
4.2 Designation..................................................................................................................................................... 17
4.3 Name plate...................................................................................................................................................... 18
4.4 Design details.................................................................................................................................................. 18
4.5 Configuration and function........................................................................................................................... 19
4.6 Noise characteristics ....................................................................................................................................... 20
4.7 Scope of supply............................................................................................................................................... 21
4.8 Dimensions and weights ................................................................................................................................ 21
5 Installation at Site ................................................................................................................................ 22
5.1 Safety regulations........................................................................................................................................... 22
5.2 Checks to be carried out prior to installation............................................................................................... 22
5.3 Installing the pump set .................................................................................................................................. 22
5.3.1 Type of installation 3E ...................................................................................................................... 23
5.3.2 Type of installation DJ ....................................................................................................................... 24
5.3.3 Installation type DJ with universal-joint shaft ................................................................................. 26
5.3.4 Type of installation DB and DK......................................................................................................... 26
5.3.5 Type of installation DP ...................................................................................................................... 27
5.4 Connecting the piping ................................................................................................................................... 30
5.5 Enclosure/insulation ....................................................................................................................................... 31
5.6 Aligning the pump and motor ...................................................................................................................... 32
5.6.1 Aligning the motor with adjusting screws ....................................................................................... 32
5.6.2 Aligning the motor without adjusting screws ................................................................................. 33
5.7 Permissible forces and moments at the pump nozzles ................................................................................ 34
5.8 Auxiliary connections ..................................................................................................................................... 35
5.9 Connection to power supply.......................................................................................................................... 37
Omega / Omega V 3 of 96
Contents
5.9.1 Earthing .............................................................................................................................................. 38

5.10 Checking the direction of rotation................................................................................................................ 38
5.11 Removing the transport lock ......................................................................................................................... 38
6 Commissioning/Start-up/Shutdown................................................................................................... 40
6.1 Commissioning/Start-up ................................................................................................................................. 40
6.1.1 Prerequisites for commissioning/start-up ......................................................................................... 40
6.1.2 Priming and venting the pump......................................................................................................... 40
6.1.3 Start-up............................................................................................................................................... 41
6.1.4 Checking the shaft seal...................................................................................................................... 42
6.1.5 Shutdown ........................................................................................................................................... 43
6.2 Operating limits.............................................................................................................................................. 43
6.2.1 Maximum operating pressure ........................................................................................................... 44
6.2.2 Hydraulic operating range ................................................................................................................ 44
6.2.3 Frequency of starts............................................................................................................................. 45
6.2.4 Fluid handled ..................................................................................................................................... 45
6.3 Shutdown/storage/preservation .................................................................................................................... 46
6.4 Returning to service ....................................................................................................................................... 46
7 Servicing/Maintenance ........................................................................................................................ 48
7.1 Safety regulations........................................................................................................................................... 48
7.2 Servicing/inspection........................................................................................................................................ 49
7.2.1 Supervision of operation ................................................................................................................... 49
7.2.2 Inspection work.................................................................................................................................. 51
7.3 Drainage/cleaning .......................................................................................................................................... 54
7.4 Dismantling the pump set.............................................................................................................................. 54
7.4.1 General information/Safety regulations........................................................................................... 54
7.4.2 Preparing the pump set..................................................................................................................... 55
7.4.3 Opening the volute casing ................................................................................................................ 60
7.4.4 Removing the rotor ........................................................................................................................... 60
7.4.5 Dismantling the rotor ........................................................................................................................ 61
7.5 Reassembling the pump set ........................................................................................................................... 62
7.5.1 General information/Safety regulations........................................................................................... 62
7.5.2 Installing the rotor ............................................................................................................................ 63
7.5.3 Mounting the pump set on the baseplate ....................................................................................... 68
7.6 Tightening torques......................................................................................................................................... 68
7.7 Spare parts stock............................................................................................................................................. 69
7.7.1 Ordering spare parts.......................................................................................................................... 69
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296........................................... 69
8 Trouble-shooting.................................................................................................................................. 71
8.1 Explanation of faults ...................................................................................................................................... 75
9 Related Documents .............................................................................................................................. 76
9.1 Weights of individual components ............................................................................................................... 76
9.2 General assembly drawing with list of components .................................................................................... 77
9.2.1 Horizontally installed pump.............................................................................................................. 77
9.2.2 Vertically installed pump, installation type DJ................................................................................. 80
9.2.3 Vertically installed pump, installation type DB................................................................................ 83
9.2.4 Vertically installed pump, installation type DK................................................................................ 86
9.2.5 Vertically installed pump, installation type DP ................................................................................ 89
10 EU Declaration of conformity.............................................................................................................. 92
11 Certificate of Decontamination........................................................................................................... 93
Index ..................................................................................................................................................... 94
4 of 96 Omega / Omega V
Glossary
Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Discharge line
The pipeline which is connected to the discharge
nozzle
Drive end
The side of the pump which faces the motor
Hydraulic system
The part of the pump in which the kinetic energy
is converted into pressure energy
Non-drive end
The side of the pump which faces away from the
motor
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Suction lift line/suction head line

The pipeline which is connected to the suction
nozzle
1 General
1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The manual describes the proper and safe use of this equipment in all phases of
operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
clearly identify the pump set and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB Service centre to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery

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

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ð Section 2.4, Page 9)
1.4 Other applicable documents

Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
General arrangement drawing/ Description of mating and installation dimensions
outline drawing for the pump (set), weights
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
1)
Sub-supplier product literature Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
1)
List of components Description of all pump components
Drawing for assembly1) Sectional drawing of the installed shaft seal
For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1) If agreed upon in scope of supply
1 General
Symbol Description
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
2 Safety
2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings
Symbol Description
! DANGER DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
! WARNING WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
General hazard
hazard which will or could result in death or serious injury.
Electrical hazard
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
2 Safety
2.3 Intended use

▪ The pump (set) must only be operated in the fields of application and within the
use limits specified in the other applicable documents. (ð Section 1.4, Page 6)
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate the pump (set) in partially assembled condition.
▪ Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model or variant.
▪ Never operate the pump without the fluid to be handled.
▪ Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪ Observe the minimum flow rate and maximum flow rate indicated in the data
sheet or product literature (to prevent overheating, mechanical seal damage,
cavitation damage, bearing damage, etc).
▪ Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪ Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with this manual

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

In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health regulations and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards, directives and laws
2 Safety
2.7 Safety information for the operator/user

▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪ Do not remove any protective equipment (e.g. contact guards) during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪ If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪ Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪ The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪ Only carry out work on the pump (set) during standstill of the pump.
▪ Only perform work on the pump set when it has been disconnected from the
power supply (de-energised).
▪ The pump (set) must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pump set out of service always adhere to the procedure
described in the manual. (ð Section 6.3, Page 46)
▪ Decontaminate pumps which handle fluids posing a health hazard.
(ð Section 7.3, Page 54)
▪ As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ð Section 6.1, Page 40)
2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
2.10 Explosion protection

Always observe the information on explosion protection given in this section when
! DANGER operating the product in potentially explosive atmospheres.
Only pumps/pump sets marked as explosion-proof and identified as such in the data
sheet may be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof pump sets to EU
Directive 2014/34/EU (ATEX).
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
Never operate the pump set outside the limits stated in the data sheet and on the
name plate.
2 Safety
Prevent impermissible modes of operation at all times.

For information on application options of individual components (if any) in
potentially explosive atmospheres, refer to the manufacturer's product literature.
2.10.1 Marking
Pump The marking on the pump refers to the pump part only.
Example of such marking: II 2 G c TX
Refer to the Temperature Limits table for the temperatures permitted for the
individual pump variants. (ð Section 2.10.2, Page 11)
Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor The motor must be considered separately.
2.10.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected at the
surface of the pump casing, at the shaft seal and in the bearing areas.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated, the operator of the system is responsible for
observing the specified temperature class and fluid temperature (operating
temperature).
The table below lists the temperature classes and the resulting theoretical
temperature limits of the fluid handled (a possible temperature rise in the shaft seal
area has already been taken into account).
The temperature class specifies the maximum permissible temperature at the surface
of the pump set during operation. For the permissible operating temperature of the
pump in question refer to the data sheet.
Table 4: Temperature limits

Temperature class to EN 13463-1 Maximum permissible fluid
temperature
T1 Maximum 140 °C
T2 Maximum 140 °C
T3 Maximum 140 °C
T4 80 °C
T5 45 °C
T6 Impermissible
Temperature class T5 Based on an ambient temperature of 40 °C and proper maintenance and operation,
compliance with temperature class T5 is warranted in the area of the rolling element
bearings. If the ambient temperature exceeds 40 °C, contact the manufacturer.
2.10.3 Repair
Special regulations apply to repair work on explosion-proof pumps. Modifications or
alterations of the pump set can affect explosion protection and are only permitted
after consultation with the manufacturer.
Repair work at the flameproof joints must only be performed in accordance with the
manufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 is
not permitted.
3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
DANGER
Lifting lugs of pump/motor/base frame overloaded
▷ Never transport the pump set components (pump/motor/base frame) in any way
other than as described in the Transport section.
▷ Refer to the weights of the individual components stated in the manufacturer's
product literature.
DANGER
The pump (set) could slip out of the suspension arrangement
▷ Always transport the pump (set) in the specified position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Observe the information about weights, centre of gravity and fastening points.
▷ Observe the applicable local accident prevention regulations.
▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
For transporting the motor, observe the motor supplier's product literature!
To transport the pump/pump set suspend it from the lifting tackle as shown.
Fig. 1: The angle of pull must not be greater than 90°!
Table 5: Transport options
Transporting the pump horizontally Transporting the pump vertically

(figure 0) (figure 0 or installation type DJ)
Transporting the pump with base frame (figure 0)

▪ Motor size 315 and larger
▪ Total weight (of the pump set) more than 1500 kg
Transporting the pump vertically

(installation types DB and DK)
Transporting the pump set on the base frame Transporting the pump set on the base frame
(installation type 3E) (installation type 3E)
▪ Up to motor size 280 (IEC standard) Use the hooks welded to the baseplate!
▪ Up to a total weight (of the pump set) of 1500 kg ▪ Up to motor size 280 (IEC standard)
▪ Up to a total weight (of the pump set) of 1500 kg
Transporting the base frame (installation type DP)
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
CAUTION
Damage during storage due to humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump!
▷ Clean and cover pump openings and connections as required prior to putting
the pump into storage.
CAUTION
Bearings in the same position for a prolonged period of time
Damage to the bearings!
▷ Manually rotate the shaft once a month with suitable tools.
▷ Store the pump in a room isolated from vibrations.
CAUTION
Pump stored too long or incorrectly
Damage to the pump!
▷ Check especially the rolling element bearings and the lubricant. If any damage
is suspected, replace the rolling element bearings.
▪ Store the pump and supplied components under dry, vibration-free conditions, if
possible in their original packaging.
▪ The ambient temperatures for transport and storage must not be below -20 °C or
above 60 °C.
1. Manually rotate the pump shaft once a month with a suitable tool.
2. Spray the preservative through the suction and discharge nozzles.
It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).
NOTE
Observe the manufacturer's instructions for application/removal of the preservative.
3.4 Return to supplier

1. Drain the pump as per operating instructions. (ð Section 7.3, Page 54)
2. Flush and clean the pump, particularly if it has been used for handling noxious,
explosive, hot or other hazardous fluids.
3. If the pump has handled fluids whose residues could lead to corrosion damage
in the presence of atmospheric humidity or could ignite upon contact with
oxygen also neutralise the pump and blow through with anhydrous inert gas to
ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump.
Indicate any safety measures and decontamination measures taken.
(ð Section 11, Page 93)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
3.5 Disposal
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
▷ Collect and properly dispose of flushing fluid and any fluid residues.
▷ Wear safety clothing and a protective mask if required.
1. Dismantle the pump (set).

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

▪ Volute casing pump installed in a horizontal or vertical position
▪ Volute casing pump with double-entry radial impeller
Pump for handling fluids in water works, irrigation and drainage pumping systems,
power stations and industrial water supply.
4.2 Designation
Example: Omega V 150 - 460 A GB P M
Table 6: Designation key

Code Description
Omega Type series
V Design
2)
Horizontal installation
V Vertical installation
150 Nominal discharge nozzle diameter [mm]
460 Nominal impeller diameter [mm]
A Impeller type
GB Material variant
GB Grey cast iron / bronze
GC Grey cast iron / chrome steel
SB Nodular cast iron / bronze
SC Nodular cast iron / chrome steel
DD35 Duplex stainless steel / duplex stainless steel
P Shaft seal
P Gland packing
G Mechanical seal
M Bearing lubrication
F Grease
M Fluid handled
2) Blank
4.3 Name plate
KSB SE & Co. KGaA

Johann-Klein-Straße 9
67227 Frankenthal
Deutschland
1 6
2016
2 Omega 250 - 600 A 7
3
P-No. 9971423078 / 000100 8
4 Q 1050 m3/h H 120 m
9
5 n 1475 1/min SNr. 24 15 26
Gew. 1090 kg
Mat.-No. 01 111 383 ZN 3804 - D 74 x 105
Fig. 2: Name plate (example)

1 Designation of the pump set 2 Order number
3 Flow rate 4 Speed
5 Weight of Fig. 0 pump 6 Year of supply
7 Order item number 8 Head
9 Serial number
4.4 Design details
Design
▪ Volute casing pump
▪ Horizontal installation / vertical installation
▪ Single-stage
▪ Nominal diameter of the discharge nozzles: 80 mm - 350 mm
Pump casing
▪ Axially split volute casing
▪ Volute casing with integrally cast pump feet
▪ Replaceable casing wear rings
▪ Mating dimensions to EN or ASME
Impeller type
▪ Double-entry radial impeller3)
Pump shaft
▪ Completely dry shaft
▪ Shaft protecting sleeves in the seal area
Shaft seal
▪ Gland packing
▪ Mechanical seal
Bearings
For horizontal installation:
▪ Grease-packed rolling element bearings sealed for life
3) Optionally with impeller wear rings
For vertical installation:

▪ Product-lubricated plain bearing at the bottom / rolling element bearings,
greased for life, on top
4.5 Configuration and function

4 5
6
3 7
2 8
1 9
10
Fig. 3: Sectional drawing

1 Suction nozzle 2 Bearing housing
3 Rolling element bearing 4 Volute casing
5 Impeller 6 Clearance gap
7 Shaft 8 Rolling element bearing
9 Shaft seal 10 Discharge nozzle
Design The pump is designed with a tangential fluid inlet and a tangential fluid outlet. The
hydraulic system runs in its own bearings and is connected to the motor by a shaft
coupling.
Function The fluid enters the pump tangentially via the suction nozzle (1) and is accelerated
outward by the rotating impeller (5). In the flow passage of the pump casing the
kinetic energy of the fluid is converted into pressure energy. The fluid is pumped to
the discharge nozzle (10), where it leaves the pump. The clearance gap (6) prevents
any fluid from flowing back from the casing to the suction nozzle. The shaft (7)
enters the hydraulic system through the volute casing (4). The shaft passage through
the sealing housing is sealed to atmosphere with a shaft seal (9). The shaft runs in
rolling element bearings (3 and 8) located in a bearing housing (2) which is
connected to the volute casing (4).
Sealing The pump is sealed by a shaft seal (standardised mechanical seal or gland packing).
4) Spatial average; as per ISO 3744 and DIN EN ISO 20361; valid for pump operation in the Q/Qopt = 0.8 - 1.1 range and for
non-cavitating operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance. The
values indicated do not apply to operation on a frequency inverter.
4.6 Noise characteristics

Pump Table 7: Surface sound pressure level LpA4) depending on the speed
Rated Surface sound pressure level LpA4)
power Pump
PN [kW]
3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 / 870 960 / 750
rpm rpm
[dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)] [dB (A)]
10 69,5 69,0 67,4 67,0 65,6 64,6
15 70,8 70,3 68,7 68,3 66,9 65,9
20 71,8 71,3 69,7 69,3 67,8 66,8
30 73,1 72,7 71,0 70,6 69,1 68,2
40 74,1 73,6 71,9 71,5 70,1 69,1
50 74,8 74,3 72,7 72,2 70,8 69,8
60 75,4 75,0 73,3 72,8 71,4 70,4
70 75,9 75,5 73,8 73,3 71,9 70,9
80 76,4 75,9 74,2 73,8 72,3 71,3
90 76,8 76,3 74,6 74,2 72,7 71,7
100 77,1 76,7 74,9 74,5 73,1 72,1
150 78,5 78,0 76,3 75,8 74,4 73,4
200 79,4 79,0 77,2 76,8 75,3 74,3
250 80,2 79,7 77,9 77,5 76,0 75,0
300 80,8 80,3 78,5 78,1 76,6 75,6
350 81,3 80,8 79,0 78,6 77,1 76,1
400 82,0 81,5 79,8 79,3 77,8 76,8
450 82,1 81,6 79,9 79,4 77,9 76,9
500 82,5 82,0 80,2 79,7 78,3 77,3
600 83,1 82,6 80,8 80,3 78,9 77,8
700 83,6 83,1 81,3 80,8 79,4 78,3
800 84,0 83,6 81,7 81,3 79,8 78,8
900 84,4 84,0 82,1 81,7 80,2 79,2
1000 84,8 84,3 82,5 82,0 80,5 79,5
Pump set Table 8: Surface sound pressure level LpA5) depending on the speed
power Pump set
PN [kW]
3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 / 870 960 / 750
rpm rpm
10 74,5 74,0 70,0 69,0 66,4 64,6
15 75,7 75,2 71,4 70,5 67,9 66,2
20 76,6 76,1 72,4 71,5 69,0 67,4
30 77,8 77,3 73,8 72,9 70,6 69,0
40 78,7 78,2 74,8 74,0 71,7 70,1
50 79,4 78,9 75,6 74,8 72,6 71,0
60 79,9 79,4 76,3 75,4 73,3 71,8
70 80,4 79,9 76,8 76,0 73,8 72,4
80 80,8 80,3 77,3 76,5 74,4 72,9
90 81,2 80,7 77,7 76,9 74,8 73,4
5) Spatial average; as per ISO 3744 and DIN EN ISO 20361; valid for pump operation in the Q/Qopt = 0.8 - 1.1 range and for
non-cavitating operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance. The
values indicated do not apply to operation on a frequency inverter.

power Pump set
PN [kW]
3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 / 870 960 / 750
rpm rpm
100 81,5 81,0 78,0 77,2 75,2 73,8
150 82,7 82,2 79,4 78,7 76,8 75,4
200 83,6 83,1 80,4 79,7 77,9 76,6
250 84,3 83,8 81,2 80,5 78,7 77,5
300 84,8 84,3 81,8 81,2 79,4 78,2
350 85,3 84,8 82,4 81,7 80,0 78,8
400 85,7 85,2 82,8 82,2 80,5 79,3
450 86,0 85,6 83,2 82,6 81,0 79,8
500 86,4 85,9 83,6 83,0 81,4 80,2
600 86,9 86,4 84,2 83,7 82,1 81,0
700 87,4 86,9 84,8 84,2 82,7 81,6
800 87,8 87,3 85,2 84,7 83,2 82,1
900 88,2 87,7 85,7 85,1 83,6 82,6
1000 88,5 88,0 86,0 85,5 84,0 83,0
4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:
▪ Pump
▪ Drive
▪ Baseplate
▪ Coupling
▪ Coupling guard
▪ Universal-joint shaft
▪ Fasteners for pump and base frame
Optional accessories:
▪ Vibration monitoring equipment
▪ Pt100 resistance thermometer
▪ Pressure gauge
▪ Measuring nipple for shock pulse measurement
▪ Cyclone
4.8 Dimensions and weights

For dimensions and weights please refer to the data sheet of the pump (set).
▪ Pump weight: See name plate of the pump.
▪ Motor weight: See motor product literature.
▪ Weight of the shipping unit base frame with pump: See weight indicated on the
base frame.
▪ Weight of the shipping unit base frame with pump and motor: See weight
indicated on the base frame.
NOTE
Some individual components weigh more than 25 kg. Observe the weights
indicated ( (ð Section 9.1, Page 76) or other applicable documents).

For all work involving assembly, reassembly and installation, observe the following
safety information:
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
▷ Comply with the applicable local explosion protection regulations.
▷ Observe the information in the data sheet and on the name plates of pump and
motor.
DANGER
Improper transport
Risk of injury from lifting heavy components!
▷ Select lifting accessories which are suitable for the component weight.
▷ Always use the attachment points provided for the lifting accessories.
▷ Comply with the applicable health and safety regulations.
5.2 Checks to be carried out prior to installation
Place of installation
WARNING
Installation on mounting surface which is unsecured and cannot support the load
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN 206-1.
▷ The mounting surface must be set, flat, and level.
▷ Observe the weights indicated.
1. Check the structural requirements.

All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.3 Installing the pump set
WARNING
Hands or foreign objects in the pump casing
Risk of injuries, damage to the pump!
▷ Check that the inside of the pump is free from any foreign objects. Remove any
foreign objects.
▷ Never insert your hands or any other objects into the pump, if the pump set has
not been disconnected from the power supply and secured against
Depending on the type of installation, several instructions need to be carried out as

applicable:
▪ Prepare and install the base frame/support frame.
▪ Install the pump and motor on the prepared base frame/support frame.
▪ Check the alignment of pump and motor.
▪ Align the pump with the piping.
▪ Install and align the coupling.
▪ Connect the piping.
▪ Perform precision alignment of pump and motor.
▪ Remove any transport locks.
5.3.1 Type of installation 3E
DANGER
The pump or individual components could slip out of the suspension arrangement
▷ Always transport the pump or components in the specified position.
▷ Never suspend the pump from its free shaft end.
▷ Observe the information given for the individual components regarding
weights, centre of gravity and fastening points.
▷ Use suitable, approved lifting accessories.
Fig. 4: 3E installation – pump and motor on a common base frame

ü The relevant general arrangement drawing is available.
ü The foundation has the required strength and characteristics.
ü The foundation has been prepared in accordance with the dimensions given in
the general arrangement drawing.
1
2
3
4
Fig. 5: Installation drawing

1 Base frame, part No. 891 2 Adjusting screw, part No. 901.05
3 Shim, part No. 89-4.03 4 Foundation bolt, part No. 900.01
1. Screw adjusting screws (2) into the threaded holes provided in the base frame
(1).
2. Insert the foundation bolts (4) into the drilled holes of the base frame (1).
3. Place the shim (3) next to the holes for the foundation bolts (4) in accordance
with the general arrangement drawing.
4. Place the base frame (1) with the inserted foundation bolts (4) and the screwed-
in adjusting screws (2) on the shims (3). Use the adjusting screws to align the
base frame.
5. If the coupling is not already fitted, align both pump and motor on the base
frame by placing a straight-edge on the shaft stub. Then tighten the adjusting
screws (2) accordingly. If the coupling is already fitted, align both pump and
motor on the base frame by placing a straight-edge on the coupling. Then
tighten the adjusting screws (2) accordingly.
6. Align the pump / base frame assembly with the piping. For lifting and aligning
observe the transport instructions. (ð Section 3.2, Page 12) The position of the
pump on the base frame must not be changed during this alignment.
7. Grout the holes for the foundation bolts with a quick-setting, low-shrinkage
concrete mixture6).
8. When the concrete has set, tighten the foundation bolts evenly until no
clearance remains between the nuts and the base frame.
9. Grout the base frame with a quick-setting, low-shrinkage concrete mixture6).
Make sure that the base frame is completely grouted and that no cavities
remain.
10. When the concrete has set, tighten the foundation bolts.
11. If the motor was not already mounted when the pump was aligned with the
piping, lift the motor onto the base frame with suitable lifting equipment. Align
the shafts with each other. Mount the motor as described in the motor
manufacturer's operating manual.
12. Connect the piping to the pump without transmitting any stresses or strains.
13. Align the coupling as described in the coupling manufacturer's operating
manual.
5.3.2 Type of installation DJ
DANGER
6) Minimum strength class C25/30
Fig. 6: Pump on its own foot (baseplate), drive on a different construction level
ü The motor is installed on a separate base frame which is arranged on a higher
level in the building in accordance with the manufacturer's operating manual.
1

1 Foot, part No. 182 2 Hexagon head bolt, part No. 901-11
3 Disc, part No. 550.05 4 Foundation block, part No. 898.01
5 Adjusting screw, part No. 901.10 6 Shim, part No. 89-4.04
1. Screw the foundation blocks (4) with hexagon head bolts (2) and discs (3) to the
foot (1).
2. Screw the adjusting screws (5) into the foundation blocks (4).
3. Place the shim (6) into the recesses for the foundation blocks (4) in accordance
4. Place the foot (1) including the foundation blocks (4) with the adjusting screws
(5) on the shims (6). Use the adjusting screws to align the foot.
5. Align the pump with the piping.
6. Grout the recesses for the foundation blocks with a quick-setting, low-shrinkage
concrete mixture7).
7. When the concrete has set, tighten the foundation bolts (2).
5.3.3 Installation type DJ with universal-joint shaft
WARNING
Exposed rotating coupling or universal-joint shaft
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.
NOTE
If the customer specifically requests not to include a universal-joint shaft guard in
our delivery, then the operator must supply one.
For installing and aligning the universal-joint shaft refer to the technical product
literature of the universal-joint shaft manufacturer.
5.3.4 Type of installation DB and DK
DANGER
Fig. 8: DB and DK – installation


foot (1).
(5) on the shims (6). Use the adjusting screws to align the foot so that the
machined motor flange of the drive lantern is horizontal in all directions.
concrete mixture8).
9. Mount the motor on the drive lantern as described in the motor manufacturer's
operating instructions.
10. Align the coupling as described in the coupling manufacturer's operating
manual.
5.3.5 Type of installation DP
DANGER
Fig. 10: Pump on foot (baseplate), drive on support frame

1

foot (1).
(5) on the shims (6). Use the adjusting screws to align the foot.
Installing the motor support frame

1. Screw adjusting screws (2) into the foundation rails (1) in accordance with the
general arrangement drawing.
2. Insert the foundation bolts (4) into the drilled holes of the foundation rails (1).
3. Place shims (3) into the recesses for the foundation rails (1) in the foundation.
4. Use suitable lifting equipment to place the motor support frame on the
foundation together with the pre-assembled foundation rails (1), the adjusting
screws (2) and the inserted foundation bolts (4). Vertically position the adjusting
screws (2) on the shims (3).
DANGER
Unsecured motor
Danger from falling components!
▷ Always secure the motor additionally with a crane until the support frame has
been completely grouted and the concrete has reached its full strength.
5. Align the motor support frame with the pump. For the alignment, the motor
can be fastened to the support frame. See the manufacturer's product literature
included with the supplied documentation.
6. Grout the holes for the foundation bolts with quick-setting, low-shrinkage
concrete9) up to and including the lower edge of the foundation rails. Make
sure that the space underneath the foundation rails is completely grouted.
7. When the concrete has set, tighten the foundation bolts.
8. Grout the recesses in the foundation for the foundation rails with a quick-
setting, low-shrinkage concrete mixture9).
9. When the concrete has set, the motor can be fastened to the support frame.
Observe the motor manufacturer's operating manual.
Final assembly
1. Align the pump on the foot (baseplate) with the motor on the support frame.
Align and connect the pump with the piping. (ð Section 5.4, Page 30)
concrete mixture9).
9) Refer to the general arrangement drawing for the required concrete quality.
5. Fasten the motor to the support frame in accordance with the general
arrangement drawing.
6. Install and align the coupling as described in the coupling manufacturer's
operating manual. See the manufacturer's product literature included with the
supplied documentation.
5.4 Connecting the piping
DANGER
Impermissible loads acting on the pump nozzles
Danger to life from escaping hot, toxic, corrosive or flammable fluids!
▷ Do not use the pump as an anchorage point for the piping.
▷ Anchor the pipes in close proximity to the pump and connect them properly
without transmitting any stresses or strains.
▷ Observe the permissible forces and moments at the pump nozzles.
▷ Take appropriate measures to compensate for thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.
NOTE
Installing check and shut-off elements in the system is recommended, depending on
the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
ü Suction lift lines have been laid with a rising slope, suction head lines with a
downward slope towards the pump.
ü A flow stabilisation section having a length equivalent to at least five times the
diameter of the suction flange has been provided upstream of the suction flange.
ü The nominal diameters of the pipes are equal to or greater than the nominal
diameters of the pump nozzles.
ü To prevent excessive pressure losses, adapters to larger diameters have a diffuser
angle of approx. 8°.
ü The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove any flange covers on the
suction and discharge nozzles of the pump.
Fig. 13: Connection with expansion joints
CAUTION
Pumps connected with unbraced expansion joints
Machine damage by impermissible nozzle loads!
▷ Never connect the pump with unbraced expansion joints.
3. If the owner/operator supplies an expansion joint, it has to be braced with

external tie rods to prevent impermissible nozzle loads.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Remove any impurities from the piping.
▷ If necessary, install a filter.
▷ Observe the information in (ð Section 7.2.2.4, Page 53) .
4. If required, install a filter in the piping.

5. Connect the pump nozzles to the piping.
CAUTION
Aggressive flushing liquid and pickling agent
Damage to the pump!
▷ Match the cleaning operation mode and duration of flushing and pickling to
the casing materials and seal materials used.
5.5 Enclosure/insulation
WARNING
Risk of injury from moving parts or escaping fluid!
▷ As soon as the work is completed, re-install and/or re-activate any safety-
relevant and protective devices.
CAUTION
Heat build-up in the bearing housing
Damage to the bearing!
▷ Never insulate the bearing housing and bearing cover.
5.6 Aligning the pump and motor
DANGER
Inadmissible temperatures at the coupling or bearings due to misalignment of the
coupling
Explosion hazard!
Risk of burns!
▷ Make sure that the coupling is correctly aligned at all times.
CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷ Always check the coupling after the pump has been installed and connected to
the piping.
▷ Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
5.6.1 Aligning the motor with adjusting screws
1
2
3
Fig. 14: Aligning the motor with adjusting screws

1 Hexagon head bolt 2 Adjusting screw
3 Locknut
c ü The coupling guard and the footboard for the coupling guard, if any, have been
removed.
A B 1. Place the straight-edge (c) axially on both coupling halves.
2. Leave the straight-edge (c) in this position and turn the coupling by hand.
ð The coupling is correctly aligned if the distances A and B to the respective
A B shafts are the same at all points around the circumference. The radial and
axial deviation of the two coupling halves must not exceed 0.05 mm.
Observe the coupling manufacturer's operating instructions!
c d 3. Unscrew the hexagon head bolts (1) at the motor and the locknuts (3) at the
Fig. 15: Checking the baseplate.
coupling alignment 4. Turn the adjusting screws (2) by hand or by means of an open-end wrench until
the coupling alignment is correct and all motor feet rest squarely on the
baseplate.
5. Re-tighten the hexagon head bolts (1) at the motor and the locknuts (3) at the
baseplate.
6. Check that coupling/shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
DANGER
Risk of ignition by frictional sparks
Explosion hazard!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
7. Re-install the coupling guard and the footboard for the coupling guard, if any.
8. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
5.6.2 Aligning the motor without adjusting screws
Fig. 16: Aligning the motor without adjusting screw

1 Shim
c ü The coupling guard and the footboard for the coupling guard, if any, have been
removed.
A B 1. Place the straight-edge (c) axially on both coupling halves.
2. Leave the straight-edge (c) in this position and turn the coupling by hand.
ð The coupling is correctly aligned if the distances A and B to the respective
A B shafts are the same at all points around the circumference. The radial and
axial deviation of the two coupling halves must not exceed 0.05 mm.
Observe the coupling manufacturer's operating instructions!
c d 3. In case of a misalignment loosen the hexagon head bolts at the motor.
Fig. 17: Checking the 4. Insert shims (1) underneath the motor feet until the difference in shaft
coupling alignment centreline height has been compensated.
5. Re-tighten the hexagon head bolts.
6. Check that coupling/shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
DANGER
Risk of ignition by frictional sparks
Explosion hazard!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
7. Re-install the coupling guard and the footboard for the coupling guard, if any.
8. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
5.7 Permissible forces and moments at the pump nozzles

The resulting permissible forces have been determined according to
The forces and moments indicated refer to external, simultaneous loads in 3

dimensions (Fx = Fy = Fz and Mx = My = Mz). They only apply if the pump set has been
properly installed in accordance with the installation/operating manual. The forces
and moments in any direction must not exceed the values given in the table. The
data on forces and moments apply to static piping loads only. If the limits are
exceeded, the values must be checked and verified. The piping must be connected
without transmitting any stresses or strains. The pump must not be used as support
for the piping. The pump is not an anchorage point for the piping. The piping must
be fastened without transmitting any forces, vibrations or pipe weights to the pump.
Observe the limits for forces and moments at the suction and discharge nozzle. The
pump must not be connected with unbraced expansion joints.
Fz
Mz
Fy
My
Fx
Mx
Fig. 18: Flange coordinates
Table 9: Forces and moments at the pump nozzles depending on the material [N/Nm]
Size Grey cast iron (GB/GC) Nodular cast iron (SB/SC) Cast steel (DD35)
Fx / Fy / Fz Mx / My / Mz Fx / Fy / Fz Mx / My / Mz Fx / Fy / Fz Mx / My / Mz
[N] [Nm] [N] [Nm] [N] [Nm]
80 - 210 800 500 1120 700 1520 950
80 - 270 800 500 1120 700 1520 950
80 - 370 800 500 1120 700 1520 950
100 - 250 1000 700 1400 980 1900 1330
100 - 310 1000 700 1400 980 1900 1330
100 - 375 1000 700 1400 980 1900 1330
125 - 230 1500 1000 2100 1400 2850 1900
125 - 290 1500 1000 2100 1400 2850 1900
125 - 365 2000 1500 2800 2100 3800 2850
125 - 500 2000 1500 2800 2100 3800 2850
150 - 290 2500 1500 3500 2100 4750 2850
150 - 360 2500 2000 3500 2800 4750 3800
150 - 460 2500 2000 3500 2800 4750 3800
150 - 605 3000 2000 4200 2800 5700 3800
200 - 320 4000 2750 5600 3850 7600 5225
200 - 420 4000 2750 5600 3850 7600 5225
200 - 520 4000 2750 5600 3850 7600 5225
200 - 670 4000 2750 5600 3850 7600 5225
250 - 370 4000 2750 5600 3850 7600 5225
250 - 480 4000 2750 5600 3850 7600 5225
250 - 600 4000 2750 5600 3850 7600 5225
250 - 800 4000 2750 5600 3850 7600 5225
300 - 300 4000 3000 5600 4200 7600 5700
300 - 435 4000 3000 5600 4200 7600 5700
300 - 560 5000 3000 7000 4200 9500 5700
300 - 700 5000 3000 7000 4200 9500 5700
300 - 860 5000 3000 7000 4200 9500 5700
350 - 360 5000 3000 7000 4200 9500 5700
350 - 430 5000 3000 7000 4200 9500 5700
350 - 510 5000 3000 7000 4200 9500 5700
5.8 Auxiliary connections
WARNING
Screw plugs subjected to pressure
Risk of injuries by parts flying off and escaping fluid!
▷ Never use screw plugs for releasing pressure from the pump casing.
▷ Always use suitable venting devices (e.g. vent valve).
WARNING
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing
liquid, etc.)
Risk of injury from escaping fluid!
Risk of burns!
Malfunction of the pump!
▷ Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the quantity, dimensions and locations of auxiliary
connections.
▷ Use the auxiliary connections provided.
WARNING
Open pipelines
Risk of injuries by escaping fluid!
Risk of burns!
▷ Always close the shut-off valve (e.g. ball valve), if any, with the safety device
engaged to prevent it from being opened unintentionally.
▷ Guide open pipelines away from the system in such a way that hazards by
escaping fluid are prevented.
The pump is supplied with a flushing line fitted at the factory.

The following auxiliary connections are available:
6D 4M.1 6D
26M.1 8A
4M.2 26M.2
4M.1 26M.1
1M.1 1M.2
1M.1
1M.2
6B.2
8A 6B.1 6B
Fig. 19: Auxiliary connections
Table 10: Auxiliary connections

Connection Description Type of
connection
1M.1 Connection for pressure measurement on G 1/2
the suction side
1M.2 Connection for pressure measurement on G 1/2
the discharge side
4M.1 Connection for temperature measurement G 3/8
at the drive end
4M.2 Connection for temperature measurement G 3/8
at the non-drive end
6B Connection for pump drain on the suction side G 1/2
6B.110) Connection for pump drain on the suction side G 1/2
6B.2 Connection for pump drain on the discharge side G 1/2
10) Applies to sizes 100 - 375, 150 - 290, 150 - 360, 150 - 605, 200 - 420, 200 - 520, 200 - 670, 250 - 600, 250 - 800, 300 - 300, 300 -
435, 300 - 560, 300 - 700, 300 - 860, 350 - 360, 350 - 430, 350 - 510
Connection Description Type of

connection
6D Connection for venting the pump G 1/2
8A Connection for leakage drain G 3/4
26M.1 Connection for vibration measurement M8
at the drive end
26M.2 Connection for vibration measurement M8
at the non-drive end
5.9 Connection to power supply
DANGER
Incorrect electrical installation
Explosion hazard!
▷ For electrical installation, also observe the requirements of IEC 60079-14.
▷ Always use a motor protection switch for explosion-proof motors.
DANGER
Electrical connection work by unqualified personnel
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.
▷ Observe the motor manufacturer's operating instructions.
WARNING
Unintentional starting of the pump set
Risk of injury by moving components and shock currents!
▷ Ensure that the pump set cannot be started unintentionally.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method.
NOTE
A motor protection device is recommended.
5.9.1 Earthing
DANGER
Electrostatic charging
Explosion hazard!
▷ Connect the potential equalisation conductor to the earthing terminal
provided.
▷ Make sure that the connection between pump and baseplate is electrically
conductive.
▷ Screws, bolts, nuts and shims must not be coated or the coating must be
removed.
▷ Provide potential equalisation between the pump set and the foundation.
5.10 Checking the direction of rotation
DANGER
Temperature increase resulting from contact between rotating and stationary
components
Explosion hazard!
▷ Never check the direction of rotation by starting up the unfilled pump set.
▷ Separate the pump from the motor to check the direction of rotation.
DANGER
Rotating shaft during direction of rotation check
Risk of injury!
▷ Maintain a safe distance to the pump set.
▷ Comply with the general health and safety regulations.
CAUTION
Drive and pump running in the wrong direction of rotation
Damage to the pump!
▷ Refer to the arrow indicating the direction of rotation on the pump.
▷ Check the direction of rotation. If required, check the electrical connection and
correct the direction of rotation.
ü The pump has been completely separated from the motor.

ü All components at the motor (e.g. coupling half at the motor shaft) have been
secured.
1. Start the motor and stop it again immediately to determine the motor's
direction of rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction
of rotation on the pump.
3. If the motor runs in the wrong direction of rotation, check the electrical
connection of the motor and the control system, if applicable.
5.11 Removing the transport lock

This type of transport lock is only used for vertical pumps with a product-lubricated
plain bearing.
160 901.17
Fig. 20: Transport lock

1. Undo bolt 901.17 at cover 160.
2. Connect a flushing line to the drilled hole in cover 160.
6.1 Commissioning/Start-up
6.1.1 Prerequisites for commissioning/start-up

Before starting up the pump set make sure that the following requirements are met:
▪ The pump set has been properly connected to the electric power supply and is
equipped with all protection devices. (ð Section 5.9, Page 37)
▪ The pump has been primed with the fluid to be handled.
▪ The direction of rotation has been checked. (ð Section 5.10, Page 38)
▪ All auxiliary connections required are connected and operational.
▪ The transport lock has been removed.
▪ The lubricants have been checked and filled in.
▪ After prolonged shutdown of the pump (set), the activities described in
(ð Section 6.4, Page 46) have been carried out.
▪ The coupling alignment has been checked.
6.1.2 Priming and venting the pump
DANGER
Explosion hazard!
▷ The fluid for priming the pump must not be combustible.
▷ When the fluid for priming the pump is taken from a potentially explosive
atmosphere, make sure that no potentially explosive atmosphere can enter the
pump.
▷ If the pump is in slurp mode, stop the pump immediately.
DANGER
Shaft seal failure caused by insufficient lubrication
Hot fluid may escape!
1. Close all drains and drain lines.

2. Vent the pump and suction line and prime both with the fluid to be handled.
For suction lift operation evacuate the pump.
3. Fully open the shut-off element in the suction line.
4. If the discharge line is equipped with a check valve and back pressure is present,
the shut-off element in the discharge line may remain open. If this is not the
case, the shut-off element in the discharge line must be closed.
5. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc).
6.1.3 Start-up
DANGER
Non-compliance with the permissible pressure and temperature limits if the pump
is operated with the suction and/or discharge line closed.
Explosion hazard!
Hot or toxic fluids escaping!
▷ Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷ Only start up the pump set with the discharge-side shut-off element slightly or
fully open.
DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid
handled
Explosion hazard!
▷ Never operate the pump set without a liquid fill.
▷ Prime the pump as per operating instructions.
▷ Always operate the pump within the permissible operating range.
WARNING
Pump sets with high noise levels
Damage to hearing!
▷ Persons must only enter the vicinity of the running pump set if they are
wearing protective clothing/ear protection.
▷ See noise characteristics. (ð Section 4.6, Page 20)
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
ü The system piping has been cleaned.

ü Pump, suction line and inlet tank, if any, have been vented and primed with the
fluid to be pumped.
ü The lines for priming and venting have been closed.
CAUTION
Start-up against open discharge line
Motor overload!
▷ Make sure the motor has sufficient power reserves.
▷ Use a soft starter.
▷ Use speed control.
1. Fully open the shut-off element in the suction head/suction lift line.
2. Close or slightly open the shut-off element in the discharge line.
3. Start up the motor.

4. Immediately after the pump has reached full rotational speed, slowly open the
shut-off element in the discharge line and adjust it to comply with the duty
point.
6.1.4 Checking the shaft seal

Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
Gland packing The gland packing must drip slightly during operation.
DANGER
The temperatures at the gland packing have risen above the permissible limits
Explosion hazard!
▷ Gland packings are not approved for use in potentially explosive atmospheres.
▷ Immediately switch off the pump set!
The minimum leakage required depends on the fluid handled, pressure, slip velocity
and temperature.
Table 11: Leakage rates at the gland packing

Limits Leakage
Minimum 10 drops/min. (approx. 0.5 ml)
Maximum 120 drops/min. (approx. 6 ml)
CAUTION
Excessive leakage or no leakage at the gland packing
Damage to the pump!
▷ Excessive leakage: Re-tighten the gland follower until the required leakage rate
is reached.
▷ No leakage: Switch off the pump set immediately.
Adjusting the leakage

Prior to commissioning 1. Only lightly tighten the nuts of the gland follower by hand.
2. Use a feeler gauge to verify that the gland follower is mounted centred and at a
right angle to the shaft.
ð The gland must leak after the pump has been primed.
After five minutes of
operation
WARNING
Unprotected rotating parts
Risk of personal injury!
▷ Do not touch rotating parts.
▷ When the pump is running, perform any work with utmost caution.
The leakage can be reduced.

1. Tighten the nuts on the gland follower by 1/6 turn.
2. Monitor the leakage for another five minutes.
Excessive leakage:
Repeat steps 1 and 2 until the minimum value has been reached.
Not enough leakage:
Slightly loosen the nuts at the gland follower.
No leakage:
Immediately switch off pump set!
Loosen the gland follower and repeat commissioning.
Checking the leakage

After the leakage has been adjusted, monitor the leakage for about two hours at
maximum fluid temperature.
Check that enough leakage occurs at the gland packing at minimum fluid pressure.
6.1.5 Shutdown
CAUTION
Backflow of the fluid handled
Motor or winding damage!
Excessive reverse runaway speed of the motor!
▷ Observe the permissible reverse runaway speed of the motor. See the
manufacturer's product literature included with the supplied documentation.
▷ Close the shut-off elements.
ü The shut-off element in the suction line is and remains open.

1. Close the shut-off element in the discharge line.
2. Switch off the motor and make sure the pump set runs down smoothly to a
standstill.
NOTE
If the discharge line is equipped with a non-return or check valve, the shut-off
element may remain open provided that the system conditions and system
regulations are considered and observed.
For prolonged shutdown periods:

1. Close the shut-off element in the suction line.
2. Close the auxiliary connections.
CAUTION
Risk of freezing during prolonged pump shutdown periods
Damage to the pump!
▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect
them against freezing.
6.2 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature, fluid handled and
speed
Explosion hazard!
Hot or toxic fluid could escape!
▷ Comply with the operating data indicated in the data sheet.
▷ Never use the pump for handling fluids it is not designed for.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures, pressures or rotational speeds
exceeding those specified in the data sheet or on the name plate unless the
written consent of the manufacturer has been obtained.
6.2.1 Maximum operating pressure
CAUTION
Permissible operating pressure exceeded
Damage to connections and seals!
▷ Never exceed the operating pressure specified in the data sheet.
The maximum operating pressure depends on the pump size, pump material and
nominal pressure of the flange design.
Neither the material/size-dependent maximum pressure indicated in the data sheet
nor the maximum nominal flange pressure must be exceeded.
6.2.2 Hydraulic operating range
CAUTION
Non-compliance with hydraulic operating limits
Damage to the pump and motor
▷ Observe the limits in the data sheet.
▷ Brief passage through the critical range below Qmin is permissible during start-
up.
General information on the hydraulic operating range
Qmin
System curve
B
H/Q curve
Qmax
NPSHPump
NPSHSystem
A A Q
C
Fig. 21: Pump operating range
NPSH Available Inlet pressure available in the NPSH Required Required inlet pressure
system
A Operating limit B Operating point
C Operating range without
NPSH margin
The flow rate Q will develop automatically as a function of the discharge head H, in
line with the pump's characteristic curve. The pump's permissible operating range has
limits that are independent of each other in terms of their cause.
Part load operating limit
This limit is indicated in the H/Q characteristic by Qmin or by discontinuation of the
characteristic curve in the diagram.
NPSH-related limits under off-design conditions
The part load and overload limits are determined by the ratio of NPSHRequired to
NPSHAvailable.
The NPSH limits are determined as follows:

The intersections of NPSHRequired and NPSHAvailable are projected onto the H/Q
characteristic, where they represent the operating limits.
If the pump set is operated outside its operating limits or system-related changes
occur, check the NPSH values.
If necessary, consult your nearest customer service centre.
6.2.3 Frequency of starts
DANGER
Excessive surface temperature of the motor
Explosion hazard!
Damage to the motor!
▷ In case of explosion-proof motors, observe the frequency of starts specified in
the manufacturer's product literature.
CAUTION
Re-starting while motor is still running down
Damage to the pump (set)!
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
The frequency of starts is usually determined by the maximum temperature increase

of the motor. This largely depends on the power reserves of the motor in steady-
state operation and on the starting conditions (DOL, star-delta, moments of inertia,
etc).
Observe the motor manufacturer's operating instructions.
6.2.4 Fluid handled
6.2.4.1 Temperature of the fluid handled
CAUTION
Fluid temperature too high or too low
Damage to the pump!
▷ Never operate the pump set against a closed shut-off element.
▷ Never operate the pump at temperatures above or below those specified in the
data sheet or on the name plate unless the written consent of the
manufacturer has been obtained.
If the values are not indicated in the data sheet, the following temperature limits
apply. The temperatures must neither be below nor above these limits.
Table 12: Temperature limits of the fluid handled

Minimum fluid temperature 0 °C
Maximum fluid temperature + 80 °C
6.2.4.2 Abrasive fluids/solids
CAUTION
Abrasive particles or solids in the fluid
Damage to the pump!
▷ Comply with the limits indicated in the data sheet.
▷ Flush the piping prior to commissioning.
▷ Install a filter in the system, if required.
Do not exceed the maximum permissible solids content specified in the data sheet.
When the pump handles fluids containing abrasive substances, increased wear of the
hydraulic system and shaft seal are to be expected. In this case, reduce the commonly
recommended inspection intervals.
NOTE
Solids, especially long fibres, plastic residues or similar, can lead to clogging of the
barrier or flushing lines and to mechanical seal damage.
6.3 Shutdown/storage/preservation
CAUTION
Corrosion caused by stagnant aggressive fluids, e.g. fluids containing chloride
Damage to the pump!
▷ Every 24 hours operate the pump for a minimum of 30 minutes or flush it with
clean, pure water.11)
The pump (set) remains installed

ü Sufficient fluid is supplied for the operation check run of the pump.
1. For prolonged shutdown periods, start up the pump (set) regularly between
once a month and once every three months for approximately five minutes.
ð This will prevent the formation of deposits within the pump and the pump
intake area.
The pump (set) is removed from the pipe and stored

ü The pump has been properly drained. (ð Section 7.3, Page 54)
ü The safety instructions for dismantling the pump have been observed.
1. Spray-coat the inside wall of the pump casing and, in particular, the impeller
clearance areas with a preservative.
2. Spray the preservative through the suction nozzle and discharge nozzle.
It is advisable to then close the pump nozzles (e.g. with plastic caps).
3. Oil or grease all exposed machined parts and surfaces of the pump (with
silicone-free oil and grease, food-approved if required) to protect them against
corrosion.
Observe the additional instructions on preservation. (ð Section 3.3, Page 14)
6.4 Returning to service

For returning the equipment to service, observe the sections on commissioning/start-
up (ð Section 6.1, Page 40) and the operating limits (ð Section 6.2, Page 43) .
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (ð Section 7, Page 48)
11) E.g. drinking water or demineralised water
WARNING
Risk of injury from moving parts or escaping fluid!
▷ As soon as the work is completed, re-install and re-activate any safety-relevant
devices and protective devices.
NOTE
On pumps/pump sets older than 5 years we recommend replacing all elastomer
seals.
DANGER
Sparks produced during servicing work
Explosion hazard!
▷ Observe the safety regulations in force at the place of installation!
▷ Always perform maintenance work on explosion-proof pump sets outside
potentially explosive atmospheres.
DANGER
Improperly serviced pump set
Explosion hazard!
▷ Service the pump set regularly.
▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.
DANGER
Improper cleaning of coated pump surfaces
Explosion hazard by electrostatic discharge!
▷ When cleaning coated pump surfaces in atmospheres of Explosion group IIC,
use suitable anti-static equipment.
DANGER
Excessive temperatures due to dry running
Explosion hazard!
Fire hazard!
pump operation.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing
seals
Explosion hazard!
Fire hazard!
The operator ensures that maintenance, inspection and installation is performed by

authorised, qualified specialist personnel who are thoroughly familiar with the
manual.
WARNING
WARNING
hazard
Risk of injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps which handle fluids posing a health hazard.
WARNING
Insufficient stability
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.
A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump, pump set and pump parts with a
minimum of servicing/maintenance expenditure and work.
NOTE
All maintenance work, service work and installation work can be carried out by KSB
Service or authorised workshops. For contact details please refer to the enclosed
"Addresses" booklet or visit "www.ksb.com/contact" on the Internet.
Never use force when dismantling and reassembling the pump set.
7.2 Servicing/inspection
7.2.1 Supervision of operation
DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.
DANGER
seals
Explosion hazard!
Fire hazard!
Risk of burns!
▷ Regularly check the lubricant level.
DANGER
Excessive temperatures due to dry running
Explosion hazard!
Fire hazard!
pump operation.
CAUTION
Impermissibly high temperature of fluid handled
Damage to the pump!
▷ Prolonged operation against a closed shut-off element is not permitted
(heating up of the fluid).
▷ Observe the temperature limits in the data sheet and in the section on
operating limits. (ð Section 6.2, Page 43)
CAUTION
Corrosion caused by stagnant aggressive fluids, e.g. fluids containing chloride
Damage to the pump!
▷ Every 24 hours operate the pump for a minimum of 30 minutes or flush it with
clean, pure water.12)
While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.
▪ Check the shaft seal. (ð Section 6.1.4, Page 42)
▪ Check the static sealing elements for leakage.
▪ Check the rolling element bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
▪ Monitor the correct functioning of any auxiliary connections.
▪ Monitor the stand-by pump.
To make sure that stand-by pumps are ready for operation, start them up once a
week.
▪ Monitor the bearing temperature.
The bearing temperature must not exceed 90 °C (measured on the outside of the
bearing bracket).
12) E.g. drinking water or demineralised water
▪ Check the flexible elements of the coupling and replace them, if required.
▪ Check any pressure gauges.
▪ Check the drive as described in the manufacturer's product literature.
▪ Check that the fitted coupling guard does not touch the coupling.
▪ Make sure that the earth connection has been fitted and marked.
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured
on the outside of the bearing bracket).
NOTE
After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is
only reached after a certain period of operation (up to 48 hours depending on the
conditions).
7.2.1.1 Warning and cut-out values

As an option, the pump can be fitted with various sensors. If such sensors are fitted,
observe the following warning and cut-out values:
Table 13: Warning and cut-out values

Sensors Warning value Cut-out value
Vibrations 13) for pumps with a drive rating < 200 kW 6.314) 9.5
[mm/s - rms]
Vibrations 15) for pumps with a drive rating > 200 kW 7.616) 11.9
[mm/s - rms]
Bearing temperature at the outer bearing ring 85 90
[°C]
7.2.2 Inspection work
DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
▷ Regularly check the coupling guard, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.
7.2.2.1 General information

Check and service all components of the pump set as described in the corresponding
operating manuals provided by the manufacturers.
For the manufacturer's product literature see other applicable documents.
13) To DIN ISO 10816-7, category II, zone A

14) Within the preferred operating range of 0.7 ≤ Q/Qopt ≤ 1.2 the vibration values of newly commissioned pumps with good
system conditions (piping layout, approach flow at the pump, etc.) are below the boundary of zone A to DIN ISO 10816-7,
i.e. below 3.5 mm/s rms.
15) To DIN ISO 10816-7, category II, zone A
16) Within the preferred operating range of 0.7 ≤ Q/Qopt ≤ 1.2 the vibration values of newly commissioned pumps with good
system conditions (piping layout, approach flow at the pump, etc.) are below the boundary of zone A to DIN ISO 10816-7,
i.e. below 4.2 mm/s rms.
7.2.2.2 Routine maintenance and inspection intervals
Table 14: Routine maintenance and inspection intervals

Interval Number of Time Maintenance task
persons
Daily 1 6 min. ▪ Check the leakage at the
mechanical seal or the leakage
rate at the gland packing.
Weekly 1 15 min. ▪ Check the pump operation
(inlet pressure, head, bearing
temperature, noises and
vibrations).
Monthly 1 15 min. ▪ Verify the torsional clearance of
the coupling (see operating
instructions of the coupling).
1 15 min. ▪ Switch to a stand-by pump, if
any, or carry out a functional
check run (5 minutes).
Every 20,000 operating 2 3h ▪ Replace the rolling element
hours bearings.
Every 4 years or if 2 6h ▪ Generally inspect and overhaul
discharge head drops the pump in accordance with the
operating instructions.
▪ Check and replace, if necessary:
– bearings, casing wear ring,
impeller wear ring, shaft
protecting sleeve
– impeller and shaft
– Fit new seal elements.
7.2.2.3 Checking the clearances

Excessive clearances will affect pump performance. Losses in efficiency and discharge
head will occur.
To check the clearances, remove the rotor. If the clearance is larger than permitted,
replace the casing wear ring and impeller wear ring.
Table 15: Clearances [mm]

S
Pump size Maximum Minimum clearance Maximum clearance

permissible nominal
clearance
(wear limit)
D2
D2 - D1 S min S max.
D1
2
80 - 210 0.3 0.15 0.2
80 - 270 0.3 0.15 0.2
80 - 370 0.3 0.15 0.2
Fig. 22: Impeller clearance
100 - 250 0.35 0.17 0.2
100 - 310 0.35 0.17 0.2
100 - 375 0.35 0.17 0.2
125 - 230 0.35 0.18 0.23
125 - 290 0.35 0.18 0.23
125 - 365 0.35 0.18 0.23
125 - 500 0.35 0.18 0.23
150 - 290 0.45 0.22 0.26
150 - 360 0.45 0.22 0.26
Pump size Maximum Minimum clearance Maximum clearance

permissible nominal
clearance
(wear limit)
D2 - D1 S min S max.
2
150 - 460 0.45 0.22 0.26
150 - 605 0.45 0.22 0.26
200 - 320 0.5 0.24 0.28
200 - 420 0.5 0.24 0.28
200 - 520 0.5 0.24 0.28
200 - 670 0.5 0.24 0.28
250 - 370 0.5 0.24 0.28
250 - 480 0.5 0.24 0.28
250 - 600 0.5 0.24 0.28
250 - 800 0.5 0.24 0.28
300 - 300 0.5 0.24 0.28
300 - 435 0.6 0.29 0.35
300 - 560 0.6 0.29 0.35
300 - 700 0.6 0.29 0.35
300 - 860 0.6 0.29 0.35
350 - 360 0.5 0.24 0.28
350 - 430 0.6 0.32 0.37
350 - 510 0.6 0.32 0.37
NOTE
The listed maximum clearances are based on an efficiency loss of approximately 3 %
compared to the clearances of the pump in as-new condition.
7.2.2.4 Cleaning filters
CAUTION
Insufficient inlet pressure due to clogged filter in the suction line
Damage to the pump!
▷ Monitor contamination of filter with suitable means (e.g. differential pressure
gauge).
▷ Clean filter at appropriate intervals.
7.2.2.5 Lubricating the rolling element bearings
DANGER
seals
Explosion hazard!
Fire hazard!
▷ Regularly check the bearing seals.
CAUTION
Temporary storage of the pump set too long
Formation of deposits or condensate, resinification or leakage of grease!
▷ Replace the complete rolling element bearings before returning the pump set
to service.
CAUTION
Pump stored too long or incorrectly
Damage to the pump!
▷ Check especially the rolling element bearings and the lubricant. If any damage
is suspected, replace the rolling element bearings.
The rolling element bearings are supplied greased for life. No re-lubrication is
required.
7.3 Drainage/cleaning
WARNING
hazard
▷ Collect and properly dispose of flushing fluid and any fluid residues.
▷ Wear safety clothing and a protective mask if required.
If the pump set has handled fluids whose residues could lead to corrosion damage in
the presence of atmospheric humidity or could ignite upon contact with oxygen, the
pump set must be neutralised, and anhydrous inert gas must be blown through the
pump to ensure drying.
Use connection 6B to drain the fluid handled (see drawing of auxiliary connections).
7.4 Dismantling the pump set
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set.
▷ Close the shut-off elements in the suction line and discharge line.
▷ Drain the pump and release the pump pressure. (ð Section 7.3, Page 54)
▷ Shut off any auxiliary feed lines.
WARNING
Risk of injury!
▷ Always have repair work and maintenance work performed by specially trained,
WARNING
WARNING
WARNING
Hot surface
Risk of injury!
WARNING
Components with sharp edges
Risk of cutting or shearing injuries!
▷ Always use appropriate caution for installation and dismantling work.
▷ Wear work gloves.
Observe the general safety instructions and information. (ð Section 2.8, Page 10)

manufacturer.
For dismantling and reassembly refer to the general assembly drawing.
In the event of damage you can always contact our service staff.
7.4.2 Preparing the pump set
DANGER
eyebolt.
NOTE
Horizontal installation
The pumps have been designed in such a way that the complete rotor can be
removed and dismantled without the need to remove the suction and discharge
line and without disturbing the alignment of the pump set.
NOTE
Vertical installation
For dismantling a vertically installed pump, the complete pump has to be removed
and placed in a horizontal position. Then, the complete rotor can be removed and
dismantled.
Preparing for dismantling

ü The gate valves in the suction and discharge lines have been closed.
ü The motor has been disconnected from the power supply and secured against
ü The pump has been drained.
1. Remove the flushing line and any auxiliary feed lines connected to the pump.
2. Remove the coupling guard and any other guards.
3. Separate the pump from the motor.
Removing vertically installed pumps in DJ installation

DJ installation 901.13
920.08
593.01
102
904.02
182
550.04
901.12
Fig. 23: DJ installation
ü Lifting equipment of suitable dimensions for the indicated component weights is
available.
ü Any auxiliary feed lines have been removed.
ü The pump has been separated from the motor.
1. Undo the connecting elements between the pump flanges and the pipes.
2. Suspend volute casing 102 from the lifting equipment and secure it.
3. Undo screwed connection 901.13/920.08 between the pump and rail 593.01.
Remove the rail.
4. Remove stud 904.02.
5. Undo screwed connection 901.12 between the pump and foot 182. Lift up the
pump and place it down in a horizontal position on a suitable surface.
Removing vertically installed pumps in DB installation

DB installation
901.14
920.12
901.13
341
102
920.08
182
904.02
901.12 550.04
550.04
Fig. 24: DB installation
available.
1. Undo screwed connection 901.14/920.12 between the motor and drive lantern
341.
2. Use suitably dimensioned lifting equipment to lift up the motor and place it on
a suitable surface.
3. Suspend drive lantern 341 from the lifting equipment and secure it.
4. Undo screwed connection 901.13/920.08 between drive lantern 341 and the
pump. Lift up drive lantern 341 and place it down on a suitable surface.
Removing vertically installed pumps in DK installation

DK installation
901.14
901.51
550.51
920.12
901.13
341
183
920.08
102
901.52
550.52 904.02
920.52
550.04
182 901.12
550.04
Fig. 25: DK installation
available.
1. Undo screwed connection 901.14/920.12 between the motor and drive lantern
341.
a suitable surface.
3. Suspend drive lantern 341 from the lifting equipment and secure it.
4. Undo screwed connection 901.51 between drive lantern 341 and support foot
183. Undo screwed connection 901.52/920.52 between support foot 183 and
foot 182.
5. Undo screwed connection 901.13/920.08 between drive lantern 341 and the
pump. Lift up drive lantern 341 and place it down on a suitable surface.
Removing vertically installed pumps in DP installation

DP installation
901.14
920.14
550.14
901.15
901.13
593.01
920.08
102 904.02
89-12
901.17
550.17
182 901.12 550.04
Fig. 26: DP installation
available.
1. Undo the connecting elements between the motor and motor bracket 89-12.
a suitable surface.
3. Secure the motor bracket. Undo the connecting elements 901.17 of the motor
bracket. Remove motor bracket 89-12.
6. Undo screwed connection 901.13/920.08 between the pump and rail 593.01.
Remove the rail.
7.4.3 Opening the volute casing

102 / 105.02
102 / 105.01
471 901.16
Fig. 27: Opening the volute casing

ü The pump has been placed in a horizontal position on a solid and level surface.
ü Suitably dimensioned lifting equipment is available.
2. Undo screwed connections 901.16 at seal cover 47117) and slide back the seal
cover.
3. Remove bolts 901.1/901.02 from the casing split flange. Separate upper casing
half 105.02 from lower casing half 105.01 with forcing screws and lift it off with
lifting equipment. Take care to lift the upper part up straight without tilting it.
4. Place the upper part of volute casing 105.02 on a clean assembly surface.
7.4.4 Removing the rotor

901.07 920.05
550.11
904
360
350.01
901.04
471 901.16
102 / 105.01
Fig. 28: Removing the rotor

ü The upper section of the volute casing has been removed.
ü Suitably dimensioned lifting tackle is available.
1. Undo screwed connection 901.4 between bearing housing 350.1 and the
bearing brackets. Undo screwed connection 901.07 / 920.05 for fastening
bearing cover 360.
2. Press the bearing housing out of the centring hub of the volute casing. Use
suitable lifting equipment, e.g. looped ropes, to lift the rotor out of the lower
casing half and securely place it down in a horizontal position.
17) Only for mechanical seal
7.4.5 Dismantling the rotor
Dismantling the rotor of a horizontally installed pump

ü The rotor has been placed on a clean assembly surface and secured against
rolling off.
ü The general assembly drawing is available.
1. Dismantle the pump-end coupling half.
2. Pull off the bearing housing of the fixed bearing (opposite the drive end).
3. Remove slotted round nut 920.03.
4. Take deep groove ball bearing 312 with bush 520 off the shaft.
5. Remove bearing cover 360.
6. Pull V-ring 411.01 off the shaft protecting sleeve.
7. Remove seal cover 471 with the mating ring of the mechanical seal.
8. Pull off shaft protecting sleeve 524.01 with mechanical seal 433.
9. Remove shaft seal housing 441.
10. Impeller 234 sits on the shaft with a sliding fit. Normally, it can be removed
easily. If the impeller is hard to remove, it can be loosened by gently tapping the
hub with a wooden mallet.
11. If applicable, remove the complete second shaft protecting sleeve 524.01 with
shaft seal housing 441 and shaft seal ring.
12. Pull off bearing housing 350.01.
13. Remove circlip 932 and pull off deep groove ball bearing 321.
Dismantling the rotor of a vertically installed pump

ü The rotor has been placed on a clean assembly surface and secured against
rolling off.
ü The general assembly drawing is available.
1. Dismantle the pump-end coupling half.
2. Undo nuts 920.02. Remove bearing cover 160. Then remove locknut 920.01, disc
springs 950 and disc 550.03.
3. Remove bearing housing 350.02, shaft protecting sleeve 524.02, bearing bush
545 and spacer sleeve 525.
4. Impeller 234 sits on the shaft with a sliding fit. Normally, it can be removed
easily. If the impeller is hard to remove, it can be loosened by gently tapping the
hub with a wooden mallet.
5. Pull off shaft seal housing 441 with the shaft seal and shaft protecting sleeve
524.01.
6. Remove nuts 920.05, bearing housing 350.01 with spacer ring 550.02 and circlip
932 as well as spacer ring 550.01.
7. Pull off bearing cover 360 and deep groove ball bearing 321.
7.5 Reassembling the pump set
DANGER
eyebolt.
WARNING
WARNING
Risk of injury!
▷ Always have repair work and maintenance work performed by specially trained,
WARNING
WARNING
Components heated up for installation
Risk of burns to hands!
▷ Wear protective gloves suitable for installation work.
▷ Let components cool down after installation.
CAUTION
Improper reassembly
Damage to the pump!
▷ Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
▷ Use original spare parts only.
Always observe the safety instructions and information. (ð Section 2.8, Page 10)

manufacturer.
For dismantling and reassembly, refer to the general assembly drawing.

In the event of damage, you can always contact our service department.
Sequence Always reassemble the pump in accordance with the corresponding general assembly
drawing and installation instructions.
O-rings/V-rings ▪ Never use O-rings that have been made by cutting an O-ring cord to size and
gluing the ends together.
▪ Replace all O-rings and V-rings and clean their seats on the shaft. Place all sealing
elements into their seats in the relevant components before assembling the
components.
Tension spring ▪ Remove the tension spring (2) of shaft seal ring 421.02.
2 4
3
Fig. 29: Removing the tension spring

1 Metal insert 2 Tension spring
3 Sealing lip 4 Elastomer component
Assembly adhesives ▪ Observe the installation instructions regarding cleaning, lubricating and sealing
agents.
▪ Remove any residues of liquid sealants prior to assembly.
▪ Coat the locating surfaces of the individual components and screwed connections
with graphite or similar before reassembly.
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.
7.5.2 Installing the rotor

ü Suitably dimensioned lifting equipment is available.
ü The pump shaft has been placed down in a horizontal position on a level and
clean assembly surface and secured against rolling off.
ü The corresponding general assembly drawing and installation instructions are
available.
1. The locating surfaces, threads and sliding fits of pump shaft 211 have been
cleaned. Assembly paste has been applied in accordance with the installation
instructions.
2. Fit keys into the keyways of pump shaft 211.
3. Fit impeller 234. Check that the direction of rotation of the impeller is correct!
Fig. 30: Direction of rotation of the impeller
NOTE
Looking onto the shaft from the drive end
Suction nozzle left = direction of rotation left (anti-clockwise)
Suction nozzle right = direction of rotation right (clockwise)
Watch the vane position of the impeller!
4. Fit the wear rings on the running surfaces of the impeller. Make sure that the
chamfered side of the rings is facing outwards (facing the bearing). Fit the studs
required to hold the wear rings in position.
5. Slide shaft protecting sleeves 524.01 onto pump shaft 211. Make sure that the
key of the impeller is engaged in the keyway provided.
7.5.2.1 Installing the mechanical seal
Pump set with KSB mechanical seal

ü The individual parts have been placed in a clean and level assembly area.
ü All dismantled parts have been cleaned and checked for wear.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
1. Slide shaft seal housing 441 onto the shaft.
2. Slide the sub-assembly of rotating components of the mechanical seal (torque-
transmitting element, springs, primary ring, secondary seal, etc.) onto shaft
protecting sleeve 524.01 as far as it will go.
3. Tighten grub screws with cup point evenly, alternately and gradually to the
torques specified, depending on the nominal thread diameter.
Grub screws with cup point may be used without applying a thread-locking
agent. Grub screws with cup point must not be re-used.
Table 16: Tightening torques for grub screws with cup point

Thread Tightening torque [Nm]
M6 8
M8 15
M10 20
CAUTION
Incorrect position of the mechanical seal
Hot fluid or steam may spurt out during operation!
▷ Make sure the mechanical seal is seated properly.
4. Slide shaft protecting sleeve 524.01 with the shaft seal ring onto the shaft.
5. Insert the mating ring with the corresponding O-ring into the seal cover (see
general assembly drawing). A lubricant can be applied to the O-ring. Press it in
evenly. Make sure the contact faces are dry.
6. Fit seal cover 471 with the mating ring.
Pump set with standardised mechanical seal

1. Pull spacer sleeve 525.02 onto shaft protecting sleeve 524.01.
2. Slide shaft seal housing 441 onto the shaft and install the mechanical seal as
described in the manufacturer's operating instructions.
3. Slide the complete rotating assembly onto the shaft protecting sleeve. Observe
the installation dimension given in the installation drawing of the mechanical
seal or slide it further until it abuts against the spacer sleeve. Then tighten the
grub screws firmly and secure them with LOCTITE.
4. Insert the mating ring with the corresponding O-ring into the seal cover (see
general assembly drawing). A lubricant can be applied to the O-ring. Press it in
evenly. Make sure the contact faces are dry.
5. Fit seal cover 471 with the mating ring.
7.5.2.2 Fitting the gland packing

ü The gland packing chamber is clean and free from any packing residues.
ü The shaft protecting sleeve has a bright metal surface which is free from score
marks. If required, the shaft protecting sleeve has been replaced.
1. Slide shaft seal housing 441 onto shaft protecting sleeve 524.1.
2. Use stuffing box insert 455 to tamp down the individual packing rings in the
gland packing chamber. Insert subsequent packing rings one at a time, with
their joints staggered at 90°-180°. Refer to the general assembly drawing for the
number of rings and the position of neck ring 457 or lantern ring 458, if
applicable. Preferably use compression-moulded packing rings.
3. Position gland follower 452 and tighten it lightly to allow the packing rings in
the gland packing chamber to adjust.
4. Loosen the gland follower to relieve the load on the packing.
7.5.2.3 Installing the bearings
WARNING
Components heated up for installation
Risk of burns to hands!
▷ Wear protective gloves suitable for installation work.
▷ Let components cool down after installation.
Installing the drive end bearings

ü The impeller has been fitted.
ü The shaft seal has been fitted.
available.
1. Slide bearing cover 360 with inserted lip seal 421.02 (for ATEX-version labyrinth
ring 423.02) on shaft protecting sleeve 524.
2. Heat up deep groove ball bearing 321 and pull it onto pump shaft 211. Take
utmost care to prevent any one-sided pressure or impacts which have to be
compensated by the outer rings. Secure the bearing with disc 550.01 and circlip
932.
Installing the non-drive end bearing

Horizontal ü The impeller has been fitted.
installation ü The shaft seal has been fitted.
available.
1. Slide bearing cover 360 with inserted lip seal 421.02 (for ATEX-version labyrinth
seal 423.02) on shaft protecting sleeve 524.
2. Heat up deep groove ball bearing 321 and fit it onto sleeve 520.
3. Slide sleeve 520 with deep groove ball bearing 321 onto pump shaft 211 with
the key 940.01 inserted.
4. Load the rotor parts elastically by means of slotted round nut 920 and disc
spring 950. For this purpose, compress disc spring 950 to blocking point and
then undo slotted round nut 920 again by half a turn (180°).
5. Position shaft seal housing 441 with the anti-vortex vanes pointing vertically
upwards. For shaft unit DW 9018) position shaft seal housing 441 with the anti-
vortex vanes at an angle of 45° off the horizontal, leading upwards as an
extension of the suction nozzle.
a
Fig. 31: Position of the anti-vortex vane for shaft unit DW 90

a Anti-vortex vane at the shaft seal b Suction nozzle
housing
Vertical installation with ü The impeller has been fitted.
plain bearing ü The shaft seal has been fitted.
available.
1. Fit non-drive end spacer sleeve 525 like shaft protecting sleeve 524.01.
2. Pull on shaft protecting sleeve 524.02 and mount bearing housing 350.02 with
fitted bearing bush 545 and O-ring 412.1.
3. Fasten shaft protecting sleeve 524.02 to the shaft with disc 550.03, disc spring
950 and nut 920.01.
4. Load the rotor parts elastically by means of slotted round nut 920 and disc
spring 950. For this purpose, compress disc spring 950 to blocking point. Then
undo slotted round nut 920 again by half a turn (180°).
5. Fit bearing cover 160.
6. Position shaft seal housing 441 with the anti-vortex vanes pointing vertically
upwards. For shaft unit DW 9019) position shaft seal housing 441 with the anti-
vortex vanes at an angle of 45° off the horizontal, leading upwards as an
extension of the suction nozzle.
18) Applies to the following sizes only: Omega 250-800, 300-560, 300-700, 350-430 and 350-510
19) Applies to the following sizes only: Omega 250-800, 300-560, 300-700, 350-430 and 350-510
Fig. 32: Position of the anti-vortex vane

a Anti-vortex vane at the bearing b Suction nozzle
housing
7.5.2.4 Final installation of the rotor

ü The rotor has been assembled.
ü The direction of rotation of the impeller has been verified.
ü The position of the anti-vortex vanes of the shaft seal housing and/or bearing
housing has been verified.
available.
1. Apply Loctite 574 to the contact faces of the casing wear ring and the seal
housing.
2. Insert the rotor. Observe the direction of rotation.
3. Align the rotor. Make sure that the fastening studs are correctly inserted into
the pump casing.
4. Observe the position of pins 561.01.
561.01
Fig. 33: Position of pins 561.01

a Casing wear rings
5. Slide bearing housing 350.01 with inserted discs 550.02/.0320) over deep groove
ball bearings 321.
6. Screw bearing housing 350.01 to the bearing brackets with bolted connections
901.04. Their locations are determined by the centring recesses.
7. Fit the bearing cover.
8. Apply Loctite 5203 to the contact face of the lower casing section.
20) Applies to fixed bearings. For horizontal installation: non-drive end; for vertical installation: drive end
9. Tighten the bolts at the casing split flange diagonally, starting with the bolts
nearest the volute.
10. Insert the key for the coupling into pump shaft 211.
11. Install the coupling in accordance with the manufacturer's operating
instructions.
7.5.3 Mounting the pump set on the baseplate

Type of installation 3E Refer to the corresponding sections on how to install the pump set.
Type of installation DJ, DB ü Suitably dimensioned lifting tackle is available.
and DK ü The corresponding general assembly drawing and/or installation instructions are
available.
ü The pump has been completely assembled.
1. Use lifting equipment to lift up the pump, position it vertically and place it on
foot 182 (base frame).
2. Tighten screwed connection 901.12 between pump 655 and foot 182.
3. Use lifting equipment to lift drive lantern 341 and position it on the pump.
Align drive lantern 341 with locking sleeve 531.01. Tighten screwed connection
901.13 / 920.06 between pump and drive lantern.
4. For DK installation, fasten support foot 183 to drive lantern 341 with screwed
connection 901.60 and to foot 182 with screwed connection 901.61.
5. Proceed with the installation as described in the corresponding sections.
(ð Section 5.3.2, Page 24) , (ð Section 5.3.4, Page 26)
7.6 Tightening torques

With the exception of the following screwed connections, all screws/bolts must be
tightened as per the "Tightening torques” table.
Part No. Description [Nm]
900.01 Foundation bolts (M16) 48
900.01 Foundation bolts (M20) 96
901.54 Motor screws/bolts Refer to the motor
901.14 manufacturer's product
literature.
920.2 Gland follower nuts (ð Section 6.1.4, Page 42)
Observe the following values:
Table 17: Tightening torques 21)

Tightening torque MA [Nm]
Steel grade A2, A4 A2, A4 A2, A4 C3 1.4410 1.4462
Property class 8.8 10.9 -50 -70 -80 -80
Minimum
Minimum
Minimum
Minimum
Minimum
Minimum
Minimum
Minimum
Thread
torque
torque
torque
torque
torque
torque
torque
torque
Rated
Rated
Rated
Rated
Rated
Rated
Rated
Rated
M4 3,0 3,0 4,5 5,0 1,0 1,1 2,1 2,4 2,9 3,2 3,0 3,4 2,5 2,8 2,1 2,4
M5 6,1 6,8 9,0 9,9 2,0 2,2 4,3 4,8 5,7 6,3 6,1 6,8 5,0 5,6 4,3 4,8
M6 10,3 11 15 17 3,4 3,7 7,2 8,0 9,6 11 10 11 8,5 9,5 7,2 8,0
M8 25 28 37 41 8,2 9,1 18 19 23 26 25 28 21 23 18 19
M10 49 55 72 80 16 18 35 38 46 51 49 55 41 45 35 38
M12 85 94 124 138 28 31 59 66 79 88 85 94 70 78 59 66
M14 134 149 197 219 44 49 94 105 126 140 134 149 111 124 94 105
21) For µTotal = 0.14 and 90 % of the minimum yield strength
Tightening torque MA [Nm]

Steel grade A2, A4 A2, A4 A2, A4 C3 1.4410 1.4462
Property class 8.8 10.9 -50 -70 -80 -80
Minimum
Minimum
Minimum
Minimum
Minimum
Minimum
Minimum
Minimum
Thread
torque
torque
torque
torque
torque
torque
torque
torque
Rated
Rated
Rated
Rated
Rated
Rated
Rated
Rated
M16 209 232 307 341 69 76 147 163 196 218 209 232 173 192 147 163
M20 408 453 599 666 134 149 287 319 382 425 408 453 338 375 287 319
M24 704 782 1034 1149 231 257 495 550 660 733 704 782 583 648 495 550
M27 1025 1139 1506 1673 336 374 721 801 961 1068 1025 1139 849 944 721 801
M30 1403 1559 2060 2289 460 511 986 1096 1315 1461 1403 1559 1162 1291 986 1096
M33 1888 2098 2773 3081 619 688 1327 1475 1770 1966 1888 2098 1563 1737 1327 1475
M36 2445 2717 3591 3990 802 891 1719 1910 2292 2547 2445 2717 2025 2250 1719 1910
M42 3904 4338 5734 6371 1281 1423 2745 3050 3660 4067 3904 4338 3233 3592 2745 3050
M48 5880 6534 8637 9596 1929 2144 4135 4594 5513 6125 5880 6534 4870 5411 4135 4594
7.7 Spare parts stock
7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:
▪ Order number
▪ Order item number
▪ Type series
▪ Size
▪ Material variant
▪ Year of construction
Refer to the name plate for all data.
Also specify the following data:
▪ Part number and description (ð Section 9.2, Page 77)
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)
7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296
Table 18: Quantity of spare parts for recommended spare parts stock

Part No. Description Installation Version Number of pumps (including stand-by
pumps)
Mechanical
1 2 3 4 5 6 7 8 9 10 and
Horizontal
Vertical
more
packing
Gland
seal
Casing wear rings

502 Casing wear ring ✘ ✘ ✘ ✘ 2 4 4 4 6 6 6 8 8 50 %
561.1 Grooved pin ✘ ✘ ✘ ✘ 4 8 8 8 12 12 12 16 16 50 %
Impeller wear ring
503 Impeller wear ring ✘ ✘ ✘ ✘ 2 4 4 4 6 6 6 8 8 50 %
Fastening elements for the shaft
920.1 Nut - ✘ ✘ ✘ 1 1 1 1 2 2 2 2 2 20 %
920.3 Nut ✘ - ✘ ✘ 1 1 1 1 2 2 2 2 2 20 %
Part No. Description Installation Version Number of pumps (including stand-by

pumps)
Mechanical
1 2 3 4 5 6 7 8 9 10 and
Horizontal
Vertical
more
packing
Gland
seal
932 Circlip ✘ ✘ ✘ ✘ 1 1 1 1 2 2 2 2 2 20 %
940.1 Key ✘ ✘ ✘ ✘ 1 1 1 1 2 2 2 2 2 20 %
940.2 Key ✘ ✘ ✘ ✘ 1 1 1 1 2 2 2 2 2 20 %
940.3 Key ✘ ✘ ✘ ✘ 1 1 1 1 2 2 2 2 2 20 %
950 Disc spring ✘ ✘ ✘ ✘ 1 1 1 1 2 2 2 2 2 20 %
Bearing assembly
321 Deep groove ball ✘ ✘ ✘ ✘ 2 2 2 2 4 4 6 8 8 50 %
bearing22)
350.2 Bearing housing - ✘ ✘ ✘ 1 1 1 1 2 2 3 4 4 50 %
520 Sleeve ✘ - ✘ ✘ 1 1 1 1 2 2 3 4 4 50 %
524.2 Shaft protecting sleeve - ✘ ✘ ✘ 1 1 1 1 2 2 3 4 4 50 %
545 Bearing bush - ✘ ✘ ✘ 1 1 1 1 2 2 3 4 4 50 %
550.1 Disc ✘ ✘ ✘ ✘ 2 2 2 2 4 4 6 8 8 50 %
550.2 Disc ✘ ✘ ✘ ✘ 3 3 3 3 6 6 9 12 12 50 %
Sealing elements
411.1 V-ring22) ✘ ✘ ✘ ✘ 4 8 12 16 16 18 18 24 24 150 %
412.1 O-ring22) ✘ ✘ ✘ ✘ 4 8 12 16 16 18 18 24 24 150 %
412.2 O-ring ✘ ✘ ✘ ✘ 4 8 12 16 16 18 18 24 24 150 %
412.3 O-ring ✘ ✘ ✘ ✘ 4 8 12 16 16 18 18 24 24 150 %
412.4 O-ring - ✘ ✘ ✘ 2 4 6 8 8 9 9 12 12 150 %
412.5 O-ring - ✘ ✘ ✘ 2 4 6 8 8 9 9 12 12 150 %
412.6 O-ring - ✘ ✘ ✘ 2 4 6 8 8 9 9 12 12 150 %
421.1 Shaft seal ✘ ✘ ✘ ✘ 2 4 6 8 8 9 9 12 12 150 %
421.2 Shaft seal 22)
✘ ✘ ✘ ✘ 4 8 12 16 16 18 18 24 24 150 %
Shaft protecting sleeve
524.1 Shaft protecting sleeve22) ✘ ✘ ✘ ✘ 2 2 2 4 4 4 4 6 6 25 %
Mechanical seal
433 Mechanical seal22) ✘ ✘ - ✘ 2 2 2 4 4 4 4 6 6 25 %
Mechanical seal installation kit
457.2 Neck ring22) ✘ ✘ - ✘ 0 0 0 0 0 0 0 0 0 0%
471 Seal cover 22)
✘ ✘ - ✘ 0 0 0 0 0 0 0 0 0 0%
525.2 Spacer sleeve22) ✘ ✘ - ✘ 0 0 0 0 0 0 0 0 0 0%
Gland packing
461 Packing rings22) ✘ ✘ ✘ - 6 12 24 24 36 36 36 48 48 0%
Gland packing kit
452 Gland follower22) ✘ ✘ ✘ - 2 4 4 8 8 8 12 12 16 30 %
455 Stuffing box insert 22)
✘ ✘ ✘ - 2 4 4 8 8 8 12 12 16 30 %
457 Neck ring22) ✘ ✘ ✘ - 2 4 4 8 8 8 12 12 16 30 %
458 Lantern ring22) ✘ ✘ ✘ - 2 4 4 8 8 8 12 12 16 30 %
22) For vertical installation with product-lubricated plain bearing, halve the number of spare parts.
8 Trouble-shooting
8 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work performed to remedy faults, observe the relevant information
given in this operating manual and/or in the product literature provided by the
accessories manufacturer.
If problems occur that are not described in the following table, consultation with the
KSB customer service is required.
A Pump discharge pressure is too low
B Excessive discharge pressure
C Excessive flow rate
D Insufficient flow rate
E Excessive power consumption
F Pump is running, but does not deliver
G Pump stops during operation
H Vibrations and noise during pump operation
I Impermissible temperature increase in the pump
J Excessive bearing temperature
K Excessive leakage at the shaft seal
L Motor is overloaded
M Leakage at the pump
Table 19: Trouble-shooting
A B C D E F G H I J K L M Possible causes Remedy23)
✘ ✘ ✘ ✘ ✘ ✘ - ✘ ✘ - - ✘ - Operating point B does not match ▪ Re-adjust to duty point.
the Q and H performance data
calculated in advance.
- - - - - ✘ - - - - - - - Pump and/or piping are not ▪ Vent.
completely vented or primed.
✘ - - ✘ - ✘ ✘ ✘ ✘ - - - - Supply line or impeller clogged ▪ Clean the impeller.
▪ Check system for impurities.
▪ Remove deposits in pump and/
or piping.
▪ Check any strainers installed/
suction opening.
- - - - - ✘ ✘ ✘ - - - - - Formation of air pockets in the ▪ Correct suction conditions.
piping ▪ Alter piping layout.
✘ - - ✘ - ✘ ✘ ✘ - - - - - Suction head too high (NPSH ▪ Check operating mode.
available too low) / water level too ▪ Correct suction conditions.
low
▪ Increase suction head.
▪ Increase back pressure by
throttling.
▪ Install pump at a lower level.
▪ Alter suction/inlet line, if
piping losses are too high.
23) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
8 Trouble-shooting

✘ - - ✘ - ✘ ✘ - - - - - - Air intake at the shaft seal ▪ Clean barrier fluid line, supply
external barrier fluid, if
necessary, or increase barrier
fluid pressure.
▪ Check liquid supply system.
▪ Fit new shaft seal.
▪ Replace shaft protecting
sleeve.
✘ - - ✘ ✘ - - ✘ - - - ✘ - Wrong direction of rotation ▪ Interchange two of the phases
of the power cable.
▪ Check electrical connections.
▪ Check impeller position;
correct if necessary.
✘ - - ✘ - - - ✘ - - - - - Speed is too low. ▪ Increase speed.
▪ Check switchgear.
▪ Fit larger impeller.
✘ - - ✘ - ✘ ✘ - - - - - - Wear of internal components ▪ Check duty point/pump
selection.
▪ Increase back pressure by
throttling.
▪ Check fluid handled for
contamination by chemicals;
check solids content.
▪ Replace worn components by
new ones.
- - - - ✘ - - - - - - ✘ - Pump pressure lower than ▪ Re-adjust to duty point.
specified in the purchase order ▪ Increase back pressure by
throttling.
- - - - ✘ - - - - - - ✘ - Density or viscosity of fluid ▪ Reduce speed.
handled higher than stated in ▪ In the case of persistent
purchase order overloading, turn down
impeller, if possible.
- ✘ ✘ - ✘ - - ✘ - - - ✘ - Speed is too high. ▪ Reduce speed.
▪ In the case of persistent
overloading, turn down
impeller, if possible.
- - - - - - - - - - - - ✘ Assembly bolts/sealing elements ▪ Check.
▪ Re-tighten the bolts.
▪ Fit new sealing elements.
▪ Check pipeline connections
and secure fixing of pump;
improve fixing of pipelines, if
necessary.
8 Trouble-shooting

- - - - - - - - - - ✘ - - Worn shaft seal ▪ Check flushing liquid/barrier
fluid pressure.
▪ Clean barrier fluid line, supply
fluid pressure.
▪ Fit new shaft seal.
new ones.
▪ Replace shaft protecting
sleeve.
✘ - - ✘ - - - ✘ - ✘ - - - Unfavourable flow to pump ▪ Alter piping layout.
suction nozzle ▪ Alter suction/inlet line, if
piping losses are too high.
▪ Check whether pipe routing
results in swirling or irregular
flow (e.g. downstream of
elbow) and correct, if
necessary.
- - - - - - - - ✘ - ✘ - - Gland follower or seal cover ▪ Adjust.
tightened incorrectly; wrong ▪ Replace.
packing material.
▪ Correct.
▪ Replace gland packing.
new ones.
- - - - - - - - ✘ - ✘ - - Lack of cooling liquid or dirty ▪ Check flushing liquid/barrier
cooling chamber fluid pressure.
▪ Clean barrier fluid line, supply
fluid pressure.
▪ Increase cooling liquid
quantity.
▪ Purify/clean cooling liquid.
- - - - - - - ✘ - ✘ - - - Pump is warped or sympathetic ▪ Re-align pump/drive.
vibrations in the piping. ▪ Check pipeline connections
and secure fixing of pump;
improve fixing of pipelines, if
necessary.
▪ Fix pipelines using anti-
vibration material.
- - - - - - - - - ✘ - - - Increased axial thrust ▪ Check duty point/pump
selection.
▪ Check operating mode.
▪ Check suction-side flow
conditions.
- - - - - - - - - ✘ - - - Insufficient or excessive quantity of ▪ Clean the bearings.
lubricant or unsuitable lubricant ▪ Top up, reduce or change
lubricant.
▪ Check oil lubrication system24).
▪ Check oil supply24).
24) If any
8 Trouble-shooting

✘ - - ✘ ✘ - - - - - - ✘ - Motor is running on 2 phases only. ▪ Replace defective fuses.
▪ Check electrical connections.
▪ Check switchgear.
- - - - - - - ✘ - ✘ ✘ - - Rotor out of balance ▪ Clean the rotor.
▪ Check run-out; re-align, if
necessary.
▪ Re-balance the rotor.
- - - - - - - ✘ - ✘ ✘ - - Defective bearing(s) ▪ Replace.
- - - - - - - ✘ ✘ - - - - Flow rate is too low. ▪ Re-adjust to duty point.
▪ Fully open shut-off element in
suction/inlet line.
▪ Fully open shut-off element in
discharge line.
▪ Re-calculate or measure
hydraulic losses HV.
✘ - - ✘ - - - - - - - - - In star-delta operation, motor ▪ Check electrical connections.
stuck at star stage ▪ Check switchgear.
✘ - - ✘ - - - ✘ - - - - - Impermissible air or gas content in ▪ Vent.
fluid handled ▪ Check suction line for leakage,
seal if necessary.
✘ - - ✘ - ✘ ✘ ✘ - - - - - Air intake at pump inlet ▪ Correct suction conditions.
▪ Reduce flow velocity at suction
line inlet.
▪ Check suction line for leakage,
seal if necessary.
▪ Replace defective pipes.
- - - - - - - ✘ - - - - - Cavitation (rattling noise) ▪ Correct suction conditions.
▪ Check operating mode.
▪ Install pump at a lower level.
- - - - - - - ✘ - ✘ - - - Foundation not rigid enough ▪ Check.
▪ Adjust.
✘ - - ✘ - ✘ ✘ ✘ - - - - - Impermissible parallel operation ▪ Re-adjust to duty point.
▪ Adjust pump characteristic H.
- - - - - - - ✘ - - ✘ - - Shaft is out of true. ▪ Replace.
- - - - ✘ - - ✘ ✘ ✘ - - - Impeller rubs against casing ▪ Check rotor.
components. ▪ Check impeller position.
▪ Verify that piping has been
connected without
transmitting any stresses or
strains.
8 Trouble-shooting
8.1 Explanation of faults

The example illustrated in the diagram serves to facilitate understanding of the
causes of faults/malfunctions and their remedies described in the Trouble-shooting
section.
Many operating faults/malfunctions on pumps are caused by hydraulic phenomena.
The hydraulic behaviour of a pump is illustrated by its characteristic curves H, P, Eta
and NPSH in combination with the system characteristic curves HA and NPSHA as a
function of flow rate Q. The operating point B is given by the intersection between
the system curve HA and the pump's characteristic curve H.
If the cause of a fault or malfunction is unclear, consult your nearest KSB service
centre.
P
HA
B
HV
Eta
H
Hgeo
NPSH
NPSHA
Q
Fig. 34: Adjusting to the duty point
P Pump power output HA System curve
B Operating point Hv Hydraulic losses (system)
H Head NPSH Required inlet pressure
Eta Efficiency NPSHA Inlet pressure available in the system
Q Flow rate Hgeo Static head
9 Related Documents
9 Related Documents
9.1 Weights of individual components
DANGER
Improper transport
Risk of injury from lifting heavy components!
▷ Select lifting accessories which are suitable for the component weight.
▷ Always use the attachment points provided for the lifting accessories.
▷ Comply with the applicable health and safety regulations.
Table 20: Weights of individual components [kg]

Size Volute casing Impeller Shaft Bearing housing Shaft seal Casing wear
Lower Upper housing ring
section section
80 - 210 132 48 < 25 < 25 < 25 < 25 < 25
80 - 270 134 48 < 25 < 25 < 25 < 25 < 25
80 - 370 140 54 < 25 < 25 < 25 < 25 < 25
100 - 250 152 52 30 < 25 < 25 < 25 < 25
100 - 310 150 54 30 < 25 < 25 < 25 < 25
100 - 375 170 61 35 < 25 < 25 < 25 < 25
125 - 230 226 66 30 < 25 < 25 < 25 < 25
125 - 290 231 70 30 < 25 < 25 < 25 < 25
125 - 365 234 79 55 < 25 < 25 < 25 < 25
125 - 500 285 110 55 < 25 < 25 < 25 < 25
150 - 290 253 88 53 < 25 < 25 < 25 < 25
150 - 360 255 92 53 < 25 < 25 < 25 < 25
150 - 460 307 109 95 < 25 < 25 < 25 < 25
150 - 605 458 168 98 < 25 < 25 < 25 < 25
200 - 320 365 128 67 < 25 < 25 < 25 < 25
200 - 420 389 122 67 < 25 < 25 < 25 < 25
200 - 520 580 200 109 30 27 31 < 25
200 - 670 667 276 109 30 27 31 < 25
250 - 370 540 160 129 30 27 31 < 25
250 - 480 610 202 120 44 32 34 < 25
250 - 600 777 278 119 44 32 34 < 25
250 - 800 1097 509 239 63 35 43 < 25
300 - 300 558 189 87 30 27 31 < 25
300 - 435 725 250 126 44 32 34 < 25
300 - 560 1065 360 194 63 35 43 < 25
300 - 700 1295 444 194 63 35 43 < 25
300 - 860 2064 945 220 108 55 32 < 25
350 - 360 774 252 131 44 32 34 < 25
350 - 430 1050 344 136 63 35 43 < 25
350 - 510 889 378 172 63 35 43 < 25
9 Related Documents
9.2 General assembly drawing with list of components
9.2.1 Horizontally installed pump
550.02 903.02 412.03 102 502 524.01 550.01 550.01

950 903.03 441 903.01 234 412.02 421.02* 903.04 932
903.08
920.05
901.07 550.11
920.03 904
421.01**
580
211
940.01 940.03
520 321
360
350.01
901.04
940.02 525.02**** 471 411.01***

457.02 433 901.16 412.01
Fig. 35: General assembly drawing for horizontal installation
* For ATEX version labyrinth ring 423.02
** For ATEX version labyrinth ring 423.01
*** Does not apply to ATEX version
**** Does not apply to version with KSB mechanical seal 4OM
9 Related Documents
Detailed view: gland packing Detailed view: pin position

524.01
502
561.01
L
5203
412.01
441
457 458 452 902.01 561.02
461 455 920.02 411.01
Detailed view: casing wear ring / impeller wear ring Detailed view: bolts at the casing split flange
502 901.03
901.02
901.01
L
5203
503

102 Volute casing 471 Seal cover
211 Pump shaft 502 Casing wear ring
234 Impeller 503 Impeller wear ring
321 Radial ball bearing 520 Sleeve
350.01 Bearing housing 524.01 Shaft protecting sleeve
360 Bearing cover 525.02 Spacer sleeve
411.01 Joint ring 550.01/.02/.11 Disc
9 Related Documents

412.01/.02/.03 O-ring 561.01/.02 Grooved pin
421.01/.02 Lip seal 580 Cap
433 Mechanical seal 901.01/.02/.03/.04/.07/.16 Hexagon head bolt
441 Shaft seal housing 902.01 Stud
452 Gland follower 903.01/.02/.03/.04/.08 Screw plug
455 Stuffing box insert 904 Grub screw
457.02 Neck ring 920.02/.03/.05 Nut
458 Lantern ring 932 Circlip
461 Gland packing 940.01/.02/.03 Key
950 Spring
9 Related Documents
9.2.2 Vertically installed pump, installation type DJ

211
940.03
904
920.05 421.01**
932 350.01
903.03
903.04 901.04
550.01 360
550.02
321 901.16
421.02* 904.02
411.01*** 471
903.02
920.08
524.01
412.03 593
903.01
441
433
940.02 412.02
234 525.02****
102
457.02
502
412.06
525.01
412.01
524.02
545
550.04
550.03 920.01 160 920.02 350.02 182

412.05 550.05
950 914.01 412.04 902.02
898.01
930.01
901.10
901.11
89-4.04
Fig. 36: General assembly drawing for installation type DJ
9 Related Documents

920.02 L
411.01 5203
452
524.01
561.01
902.01
903.02 502
455
L
5203
458
561.02
441 461
457 441
L
5203
561.04
350.02
503 502 901.03
901.02 901.13
901.01 901.12
L
5203

102 Volute casing 503 Impeller wear ring
160 Cover 524.01/.02 Shaft protecting sleeve
182 Foot 525.01/.02 Spacer sleeve
211 Pump shaft 545 Bearing bush
234 Impeller 550.01/.02/.03/.04/.05 Disc
321 Radial ball bearing 561.01/.02/.04 Grooved pin
9 Related Documents

350.01/.02 Bearing housing 593 Rail
360 Bearing cover 89-4.04 Shim
411.01 Joint ring 898.01 Foundation block
412.01/.02/.03/.04/.05/.06 O-ring 901.01/.02/.03/.04/.10/.11/.1 Hexagon head bolt
2/.13/.16
421.01/.02 Lip seal 902.01/.02 Stud
433 Mechanical seal 903.01/.02/.03/.04 Screw plug
441 Shaft seal housing 904.02 Grub screw
452 Gland follower 914.01 Hexagon socket head cap
screw
455 Stuffing box insert 920.01/.02/.05/.08 Nut
457.02 Neck ring 930.01 Safety device
461 Gland packing 940.02/.03 Key
471 Seal cover 950 Spring
502 Casing wear ring
9 Related Documents
9.2.3 Vertically installed pump, installation type DB
901.15
901.14
920.12
211
940.03 341
904 421.01**
920.05 350.01
903.03 932 901.04
903.04 360
550.01 901.16
550.02
471
321
421.02*
411.01*** 904.02
903.02
524.01 920.08
412.03
903.08
433
903.01
441
412.02 525.02****
940.02
234 457.02
102
502 550.04
412.06
525.01
412.01
524.02
545
182
550.05
898.01
914.01 901.10
950 930.01 412.04 902.02 412.05 901.11
550.03 920.01 160 920.02 350.02 89-4.04
Fig. 37: General assembly drawing for installation type DB
9 Related Documents

920.02 L
411.01 5203
452
524.01
561.01
902.01
903.02 502
455
L
5203
458
561.02
441 461
457 441
L
5203
561.04
350.02
503 502 901.03
901.02 901.13
901.01 531.01 901.12
L
5203

102 Volute casing 502 Casing wear ring
160 Cover 503 Impeller wear ring
182 Foot 524.01/.02 Shaft protecting sleeve
211 Pump shaft 525.01/.02 Spacer sleeve
234 Impeller 531.01 Locking sleeve
321 Radial ball bearing 545 Bearing bush
341 Drive lantern 550.01/.02/.03/.04/.05 Disc
9 Related Documents

350.01/.02 Bearing housing 561.01/.02/.04 Grooved pin
2/.13/.14/.15/.16
421.01/.02 Lip seal 902.01/.02 Stud
433 Mechanical seal 903.01/.02/.03/.04/.08 Screw plug
screw
455 Stuffing box insert 920.01/.02/.05/.08/.12 Nut
9 Related Documents
9.2.4 Vertically installed pump, installation type DK
901.15 901.14
920.12
901.61
211
940.03 341
904
920.05 421.01**
932
903.03 350.01
903.04 901.04
360
550.01 901.16
550.02
471
321
421.02*
411.01***
524.01 904.02
412.03 920.08
903.01
441 433
412.02 525.02****
940.02
457.02
234
102
183
502
412.06
525.01
412.01
550.60
920.60
901.60
524.02
545
914.01
950 412.04 902.02 412.05 550.04
930.01
182
550.03 920.01 160 920.02 350.02
550.05
898.01
901.10
901.11
89-4.04
Fig. 38: General assembly drawing for installation type DK
9 Related Documents

920.02 L
411.01 5203
452
524.01
561.01
902.01
903.02 502
455
L
5203
458
561.02
441 461
457 441
L
5203
561.04
350.02
503 502 901.03
901.02 901.13
901.01 531.01 901.12
L
5203

102 Volute casing 502 Casing wear ring
160 Cover 503 Impeller wear ring
182 Foot 524.01/.02 Shaft protecting sleeve
183 Support foot 525.01/.02 Spacer sleeve
211 Pump shaft 531.01 Locking sleeve
234 Impeller 545 Bearing bush
321 Radial ball bearing 550.01/.02/.03/.04/.05/.60 Disc
9 Related Documents

341 Drive lantern 561.01/.02/.04 Grooved pin
350.01/.02 Bearing housing 89-4.04 Shim
360 Bearing cover 898.01 Foundation block
411.01 Joint ring 901.01/.02/.03/.04/.10/.11/.1 Hexagon head bolt
2/.13/.14/.15/.16/.60/.61
412.01/.02/.03/.04/.05/.06 O-ring 902.01/.02 Stud
421.01/.02 Lip seal 903.01/.02/.03/.04 Screw plug
433 Mechanical seal 904.02 Grub screw
441 Shaft seal housing 914.01 Hexagon socket head cap
screw
452 Gland follower 920.01/.02/.05/.08/.12 Nut
455 Stuffing box insert 930.01 Safety device
457.02 Neck ring 932 Circlip
458 Lantern ring 940.02/.03 Key
461 Gland packing 950 Spring
471 Seal cover
9 Related Documents
9.2.5 Vertically installed pump, installation type DP

901.14
550.01 920.05 211 421.01** 360 920.14
903.03 932 904 940.03 350.01 (901.15) 550.14
903.04
550.02
901.04
321
421.02* 901.16
411.01***
471
903.02
433
903.08
904.02
920.08
412.03 593
903.01 525.02****
441
457.02
524.01
412.02
89-12
89-8.40
234 901.17
102 550.17
901.44
940.02 89-4.43
502 550.42
412.06 901.41
525.01 545 550.03 920.01 160 902.02 350.02 182

412.01 524.02 950 914.01 412.04 920.02 412.05 898.01 550.04
930.01 901.10
901.11
89-4.04
Fig. 39: General assembly drawing for installation type DP

9 Related Documents

920.02 L
411.01 5203
452
524.01
561.01
902.01
903.02 502
455
L
5203
458
561.02
441 461
457 441
L
5203
561.04
350.02
503 502 901.03
901.02 901.13
901.01 901.12
L
5203

102 Volute casing 503 Impeller wear ring
160 Cover 524.01/.02 Shaft protecting sleeve
182 Foot 525.01/.02 Spacer sleeve
211 Pump shaft 545 Bearing bush
234 Impeller 550.01/.02/.03/.04/.05/.17 Disc
321 Radial ball bearing 561.01/.02/.04 Grooved pin
9 Related Documents

350.01/.02 Bearing housing 593 Rail
2/.16/.17
421.01/.02 Lip seal 902.01/.02 Stud
433 Mechanical seal 903.01/.02/.03/.04 Screw plug
screw
455 Stuffing box insert 920.01/.02/.05/.08 Nut
502 Casing wear ring
10 EU Declaration of conformity
10 EU Declaration of conformity
Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the product:
Omega, Omega V
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
Person authorised to compile the technical file:
Name
Function
Address (company)
Address (Street, No.)
Address (post or ZIP code, city) (country)
The EU Declaration of Conformity was issued in/on:
Place, date
..............................25).............................
Name
Function
Company
Address
25) A signed, legally binding EU Declaration of Conformity is supplied with the product.
Type: ................................................................................................................................
Order number/
Order item number26): ................................................................................................................................
Delivery date: ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled : 26)
................................................................................................................................
Please tick where applicable26):
⃞ ⃞ ⃞ ⃞
Radioactive Explosive Corrosive Toxic
⃞ ⃞ ⃞ ⃞
Harmful Bio-hazardous Highly flammable Safe
Reason for return26): ................................................................................................................................

Comments: ................................................................................................................................
................................................................................................................................
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.
For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has been
removed from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern,
leakage barrier and bearing bracket or adapter have also been cleaned.
For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage at
the stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it has
been removed.
⃞ No special safety precautions are required for further handling.
⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:
...............................................................................................................................................................
...............................................................................................................................................................
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the
relevant legal provisions.
.................................................................... ....................................................... .......................................................

Place, date and signature Address Company stamp
26) Required fields
Index
Index
A O
Abrasive fluids 46 Operating limits 43
Auxiliary connections 36 Order number 6
Other applicable documents 6
B
Bearing temperature 50 P
Bearings 18 Partly completed machinery 6
Piping 30
C Preservation 14
Certificate of decontamination 93 Priming and venting 40
Commissioning/start-up 40 Product description 17
Pump casing 18
D Pump shaft 18
Design 18
Designation 17 R
Dismantling 55 Reassembly 63
Disposal 16 Return to supplier 15
Returning to service 46
E Running noises 50
Event of damage 6
Ordering spare parts 69 S
Explosion protection 10, 22, 32, 33, 34, 37, 38, 40, 41, Safety 8
42, 43, 45, 48, 49, 50, 51, 53
Safety awareness 9
F Scope of supply 21
Faults Shaft seal 18
Causes and remedies 71 Spare part
Ordering spare parts 69
Fields of application 9
Spare parts stock 69
Filter 31, 53
Start-up 41
Frequency of starts 45
Storage 14
G
Gland packing 42
T
Temperature limits 11
I
Impeller type 18
W
Warnings 8
Installation at site 22
Warranty claims 6
Intended use 9
K
Key to safety symbols/markings 8
M
Maintenance 49
Mechanical seal 42
N
Noise characteristics 20
(01059616)
1384.8/11-EN
KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com
Appendix C
Operating coupling
CENTAFLEX-A
Assembly and operating instructions
008A-00001...00600-.N/S..
M008-00073-EN
Rev. 2
Assembly and operating instructions M008-00073-EN
CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
Contents
1 General remarks ..................................................................................... 7
2 Safety ..................................................................................................... 8
2.1 Safety remarks .................................................................................. 8
2.1.1 Signal words ......................................................................... 8
2.1.2 Pictograms ............................................................................ 9
2.2 Qualification of deployed personnel ...................................................... 9
2.3 Intended application........................................................................... 9
2.4 Application not in compliance with the intended use ..............................11
3 Delivery, transport, storage and disposal ............................................. 12

3.1 Delivery ...........................................................................................12
3.2 Transport .........................................................................................12
3.3 Storage ...........................................................................................12
3.3.1 Storage location....................................................................13
3.3.2 Storage of couplings / flexible elements ...................................13
3.4 Disposal...........................................................................................13
4 Technical description ............................................................................ 14

4.1 Characteristics..................................................................................14
4.2 Specifications ...................................................................................14
5 Alignment of the units being connected ................................................ 15

5.1 Axial alignment.................................................................................15
5.2 Radial alignment ...............................................................................17
5.3 Angular alignment.............................................................................19
6 Mounting .............................................................................................. 21
6.1 General assembly instructions ............................................................21
6.2 Mounting the coupling according to the supplied type ............................23
6.3 Preparing the hub/adapter/flange (6/9/B) for mounting .........................25
6.3.1 Prepare the hub/adapter/flange (6/9/B) for mounting (Type
008A-00016..00600-.N..).......................................................26
008A-00001..00250-.S..) .......................................................27
008A-00400..00600-.S..) .......................................................28
6.4 Mounting the hub (2/6; Type 1 and 2) .................................................29
6.4.1 Mounting the hub (2/6) with cylindrical drilling and feather
key .....................................................................................30
6.4.2 Mounting the hub (2/6) with conical drilling and feather key .......32
6.4.3 Mounting the hub (2/6) with toothing ......................................33
6.4.4 Mounting the CENTALOC-clamping hub (2/6)............................34
6.4.5 Mounting the CENTA-conical clamping hub (2/6) .......................36
6.4.6 Mounting the hub (2/6) with conical oil interference fit ..............39
CENTA Antriebe Kirschey GmbH 2 / 71
CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.5 Mounting the adapter (Type 3) ...........................................................42

6.6 Positioning the rubber element (1) ......................................................43
6.7 Mounting the rubber element (1) ........................................................44
6.8 Mounting the rubber element (1; Type .N..) .........................................44
6.8.1 Aligning the units ..................................................................44
6.8.2 Mounting the rubber element (Coupling size 00001...00012) ......45
6.8.4 Mounting the rubber element (Coupling size 00250) ..................49
6.9 Mounting the rubber element (1; Type .S..) .........................................52
6.9.2 Mounting the rubber element (Coupling size 00250) ..................54
6.9.4 Connecting the driving and driven units (Coupling size
00600) ................................................................................56
6.10 After completed mounting ..................................................................57
7 Operation.............................................................................................. 58
7.1 Operating faults, root causes and remedy ............................................58
7.2 Admissible overall misalignment of the coupling ...................................58
8 Care and maintenance .......................................................................... 59

8.1 Work to be performed .......................................................................59
8.1.1 Cleaning the coupling ............................................................59
8.1.2 Visual inspection of the coupling .............................................59
8.1.3 Visual inspection of the rubber element ...................................60
8.1.4 Inspection of the screw connections ........................................61
8.2 Replace defective parts ......................................................................61
9 Dismantling .......................................................................................... 62
9.1 General dismantling instructions .........................................................62
9.2 Dismantling the rubber element (1) ....................................................63
9.2.1 Dismantling the rubber element (1; Type .N..) .........................63
9.2.2 Dismantling the rubber element (1; Type .S..) ..........................63
9.3 Dismantling the hub (2/6; if necessary) ...............................................64
9.3.1 Dismantling the hub (2/6) with cylindrical drilling and feather
key .....................................................................................64
9.3.2 Dismantling the hub (2/6) with conical drilling and feather
key .....................................................................................64
9.3.3 Dismantling the hub (2/6) with toothing ..................................64
9.3.4 Dismantling the CENTALOC clamping hub(2/6) .........................64
9.3.5 Dismantling the CENTA-conical clamping hub (2/6) ...................65
9.3.6 Dismantling the hub (2/6) with conical oil interference fit ...........65
9.4 Dismantling the adapter (Type 3) .......................................................66

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
9.5 Dismatling the hub/adapter/flange (6/9/B; if necessary) .......................67

9.5.1 Dismatling the hub/adapter/flange (6/9/B) (Type 008A-
00001...00600-.N..) ..............................................................67
00001...00250-.S..) ..............................................................67
00400...00600-.S..) ..............................................................67
9.6 Reassembling the coupling .................................................................67
10 Wearing and spare parts....................................................................... 68
11 Annex ................................................................................................... 69
11.1 CENTA data sheet D013-019 (screw connections with
microencapsulated screw locking medium) ...........................................69
11.2 CENTA data sheet D013-016 (unlubricated screw connections) ...............70
11.3 CENTA data sheet D008-900, Declaration of incorporation according
to the EC Machinery Directive 2006/42/EC, Appendix II B ......................70

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
Index of illustrations
Fig. 5-1 Axial alignment............................................................................. 15
Fig. 5-2 Radial alignment ........................................................................... 17
Fig. 5-3 Angular alignment......................................................................... 19
Fig. 6-1 Detail from the installation drawing title block .................................. 23
Fig. 6-2 Prepare the hub/adapter/flange (6/9/B) for mounting
(Type 008A-00016..00600-.N..) ...................................................... 26
(Type 008A-00001..00250-.S..) ...................................................... 27
(Type 008A-00400..00600-.S..) ...................................................... 28
Fig. 6-5 Mounting the hub (2/6) with cylindrical drilling and feather key .......... 30
Fig. 6-6 Mounting the hub (2/6) with conical drilling and feather key .............. 32
Fig. 6-7 Mounting the hub (2/6) with toothing .............................................. 33
Fig. 6-8 Mounting the CENTALOC-clamping hub (2/6) ................................... 34
Fig. 6-9 Mounting the CENTA-conical clamping hub (2/6) ............................... 36
Fig. 6-10 Mounting the hub (2/6) with conical oil interference fit .................... 39
Fig. 6-11 Mounting the adapter (Type 3) ..................................................... 42
Fig. 6-12 Positioning the rubber element (1) ................................................ 43
Fig. 6-13 Mounting the rubber element (Type 008A-00001...00012-.N..) ......... 45
Fig. 6-15 Mounting the rubber element (Type 008A-00250-.N..) ..................... 49
Fig. 6-17 Mounting the rubber element (Type 008A-00001...00200-.S..) ......... 53
Fig. 6-18 Mounting the rubber element (Type 008A-00250-.S..) ..................... 54
Fig. 6-19 Mounting the rubber element (Type 008A-00400...00600-.S..) ......... 55
Fig. 6-20 Connecting the driving and driven units (Type 008A-00600-.S..) ...... 56
Fig. 8-1 Examples of wear zones at the CENTAFLEX-A rubber element
indicated by arrows ....................................................................... 60

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
Index of tables
Table 2-1 Shape and size of ventilation holes ................................................... 10
Table 5-1 Installation dimension (Size 008A-00001...00600) ............................. 16
Table 5-2 Permissible radial alignment tolerance (Size 008A-00001...00600) ....... 18
Table 5-3 Permissible angular alignment tolerance (Size 008A-00001...00600).....20
Table 6-1 Overview of possible types .............................................................. 24
Table 6-2 Overview of possible hub/flange hub design ....................................... 29
Table 6-3 Tightening torques for threaded pins................................................. 31
Table 7-1 Troubleshooting table ..................................................................... 58
Table 8-1 Permissible crack depth at the CENTAFLEX-A-rubber element
(Sizes 00001 to 00600) ................................................................. 60

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
1 General remarks
These assembly and operating instructions form a constituent part of the
coupling delivery and must be kept in an easily accessible place at all times.
CENTA products are developed and produced to quality standard

DIN EN ISO 9001:2000.
In the interests of further development, CENTA reserves the right to make

technical changes.
IMPORTANT
CENTA is unable to accept liability for damage and operating faults caused by failure to
observe the operating instructions.
These operating instructions are protected under copyright to CENTA Antriebe

Kirschey GmbH.
In case of technical questions, please enquire with our head office:
CENTA Antriebe
Kirschey GmbH
Bergische Strasse 7
42781 Haan
GERMANY
Phone +49-2129-912-0
Fax +49-2129-2790
centa@centa.de
www.centa.info

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
2 Safety
The purpose of these operating instructions is to enable users to:
 use the coupling safely and correctly
 maximize efficiency
 ensure that care and maintenance are carried out correctly
For this reason, these operating instructions must be thoroughly read and
understood prior to work on and with the coupling.
WARNING
Injury and material damage can occur as a result of:
 Failure to adhere to the safety and accident prevention regulations
valid at the relevant installation site
The safety and accident prevention regulations valid at the installation
site in question must be adhered to when performing any of the tasks
described in these operating instructions.
2.1 Safety remarks

In these operating instructions, safety remarks are indicated by a pictogram and
a signal word.
2.1.1 Signal words

The following signal words are used in the safety remarks:
Denotes the immediate threat of danger.

DANGER If not prevented, fatal or extremely serious injuries can result.
Denotes a potentially dangerous situation.

WARNING If not prevented, fatal or extremely serious injuries can result.
Denotes a potentially dangerous situation.

CAUTION If not prevented, minor injuries and/damage to property may result.
Denotes application tips and particularly useful information. This is not

IMPORTANT a signal word denoting a dangerous or damaging situation.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
2.1.2 Pictograms
Possible pictograms in the safety precautions:
Warning of a hazardous area
Do not switch
Use protective gloves
Use protective goggles
2.2 Qualification of deployed personnel

All the work described in these operating instructions may only be performed by
authorized persons with adequate training and instruction.
WARNING
 Work at the coupling which is not described in these instructions
Only carry out work which is described in these operating instructions.
2.3 Intended application
WARNING
 Application not in compliance with the intended use
The couplings are intended exclusively for use in accordance with the
relevant design. They may only be used under the specified conditions.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
WARNING
Injuries can occur as a result of:
 Contact with rotating parts
Shield the coupling in accordance with the applicable accident
prevention regulations with an enclosure.
Exception:
The coupling is encased by the driving and driven units.
The scope of delivery provided by CENTA does not include a protective

enclosure.
This enclosure must fulfil the following criteria:

 Provide protection against persons gaining access to rotating parts
 Restrain any rotating parts which may be work loose
 Guarantee sufficient ventilation for the coupling
This enclosure must be made of stable steel components. In order to ensure

adequate ventilation for the coupling, the enclosure must be fitted with regular
openings. For safety reasons, these openings must not exceed the dimensions
outlined in table 2-1.
Component Circular openings Rectangular openings

[mm] [mm]
Top of the enclosure Ø8 8
Side elements of the Ø8 8

enclosure
Table 2-1 Shape and size of ventilation holes
The enclosures must be positioned a minimum of 15 mm distant from rotating

parts. The enclosure must be electrically conductive and be included in the
equipotential bonding.
Before commencing long-term operation, the plant must successfully complete a

test run.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
2.4 Application not in compliance with the intended use
WARNING
 Inadmissibly high torque
 Inadmissibly high or low speeds
 Exceeding the specified ambient temperature
 Inadmissible ambient medium
 Inadmissible coupling enclosure
 Exceeding the admissible overall misalignment values
Only use the coupling for the specified application.
CENTA bears no liability for damage resulting from application not in compliance
with the intended use of the equipment.
Should there be a change of plant parameters, the coupling design must be
reviewed by CENTA (address see chapter 1).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
3 Delivery, transport, storage and disposal

3.1 Delivery
After delivery, the coupling:
 must be checked for completeness and correctness of the delivery.
 must be examined for possible transport damage (which must be reported
immediately to the carrier).
3.2 Transport
CAUTION
 Incorrect transportation of couplings
Ensure that the coupling is correctly transported.
CAUTION
Material damage to coupling components can occur as a result
of:
 Contact with sharp-edged objects
Protect coupling components for transportation.
Only hoist coupling components with nylon belts or ropes.
Always cushion parts when supporting them from below.
Following transportation damage:

 Check the coupling carefully for damage.
 Consult the manufacturer (Address see chapter 1).
3.3 Storage
CAUTION
Material damage to elastic elements and rubber parts can occur
as a result of:
 Incorrect storage
These parts must be stored laid flat and so they cannot distort, and
protected from ozone, heat, light, moisture and solvents.
IMPORTANT
Rubber parts are marked where possible with their production date. From this date,
they may only be stored for a maximum of 5 years.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
3.3.1 Storage location

Requirements imposed on the storage location:
 Moderately ventilated and low in dust
 Dry (max. 65% humidity)
 Temperature stabilized (-10°C to +25°C)
 Free of ozone-producing devices such as light sources and electric motors
 Free of UV light sources and direct sunlight
 Do not store solvents and disinfectants, fuels or lubricants, acids, chemicals
etc. in the same location
For more details, refer to DIN 7716.
3.3.2 Storage of couplings / flexible elements

 Unpack the parts.
 Check the packaging for damage. Replace if necessary.
 Check that the wax protection on steel components is intact. If necessary,
patch or renew.
 Package the parts (for prolonged periods of storage, enclose desiccant and
weld into film).
 Place the parts into storage.
3.4 Disposal
RECYCLING
Ensure safe, environmentally responsible disposal of operating supplies
and exchange parts. For this, locally provided recycling facilities and
regulations must be utilized.
For disposal, the coupling parts must be separated where possible and sorted
according to material type.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
4 Technical description
4.1 Characteristics
CENTAFLEX-A couplings are proven, extremely simple, versatile and offer good
torsional flexibility.
 Simple, compact smooth-faced design.

 Low weight, low moment of inertia.
 High output, high admissible speeds, large bores permitted, rupture-proof
 Large angle of twist with almost linear curve
(appr. 6-8° at nominal torque).
 High elasticity and considerable flexibility in any direction (radial, axial,
angular) with low counter forces acting on shafts and bearings.
 The CENTAFLEX coupling has a shock and vibration absorbing action.
 Torque transmission is absolutely free of play, uniform, silent and electrically
insulating.
 The coupling is low-maintenance. The rubber parts are not subject to wear,
resulting in a long service life and no generation of dirt (rubber particles).
 The rubber element is air flushed all round, resulting in good dissipation of
the generated heat. The rubber element remains cool.
 By slackening the radial screws, the drive can be conveniently separated and
rotated without dismantling.
 Because of the torque, no axial reaction forces at all are applied to the shaft
and bearings.
 The rubber elements are available in a number of different shore hardnesses.
 This allows the torsional stiffness to be varied within wide limits and so
adjusted to the vibration-specific requirements.
 Material: Normal version: Natural rubber, capable of withstanding dynamic
loads and temperature resistant.
4.2 Specifications
The specifications can be found in the catalogue and the dimensions in the
installation drawing.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
5 Alignment of the units being connected

5.1 Axial alignment
Fig. 5-1 Axial alignment
Item Info Designation Remark
1 Rubber element
2 Hub
6/9 Hub/Adapter Illustrated is the adapter (9)
B Flange Customer part
C Hub Customer part
 Determine the installation dimension S from the table 5-1.

 Align the units axially (installation dimension = S±∆KA max).
Permissible axial alignment tolerance: ∆KA max=0,3 mm

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
CENTAFLEX-A S
size [mm]
00001 2
00002 / 00004 / 00008 / 00012 4
00016 / 00022 / 00025 / 00028 6
00030 / 00050 8
00080 4
00090 / 00140 / 00200 / 00250 8
00400 10
00600 15
Table 5-1 Installation dimension (Size 008A-00001...00600)

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
5.2 Radial alignment
Fig. 5-2 Radial alignment
1 Rubber element
2 Hub
C Hub Customer part
 Determine the radial misalignment (see Fig. 5-2).

 The permissible radial alignment tolerance ∆KR max can be found in the
table 5-2.
 Align the units correspondingly.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
CENTAFLEX-A ∆KR max

size [mm]
00001 / 00002 / 00004 ±0,22
00008 / 00012 / 00016 / 00022 / 00025 ±0,30

00028 / 00030 / 00050
00080 ±0,22
00090 / 00140 / 00200 / 00250 ±0,30

00400 / 00600
Table 5-2 Permissible radial alignment tolerance (Size 008A-00001...00600)

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
5.3 Angular alignment
Fig. 5-3 Angular alignment
1 Rubber element
2 Hub
C Hub Customer part
 Determine the angular misalignment (see Fig. 5-3).

 The permissible angular alignment tolerance ∆KW max can be found in the
table 5-3.
 Align the units correspondingly.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
CENTAFLEX-A ∆Kw max

size [°]
00001 / 00002 / 00004 / 00008 0,45
00012 0,30
00016 0,45
00022 0,30
00025 0,45
00028 0,30
00030 0,45
00050 / 00080 0,30
00090 0,45
00140 / 00200 / 00250 / 00400 / 00600 0,30
Table 5-3 Permissible angular alignment tolerance (Size 008A-00001...00600)

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6 Mounting
6.1 General assembly instructions
Any work method which impairs the safety of the coupling is prohibited.
The user undertakes to notify the manufacturer immediately of any changes
occurring at the coupling which could impair safety (address see chapter 1).
WARNING
Before starting work at the coupling, switch off the plant and secure
against unintentional start-up.
WARNING
 Assembly of the coupling in the wrong sequence
Only ever assemble the coupling in the described sequence.
WARNING
 Falling coupling components
Secure coupling components against falling to the floor.
CAUTION
of:
CAUTION
Material damage can occur as a result of:
 Soiled joint surfaces
The surfaces that are to be joined must be free of dirt, preservatives
and lubricants.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
CAUTION
of:
 Anaerobic adhesives (e.g. Loctite) used for screw locking
This type of screw locking medium may not be in contact with rubber
parts.
IMPORTANT
 Screw preparation and tightening torque levels for screws item(s) 2.4, 6.4 in
accordance with CENTA data sheet D013-016 (see chapter 11.1).
 Screw preparation and tightening torque levels for screws item(s) 3, 7, 40, 42 in
accordance with CENTA data sheet D013-019 (see chapter 11.2)
 The tightening torques for the threaded pins of hubs according to
table 6-1 (see chapter 6.4.1).
 Use suitable lifting devices for assembly.
 Elements for connection of the coupling to customer components do not form part
of the delivery.
 The following assembly stages are described for coupling 008A-00030, -
00250, -00400.
 Part illustration and marking may differ slightly from installation drawing and
delivery state.
IMPORTANT
Use exclusively new screws supplied by CENTA.
These are coated with microencapsulated adhesive which serves as a screw locking
medium.
IMPORTANT
To ensure optimum screw locking, after tightening the curing time for the
microencapsulated adhesive must be observed:
 Appr. 4-5 hours at room temperature (20°C)
 Higher temperatures will accelerate the curing time
(e.g. 15 minutes at 70°C created by a hot air blower)
After 24 hours, the adhesive is completely cured.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.2 Mounting the coupling according to the supplied type

Mount the coupling as appropriate for the supplied design as well as the size and
shore hardness of the rubber elements.
These informations can be found in the title block of the installation drawing.
They are explained below.
Fig. 6-1 Detail from the installation drawing title block
 Overview of possible types, see following table.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
Type -.N.. Type -.S..
Type 0 Type 0
Type 1 Type 1
Type 2 Type 2
Type 3 Type 3
Table 6-1 Overview of possible types

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
1 Rubber element
2 Hub
3 Screw
5 Spring pin Coupling size 00016 and

larger
6 Hub
7 Screw
9 Adapter
40 Bolt
IMPORTANT
This assembly instruction describes the mounting of several design.
Mount the coupling as appropriate for the supplied design (see installation drawing).
 Mounting the coupling according to the supplied type in the following order.
From the installation drawing, read off the supplied type and the build-in
parts.
 Preparing the hub/adapter/flange (6/9/B) for mounting,
see chapter 6.3 .
 Mounting the hub (2/6; Type 1 and 2), see chapter 6.4 .
 Mounting the adapter (9; Type 3), see chapter 6.5 .
 Positioning the rubber element (1), see chapter 6.6 .
 Mounting the rubber element (1), see chapter 6.7; 6.8 and 6.9 .
6.3 Preparing the hub/adapter/flange (6/9/B) for mounting

 Prepare the hub/adapter/flange (6/9/B) according to the supplied coupling
type and size (see installation drawing).
 Preparing the type 008A-00001..00600-.N.., see chapter 6.3.1 .
 Preparing the type 008A-00001..00250-.S.., see chapter 6.3.2 .
 Preparing the type 008A-00400..00600-.S.., see chapter 6.3.3 .

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.3.1 Prepare the hub/adapter/flange (6/9/B) for mounting

(Type 008A-00016..00600-.N..)

(Type 008A-00016..00600-.N..)
5 Spring pin DIN7346 Coupling size 00016 and

larger
6/9 Hub/Adapter Illustrated is the hub (6)
B Flange Costumer part
Coupling sizes 00001…00012

 Not necessary preparing the hub/adapter/flange (6/9/B).
Coupling sizes 00016…00600

 Drive in the spring pins (5) into the hub/adapter/flange (6/9/B).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..

(Type 008A-00001..00250-.S..)

(Type 008A-00001..00250-.S..)
40 Bolt
 Screw the bolts (40) into the hub/adapter/flange (6/9/B).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..

(Type 008A-00400..00600-.S..)

(Type 008A-00400..00600-.S..)
41 Bush
42 Screw
 Screw the bushes (41) to the hub/adapter/flange (6/9/B) using the

screws (42).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.4 Mounting the hub (2/6; Type 1 and 2)

 Mounting the hub (2/6) as appropriate for the supplied design
(see installation drawing).
 Overview of possible hubs and chapters of mounting, see following table.
Possible Mounting the hub with … see chapter

design
cylindrical drilling and feather key 6.4.1
conical drilling and feather key 6.4.2
toothing 6.4.3
CENTALOC-clamping 6.4.4
CENTA-conical clamping 6.4.5
conical oil interference fit 6.4.6
Table 6-2 Overview of possible hub/flange hub design

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.4.1 Mounting the hub (2/6) with cylindrical drilling and feather key
Fig. 6-5 Mounting the hub (2/6) with cylindrical drilling and feather key
2/6 Hub Illustrated is the hub (2)
16 Threaded pin DIN914 see installation drawing
A Shaft Costumer part
a Face of the shaft
b Face of the hub
w Bevel of the hub
CAUTION
 Incorrect heating of the hubs
Heat the hubs steadily in a fan oven, on an electric hot plate, either
inductive or with a flame (ring burner).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
CAUTION
 Hot coupling components
Use suitable protective gloves.
 Heat the hub (2/6) to a temperature of 80° - 100°C.

 Push the hub (2/6) onto the shaft (A) with feather key.
The bevel of the hub (w) must point towards the shaft (A).
IMPORTANT
The face of the shaft must not protrude to the face of the hub. Otherwise the operation
of the coupling is not guaranteed.
CAUTION
 Incorrect heating of the hubs
Heat the hubs steadily in a fan oven, on an electric hot plate, either
inductive or with a flame (ring burner).
 Secure the hub (2/6; if necessary) with the threaded pin (16).
Threaded pin: size acc. the installation drawing
tightening torque see table below.
Threaded pin M6 M8 M10 M12 M14 M16 M20
Tightening torque 7 16 30 50 70 120 200

[Nm]
Table 6-3 Tightening torques for threaded pins

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.4.2 Mounting the hub (2/6) with conical drilling and feather key
Fig. 6-6 Mounting the hub (2/6) with conical drilling and feather key
E Nut Costumer part
H Washer Costumer part
b Face of the hub
 Push the hub (2/6) onto the shaft (A).

 Brace the hub (2/6) against the shaft (A), using the washer (H) and the
nut (E).
IMPORTANT
The screw connection of the shaft must not protrude to the face of the hub. Otherwise
the operation of the coupling is not guaranteed.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.4.3 Mounting the hub (2/6) with toothing
Fig. 6-7 Mounting the hub (2/6) with toothing
G Screw Costumer part
H Washer Costumer part
b Face of the hub
h Shaft shoulder
 Push the hub (2/6) onto the shaft (A) against the shaft shoulder (h). Take
the mounting position of the hub (2/6) from the installation drawing.
 Brace the hub (2/6) against the shaft (A), using the washer (H) and the
screw (G).
IMPORTANT
The screw connection of the shaft must not protrude to the face of the hub. Otherwise
the operation of the coupling is not guaranteed.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.4.4 Mounting the CENTALOC-clamping hub (2/6)
Fig. 6-8 Mounting the CENTALOC-clamping hub (2/6)
2/6 Hub Pre-mounted;

Illustrated is the hub (2)
27/28 Parallel pin DIN7 See installation drawing
29 Threaded pin
30 Circlip DIN472 See installation drawing
e Shaft end
h Shaft shoulder
j Back side of circlip

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
 Push the hub (2/6) as appropriate for the supplied design with / without
circlip (30; see installation drawing) onto the shaft (A):
 with circlip (30):
Push the hub (2/6) onto the shaft (A), until the shaft end (e) touches the
back side of the circlip (j).
IMPORTANT
Ensure that the hub is correctly positioned on the shaft (against shaft end).
If necessary brace hub with washer against the shaft.
 without circlip (30):

Push the hub (2/6) onto the shaft (A) against the shaft shoulder (h).
IMPORTANT
Ensure that the hub is correctly positioned on the shaft (against shaft shoulder).
If necessary brace hub with washer against the shaft.
 Secure the hub (2/6) with the parallel pins (27/28) and the threaded pins
(29, size acc. the installation drawing, tightening torque see table 6-3).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.4.5 Mounting the CENTA-conical clamping hub (2/6)
Fig. 6-9 Mounting the CENTA-conical clamping hub (2/6)
2/6 Hub Pre-mounted assembly;

Illustrated is the hub (2)
2.1/6.1 Hub Pre-mounted
2.2/6.2 Hub-taper Pre-mounted
2.3/6.3 Circlip Design see installation

drawing
2.4/6.4 Screw
A Shaft Customer part
e Shaft end
f Shaft extension
h Shaft shoulder
j Back side of circlip
k Conical surface
l Forcing thread
m Drilling

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
IMPORTANT
The surfaces of the conical clamping connection and the hub-shaft connection must be
free of oil, grease and dirt.
 Preparing the hub (2.1/6.1), hub-taper (2.2/6.2) and the

shaft (A) for mounting:
 Clean and degrease the drilling (m) and the conical surface (k) of the
hub-taper (2.2/6.2).
 Clean and degrease the conical surface (k) of the hub (2.1/6.1).
 Clean and degrease the shaft extension of the shaft (f).
 Insert the hub-taper (2.2/6.2) into the hub (2.1/6.1).

 Screw the hub-taper (2.2/6.2) with screws (2.4/6.4) loosely into the hub
(2.1/6.1).
Screw preparations according to CENTA data sheet D013-016, see chapter
11.2.
 Push the hub-taper (2.2/6.2) as appropriate for the supplied design with /
without circlip (2.3/6.3; see installation drawing) onto the shaft (A):
 with circlip (2.3/6.3):
Push the hub-taper (2.2/6.2) with the hub (2.1/6.1) onto the shaft (A),
until the shaft end (e) touches the back side of the circlip (j).
IMPORTANT
Ensure that the hub-conus is correctly positioned on the shaft (against shaft end).
If necessary brace hub-conus with washer against the shaft.
 without circlip (2.3/6.3):

Push the hub-taper (2.2/6.2) with the hub (2.1/6.1) onto the shaft (A)
against the shaft shoulder (h).
IMPORTANT
Ensure that the hub-conus is correctly positioned on the shaft (against shaft shoulder).
If necessary brace hub-conus with washer against the shaft.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
 Evenly hand tighten the screws (2.4/6.4) crosswise.
 Tighten the screws (2.4/6.4) one after the other with 40% of the specified
tightening torque, until it has been achieved for all screws.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.4.6 Mounting the hub (2/6) with conical oil interference fit
WARNING
 Non-compliance with the operating instructions for the hydraulic
pumps
Before carrying out work with the hydraulic pumps, do not fail to read
their operating instructions. Only ever work with hydraulic pumps as
described in their operating instructions.
WARNING
 Hydraulic fluid spraying out
Use protective goggles.
Fig. 6-10 Mounting the hub (2/6) with conical oil interference fit

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
26 Screw plug G¼; see installation drawing
a Face of shaft
b Face of flange hub
g Thread G¼; see installation drawing
IMPORTANT
We recommend the following mounting fluids:
 For mounting:
Oil with a viscosity 300 mm2/s at 20°C, e.g. SKF LHMF300
 For dismantling:
Oil with a viscosity 900 mm2/s at 20°C, e.g. SKF LHDF900
 Lightly oil the cone of the shaft (A).

 Push the hub (2/6) onto the shaft (A).
 Remove the screw plug (26) from the hub (2/6).
 Connect the pump for expanding the hub (2/6) to the
thread G¼ (g).
 Screw the pump for pushing on the hub (2/6) to the shaft.
 Build up the oil pressure to push on the hub (2/6).
WARNING
 Insufficient expanding pressure in the hub
If the expanding pressure is too low, the necessary pushing pressure is
too high.
 Build up the oil pressure for expanding the hub (2/6) slowly.
 Build up the oil pressure alternately until the lift path (p up) of the hub (2/6)
is reached (for p up and reference faces, see installation drawing).
 Decrease the oil pressure for expanding the hub (2/6).
 Remove the pump for expanding the hub (2/6) from the hub (2/6).
 Maintain the oil pressure for pushing on the hub (2/6) for one hour.
 Decrease the oil pressure for pushing on the hub (2/6).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
 Remove the pump for pushing on the hub (2/6) from the shaft.
 Turn the hub (2/6), allow the oil to run out of the thread G¼ (g) and dispose
of it correctly.
 Screw the screw plug (26) into the hub (2/6).
IMPORTANT
Do not place a load on the hub for 24 hours.
IMPORTANT
Face of shaft must not protrude to face of hub. Otherwise radial replacement of other
coupling parts is not guaranteed.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.5 Mounting the adapter (Type 3)
Fig. 6-11 Mounting the adapter (Type 3)
9 Adapter
D Screw Costumer part
K Hub Costumer part
 Push the adapter (9) onto the centring of the hub (K).
 Screw the adapter (9) to the hub (K) using the screws (D).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.6 Positioning the rubber element (1)
Fig. 6-12 Positioning the rubber element (1)
1 Rubber element
2 Hub
C Hub Customer part
b Face of hub
c Contact surface of rubber element
 Push the rubber element (1) centred onto the hub (2/C). The contact
surfaces of the rubber element (c) must be on the side of face of the hub (b).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.7 Mounting the rubber element (1)

 Mounting the rubber element as appropriate for the supplied type (see
installation drawing).
 Mounting the rubber element (1; Type .N..), see chapter 6.8 .
 Mounting the rubber element (1; Type .S..), see chapter 6.9 .
6.8 Mounting the rubber element (1; Type .N..)

 Mounting the rubber element:
 Aligning the units,
see chapter 6.8.1 .
 Mounting the rubber element (Coupling size 00001...00012),
see chapter 6.8.2 .
see chapter 6.8.3 .
 Mounting the rubber element (Coupling size 00250),
see chapter 6.8.4 .
see chapter 6.8.5 .
6.8.1 Aligning the units

 Align the units to be connected (see chapter 5).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.8.2 Mounting the rubber element (Coupling size 00001...00012)
Fig. 6-13 Mounting the rubber element (Type 008A-00001...00012-.N..)
1 Rubber element
2 Hub
3 Screw
6/9 Hub/Adapter
7 Screw
C Hub Customer part
CAUTION
Material damage to rubber part can occur as a result of:
 Twisted rubber element mounted by friction between screw head
and vulcanized aluminium part
Use a suitable tool for applying counter pressure on the rubber element
to prevent twisting of the rubber element during tightening of the
screws.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
 Turn the rubber element (1) towards the hub/adapter/flange (6/9/B) until
the drillings for the screws (3) are aligned.
 Screw the rubber element (1) to the hub/adapter/flange (6/9/B) using the
screws (3). While tightening the screws (3) exert counter pressure on the
rubber element (1) to avoid twisting.
 Push the screws (7) into the rubber element (1) and screw them first two to
three threads into the hub (2/C).
 Tighten all screws (7) until the prescribed tightening torque
(see chapter 11.1) has been achieved.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
1 Rubber element
2 Hub
3 Screw
5 Spring pin
6/9 Hub/Adapter
7 Screw
C Hub Customer part
d Drilling for spring pin

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
the drillings (d) and the spring pins (5) are aligned.
screws (3).
 Tighten all screws (7) until the prescribed tightening torque

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.8.4 Mounting the rubber element (Coupling size 00250)
Fig. 6-15 Mounting the rubber element (Type 008A-00250-.N..)
1 Rubber element
2 Hub
3 Screw
5 Spring pin
6/9 Hub/adapter
7 Screw
99 Screw ISO4762-10.9 M20x90 1 pc. for mounting
C Hub Customer part
I - IV Order of mounting

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
the drillings (d) and the spring pins (5, coupling size 16 and larger) are
aligned.
screws (3).
 Repeat the following mounting section in order I – IV, until all screws (7) are
screwed in two to three threads:
 Pull up the rubber element (1) to the hub (2/C) using the screw (99) and
screw in next to this a screw (7) two to three threads.
 Remove the screw (99) and replace it by another screw (7), at first screw
it two to three threads in the hub (2/C).
 Tighten in order I – IV all screws (7) until the prescribed tightening torque

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
1 Rubber element
2 Hub
3 Screw
4 Washer
5 Spring pin
6/9 Hub/Adapter
7 Screw
8 Washer
C Hub Customer part

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
the drillings (d) and the spring pins (5) are aligned.
screws (3) and washers (4).
 Push the screws (7) and the washers (8) into the rubber element (1) and
screw them first two to three threads into the hub (2/C).
 Fasten all screws (7) crosswise with the prescribed tightening torque
(see chapter 11.1).
6.9 Mounting the rubber element (1; Type .S..)

 Mounting the rubber element:
see chapter 6.9.1.
 Mounting the rubber element (Coupling size 00250),
see chapter 6.9.2 .
see chapter 6.9.3 .
 Connecting the driving and driven units,
see chapter 6.9.4 .

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
Fig. 6-17 Mounting the rubber element (Type 008A-00001...00200-.S..)
1 Rubber element
2 Hub
6/9 Hub/adapter
7 Screw
C Hub Customer part
 Tighten all screws (7) until the prescribed tightening torque (see chapter
11.1) has been achieved.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.9.2 Mounting the rubber element (Coupling size 00250)
Fig. 6-18 Mounting the rubber element (Type 008A-00250-.S..)
1 Rubber element
2 Hub
6/9 Hub/adapter
7 Screw
99 Screw ISO4762-10.9 M20x90 1 piece for mounting
C Hub Customer part
I - IV Order of mounting
 Pull up the rubber element (1) with screw (99) to the hub (2/C) and
screw in next to this a screw (7) two to three threads.
 Remove the screw (99) and replace it by another screw (7), at first screw
it two to three threads in the hub (2/C).
 Repeat the mounting section above in order I – IV until all screws (7) are
screwed in two to three threads.
 Tighten in order I – IV all screws (7) until the prescribed tightening torque

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
Fig. 6-19 Mounting the rubber element (Type 008A-00400...00600-.S..)
1 Rubber element
2 Hub
6/9 Hub/Adapter
7 Screw
8 Washer
C Hub Customer part
 Push the screws (7) and the washers (8) into the rubber element (1) and
screw them first two to three threads into the hub (2/C).
 Tighten all screws (7) until the prescribed tightening torque (see chapter
11.1) has been achieved.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.9.4 Connecting the driving and driven units (Coupling size 00600)
Fig. 6-20 Connecting the driving and driven units (Type 008A-00600-.S..)
1 Rubber element
6/9 Hub/Adapter
40 Bolt
n Drilling for bolt
 Lightly grease the drillings for socket bolt (n).

the drillings (n) and the bolt (40) are aligned.
 Push the driving and driven units together.
 Ensure, that the offset between the driving and driven units are within the
alignment tolerances (see chapter 5).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
6.10 After completed mounting
WARNING
 Loose screw connections
Before commissioning, the tightening torque levels of all screws must
be checked and corrected if necessary.
IMPORTANT
After completion of assembly, check the alignment of the coupling again and if
necessary correct.
Before commencing long-term operation, the plant must successfully complete a

test run.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
7 Operation
WARNING
 Worn coupling components
If the running noises change and/or vibrations occur turn the plant off
immediately.
Determine the fault and its root cause, and remedy.

The troubleshooting process is simplified by the table in the next chapter.
On principle in case of a fault, an analysis of the entire plant should be
performed.
7.1 Operating faults, root causes and remedy
Faults Possible root Remedy

causes
Prior to all kinds of remedies  Switch off the plant
Running noises or Alignment error  Check alignment and correct

vibrations in the unit  Check screw torque levels and correct
Loose screws
Rubber element Alignment error  Replace defective parts

damaged  Check alignment and correct
Inadmissibly high
torque  Eliminate the cause for inadmissibly
high torque
After all remedies  Trial run
Table 7-1 Troubleshooting table
In case of uncertainty or if you have questions, please contact our head office
(address see chapter 1).
7.2 Admissible overall misalignment of the coupling

The overall misalignment values can be found in the catalogue.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
8 Care and maintenance
WARNING
The coupling requires low maintenance. We recommend a visual inspection at

the regular scheduled maintenance intervals for the whole unit.
8.1 Work to be performed

8.1.1 Cleaning the coupling
 Remove any loose dirt from the coupling.
8.1.2 Visual inspection of the coupling

 Inspect the coupling for cracks, chips or missing parts.
 Replace faulty and missing parts.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
8.1.3 Visual inspection of the rubber element

Visual inspection of the CENTAFLEX-A rubber element (see fig. below). Pay
particular attention to cracks or to the adhesion of rubber and metal parts in the
zones indicated by the arrows. Pressure folds (creasing) in these zones may be
considered normal.
Fig. 8-1 Examples of wear zones at the CENTAFLEX-A rubber element

indicated by arrows
In the event of cracks, deeper than permissible (see table below) or rubber-to-
metal connections have become detached, the rubber parts must be exchanged.
CENTAFLEX-A permissible crack depth

Sizes [mm]
00001 / 00002 / 00004 / 00008 / 00012 1.5
00016 / 00022 / 00025 / 00028 / 00030 / 00050 2.0
00080 / 00090 / 00140 / 00200 / 00250 3.0
00400 / 00600 5.0
Table 8-1 Permissible crack depth at the CENTAFLEX-A-rubber element (Sizes

00001 to 00600)

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
8.1.4 Inspection of the screw connections

 Check the tightening torque levels of all screws and if necessary, correct.
8.2 Replace defective parts
IMPORTANT
Exchange the rubber elements in the event of damage.
 Remove the coupling as described in chapter 9.

 Replace wearing parts.
IMPORTANT
medium.
 Mount the coupling as described in chapter 6.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
9 Dismantling
9.1 General dismantling instructions
Any work method which impairs the safety of the coupling is prohibited.
The user undertakes to notify the manufacturer immediately of any changes
occurring at the coupling which could impair safety (address see chapter 1).
WARNING
WARNING
 Dismantling of the coupling in the wrong sequence
Only ever dismantle the coupling in the described sequence.
WARNING
 Falling coupling components
Secure coupling components against falling to the floor.
CAUTION
of:
IMPORTANT
Use suitable lifting devices for dismantling.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
9.2 Dismantling the rubber element (1)

 Dismantling the rubber element as appropriate for the delivered design (see
installation drawing).
 Dismantling the rubber element (1; Type .N), see chapter 9.2.1 .
 Dismantling the rubber element (1; Type .S), see chapter 9.2.2 .
9.2.1 Dismantling the rubber element (1; Type .N..)

See fig. 6-13; 6-14; 6-15 or 6-16:
 Loosen the screws (7) of the connection rubber element (1) and hub (2/C)
and remove together with washers (8, coupling size 00400 and larger).
 Loosen the screws (3) of the connection rubber element (1) and
hub/adapter/flange (6/9/B) and remove together with washers (4, coupling
size 00400 and larger).
 Pull the driving and driven units apart.
See fig. 6-12:

 Remove the rubber element (1) off the hub (2/C).
9.2.2 Dismantling the rubber element (1; Type .S..)

See fig. 6-20:
 Pull the driving and driven units apart.
See fig. 6-17; 6-18 or 6-19:

 Loosen the screws (7) of the connection rubber element (1) and hub (2/C)
and remove together with washers (8, coupling size 00400 and larger).
See fig. 6-12:

 Remove the rubber element (1) off the hub (2/C).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
9.3 Dismantling the hub (2/6; if necessary)

 Dismantle the hub (2/6) as appropriate for the type supplied (see installation
drawing).
 Dismantling the hub (2/6) with cylindrical drilling and feather key,
see chapter 9.3.1 .
 Dismantling the hub (2/6) with conical drilling and feather key,
see chapter 9.3.2 .
 Dismantling the hub (2/6) with toothing,
see chapter 9.3.3 .
 Dismantling the CENTALOC-clamping hub (2/6),
see chapter 9.3.4 .
 Dismantling the CENTA-conical clamping hub (2/6),
see chapter 9.3.5 .
 Dismantling the hub (2/6) with conical oil interference fit,
see chapter 9.3.6 .
9.3.1 Dismantling the hub (2/6) with cylindrical drilling and feather key
See fig. 6-5:
 Loosen the threaded pins (16; if existing) and remove off the
hub (2/6).
 Remove the hub (2/6) from the shaft (A).
9.3.2 Dismantling the hub (2/6) with conical drilling and feather key
See fig. 6-6:
 Loosen the nut (E) and remove with the washer (H).
9.3.3 Dismantling the hub (2/6) with toothing

See fig. 6-7:
 Loosen the screw (G) and remove with the washer (H).
9.3.4 Dismantling the CENTALOC clamping hub(2/6)

See fig. 6-8:
 Loosen the threaded pins (29).

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
9.3.5 Dismantling the CENTA-conical clamping hub (2/6)

See fig. 6-9:
 Loosen the screws (2.4/6.4) and screw them out equally about 10mm.
 For each forcing thread screw out a screw (2.4/6.4) and screw them loose
into the forcing thread (l).
 Push the hub (2.1/6.1) off hub-taper (2.2/6.2) with the help of the screws
(2.4/6.4) in forcing threads.
 Remove the screws (2.4/6.4).
 Remove the hub-taper (2.2/6.2) with hub (2.1/6.1) off the
shaft (A).
9.3.6 Dismantling the hub (2/6) with conical oil interference fit
WARNING
 Non-compliance with the operating instructions for the hydraulic
pumps
Before carrying out work with the hydraulic pumps, do not fail to read
their operating instructions. Only ever work with hydraulic pumps as
described in their operating instructions.
WARNING
 Hydraulic fluid spraying out
Use protective goggles.
WARNING
Injuries and material damages can occur by:
 Suddenly loosening hubs
Secure the hub with a hydraulic tool against sudden axial loosening.
IMPORTANT
We recommend the following mounting fluids:
 For mounting:
Oil with a viscosity 300 mm2/s at 20°C, e.g. SKF LHMF300
 For dismantling:
Oil with a viscosity 900 mm2/s at 20°C, e.g. SKF LHDF900

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
See fig. 6-10:

 Remove screw plug (26) from hub (2/6).
 Connect the pump to the thread G¼ (g) of hub (2/6) to expand the hub.
 Screw the pump to the shaft (A), in order to hold the hub (2/6).
 Build up oil pressure in order to hold the hub (2/6).
 Slowly build up oil pressure to expand the hub(2/6; pmax= 1500 bar).
 Slowly reduce the oil pressure for holding the hub (2/6).
 Slowly reduce the oil pressure for expanding the hub (2/6).
 Repeat the above mounting section until the hub (2/6) is completely released
from the shaft (A).
 Remove the pump for holding the hub (2/6) from the shaft (A).
 Remove pump for expanding the hub (2/6) from the hub (2/6).
 Turn the hub (2/6), drain oil out of the thread G¼ (g) and dispose correctly.
 Screw the screw plug (26) into the hub (2/6).
9.4 Dismantling the adapter (Type 3)

See fig. 6-11:
 Loosen and remove the screws (D) of the connection adapter (9) and hub
(K).
 Pull the adapter (9) off the centring of the hub (K) and remove.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
9.5 Dismatling the hub/adapter/flange (6/9/B; if necessary)

 Dismatling the hub/adapter/flange (6/9/B).
 Type 008A-00001...00600-.N.., see chapter 9.5.1 .
 Type 008A-00001...00250-.S.., see chapter 9.5.2 .
 Type 008A-00400...00600-.S.., see chapter 9.5.3 .
9.5.1 Dismatling the hub/adapter/flange (6/9/B)

(Type 008A-00001...00600-.N..)
See fig. 6-2:
 Remove the spring pin (5) out of the hub/adapter/flange (6/9/B).

(Type 008A-00001...00250-.S..)
See fig. 6-3:
 Screw the bolts (40) out of the hub/adapter/flange (6/9/B) and remove.

(Type 008A-00400...00600-.S..)
See fig. 6-4:
 Loosen the screws (42) of the connection bushes (41) and the
hub/adapter/flange (6/9/B) and remove.
9.6 Reassembling the coupling

 Reassemble the coupling as described in chapter 6.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
10 Wearing and spare parts
WARNING
 Mounting and/or utilization of non-original CENTA parts
Never use parts from other manufacturers.
A stock of the most important wearing and spare parts is the most important
condition to ensure that the coupling is functional and ready for operation at all
times.
We only provide a warranty for CENTA original parts.
Wearing part of this coupling:

 Rubber element
IMPORTANT
When exchanging, all screw connections of the rubber elements must be renewed.
These must be ordered separately.
IMPORTANT
medium.
When ordering a spare, specify:

 Order no.
 Coupling order no.
 Drawing no.

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
11 Annex
11.1 CENTA data sheet D013-019 (screw connections with
microencapsulated screw locking medium)
Validity:
For all non-dynamically stressed screw connections with screws* in accordance
with ISO 4014, ISO 4017, ISO 4762 (DIN 912) and ISO 6912 with metric
standard thread in accordance with DIN ISO 262 and socket bolts* with metric
standard thread in accordance with DIN ISO 262, unless other specifications are
given on CENTA documents.
*
The threads are coated with microencapsulated screw locking medium.
Preparation of parts that are to be screwed together:
The joining areas must be free of dirt, preservatives and lubricants.
Preparation of screws with microencapsulated screw locking medium:
Give the screws extra lubrication with grease under the screw head.
Screw tightening method:
Screw in (by hand with torque wrench).
Curing time for the microencapsulated screw locking medium:
To ensure optimum screw locking, after tightening the curing time for the
microencapsulated screw locking medium must be observed:
 Appr. 4-5 hours at room temperature (20°C)

 Higher temperatures will accelerate the curing time (e.g. 15 minutes at 70°C
created by a hot air blower)
After 24 hours, the microencapsulated screw locking medium is completely

cured.
Thread Strength Tightening torques Thread Strength Tightening torques

size class size class
[Nm] [in Ibs] [Nm] [in Ibs]
±5% ±5% ±5% ±5%
M6 10 90 M18 300 2650
M8 25 220 500 4450

M20
M10 50 440 610** 5400**
8.8 10.9
M12 85 750 M22 820 7250
M14 140 1250 M24 1050 9300
M16 220 1950 M27 1550 13700
** only for: CENTAFLEX-A size 400

CENTAFLEX-T size 36x/46x

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
11.2 CENTA data sheet D013-016 (unlubricated screw connections)

Validity:
For all non-dynamically stressed screw connections with not lubricated shank
bolts in accordance with ISO 4014, ISO 4017 and ISO 4762 (DIN 912) with
metric standard thread in accordance with DIN ISO 262, unless other
specifications are given on CENTA documents.
Preparation of parts that are to be screwed together:
The joining areas must be free of dirt, preservatives and lubricants.
Preparation of screws that ARE NOT secured with liquid screw locking
medium:
Use screws as delivered.
Preparation of screws that ARE secured with liquid screw locking
medium:
Remove all grease from the thread.
Screw tightening method:
Screw in (by hand with torque wrench).
11.3 CENTA data sheet D008-900,

Declaration of incorporation according to the EC Machinery
Directive 2006/42/EC, Appendix II B

CENTAFLEX-A Rev. 2
008A-00001...00600-.N/S..
Manufacturer: Contact:
CENTA Antriebe Phone +49-2129-912-0
Kirschey GmbH Fax +49-2129-2790
Bergische Strasse 7 centa@centa.de
42781 Haan / GERMANY www.centa.info
We herewith declare that the incomplete machine
Product: Highly elastic coupling CENTAFLEX-A
Model / series code: CF-A / 008A
Installation size: 1…800
Design: all
Serial number: according to shipping documents, if applicable
- provided this is possible as far as the scope of supply is concerned - complies

with the following basic requirements of the Machinery Directive 2006/42/EC
Appendix I, subchapters 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.3, 1.3.4 and 1.5.4.
In addition, we declare that the special technical documents for this incomplete
machine were compiled according to Appendix VII Part B and undertake to
forward these to the market monitoring authorities by request via our
"Documentation Department".
Commissioning of the incomplete machine is interdicted until the incomplete
machine has been incorporated in a machine and the latter complies with the
provisions of the EC Machinery Directive and the EC Declaration of Conformity
according to Appendix II A is on hand.
The declaration is invalidated by every modification to the delivered parts.
Authorised representative for the

compilation of the relevant technical
documents:
by order of Gunnar Anderseck
(Authorised Person Documentation)
Declaration of incorporation was issued:
by proxy Dipl.-Ing. Jochen Exner

Haan, 19.11.2009
(Design Management)

Appendix D
Starter batteries
Revisionsdatum:
01.07.2015 Datenblatt Starterbatterie /
Revision: Datasheet Starter Battery
1
Formular:
Typ KA-SB-612xxx Seite von Seiten:
1 6
Innovative Merkmale innovative characteristics
 wartungsfreie AGM Konstruktion,  maintenance-free AGM engineering,

kein Wasser nachfüllen, no refilling of water,
geschlossene Ausführung closed version
 Gehäuseformation der Platten  body formation of plates
 technisch reine Schwefelsäure  commercially pure sulfuric acid
 auslaufsicher  leak proof
 Ventil reguliert, max. interner Druck 2,5psi  valve adjusted, max. internal pressure 2,5psi
 UL 94 HB  UL 94 HB
 Gehäuse und Deckel aus ABS  body and cover plate made of ABS
 niedrige Selbstentladung  low self-discharge
 12 Jahre Lebensdauer  12 years designlife
 kein Gefahrgut nach FAA und IATA  no dangerous goods according to FAA and IATA
 in Übereinstimmung mit:  in compliance with:
- IEC 896-2 - IEC 896-2
- DIN 43534 - DIN 43534
- BS 6290 Pt4 - BS 6290 Pt4
- Eurobat - Eurobat
- DIN 6280-13 - DIN 6280-13
- DIN EN 50272-1 (DIN VDE 0510-2) - DIN EN 50272-1 (DIN VDE 0510-2)
- VdS CEA 4001 - VdS CEA 4001
Typ / Spannung / Kapazität / Höhe / Länge / Breite / Gewicht / Betriebstemperatur /

Anschluss /
Type voltage capacitance height lenght width weight operation temperature
terminal
KA-SB-612xxx Volt Ah mm / inch mm / inch mm / inch kg / lbs °C / °F
051 12 51 M6 157 / 6,18 198 / 7,80 167 / 6,57 13,8 / 30,4 -20 bis 50 / -4 to 122
081 12 81 M6 173 / 6,81 349 / 13,74 168 / 6,61 24,7 / 54,5 -20 bis 50 / -4 to 122
132 12 132 M6 209 / 8,23 329 / 12,95 173 / 6,81 32,6 / 71,9 -20 bis 50 / -4 to 122
Datei:F:\PRODUKT-DOKU\Fabrikate\KAGEMA\Batterien\Word- Erstellt von : H.Wittig QM-Freigabe :

Dateien\Gebrauchsanweisung_Datenblatt_Starterbatterien_KA-SB-
612_D_GB_Rev1.docx am : 02.09.2013 am :
Verteiler : Ordner Formulare, Intranet Geprüft von : Hr. Wittig Druckdatum : 01.07.2015
am : am : 01.07.2015
Revisionsdatum:
01.07.2015 Gebrauchsanweisung /
Revision: Operating Instruction
1
Formular:
2 6
Gebrauchsanweisung beachten und sichtbar in der Nähe der Batterie anbringen!

Arbeiten an der Batterie nur nach Unterweisung durch Fachpersonal!
Observe these instructions and keep them located nearby the battery for future reference!
Work on the battery should only be carried out by qualified personnel!
Rauchen verboten! Keine offene Flamme, Glut oder Funken in der Nähe der Batterie,
da Explosions- und Brandgefahr!
Do not smoke! Do not use any naked flame or other sources of ignition.
Explosion and fire hazards are present!
Bei Arbeiten an Batterien Schutzbrille und Schutzkleidung tragen!

Die Unfallverhütungsvorschriften sowie DIN EN 50272-1 (DIN VDE 0510), VDE 0105 Teil 1 beachten!
While working on batteries wear protective eye-glasses and clothing!
Observe the accident prevention rules as well as DIN EN 50272-1 (DIN VDE 0510),,VDE 0105 part 1!
Säurespritzer im Auge oder auf der Haut mit viel klarem Wasser aus- bzw. abspülen,
danach unverzüglich einen Arzt aufsuchen!
Mit Säure verunreinigte Kleidung mit Wasser auswaschen.
Any acid splashes on the skin or in the eyes must be flushed with plenty of water immediately.
Then seek medical assistance.
Spillages on clothing should be rinsed out with water.
Explosions- und Brandgefahr! Kurzschlüsse vermeiden! Achtung! Metallteile der Batterien

stehen immer unter Spannung, deshalb keine fremden Gegenstände oder Werkzeug auf
der Batterie ablegen!
Explosion and fire hazard, avoid short circuits! Caution! Metal parts of the battery are always alive,
therefore do not place items or tools on the battery!
Elektrolyt ist stark ätzend! Im normalen Betrieb ist Berührung mit dem Elektrolyten praktisch ausgeschlossen.
Elektrolyt kann nur durch unsachgemäße Behandlung z.B. durch Überladung an den Ventilen oder am Gehäuse in
Folge mechanischer Beschädigung austreten. Wenn Sie in Kontakt mit Elektrolyt gekommen sind, bitte reichlich
mit Wasser spülen und einen Arzt aufsuchen!
Electrolyte is strongly corrosive and acidic.In normal working conditions the contact with electrolyte is nearly impossi-
ble; electrolyte may leak from the vent valves in case of over charging the battery or in case of mechanical damage to
the container. In case of any contact with electrolyte please flush with water abundantly and get in touch with a physi-
cian.
Bei Nichtbeachtung der Gebrauchsanweisung, bei Reparatur mit nicht originalen Ersatzteilen, bei nicht bestimmungs-
gemäßen Gebrauch oder eigenmächtigen Eingriffen erlischt der Gewährleistungsanspruch.
Non-compliance with operation instructions, repairs made with other than original parts, unintended use or
repairs made without authorization render the warranty void.
Zurück zum Hersteller!

Altbatterien mit diesem Zeichen sind wiederverwertbares Wirtschaftsgut und müssen, entsprechend dem Batteriege-
setz, dem Recyclingprozess zugeführt werden. Altbatterien, die nicht dem Recyclingprozess zugeführt werden, sind un-
ter Beachtung aller Vorschriften als Sondermüll zu entsorgen
Disposal of Batteries!
Batteries marked with the recycling symbol should be processed via a recognised recycling agency. By agreement,
they might be returned to the manufacturer. Batteries must not be mixed with domestic or industrial waste
Revisionsdatum:
1
Formular:
3 6
Verschlossene Batterien bestehen aus Zellen, bei denen Valve-regulated lead acid batteries consist of cells which
über die gesamte Brauchbarkeitsdauer kein Nachfüllen do not require water topping during the operation.
von entionisiertem Wasser zulässig ist. Als Verschluss- Overpressure valves are applied as vent plugs which
stopfen werden Überdruckventile verwendet, die nicht couldn´t get opened without destruction!
ohne Zerstörung geöffnet werden können!
1. Installation der Batterie 1.Battery installation

Werden Teilbatterien parallel geschaltet, sind die gleiche If a part of the battery system is wired parallel, the same
thermische Umgebung und die gleichen Leitungswider- thermal environment and the same power resistors of
stände der Teilbatterien sicherzustellen. the part of the battery system should have ensured.
1.1 Inbetriebnahme 1.1 Start up

Vor der Inbetriebnahme sind alle Blöcke auf mechanische Check all cells/blocks before start up for mechanical
Beschädigung, polrichtige Verschaltung und festem Sitz damage, correct polarity and firmly seated connectors.
der Verbinder zu prüfen. The following torques apply for screw connectors:
Folgende Drehmomente gelten für Schraubverbindun- M5-M8 5-7 Nm.
gen: M5-M8 5-7 Nm. Connect the battery with the correct polarity to the
Gegebenfalls sind die Polabdeckungen aufzubringen. Bat- charger.The charger should not be switched on during
terien polrichtig bei ausgeschaltetem Ladegerät bzw. this process, the load should not be connected (pos.pole
geöffneter Batteriesicherung und abgetrennten Verbrau- to pos. terminal). Switch on charger and start charging
chern an die Gleichstromversorgung anschließen. (positi- following chargi g oltage instruction (see below).
ver Pol an positive Anschlussklemme).
BAE anschließen, Ladegerät einschalten und gemäß „La-
despa u g (siehe unten) laden.
Ladespannung charging voltage

Erhaltung 2,275 +/- 0,005 V/Z bei 20 °C; maintenance 2,275 +/- 0,005 V/Z bei 20 °C;
Zyklisch 2,35 V/Z bei 20 °C; cyclic 2,35 V/Z bei 20 °C;
max. V/Z 2,4 V; max. V/Z 2,4 V;
max. Wechselstromanteil 0,05 C(A) max. AC rate AC 0,05 C(A)
2. Betrieb 2. Operation
Für den Aufbau und Betrieb dieser Batterie gilt DIN VDE For the installation and operation of the batteries, EN 50
0510 bzw. EN50272. Die Batterie ist so aufzustellen, dass 272-2 is mandatory. Battery installation should be made
zwischen den einzelnen Blöcken eine umgebungsbeding- such that temperature difference between individual
te Temperaturdifferenz von >3K nicht auftreten kann. units does not exceed 3 degrees Celsius/Kelvin.
2.1 Entladen 2.1 Discharge

Die dem Entladestrom zugeordnete Entladeschluss- Discharge must not be continued beyond the level speci-
spannung der Batterie darf nicht unterschritten werden. fied for the specific discharge current. Deeper discharges
Sofern keine besondere Angaben des Herstellers vorlie- must not occur unless specifically agreed with the manu-
gen, darf nicht mehr als die Nennkapazität entnommen facturer. Recharge immediately following complete or
werden. Nach Entladungen, auch Teilentladungen, ist partial discharge.
sofort zu laden. Discharge voltage: 1,7V/Z
Entladeschlussspannung: 1,7V /Z
Revisionsdatum:
1
Formular:
4 6
2.2 Ladung einer neuen Batterie 2.2 Charging

Anwendbar sind Ladeverfahren mit ihren Grenzwerten Applicable are all charging procedures with their limit
gemäß DIN 41773 (IU-Kennlinie). values according to DIN 41773 (IU-characteristic).
Je nach Ladegeräteausführung und Ladegerätekennlinie According to the charging equipment specification and
fließen während des Ladevorgangs Wechselströme durch characteristics, alternating currents (< 0,1 C (A) effective
die Batterie, die dem Ladegleichstrom überlagert sind ripple) flow through the battery superimposing into the
(<0,1 C (A) effektive Welligkeit). direct current during charging operation.
Diese überlagerten Wechselströme und die Rückwirkung These alternating current and the reaction from the
von Verbrauchern führen zu einer zusätzlichen Erwär- loads lead to an additional temperature increase of the
mung der Batterie und Belastung der Elektroden mit battery, and strain the electrodes with possible damages.
möglichen Folgeschäden.
Die folgenden Lademethoden können verwendet wer- The following charging modes can be used:
den:
 Ladung nach der IU-Ladung bei erhöhter Spannung  Charging according to IU-Charging at increased volt-
von (2,33-2,4V) x Zellenzahl mit automatischer Um- age of (2,33-2,4V) x number of cells with automatical-
schaltung auf die Betriebsspannung ly switch to operating voltage.
 Ladung nach der IUI-Kennlinie bis (2,33- 2,4V) x Zel-  Charging according to IUI-characteristic until
lenzahl, Absenkung des Stromes auf 1,5A per 100 Ah. (2,33- 2,4V) x number of cells, lowering the current to
Die Ladung ist zu überwachen. Es ist zu prüfen, ob 1,5A per 100 Ah. The charging must be monitored.
dabei die Verbraucher abzuschalten sind. Steigt die It needs to be checked, if electrical loads have to be
Batterietemperatur über 45°C, ist die Ladung zu un- switched off. If the battery-temperature exceeds
terbrechen. Der vollgeladene Zustand ist erreicht, 45°C, charging must be interrupted.
wenn die Zellenspannung während zwei Stunden The fully charged status is reached when the cell volt-
nicht mehr ansteigt. age does ’t rise a y ore ithi t o hours.
 IU-Ladung mit der Betriebsspannung (Bereit-  IU-charging with the operating voltage (standby par-
schaftsparallelbetrieb), ca. 95% der Kapazität wird allel operation), approximately 95% of the capacity
nach ca. 4-8 Wochen erreicht. will be reached after about 4-8 weeks.
2.7 Temperatur 2.7 Temperature

Der empfohlene Betriebstemperaturbereich für Bleibat- The nominal operation temperature range for lead-
terien beträgt 10°C bis 30°C. Der ideale Betriebstempera- batteries is 10°C to 30°C (best 20°C ± 5 K). Higher tem-
turbereich beträgt 20°C ± 5K. Höhere Temperaturen ver- peratures will seriously reduce service life. All technical
kürzen die Brauchbarkeitsdauer. Die technischen Daten data are produced for a nominal temperature of 20°C.
gelten für Nenntemperaturen von Lower temperatures reduce the available capacity.The
20°C. Niedrigere Temperaturen verringern die verfügbare absolute maximum temperature is 50°C and should not
Kapazität. Das Überschreiten der Grenztemperatur von permanently exceed 40°C in service.
50°C ist unzulässige. Dauernde Betriebstemperaturen
größer 40°C sind zu vermeiden.
Kapazitätskorrektur bei Temperaturschwankungen Capacity adjustment in case of temperature fluctuations

40°C (104°F) 102% 40°C (104°F) 102%
20°C (68°F) 100% 20°C (68°F) 100%
10°C (50°F) 93% 10°C (50°F) 93%
0°C (32°F) 85% 0°C (32°F) 85%
-15°C (5°F) 65% -15°C (5°F) 65%
Revisionsdatum:
1
Formular:
5 6
3. Batteriepflege und Kontrolle 3. Battery maintenance and control

Die Batterie ist stets sauber und trocken zu halten, um Keep the battery clean and dry to avoid leakage currents.
Kriechströme zu vermeiden. Kunststoffteile der Batterie Plastic parts of the battery, especially containers, must
dürfen nur mit Wasser ohne Zusatz gereinigt werden, die be cleaned with pure water without additives, any organ-
Verwendung organische Reinigungsmittel ist nicht ange- ic solvents are prohibited.
raten. Elektrostatische Aufladungen sind zu vermeiden.
Mindestens alle 6 Monate zu messen: At least every 6 months measure and record:
 Batteriespannung  battery voltage
 Oberflächentemperatur  surface temperature
 Raum-Temperatur  room temperature
Sollte die Erhaltungsladespannung um mehr als +1,2V If the difference of the average float-charge-voltage
oder -0,6V vom Mittelwert abweichen oder weicht die is exceeding +1.2V or -0.6V within a string or if the sur-
Oberflächentemperatur um mehr als 5K ab, so ist der face temperature-difference is exceeding 5K, the service
Kundendienst anzufordern. agent should be contacted.
Jährliche Sichtkontrolle Annual visual check:

 Der Schraubverbindungen, ungesicherte Schraubver-  screw-connections, any screw connections without
bindungen sind auf festen Sitz zu prüfen locking devices have to be checked for tightness
 Der Batterieaufstellung bzw. Unterbringung der Be-  battery installation, arrangement and ventilation
und Entlüftung.
4. Prüfungen 4. Tests
Zur Sicherstellung einer zuverlässigen Stromversorgung To avoid a reliable electric power supply the whole bat-
sollte die gesamte Batterie nach der zu erwartenden tery should be replaced according to the expected ser-
Brauchbarkeitsdauer unter Berücksichtigung der Einsatz- vice life taking account of the operating conditions and
bedingungen und Temperaturen ausgetauscht werden. temperatures.
5. Störungen
Werden Störungen an der Batterie oder der Ladeeinrich- 5. Faults
tung festgestellt, ist unverzüglich der Kundendienst anzu- Call the service agents immediately in case of faults in
fordern, Messdaten gemäß Punkt 3 vereinfachen die the battery or the charging unit. The availability of the
Fehlersuche und die Störungsbeseitigung. Ein Servicever- recorded data described in point 3, will be very helpful to
trag mit uns erleichtert das rechtzeitige Erkennen von find the cause of failure. A service-contract simplifies
Fehlern. troubleshooting.
6. Lagern und Außerbetriebnahme 6. Storage and taking out of operation

Werden Batterien für längere Zeit gelagert bzw. außer To store or decommission batteries for a longer period of
Betrieb genommen, so sind diese vollgeladen in einem time, they should be fully charged and stored in a dry
trockenen, frostfreien Raum unterzubringen. Um Schä- frost-free room. To avoid damage, batteries should be
den zu vermeiden, sollen Erhaltungsladungen gemäß 1.1 regulary subjected to supplementary charge cycles in
durchgeführt werden. accordance with 1.1.
Revisionsdatum:
1
Formular:
6 6
Selbstentladung Self-Discharge
1 Monat Lagerung 98% 1 month storage 98%
2 Monate Lagerung 94% 2 months storage 94%
6 Monate Lagerung 86% 6 months storage 86%
7. Transport 7. Transport
Batterien, die in keiner Weise Schäden aufweisen, wer- VRLA batteries, which by no means show any kind of
den nach der Gefahrengutverordnung Straße (GGVS) damage, are classified as non-dangerous goods for trans-
bzw. Gefahrengutverordnung Eisenbahn (GGVE) als nicht portation via rail, lorry or air (according to GGVS, GGVE
Gefahrengut behandelt, wenn diese gegen Kurzschluss, and IATA Regulations) if they are safeguardedduring
Verrutschen, Umfallen und Beschädigung gesichert sind transportation against short-circuiting, tossing about,
(GGVS.Rand-Nr.2801a). slipping or any damage. Batteries to be classified under
An den Versandstücken dürfen sich von außen keine ge- afore-mentioned paragaph must mandatorily not display
fährlichen Spuren von Säure befinden. any traces of electrolyte on the exterior of the battery
Für den Lufttransport gilt: Die Batterien sind auslaufsi- container.
cher und für den Transport gegen Kurzschluss an den As for VRLA batteries being damaged, assumed to be
Polen gesichert. Sie entsprechen den IATA-Vorschriften, leaking of electrolyte and to be transported under war-
der Verpackungsvorschrift 806 sowie der Bestimmung ranty, or assumed not to be tight in any aspect anymore,
A67 der IATA Resolution 618. they are to be handled in accordance with exeption regu-
lations of dangerous goods transportation rules con-
cerned.
Adenser Str.1
30982 Pattensen
GERMANY
Tel: +49 5069 9093 - 0
Fax: +49 5069 9093 - 90
www.kagema.com
© 2019 KAGEMA Industrieausrüstungen GmbH / A KSB Company

PART 3
FLAME ARRESTOR (PROTEGO)
Braunschweiger
Flammenfilter
for safety and environment
Operating Instruction
Translated Version
Vent Cap, Deflagration Proof
PROTEGO® BE/AD
EN ISO 16852, Rev.: 05-00

30.06.2016
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Braunschweiger Flammenfilter GmbH

Industriestraße 11
38110 Braunschweig
Germany
phone: +49 (5307) 809-0

e-Mail: office@protego.com
=== Ende der Liste für T extmar ke Adres seIOM ===
internet: www.protego.com
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PROTEGO®, FLAMMENFILTER® and FLAMEFILTER® are trademarks of Braunschweiger Flammenfilter GmbH.
© 2016 Braunschweiger Flammenfilter
The reproduction, distribution and utilization of this manual and all related documents as well as the communication
of its contents to others without express authorization by Braunschweiger Flammenfilter GmbH is prohibited.
Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or design.
Authorized representative for the completion of the technical documentation:

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Contents
Technical Director of Braunschweiger Flammenfilter GmbH
=== Ende der Liste für T extmar ke Sc hutz ===
Braunschweiger
2
Flammenfilter
®
Contents 30.06.2016 PROTEGO BE/AD
Contents
1 Basic information ................................................................................................ 5

1.1 Notes on the operating manual ............................................................................................... 5
1.2 Target group............................................................................................................................ 6
1.3 Proper use............................................................................................................................... 6
1.4 Declaration of conformity ........................................................................................................ 6
1.5 Symbols and signal words used ............................................................................................. 7
1.5.1 Highlighting in the text .............................................................................................. 7
2 Safety.................................................................................................................... 8
2.1 General safety information ...................................................................................................... 8
2.1.1 Operation .................................................................................................................. 8
2.1.2 Proper use ................................................................................................................ 8
2.1.3 Working in potentially explosive atmospheres ......................................................... 9
2.1.4 Requirements of personnel ...................................................................................... 9
2.1.5 Unauthorised people in the working area ................................................................. 9
2.2 Standards and directives ...................................................................................................... 10
2.3 The operating company’s responsibilities ............................................................................. 10
2.4 Personal protective equipment ............................................................................................. 11
2.5 Using operational materials and supplies ............................................................................. 12
3 Technical data and limitations of use .............................................................. 13

3.1 Model identification ............................................................................................................... 13
3.2 Marking ................................................................................................................................. 13
3.3 Measurements and weights .................................................................................................. 14
3.4 Limitations of use .................................................................................................................. 16
4 Technical description........................................................................................ 18
4.1 Area of use and function ....................................................................................................... 18
4.2 Set-up.................................................................................................................................... 18
4.2.1 Overview ................................................................................................................. 18
®
4.2.2 PROTEGO flame arrester unit .............................................................................. 19
4.3 Insulation and electric heating .............................................................................................. 19
Braunschweiger
Flammenfilter 3
®
PROTEGO BE/AD 30.06.2016 Contents
5 Storage and transportation .............................................................................. 20

5.1 Transportation inspection ...................................................................................................... 20
5.2 Storage .................................................................................................................................. 20
5.3 Safety information ................................................................................................................. 21
5.4 Transport securing devices ................................................................................................... 22
5.4.1 Protective caps for connections .............................................................................. 22
6 Installation and commissioning ...................................................................... 23

6.2 Installation preparations ........................................................................................................ 23
6.3 Installation ............................................................................................................................. 24
6.4 Commissioning ...................................................................................................................... 24
6.4.1 Safety information ................................................................................................... 24
7 Maintenance ...................................................................................................... 25
7.2 Maintenance intervals ........................................................................................................... 27
7.3 Cleaning and inspecting ........................................................................................................ 28
7.3.1 Tools and cleaning agents ...................................................................................... 28
®
7.3.2 Inspecting the PROTEGO flame arrester unit ...................................................... 28
®
7.3.3 Cleaning and inspecting the FLAMEFILTER ........................................................ 29
8 Malfunctions...................................................................................................... 30
8.1 Personnel .............................................................................................................................. 30
8.2 What to do in the event of a malfunction ............................................................................... 30
8.3 Troubleshooting .................................................................................................................... 31
8.4 Commissioning after remedying a fault ................................................................................. 31
9 Disposal ............................................................................................................. 32
10 Replacement and consumable parts .............................................................. 32
11 Appendix ........................................................................................................... 33
11.1 Commissioning checklist ....................................................................................................... 33
®
11.2 FLAMEFILTER types .......................................................................................................... 35
11.2.1 Marking ................................................................................................................... 35
®
11.2.2 Deviating FLAMEFILTER types ............................................................................ 36
Braunschweiger
4
Flammenfilter
®
Basic information 30.06.2016 PROTEGO BE/AD
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for s afety and envir onment
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1 Basic information
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1.1 Notes on the operating manual

This operating manual describes the set-up, function, assembly, operation, maintenance
and disposal of devices manufactured by Braunschweiger Flammenfilter GmbH.
The manual contains all of the information required to operate the devices safely and in the
event of any problems arising provides advice on possible causes and how to correct them.
The information in the operating manual is to be followed during all phases of the device’s
life.
The information contained in this manual relates to standard product designs.
 Prior to starting work, the operating company management and all relevant personnel
must have read the manual and understood it, especially the 'Safety' chapter.
 Keep this operating manual throughout the service life of the device.
 Ensure that this operating manual is always accessible to the personnel at the device's
place of use.
 Add all supplementary information from the manufacturer to the device's documents.
 Supplement with further instructions on, for instance, supervisory and reporting
obligations for taking into account special operational matters, e.g. in relation to working
structures, working processes or personnel deployed.
 Pass the operating manual on to every subsequent owner or user of the product.
NOTE
The term mixture is used in this manual to represent any mixtures of gas and/or product
vapour/air.
NOTE
The pictures shown in this manual are illustrative examples. Depending on model, the
device's appearance may vary from the pictures.
NOTE
A 'Commissioning' checklist is included in the appendix. The checklist can be copied and
provided to the personnel. The checklists should be filled in, signed and handed over to the
operating company management. They should then be added to the device's documents.
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Braunschweiger
Flammenfilter 5
®
PROTEGO BE/AD 30.06.2016 Basic information
1.2 Target group

This operating manual is aimed at personnel who need to be familiarised with the setting up,
function, assembly, operation, maintenance and disposal of the device / supplies used with
it.
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1.3 Proper use

The device is intended for use in the commercial sector.
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Figure 1: Overview (example)

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The end-of-line deflagration flame arresters serve to relieve pressure and to protect
explosion-endangered plants against flame transmission from the atmosphere.
Operating conditions must always be in line with the device’s intended area of use and their
limitations of use must not be exceeded.
Any use extending beyond this is deemed improper.
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The device can only be guaranteed to work safely if properly used as per the information in
this operating manual. The operational circumstances must at all times correspond to the
device's range of use. Adherence to the device's limitations of use is essential.
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1.4 Declaration of conformity

Declarations of conformity are provided separately and are then to be regarded as an
integral part of this operating manual.
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Braunschweiger
6
Flammenfilter
®
Basic information 30.06.2016 PROTEGO BE/AD
1.5 Symbols and signal words used

Notes of warning are marked with a pictogram and a signal word.
The nature, source and potential consequences of the danger are stated and notes of
guidance given on how to avoid them. The meaning of the pictograms and signal words is
explained below.
DANGER
… indicates a situation of direct danger that will lead to death or serious injury if not
avoided!
RISK OF EXPLOSION
… indicates a situation of direct danger in a potentially explosive area that will lead to
death or serious injury if not avoided!
WARNING
… indicates a situation of possible danger that can lead to death or serious injury if not
avoided!
CAUTION
… indicates a situation of possible danger that can lead to minor or slight injuries if not
avoided.
ATTENTION
… indicates a situation of possible danger that can lead to minor or slight injuries if not
avoided.
NOTE
Usage tips and useful information.
ENVIRONMENTAL NOTE
Information relating to environmental protection.
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1.5.1 Highlighting in the text

 References are introduced with an arrow.
■ Lists are marked with this symbol.
1. Step-by-step actions are shown numbered.
Recommended spare part
Braunschweiger
Flammenfilter 7
®
PROTEGO BE/AD 30.06.2016 Safety
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2 Safety
This section provides an overview of all key safety factors relating to protection of
personnel and safe, trouble-free operation.
You must follow and adhere to all operational instructions and safety guidance.
Over and above the information contained in this manual, the locally applicable
accident prevention regulations and general safety provisions for the device's area
of use apply.
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2.1 General safety information

2.1.1 Operation
Risk of death through improper use
 Prior to every use, check the device for any damage and make sure that it is in good
condition.
 Any damaged device must not be used / must be taken out of use at once.
 If any changes occur to the device that affect operational safety, maintenance
personnel must report these to the operating company management immediately.
 Fencing off, securing and signposting the device's hazardous area.
 In the event of danger keep to the prescribed procedures.
 When using the device, ensure that sufficient material resistance (e.g. to corrosion)
exists in relation to the substances present in the system.
2.1.2 Proper use

Risk of death through improper use
 Use the device only for the intended purpose.
 Operate the device only with the connections provided and designed for the purpose.
 Do not make any modifications to the device or convert it in any way.
 If planning to change the medium being used, consult the manufacturer to check
whether the device can be used with the new substance.
Braunschweiger
8
Flammenfilter
®
Safety 30.06.2016 PROTEGO BE/AD
2.1.3 Working in potentially explosive atmospheres

Risk of explosion through working incorrectly
 Any damaged device must not be used / must be taken out of use at once.
 Ensure that the device specifications conform to the conditions in which they are to be
used
on site. If this is not the case, do not fit the device.
 Where possible, carry out work with any potentially explosive atmosphere excluded.
 Use only clothing, tools and other resources suited to use in a potentially explosive
environment.
 In areas where there is a potential risk of explosion, do not use any sources of ignition,
e.g. sparks, open flames, hot surfaces, electrical devices or mobile telephones.
2.1.4 Requirements of personnel

Risk of death through being inadequately qualified!
Have all work done only by appropriately qualified personnel.
Qualified personnel are personnel who:
 Have been trained and instructed in their area of work
 Have read and understood the complete operating manual. This applies even if those
concerned have worked with the device before or been previously trained.
 Are familiar with operational processes in the interplay of the device with the plant
equipment
 Are familiar with the device's safety features and their correct way of working
Installing/using the devices incorrectly can lead to serious injury or damage.

 Perform all work carefully and always adhere to the prevailing laws and directives in
relation to workplace safety and environmental protection.
 Never smoke, eat or drink near the device.
 Working on the device while very tired or under the influence of drugs, alcohol or
medication is not allowed.
2.1.5 Unauthorised people in the working area

Unauthorised people in the working area create a risk of death!
 If in doubt, speak to the people and instruct them to leave the working area.
 Cease working for as long as any unauthorised people remain in the working area.
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Braunschweiger
Flammenfilter 9
®
2.2 Standards and directives

All Braunschweiger Flammenfilter GmbH devices are manufactured based on the
latest technology and are operationally safe. In addition, the necessary health and
safety requirements of the applicable laws, standards and directives have been
applied.
In addition to the safety guidelines in this operating manual, you must also observe
and adhere to the generally applicable regulations on accident prevention and
environmental protection.
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2.3 The operating company’s responsibilities

In addition to the safety advice in this manual, operating companies must also
adhere to the national laws and to the safety, accident prevention and
environmental protection regulations applicable to the location and field in which the
device is used.
The device may not be used until the operating company has:
 Carried out a risk assessment
 Pursuant to that, taken protective measures of the highest technical standard, and
 Determined that based on latest technological advances use of the device is safe.
The operating company must ensure that:
 Personnel are regularly trained. It is recommended to keep a record of such training.
 Personnel have access to theoperating manual at all times.
 Regular advice and instruction is given on possible dangers, residual risks and
measures to avoid them.
 Personnel wear the personal protective equipment, e.g. working clothes, safety boots,
protective gloves, protective goggles, hearing protection, etc.
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Braunschweiger
10
Flammenfilter
®
Safety 30.06.2016 PROTEGO BE/AD
2.4 Personal protective equipment

Risk of death through inadequate protection
 Wear protective equipment.
 Heed the signs relating to personal protective equipment put up in the working area!
The following must be worn for all jobs:
Protective work clothes

To protect the wearer from getting caught by any moving bits of
machinery.
Wear close-fitting work clothes with low resistance to tearing, narrow
sleeves and no parts sticking out.
Do not wear any rings, chains or other items of jewellery!
Hard hat
Provides protection from any parts or materials that may fall down or fly
around.
Safety boots
Provide protection from heavy falling parts and from slipping on slippery
surfaces.
Protective gloves
To protect hands from getting scuffed, grazed or pricked, from any
deeper injuries and from contact with hot surfaces or substances with an
irritant or caustic effect.
Braunschweiger
Flammenfilter 11
®
For special jobs wear:
Goggles
To protect eyes from any flying parts or splashing liquid
Protective apron
To protect the body from damp or pointed objects and from getting dirty
Conductive footwear and antistatic clothing

To provide protection from a build-up of static charge, e.g. when working
with sensitive electronic components or in potentially explosive
atmospheres
Hearing protection
To provide protection from noise hazards
Respiratory protection
To protect the airways from pollutants in the surrounding atmosphere or
from risks caused by a lack of oxygen
Table 1: Protective equipment
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2.5 Using operational materials and supplies

In respect of all lubricants, operating fluids and cleaning agents, follow the
respective manufacturer’s instructions and safety data sheets in relation to storage,
handling, usage and disposal.
If specific supplies are required for operating the device, refer to the operating
manual for details. If necessary, consult the manufacturer.
ENVIRONMENTAL NOTE
Lubricants, operating fluids, cleaning agents and their containers may not be
disposed of as domestic rubbish and must not be allowed to get into the drains or
soil. For their disposal adhere in each instance to the locally applicable
regulations.
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Braunschweiger
12
Flammenfilter
®
Technical data and limitations of use 30.06.2016 PROTEGO BE/AD
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3 Technical data and limitations of use

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3.1 Model identification

The complete model ID contains the following details (as an example):
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PROTEGO® BE/AD – 50 – IIB3

1 2 3
1 Model 3 Explosion group IIB3
2 Nominal size DN 50
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3.2 Marking
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Figure 2: Nameplate
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1 Model identification 10 Number of the notified body (production

2 Nominal size quality assurance)
3 Serial number 11 Max. permitted L/D ratio between pipeline
4 Date of production length and nominal pipe size
5 Applied standard 12 Classification for burn rating (BC)
6 Number of examination certificate 13 Burn time (tBT) for short time burn proof
7 Housing test pressure devices (BC: b)
8 DET – Detonation flame arresters in addition 14 Max. allowable operating pressure
with type number or 15 Max. allowable operating temperature
DEF – Deflagration flame arresters in addition 16 Equipment group, kind of explosive
with item 11 atmosphere and explosion group
9 Warning: Flame arresters have installation and 17 Name and address of manufacturer
application limits
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Do not remove or modify any of the signs or the details on them! If a sign or plate becomes
damaged or illegible, immediately request a replacement and have it installed by an
approved fitter. Have the device checked at the same time.
Braunschweiger
Flammenfilter 13
®
PROTEGO BE/AD 30.06.2016 Technical data and limitations of use
NOTE
On standard design devices the lettering on the nameplate is in English. Other languages
and nameplates that differ from the standard are possible.
NOTE
Where appropriate additional signs are installed on the device. Take note of these as well.
NOTE
The shape of the nameplates and layout of the fields may vary.
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3.3 Measurements and weights

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Figure 3: Assembly drawing with main measurements (example)
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G, NPT ½“ ¾“ 1“ 1¼“ 1½“ 2“

a 116 116 116 116 200 200
146 (G)
b 80 80 85 85 149
149 (NPT)
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Table 2: Measurements of devices with female thread

G, NPT Nominal size threaded connection
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a Dimension (mm) b Dimension (mm)
Braunschweiger
14
Flammenfilter
®
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DN 15 20 25 32 40 50
ANSI ½“ ¾“ 1“ 1¼“ 1½“ 2“
a 116 200 200
179 (DIN) 176 (DIN)
b 110
171 (ANSI) 171 (ANSI)
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Table 3: Measurements of devices with flange

DN, ANSI Nominal size
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a Dimension (mm) b Dimension (mm)
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DN 15 20 25 32 40 50
K W
IIB3 1,5 2 2,5 3 6 7
IIC 1,5 2 2,5 3 6 7
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Table 4: Measurements and weights

DN Nominal size W Weight (kg)
K Marking
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NOTE
Weights are benchmarks. In individual cases (due to materials, pressure limits, design etc.)
weights and sizes may differ from those shown here. Detailed figures are available from the
manufacturer on request.
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Braunschweiger
Flammenfilter 15
®
PROTEGO BE/AD 30.06.2016 Technical data and limitations of use
3.4 Limitations of use

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Attribute Value
Type of arrester End-of-line flame arrester
Atmospheric deflagration (DEF)
Prevention of flame transmission
not short time burning proof (BC: c)
Perpendicularly to the devices axis. If necessary,
Installation orientation
consult the manufacturer.
Explosion group
– BE/AD-…-IIB3 IIB3
– BE/AD-…-IIC IIC
Use with oxygen-enriched mixtures Not permitted
Max. allowable ambient conditions 1,1 bar (absolute); 60°C
Max. allowable operating pressure 1 bar, for higher operating pressure consult the
(gauge pressure) manufacturer if necessary
Max. allowable operating
60°C
temperature
Housing test pressure (gauge
1 bar
pressure)
Flow rate See appendix with volume flow diagrams
Table 5: Limitations of use
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RISK OF EXPLOSION
Ignition caused by high surface temperature
High surface temperatures can cause ignition of the flammable mixture.
Therefore:
– Limit the maximum surface temperature to 80% of the flammable mixture’s ignition
temperature.
Braunschweiger
16
Flammenfilter
®
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NOTE
The Maximum Experimental Safe Gap is a characteristic of the gases and is used for
®
determining the explosion group. It is independent of the actual FLAMEFILTER gap.
Maximum Experimental Safe Gap

Explosion group
(mm)
IIA1 ( I ) ≥ 1,14
IIA > 0,90
IIB1 ≥ 0,85
IIB2 ≥ 0,75
IIB3 ≥ 0,65
IIB ≥ 0,5
IIC < 0,5
Table 6: Explosion group based on Maximum Experimental Safe Gap
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NOTE
When using the devices ensure that they are sufficiently resistant (e. g. to corrosion) in
relation to the substances present in the system.
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Braunschweiger
Flammenfilter 17
®
PROTEGO BE/AD 30.06.2016 Technical description
4 Technical description
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4.1 Area of use and function

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The devices are vent caps that protect plants or plant components without keeping a
pressure from flame transmission. In the case of venting, the gas mixtures are guided away
®
via a PROTEGO flame arrester unit, while ventilation is directly from the atmosphere via
®
the same deflagration-proof PROTEGO flame arrester unit.
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If flammable mixtures are emitted in the operation in relatively large volumes and over a
relatively long period, it must be anticipated that after any ignition there may be stabilized
burning. In such cases suitable additional measures need to be taken to protect the plants,
as these devices are not designed / approved for stabilized burning.
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4.2 Set-up
The set-up of the device presented here is the standard design, which is available in a
range of different materials. On request from clients and in the case of special variants, non-
standard designs and materials (not listed) may be used.
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4.2.1 Overview
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Figure 4: Assembly drawing (example)

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1 Housing 5 Wing screw

®
2 FLAMEFILTER left 6 Stud screw
3 Gasket* 7 Distance pipe
4 Screw plug* 8 Weather hood
* (only for DN 40/1 ½“ and DN 50/2“) Recommended spare part

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Braunschweiger
18
Flammenfilter
®
Technical description 30.06.2016 PROTEGO BE/AD
4.2.2 PROTEGO® flame arrester unit

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®
In the case of this device the PROTEGO flame arrester unit consists solely of the
®
FLAMEFILTER .
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DN 15 20 25 32 40 50
K n*sw*h
IIB3 1*0,9*10
IIC 1*0,2*10
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®
Table 7: FLAMEFILTER
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®
DN Nominal size n Number of FLAMEFILTER
®
K Marking sw FLAMEFILTER gap (mm)
®
h FLAMEFILTER height (mm)
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4.3 Insulation and electric heating

Thermal insulation or electric heating of the devices is sometimes possible, but is only
offered by the manufacturer in individual cases. The manufacturer provides no warranty nor
accepts any liability for any insulation or electric heating of the devices performed by the
operator.
If in certain situations insulation or electric heating is unavoidable, always ensure that:
 only in-line devices are fully enclosed;
 the insulation does not block any moving parts (if available), e.g. weather hoods on
endurance burning flame arresters or valve pallets;
 openings, e.g. condensate drains and pressure compensation openings are kept clear;
 clear passage into the inlet/outlet cross sections is not covered over or obstructed. The
insulation must not impair device venting. We recommend keeping a minimum distance
of 1 x DN, and in any case at least 50 mm (c. 2”) from the flow’s edge;
 any loose insulation materials (e. g. rock wool) are enclosed, secured and covered in
such a way that fibres or particles of the material do not get sucked in;
 the functionality of the devices and the ability to maintain them is assured in every
respect;
 the electric trace heating is approved for such uses;
 the maximum heating temperature is no more than 25°C above the devices’ maximum
operating temperature.
Adapt the thickness of the insulation to each application.

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Braunschweiger
Flammenfilter 19
®
PROTEGO BE/AD 30.06.2016 Storage and transportation
5 Storage and transportation

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5.1 Transportation inspection

Check the delivery immediately upon receipt to make sure nothing is missing, for any
damage in transit and to ensure that the device matches the characteristics agreed at the
time of purchase.
If any in-transit damage is externally visible, proceed as follows:
 Do not accept the delivery or accept it only under specified conditions.
 Record the extent of the damage on the transportation documents or on the carrier’s
delivery note.
 Lodge a complaint with the manufacturer without delay.
NOTE
Whenever you spot anything wrong, lodge a complaint at once. All claims for compensation
must be made within the complaints deadlines ( Terms and Conditions).
Failure to adhere to the above makes any and all warranty claims null and void.
ENVIRONMENTAL NOTE
Dispose of all packaging materials in an environmentally friendly manner in accordance
with the statutory provisions and local regulations applicable in each instance.
Where appropriate, engage a specialist firm to handle the disposal.
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5.2 Storage
When storing the devices be sure to adhere to the following points:
 Ensure storage in a dry place, free of dust. Avoid storing the devices in places with high
air humidity or that are directly exposed to the influences of the weather.
 Do not remove any materials for preserving the devices or securing them during transit
until immediately prior to installation.
 Avoid the devices coming into direct contact with the ground.
 Store the devices on a level surface that is able to take the weight.
 Always store valve devices in an upright position.
 Pay attention to any additional instructions on the transport packaging.
If the devices were ordered and have been delivered in an unlubricated condition, also
adhere to the following:
 Wear clean gloves.
 Only remove the protective film to inspect for any damage in transit.
 After the inspection, pack the devices back up in protective film and heat-seal it.
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Braunschweiger
20
Flammenfilter
®
Storage and transportation 30.06.2016 PROTEGO BE/AD
5.3 Safety information

CAUTION
Risk of injury due to incorrect handling.
Packed equipment may unintentionally get dislodged or fall over during handling and cause
injuries.
Therefore:
– Secure the devices from unintentional slipping or tipping over.
– When transporting the device components, secure them properly as required by the
transportation equipment being used.
– For transporting the devices use only lifting gear and accessories of adequate size.
– Avoid any jolting caused by collisions.
– Always transport valve devices in an upright position (valve axis vertical).
ATTENTION
Devices at risk of damage.
Packed equipment may unintentionally get dislodged or fall over during handling and thus
get damaged or damage other packed items.
Therefore:
– Heed the warning advice listed above.
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Braunschweiger
Flammenfilter 21
®
PROTEGO BE/AD 30.06.2016 Storage and transportation
5.4 Transport securing devices

To avoid in-transit damage some models are provided with transport securing devices.
NOTE
For in-house transport we recommend to use the transport securing devices after the
reception inspection again.
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5.4.1 Protective caps for connections

Protective caps are used at the connections to protect from contamination or damage.
Figure 5: Protective cap (example)

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Braunschweiger
22
Flammenfilter
®
Installation and commissioning 30.06.2016 PROTEGO BE/AD
6 Installation and commissioning

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DANGER
Risk of unsafe operating conditions caused by restricted device functionality!
Incorrect installation and interaction with existing installations on site may prevent the
device from working properly and thus potentially lead to operating conditions that put lives
at risk.
Therefore:
– Ensure that the flow through the device in the inlet and outlet cross-sections is
unobstructed.
– Adhere to national fire protection regulations, especially in respect of the minimum
distance from external structural elements.
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6.2 Installation preparations

 Install and remove the devices only when the plant is idle (i. e. no pressure in any tank
or plant components).
 Before any installation all plant components must be free of any explosive atmosphere.
If necessary, inert components, e. g. by using nitrogen. A risk of suffocation may then
exist!
 Before starting the work, check to see whether the medium to be stored or the mixtures
could pose any health risks. Where appropriate, take protective measures, e. g. use
breathing apparatus.
 Where hot substances are in use, let the plant section cool down sufficiently.
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In order to ensure safe and correct operation, the operating company must make sure that
the following device specifications match the operating conditions:
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 The mixtures’ explosion group (if applicable)

 Equipment category (protective systems do not have an equipment category)
 Resistance to given materials
 Max. allowable operating temperature
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 Max. allowable operating pressure

 Installation orientation
 Resistance to stabilised burning (if applicable)
 Volume flow / pressure drop
 Design data
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Braunschweiger
Flammenfilter 23
®
PROTEGO BE/AD 30.06.2016 Installation and commissioning
6.3 Installation
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1. Remove protective caps from the connections.

2. Check connections for damage.
3. Secure device properly for the relevant type of connection. Ensure in the process that
the installed device is not under any strain.
4. Check and firmly tighten all screw connections  Appendix.
5. Ensure that it is possible for potential equalisation to take place across the device
connections.
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6.4 Commissioning
 Make sure that there are no unauthorised people in the hazard area.
 During the commissioning process, avoid any pressure and temperature peaks at the
devices.
NOTE
The Commissioning checklist set out in the  Appendix will help you to check that the
devices have been properly installed. It is recommended that the person responsible for
installing the devices fills out the checklist in full, signs it, gives it to the operating company
management and has it added to the plant files.
6.4.1 Safety information

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DANGER
Risk of accidents caused by unsafe operating conditions due to ice forming!
Under particular operating conditions (e. g. steam in the stored product’s evaporation
phase) and in extreme weather conditions (e. g. frost) there is a risk that mixtures in the
®
cooled device may condense out, freeze and block the FLAMEFILTER gap. This can lead
to an increase in pressure in the component and thus to danger.
Therefore:
– Take preventative measures (e. g. heating) against the formation of ice.
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 Throughout all operation do not expose the devices to any operating conditions outside
of the limitations of use.
 Shut down plant component without delay if any changes to the devices, such as leaks,
increased pressure drop etc., are detected during operation.
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Braunschweiger
24
Flammenfilter
®
Maintenance 30.06.2016 PROTEGO BE/AD
7 Maintenance
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DANGER
Risk of injury due to lack of expert knowledge!
Lacking professional know-how or doing work the wrong way can cause injuries.
Therefore:
– Do all jobs on the devices only when the plant components are idle.
– Put up a sign at the place where the plant is switched on indicating that work is being
done on the devices.
– Before starting make sure you have sufficient space to do the work.
– Keep the workplace clean and tidy! Parts or tools loosely lying around or on top of each
other are sources of accidents.
– If any components have been taken out, make sure they are installed correctly again
and that all securing elements are put properly back in place.
– Do not do any welding work on the devices!
®
– We recommend having all maintenance and repair work done only by PROTEGO
®
technical support staff or by technicians trained and certified by PROTEGO . For all
such work always adhere in each instance to the prevailing laws and directives in
relation to workplace safety and environmental protection.
DANGER
Risk of injury from pressurised components!
If any parts of the plant are in a pressurised state while maintenance work is being done, it
is possible that device components or escaping substances could cause fatal injuries.
Therefore:
– Carry out maintenance work on the devices only when the tank / plant component is at
zero pressure and is not going to be filled or emptied for the duration of the work.
DANGER
Risk of injury caused by hot and harmful substances!
Opening the device can enable harmful gases and hot substances with a caustic or irritant
effect to escape and cause serious injuries with fatal consequences.
Therefore:
– When working with substances harmful to human health take suitable protective
measures, e. g. wear gloves and breathing apparatus.
Braunschweiger
Flammenfilter 25
®
PROTEGO BE/AD 30.06.2016 Maintenance
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DANGER
®
Danger due to damaged or clogged up FLAMEFILTER !
®
Clogged up FLAMEFILTER impair the free flow of the mixture.
This creates a risk of increased pressure in the plant component.
®
FLAMEFILTER that are corroded or have been damaged by fire or flashbacks can cause a
loss of protection against flame transmission.
Therefore:
® ®
– Take out the PROTEGO flame arrester unit and clean or replace the FLAMEFILTER .
Whenever a fire or flashback is known to have happened, subsequently install a new
®
PROTEGO flame arrester unit.
®
– Swap out any deficient FLAMEFILTER .
®
– Do not misshape FLAMEFILTER and in particular do not hammer them!
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CAUTION
Risk of injury from getting limbs jammed on corners and edges.
When working on the devices, limbs can potentially get jammed on the edges and thus
injured.
Therefore:
®
– Exercise caution, e. g. when installing a cover and PROTEGO flame arrester unit.
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RISK OF EXPLOSION
Danger of death caused by explosive atmosphere!
The risk of explosion exists at the place where the devices are in use for as long as the
plant component and devices are filled with potentially explosive mixtures. Before any work
begins, plant component and devices must be free of any explosive atmosphere.
Therefore:
– Where necessary, flush plant component and devices with an inert gas, e. g. nitrogen. A
risk of suffocation may then exist!
RISK OF EXPLOSION
Danger of death caused by electrostatic charges!
When cleaning the devices and/or components at the place of use there is a risk of
explosion caused by electrostatic charges and/or sparks.
Therefore:
– Wear antistatic clothing.
– Use only antistatic cloths.
– Use only tools and supplies suited to use in a potentially explosive environment.
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Braunschweiger
26
Flammenfilter
®
NOTE
In the event of incorrect maintenance, technical modification or the use of non-original
spares, the manufacturer’s guarantee and warranty become null and void.
ENVIRONMENTAL NOTE
Dispose appropriately of any environmentally hazardous liquids, used parts or maintenance
remnants. Disposal must be in accordance with the applicable relevant laws.
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7.2 Maintenance intervals

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The operating company is responsible for the orderly operation of its plant.
 To keep the devices working perfectly they need to be inspected and maintained on a
regular basis. The necessary intervals for this are dependent on the characteristics
(e. g. condensation, sublimation, polymerisation, consistency) of the products in the
plant on the mixtures flowing through the devices and on the mechanical strain to which
they are subjected.
 In the absence of any operational experience, the operating company must inspect the
devices regularly following commission to determine at what intervals maintenance
work is necessary. Based on these findings, define the maintenance intervals and
document them in the operating guidelines.
 The service life of, for example, gaskets and diaphragms (if present), is dependent on
environmental influences, the substances being processed and mechanical strain. No
guarantee can be provided for these consumable parts. Only the operating company is
able to define the required maintenance cycles.
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 In the case of ‘clean’ products and normal mechanical strain an annual inspection is
adequate.
 Product contamination, potential polymer formation or other deposits, plus buildup of
condensate or high mechanical strains can make significantly shorter maintenance
intervals necessary. It is recommended that first maintenance is carried out after no
more than 3 months.
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NOTE
®
Deposits within the devices and clogging up of the FLAMEFILTER lead to increased
pressure loss / reduced volume flow.
 Whenever a flashback is registered, always inspect the complete device and renew the
®
PROTEGO flame arrester unit.
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Braunschweiger
Flammenfilter 27
®
PROTEGO BE/AD 30.06.2016 Maintenance
7.3 Cleaning and inspecting

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7.3.1 Tools and cleaning agents

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No special tools are required for valve maintenance.

For cleaning them use only solvents that do not attack the materials (paint, coatings,
gaskets etc.) and are not dangerous in combination with the medium.
If cleaning with compressed air, ensure that none of the parts get damaged.
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7.3.2 Inspecting the PROTEGO® flame arrester unit

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RISK OF EXPLOSION
Gasket and screw plug must be fitted. Check screw plug is firmly in place and, if necessary,
tighten.
Pospecting
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/Betriebs
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EGO® en/7 Wartung/50
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NOTE
® ®
The replacement FLAMEFILTER being used must match the original FLAMEFILTER
®
exactly. Check the marking on the rim of the FLAMEFILTER .
If necessary, consult the manufacturer.
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®
Figure 6: PROTEGO flame arrester unit (example)
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Disassembly
1. Loosen wing nuts (5) and take off weather hood (8).
®
2. Take FLAMEFILTER left (2) out of the housing (1).
Braunschweiger
28
Flammenfilter
®
Inspection
®
3. Inspect FLAMEFILTER left (2) for cleanliness and clean if visibly clogged up.
®
Proceed as described in  Cleaning and inspecting the FLAMEFILTER .
Assembly
®
4. Insert FLAMEFILTER left (2) into the housing (1).
5. Put on weather hood (8).
6. Finally, tighten the wing nuts (5).
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7.3.3 Cleaning and inspecting the FLAMEFILTER®

CAUTION
®
Damage of FLAMEFILTER .
Cleaning with hard or other mechanical equipment and abrasive leads to the damage of
®
FLAMEFILTER .
Therefore:
– do not use any hard equipment like wire brushes for cleaning.
Cleaning
®
1. Inspect FLAMEFILTER individually for cleanliness and clean by blowing out with
compressed air if visibly clogged up.
®
2. When cleaning using high pressure (air, water, steam), place FLAMEFILTER on a
supporting grate.
®
3. If badly clogged up, lie FLAMEFILTER in a bath of solvent. The solvent, however,
® ®
must not attack the FLAMEFILTER material. Afterwards, blow out the FLAMEFILTER
using compressed air.
®
4. Carefully dry FLAMEFILTER and then fit.
NOTE
®
The maximum temperature to which FLAMEFILTER made of stainless steel and Hastelloy
may be heated is 300°C. If heated evenly, neither the shape nor the structure experiences
any irreversible alteration.
Inspection
®
Renew FLAMEFILTER if:
®
 any residual debris is left in the FLAMEFILTER gaps after cleaning;
 any signs of corrosive attack or discolouration (e. g. from the effect of flames) are
visible;
®
 the FLAMEFILTER ribbons can be easily pushed against each other.
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Braunschweiger
Flammenfilter 29
®
PROTEGO BE/AD 30.06.2016 Malfunctions
8 Malfunctions
DANGER
Risk of injury caused by incorrect remedying of malfunctions!
Remedying malfunctions incorrectly can lead to serious injury or damage.
Therefore:
– Heed all warnings in  Maintenance.
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8.1 Personnel
The jobs described below may only be done by authorised specialist personnel or, in some
cases, only by the manufacturer. This is indicated separately in the description of the
individual faults.
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8.2 What to do in the event of a malfunction

The fundamental principle is as follows:
1. In the event of any faults that present a direct risk to people or physical assets,
immediately bring the affected section of the plant into a safe operating state that
enables work on remedying the faults to be carried out in a way that is free of any
danger.
2. Investigate the cause of the malfunction.
3. Inform management at the site about the malfunction without delay.
4. Have malfunction remedied by authorised specialists or the manufacturer.
5. If faults occur with increasing regularity, shorten maintenance intervals accordingly.
6. If in doubt, contact the manufacturer.
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30
Flammenfilter
®
Malfunctions 30.06.2016 PROTEGO BE/AD
8.3 Troubleshooting
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Malfunction Possible cause Corrective action (Performed by)

® ®
Increase of pressure – FLAMEFILTER – Clean FLAMEFILTER (1, 2)
in the plant clogged up
component
– Frozen products, – Insulation, heating (3)
condensation in
®
FLAMEFILTER gaps,
Polymerisation
– Condensate accumulation – Drain condensate (1, 2)
Flow rate too low See increase of pressure in the plant component
Pressure drop lower – Mixture has changed – Check operating state (1, 2, 3)
than when ® ®
– Wrong or no PROGEGO – Check PROGEGO flame
commissioned
flame arrester unit installed arrester unit replace if necessary
(1, 2)
– Pitting inside the – Check mixture is suitable for
®
FLAMEFILTER device material, replace
®
PROGEGO flame arrester
unit (1, 2, 3)
– Plant geometry has – Check limitations of use of the
changed device (1, 2, 3)
Flow rate better than
See pressure drop lower than when commissioned
when commissioned
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Table 8: Troubleshooting
1 Specialist fitter 3 Operating company
®
2 PROTEGO technical support 4 Manufacturer
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8.4 Commissioning after remedying a fault

After the malfunction has been remedied, take the following steps to recommission the
device:
1. Make sure that there are no unauthorised people in the danger area.
2. Start up the section of the plant previously shut down. Take note of chapter
 Commissioning as well.
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Braunschweiger
Flammenfilter 31
®
PROTEGO BE/AD 30.06.2016 Disposal
9 Disposal
ENVIRONMENTAL NOTE
Disposal of the devices must be carried out by specialists familiar with the applicable laws
and regulations relating to environmental protection and safety at work.
Lubricants and operating supplies must be disposed of in accordance with the directives in
the respective safety data sheets.
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10 Replacement and consumable parts

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DANGER
Risk of serious injury with possible fatal consequences due to incorrect replacement
of components!
Incorrect replacement and the use of unsuitable components/parts can prevent the devices
from working properly.
Therefore:
– Use only the manufacturer’s original spare parts!
Replacement and consumable parts are available on request. When ordering, please
provide all details on the relevant device’s nameplate, especially the complete model ID
and serial number.
Dealer network and contact details are available at www.protego.com.
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NOTE
®
The replacement FLAMEFILTER and the associated spacers must match the original
®
parts exactly. When buying these, be sure to pay attention to the required FLAMEFILTER
®
gap, diameter, height, type of material and angle of the gap inside the FLAMEFILTER
(R = right, L = left, G = straight).
®
The PROTEGO trademark, type of material, gap width and angle, in some cases
®
FLAMEFILTER type and year of manufacture are embossed on the outer rim.
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Braunschweiger
32
Flammenfilter
®
Appendix 30.06.2016 PROTEGO BE/AD
11 Appendix
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NOTE
Volume flow diagrams are provided in the appendix to these operating instructions.
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/11 Anhang/40 Chec kliste/40 10 1.1 C hec kliste Inbetriebnahme - Ü berschrift @ 0\mod_1266247174338_7448.doc x @ 8202 @ 2 @ 1
11.1 Commissioning checklist

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Type: PROTEGO Place of use
Serial number
Inspection after delivery

Delivery Delivered without any transit damage
Operating manual Operating manual is present
Declaration of conformity Declaration of conformity (if required) is present
Inspection prior to installation

Operating manual Operating manual read and followed in full
Nameplate Details on the nameplate and the declaration of conformity

(where applicable) match the conditions of use on site
Plant component switched off Plant component switched off and under no pressure
Explosive atmosphere No explosive atmosphere present
Minimum distance to any external National fire protection regulations observed

installation
Protective caps Protective caps removed from connections
Braunschweiger
Flammenfilter 33
®
PROTEGO BE/AD 30.06.2016 Appendix
Inspection prior to commissioning

Installation The device has been installed in such a way that it is not
under any strain
Limitations of use The installation has kept within the devices’ limitations of use
Flow The flow through of media in the inlet and outlet cross-
sections can take place unhindered
Installation orientation Attention has been paid to the installation orientation in
accordance with the limitations of use
FLAMEFILTER FLAMEFILTER are undamaged
Screws and nuts Screws and nuts facing each other have been firmly
tightened to an equal degree
External connections External connections (if any) connected as stipulated
Potential equalisation The electrical connection to the device’s earth is in order
Notes:
Approval given for the device to go into operation.
Date Name/Department
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Braunschweiger
34
Flammenfilter
®
11.2 FLAMEFILTER® types

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® ®
The main component of a PROTEGO flame arrester is the FLAMEFILTER . It is a very
sensible safety-related component and manufactured with great accuracy. It must be
®
ensured at any time that the right FLAMEFILTER is installed in a device. Any mistakes
®
may lead to hazardous incidents. To reduce the danger of confusion the FLAMEFILTER
®
are also indicated by their FLAMEFILTER types (A – Z). Different gaps and special device
®
types require specific FLAMEFILTER types.
®
As a standard the following types are used for FLAMEFILTER in dependence of the gaps:
® ®
FLAMEFILTER gap (mm) FLAMEFILTER type
1,2 A
0,9 A
0,7 A
0,5 B
0,3 C
0,2 C
0,15 D
®
Table 9: Standard FLAMEFILTER types
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11.2.1 Marking
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®
The complete marking of the FLAMEFILTER is embossed on the outer rim as follows:
®
PROTEGO X.XXXX SW X,X X (X) XXXX XXXX XXXX/XX
1 2 3 4 5 6 7
1 Type of material 5 Year of manufacture
2 Gap width 6 Personnel number
3 Gap angle 7 Heat number (EN 10204, 3.1)
®
4
®
FLAMEFILTER type (for FLAMEFILTER dia. ≥ 40 mm)
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Braunschweiger
Flammenfilter 35
®
11.2.2 Deviating FLAMEFILTER® types

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®
FLAMEFILTER types that differ from the standard are as follows:
® ®
FLAMEFILTER FLAMEFILTER Device type
gap (mm) type
®
1,2 Z For FLAMEFILTER diameter greater than 525 mm
E VD/SV-HR-DN-IIA with DN 80 – 100, vacuum side
E VD/SV-HRL-DN-IIA with DN 100 – 150, vacuum side
®
For FLAMEFILTER diameter greater than 525 mm
0,9 Z
(except LH/AD from DN 350 to DN 600)
E BE/AD-DN-IIB3
E DR/ES-DN-IIA-P1,2 with DN ≤ 150
E ES/ST-2-0,9-NG with NG 80 – 500
E ES/V-NG with NG 80 – 500
E FA-I-FC-0,9-NG with NG 80 – 500
G LH/AD with DN ≤ 600
E SV/E-DN with DN 50 – 300
E SV/E-DN-IIB3 with DN 50 – 300
E SV/E-S-DN with DN 50 – 150
E SV/E-S-DN-IIB3 with DN 50 – 150
G VD/SV-AD(L)-DN-IIB3, pressure side
E V/SV-AD-DN-IIB3 with DN 50 – 300
E VD/SV-AD-DN-IIB3 with DN 80 – 100, vacuum side
E VD/SV-ADL-DN-IIB3 with DN 100 – 150, vacuum side
E VD/SV-HR-DN-IIB3 with DN 80 – 100, vacuum side
VD/SV-PA(L)-AD-…-DN-IIB3 with DN 50 – 300,
E
vacuum side
E VD/TS-DN with DN 50 – 300
E VD/TS-DN-IIB3 with DN 50 – 300
®
D DR/SV-DN-IIA
E DR/ES-200-IIA-P1,2
E DR/ES-DN-IIB3-P1,2 with DN ≤ 150
E ES 1200
E ES/R-DN with DN 50 – 300
Braunschweiger
36
Flammenfilter
®
® ®
gap (mm) type
0,7 E ES/ST-2-0,7-NG with NG 80 – 500
E ES/TN-2-0,7-NG with NG 300 – 500
E FA-C-DN-IIA-P1,2 with DN 25 – 300
E FA-CN-DN-IIA1-P1,6 with DN 65 – 300
E FA-CN-DN-IIA1-P2,0 with DN 40, 50
E FA-CN-DN-IIA-P1,2 with DN 25 – 300
E FA-E-DN-IIA1-P1,9 with DN 25 – 300
E FA-E-DN-IIA-P1,2 with DN 25 – 300
E FA-G-DN-IIA-P1,4 with DN 1/2" – 1 1/4"
E FA-G-DN-IIA-P1,5 with DN 1 1/2" – 2"
E FA-I-NG/DN-IIA-P1,2 with NG 150 – 500
E FA-LH-DN-IIA-P1,2 with DN 50 – 300
E FU/S-DN-IIB3 with DN 25 – 80 (old: to 350)
E FU/ZI-DN-IIA with DN 200, 250
E FU/ZI-DN-IIB3 with DN 25 – 150
E LDA-F-DN-IIB3 with DN 25 – 65
E LDA-WF-DN-IIB3 with DN 25 – 50
E LDA-WF(W)-DN-IIB3 with DN 25 – 50
G LH/EB-400/DN-IIA1
E LH/ES-DN with DN 250 – 350
E RH/V-DN with DN 25 – 300
E RV/S-DN with DN 1/2" – 1 1/4"
®
0,5 Z
D DR/SV-DN-IIB3
E DR/ES-200-IIB3
E ES/R-DN with DN 50 – 250
E ES/TN-2-0,5-NG with NG 300 – 500
E FA-C-DN-IIB3 with DN 25 – 300
E FA-CN-DN-IIB3-P1,1 with DN 25 – 300
E FA-E-DN-IIB3-P1,1 with DN 25 – 300
Braunschweiger
Flammenfilter 37
®
® ®
gap (mm) type
0,5 E FA-G-DN-IIB3-P1,2 with DN 1/2" – 2"
E FA-I-150/DN-IIB3-P1,2
FA-I-NG/DN-IIB3-P1,1 with NG 150, 200, 300, 400,
E
500
E FA-I-NG/DN-IIB3-P1,1-X6 with NG 200, 300
E FA-I-NG/DN-IIB3-P1,1-X7 with NG 400, 500
E LDA-F-DN-IIB3 with DN 80 – 250
E LDA-WF-DN-IIB3 with DN 65 – 250
E LDA-WF(W)-DN-IIB3 with DN 65 – 250
E RH/V-DN with DN 25 – 300
®
®
0,2 Z
®
Z FA-G-VS-1”
®
Table 10: Deviating FLAMEFILTER types
=== Ende der Liste für T extmar ke Inhalt ===
Braunschweiger
38
Flammenfilter
Braunschweiger
Flammenfilter
Appendix to the Operating Instruction

Translated Version
Flame Arrester
Device selection example
Rev.: 01-00
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Braunschweiger Flammenfilter GmbH

Industriestraße 11
38110 Braunschweig
Germany
phone: +49 (5307) 809-0

e-Mail: office@protego.com
=== Ende der Liste für T extmar ke Adres se ===
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v
internet: www.protego.com
PROTEGO®, FLAMMENFILTER® and FLAMEFILTER® are trademarks of Braunschweiger Flammenfilter GmbH.
The reproduction, distribution and utilization of this manual and all related documents as well as the communication
of its contents to others without express authorization by Braunschweiger Flammenfilter GmbH is prohibited.
Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or design.
Authorized representative for the completion of the technical documentation:

=== Ende der Liste für T extmar ke Sc hutz ===
Technical Director of Braunschweiger Flammenfilter GmbH
PROTEGO® 2018-12-21 Sizing
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for s afety and envir onment
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1 Sizing
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The conditions of use of a specific device are checked based on the prescribed volume
flow / pressure drop using the associated volume flow diagrams ( Appendix).
Here, it may be required to convert the operating state to the technical standard temperature
and pressure of air ( Appendix).
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1.1 Additional conditions

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 A certain degree of clogging of the FLAMEFILTER® needs to be taken into account in

relation to the layout of the devices. Therefore take the percentages listed in the table
below into account when performing size calculations to adjust the volume flow
( example).
FLAMEFILTER® gap width Sizing (recommended)

(mm) (%)
sw ≥ 0,7 80
0,3 ≤ sw < 0,7 70
sw < 0,3 60
Table 1: Gap width and sizing
NOTE
The FLAMEFILTER® gap widths are listed under  PROTEGO® flame arresters.
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1.2 Device selection example

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NOTE
The purpose of the example flow capacity chart shown is to explain how a device’s
pressure drop and flow rate are worked out.
Using two examples and in the diagram below we show here how the flow rate/pressure
drop of a given device is determined.
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Braunschweiger
2 Flammenfilter
Sizing 2018-12-21 PROTEGO®
The following device data and details of use are known.
Specification Formula symbol Value
Nominal size of the given device for

DN 4
explosion group IIA
FLAMEFILTER® gap
sw 0,9 mm
(manufacturer’s specification)
Max. allowable pressure drop pB 50 mbar
·
Required volume flow (flow rate) V1 800 m³/h
Required flow rate with 20% clogging of · ·

V 2 = V 1 / 0.8 1000 m³/h
the FLAMEFILTER® ( table above)
Example 1) Pressure drop given, required flow rate to be tested.
Example 2) Flow rate given, max. pressure drop to be tested.
Table 2: Operator’s specifications (as an example, not specifically for this device)
airflow in thousands of CFH
pressure drop Δp – (inch W.C.)

1) Pressure drop given
pressure drop Δp (mbar)
2) Flow rate given 1) Clogging
·
flow rate V (m3/h)
Figure 1: Flow capacity chart (as an example, not specifically for this device)
Braunschweiger
3
Flammenfilter
PROTEGO® 2018-12-21 Sizing
Result:
Example 1) Pressure drop
For this DN 4 device with given pressure drop of 50 mbar the result produced is a flow rate
of 3000 m³/h. Taking into account clogging up of the FLAMEFILTER® gap (sw) of 0.9 mm
(80% sizing) the result is a maximum flow rate of 3000 m³/h x 0.8 = 2400 m³/h. As this is
more than the minimum required, the device can be used for these conditions.
Example 2) Volume flow

For this DN 4 device with given flow rate of 1000 m³/h (clogging taken into account, see
table) the result produced is a pressure drop of c. 8 mbar.
This is below the maximum allowable pressure drop. The device can therefore be used
under these conditions.
=== Ende der Liste für T extmar ke Inhalt ===
Braunschweiger
4 Flammenfilter
Flow capacity chart
DEFLAGRATION FLAME ARRESTER, END–OF LINE
PROTEGO® BE/AD-IIB3
Leistung-000231-en.doc
issue: 22.01.2014
For this technical document all rights according to ISO 16016 and changes in construction are reserved.
airflow in thousands of CFH
pressure drop Δp – (inch W.C.)

pressure drop Δp (mbar)
· 3
flow rate V (m /h)
Note
The flow capacity charts have been determined with a calibrated and TÜV certified
flow capacity test rig. They relate to as new, non-clogged FLAMEFILTER®.
3
The flow rate in m /h relates to the technical standard condition of air as per
ISO 6358 (20°C, 1 bar).

PART 4
CONTROL PANEL FOR FIRE PUMP (METRON)
Adenser Str. 1
30982 Pattensen
Germany
Fax+49 (0) 5069 / 9093 – 90
Phone+49 (0) 5069 / 9093 – 0
Diesel Fire Pump Controller

(FM approved)
Project: Export-Indonesien
Comm. No.: P05230-451

Installation: Diesel Fire Pump
Model: EFP/12/230/FD4e/NU3
Serial No.: 314070-01
Year of constr.: 2019
Connection: 230 V 50 Hz
Power consumpt.: 3,3 kW
Battery Model: KA-SB-612132
Battery charging: 24 V
Battery capacity: 132 Ah
FD4e.v5.0 OPFD4e-V5.02 Iss 8, 20/01/2016 Metron Eledyne
1. PREFACE. ...................................................................................................................................................... 3
2. CAUTION. ...................................................................................................................................................... 3
3. GENERAL. ..................................................................................................................................................... 3
4. VOLT FREE CONTACTS............................................................................................................................ 4
5. SUPPLY CONNECTIONS. .......................................................................................................................... 4
6. QUICK START FEATURE .......................................................................................................................... 4
7. INSTALLATION INSTRUCTIONS AND GUIDELINES ........................................................................ 4
8. MAINTENANCE AND INSPECTION ........................................................................................................ 5
9. OPERATOR INTERFACE DEVICE OID DISPLAY. .............................................................................. 6

SYSTEMS STATUS. (BOTH LANGUAGES) .......................................................................................................... 9
SYSTEM LOGS. (BOTH LANGUAGES) ................................................................................................................. 9
CONFIG. (BOTH LANGUAGES) ............................................................................................................................. 9
10. ENERGISING THE CONTROL SYSTEM. ............................................................................................. 10
11. LAMP TEST. ................................................................................................................................................ 10
12. RESET. ......................................................................................................................................................... 10
13. MUTE............................................................................................................................................................ 11
14. AC SUPPLY MONITORING. .................................................................................................................... 11

AC SUPPLY FAILURE...................................................................................................................................... 11
15. HEATERS. ................................................................................................................................................... 11
ENGINE HEATER (OPTION). ............................................................................................................................ 11
PANEL HEATER (OPTION). .............................................................................................................................. 11
16. DC SUPPLY MONITORING. .................................................................................................................... 12
BATTERY VOLTAGE AND CURRENT. ......................................................................................................... 12
BATTERY FAILURE. ....................................................................................................................................... 12
17. BATTERY CHARGING. ............................................................................................................................ 13
18. CHARGER MONITORING. ...................................................................................................................... 14

CHARGER FAILURE. ....................................................................................................................................... 14
19. MANUAL MODE. ....................................................................................................................................... 14
MANUAL START. ............................................................................................................................................ 14
ENGINE RUNNING. ......................................................................................................................................... 14
ENGINE SHUTDOWN (MANUAL). ................................................................................................................ 15
20. AUTOMATIC MODE. ................................................................................................................................ 15
LOW PRESSURE AUTOSTART. ..................................................................................................................... 15
DELUGE VALVE. ............................................................................................................................................. 16
REMOTE START............................................................................................................................................... 16
ENGINE RUNNING. ......................................................................................................................................... 16
ENGINE SHUTDOWN IN AUTO. .................................................................................................................... 16
21. CRANK SEQUENCE. ................................................................................................................................. 16
F:\Engineering\Standards\1 D I E S E L\EFP-FD4e\FD4e v5.02\Manuals\Op-FD4e-v5.02-English.doc 1
BATTERY FAILURE DURING CRANKING. ................................................................................................. 17

FAILED TO START........................................................................................................................................... 17
22. OVERSPEED. .............................................................................................................................................. 17
23. ENGINE LUBE OIL PRESSURE LOW. .................................................................................................. 18
24. ENGINE HIGH WATER TEMPERATURE. ........................................................................................... 18
25. ENGINE FUEL LEVEL LOW. .................................................................................................................. 18
26. ENGINE LOW COOLANT TEMPERATURE. ....................................................................................... 18
27. ENGINE HIGH COOLING WATER TEMPERATURE. ....................................................................... 19
28. ELECTRONIC ENGINES. ......................................................................................................................... 19
29. CLOGGED WATER STRAINER. ............................................................................................................. 20
30. DOUBLE SKINNED FUEL TANKS. ........................................................................................................ 20
31. WEEKLY TEST START. ........................................................................................................................... 20
32. CONTACTOR COIL FAILURE ................................................................................................................ 20
33. ENGINE QUIT (V4.1) ................................................................................................................................. 21
34. SD MEMORY CARD .................................................................................................................................. 21
35. SPECIAL MODES OF OPERATION SPECIFICALLY FOR THE FD4EU – OPTION N1 ............... 23
36. DISPOSAL.................................................................................................................................................... 23

OPERATING INSTRUCTIONS FOR CONTROLLER:

TYPE: EFP/FD4e
1. PREFACE.
This operating manual explains the operation of the complete control system.
2. CAUTION.
In order to avoid risk of personal INJURY or damage to the control equipment, READ THIS
MANUAL VERY CAREFULLY. If after reading these instructions doubt exists, do not
hesitate to contact Metron-Eledyne for further clarification.
In the interests of safety pay special attention to the CAUTION notes listed below:
If work has to be carried out on the engine or control equipment, isolate the control equipment
from the A.C and D.C supplies, and remove the start solenoid supplies from control circuit
terminals before work commences. If possible use a temporary label, which draws attention to
this fact.
Before attempting to start the engine during commissioning, ensure that the 'Fuel Stop
Solenoid' is operational. Due to the nature of the equipment, the control system may start the
engine at any time when operating in automatic mode. Ensure all concerned are aware of this
condition by means of an appropriate label, prominently displayed on the engine skid.
When the equipment is energised and on line, ensure all doors are closed and where applicable
locked.
If during commissioning the equipment is energised with the access door to the panel interior
open, make sure that any terminal cover is fitted to avoid the risk of electric shock.
3. GENERAL.
The controller is designed as a fully automatic engine start system based on the requirements of
National Fire Codes NFPA No. 20 for Engine Driven Fire Pump Controllers, IEC 62091,
UL218 and to FM class number 1321/1323.
In these instructions, the following terms used are defined as: -
Visual - Lamp, or meter.
Display - LCD display on the front door (OID).
Audible - Electronic sounder.
Volt free - Remote volt free changeover contacts.

4. VOLT FREE CONTACTS.
If the volt free is named then its title is active i.e.
Volt Free. Engine Running.

Indicates the contacts are in the engine running position.
If the volt free engine running is said to clear i.e.
Volt Free. Engine Running clears.

Indicates the contacts have changed to the standby position (engine stopped).
5. SUPPLY CONNECTIONS.
Ensure the system is correctly earthed and make interconnections referring to information
contained in the interconnection drawing. Connect AC and DC supplies.
6. QUICK START FEATURE
The quick start feature prompts the user to set up quickly the essential screens for correct use
of this fire pump controller. This feature is initiated by pressing and holding the ‘PILOT’ push
button for 2s. Then the following screens will be required to be completed in the following
order:
Start pressure Stop pressure Delay start Time
Date weekly start time Weekly start day Commissioned date
Double skinned fuel tank Electronic Engine.
7. INSTALLATION INSTRUCTIONS AND GUIDELINES
A. Location
The controller shall be located as close as practical to the diesel engine it controls and within a
line of sight. The controller should not be positioned directly under pipes that could leak water.
B. Mounting
The controller should be mounted using appropriate fixing methods:
If the controller is mounted directly to the engine skid, then anti-vibration mounts should be
used as shown on the general arrangement drawing (6x positions marked ‘A’).
If the controller is mounted to a wall, then it should be mounted using the 4internal mounting
holes (or the external lugs if provided) . Suitable fixings to the wall should be used taking into
consideration the weight of the controller, which is approximately 52 kg. It is recommended
that the controller is mounted at least 300mm above floor level.
Should the controller be mounted using optional legs (plinths) then the controller should be
secured to the floor using the fixing holes provided. Precautions should be taken to ensure that
the controller does not stand in water.

C. Electrical Connections
Only skilled electrical engineers should be used for making the electrical connections. Only the
gland plate(s) located at the bottom of the enclosure should be used for bringing in the
electrical cables. The gland plate should be removed completely from the enclosure to make
the necessary cable gland openings. On no account should other areas of the enclosure be used
for bringing in electrical cables. The correct cable glands should be used to ensure that the IP
rating and integrity of the enclosure is maintained.
The installer is responsible for ensuring that no metallic foreign objects (such as drilling chips
etc) fall inside the controller onto the electrical circuit. Failure to observe this could result in
damage to the controller and will void the controller warranty.
The cabinet should be specifically earthed, using the external earth bolt provided.
NOTE: It is highly recommended, although not essential, that the following

recommendations are considered:
All signal wiring should be separated from power feeds and supplies. Where the two must be
in close proximity, it is advisable that they located at right angles to each other, minimising the
effect of cross-talk and pick-up.
Signal wiring will be less prone to disturbances if contained within grounded conductive
conduit or trunking. Avoid passing signal cables in close proximity to known interference
sources, or high power electrical equipment where possible.
Ensure good clean areas of contact at either end of the installation, and use the largest practical
gauge of wire to improve signal quality, (maximum 2.5mm diameter cable recommended for
signal wiring).
8. MAINTENANCE AND INSPECTION
Frequent inspection should be made. A schedule for maintenance checks should be determined
by the environment and frequency of use but should be regular enough to ensure the equipment
continues to operate in the designed manner. It is recommended that it should be at least once a
week.
External parts of the enclosure should be periodically cleaned to ensure dust deposits are not
allowed to accumulate.
All components that are replaced must be in accordance with the manufacturer’s specifications.
Failure to use such components may invalidate the certification/approval/warranty on the
controller and may make the controller dangerous.
Check that all terminations are tight and correct segregation distances are maintained.
All statements, technical information and recommendations contained herein are based on
information and tests we believed to be reliable, the accuracy or completeness thereof are not
guaranteed in accordance with Metron Eledyne’s "Standard Terms & Conditions" and since
conditions of use are outside our control the purchaser should determine the suitability of the
product for its intended use and assumes all risk and liability whatsoever in connection
herewith.
9. OPERATOR INTERFACE DEVICE OID DISPLAY.
The Operator Interface Device (OID) provides visual indication of the alarms, status of system
parameters, and an interface to change set points to configure the FD4e to operate
appropriately for various installation requirements.
Common Tasks Performed Using The OID
Annunciator
Silencing Horn: If a horn is sounding and the alarm is
silence able, a quick press of the
[SILENCE/LAMPTEST] will silence the horn (less than
1 second press).
Resetting Alarms: If the alarm condition has cleared,
press the [RESET/ESC] button BRIEFLY to reset
alarms.
Operating Mode Change: The operational mode that
the controller is in can be changed via the mode switch
and by the OID push buttons. With the mode switch in
the ‘AUTO’ (automatic) position, the ‘AUTO’ indicator
will be illuminated and the controller will be in full
automatic start mode. The test push button is only active
while the mode switch is in the automatic position.
When the mode switch is on the ‘MAN’ (manual)
position, the ‘MANUAL’ indicator will be illuminated
and the controller will be available for manual starting
only. When the mode switch is in the off position,
neither the AUTO or MAN indicator is illuminated.
Test Mode: When controller is in Auto Mode, pressing

and holding the [TEST] button for two or more seconds
will open the pressure drain solenoid thus dropping the
pressure which causes the controller to start the engine.
Pressing and releasing the [TEST] button in Manual
Push buttons LCD Display Mode directly controls the opening and closing of the
drain solenoid. The engine will not automatically start
when in Manual Mode.
Lamp Test: To illuminate and check all the OID LED’s and the horn, press and hold the
[SILENCE/LAMPTEST] button 5 or more seconds or until all the lights turn on.
The Controller may be configured as either "Manual" or "Automatic" stop as required (System
Config Screen 104). "Manual" stop is set as standard. The current status of this setting is
visible on the Main System Status Screen where the letter “A” will appear in the upper right hand
corner of the screen when set to Automatic Stop and an “M” will appear when set for Manual
stop.

OID Screen Map

METRON OID202
LOSS OF DC POWER POWER

ON
1 2 3
SYSTEM SYSTEM CHANGE/
CONFIG PRINT
STATUS LOGS ENTER
SILENCE
RESET/
AUTO MANUAL TEST /LAMP
ESC
TEST
1 SYSTEM STATUS B1 SYSTEM LOGS 1 CONFIG

PRES STRT BAT1 BAT2 1) Event Log 1) SYSTEM SETPOINTS
110 100 13V 13V 2) Pressure Log 2) USER PREFERENCES
psi psi 6A 0A 3) TECH SCREENS
2 SYSTEM STATUS 2 CONFIG
Engine Countdown Tmr 1) ANALOG SIGNALS
0sec Until Start 2) AUXILLIARY ALARMS
0min Until Stop
3 SYSTEM STATUS # 1 EVENT LOG PRESSURE LOG
Engine Countdown Tmr System in Off 02/16/03 17:52:45 Continued on next
For AC Power Outage Mode Occurred 112 psi page.
0min Until Start 02/16/03 13:15:15 Skip Rate:[EACH ]
4 SYSTEM STATUS # 1 EVENT DETAILS PRESSURE LOG
Engine Hrs: 5.3 System in Off 02/16/03 17:52:30
# Of Starts: 8 Mode Occurred 112 psi
Mon02/17/03 17:53:26 02/16/03 13:15:15 Skip Rate:[EACH ]
5 SYSTEM STATUS # 1 EVENT DETAILS PRESSURE LOG
Firmware Ver SV 1.1 Pressure: 83.2psi 02/16/03 17:52:15
Commissioned Date: System Auto:Yes 113 psi
11/15/02 Engine Running:No Skip Rate:[EACH ]
6 SYSTEM STATUS # 1 EVENT DETAILS
Extended Voltage Charger #1 OK:Yes | |
BAT 1 27.10 0.00A Charger #2 OK:Yes | |
BAT 2 27.05 0.00A Battery #1 OK:Yes | |
# 1 EVENT DETAILS
Battery #2 OK:Yes
AC Power Avail:Yes
Low Fuel Level:No
# 2 EVENT LOG
Engine Failed To
Start Alarm Occurred
02/16/03 07:32:15
# 3 EVENT LOG
AC Power Failure
Alarm Cleared
02/16/03 07:09:48
| |
| |
| |

OID Screen Map

(continued) 1 CONFIG
1) SYSTEM SETPOINTS
2) USER PREFERENCES
3) TECH SCREENS 24v Defaults
2 CONFIG
1) ANALOG SIGNALS FD4e v5.02
2) AUX USER PROGRAMS
(1) 101 SYSTEM SETPOINTS (1) 201 USER PREFERENCES (2) 303 TECH SCREENS (2) 400 ANALOG SIGNALS (2) 501 AUX SETPOINTS
Engine Start Set System Real Energized To Stop Analog Input 01 Aux User Program # 1
Pressure Time Clock Fuel Solenoid Time Slope: Enabled
[100.0]psi 0-999.9 [17:03:52] [10]seconds 0-99 [0.3401360] [No]
Engine Stop Set System Date Engine Condition Analog Input 01 Aux User Program # 1
Pressure Alarm Delay Time Offset: Input Number
[110.0]psi 0-999.9 [08/10/10] DD/MM/YY [10]seconds 1-99 [- 76.1904] [30] 0-70
Engine Start Delay Set System Day Nominal Battery Analog Input 1 651 Aux User Program # 1
Time Of The Week Voltage Minimum Counts Input Contact Type
[ 1] seconds 1-999 [Sun] [24]VDC 10-99 [ 200] [NO ]
Engine Automatic Log System Pressure Battery Low Voltage Analog Input 02 Aux User Program # 1
Stop Enabled Drop Events Alarm Trip Voltage Slope: Trip Time
[Yes] [Yes] [12.0]VDC 6-99 [0.0352500] [ 0]sec 0-999
Engine Minimum Low Pressure Event Battery Low Voltage Analog Input 02 Aux User Program # 1
Run Time Trip Pressure Alarm Trip Time Offset: Reset Time
[30]minutes 30-99 [ 60.0]psi 0-999.9 [ 2]seconds 0-99 [ 0.0000] [ 0]sec 0-999
Automatic Weekly Low Pressure Event Change Tech Password Analog Input 2 1174 Aux User Program # 1
Engine Test Run Reset Time Minimum Counts Auto Reset Enabled
[No] [15] seconds 0-20 [******] [ 0] [Yes]
Auto Weekly Engine Time Between Password Logout Analog Input 03 Aux User Program # 1
Test Day Of The Week Pressure Log Samples Time Slope: Horn Enabled
[Mon] [ 15] seconds 15-999 [ 5] minutes 1-15 [0.0352500] [No ]
Auto Weekly Engine Enable Remote System Commissioned Analog Input 03 Aux User Program # 1
Test Start Time Keypad Date Offset: Horn Silence
[10:00:00] [ No] [31/12/99] DD/MM/YY [ 0.0000] [No ]
Auto Weekly Test LCD Back Light Mode DOUBLE SKINNED Analog Input 3 1225 Aux User Program # 1
Length Of Run Time 0=Always on FUEL TANK Minimum Counts LED Number
[30] minutes 30-99 [0]] 1=Power Save [No] [ 0] [ 0] 0-24
(1) 110 SYSTEM SETPOINTS (1) 213 USER PREFERENCES (2) 312 TECH SCREENS (-) ANALOG INPUT COUNTS (2) 510 AUX SETPOINTS
Auto Weekly Test Language Select ELECTRONIC ENGINE 649 1176 1221 12 Aux User Program # 1
Oil/Water Shutdown 0=English, 1=Spanish 12 Output1 Number
[No] [0] [Yes] [ 0] 0-24
(1) 111 SYSTEM SETPOINTS (1) 214 USER PREFERENCES (2) 313 TECH SCREENS (2) 424 BATTERY 1 (2) 511 AUX SETPOINTS
Power Failure Engine Change User Password Annunciator Sequence Constant A Aux User Program # 1
Startup Level 1 xA^3 + xB^2 + xC + D Output2 Number
[No] [****] [STND] [ 0.0000] [ 0] 0-24
Power Failure Engine Save ALL settings Load OID Hardware Constant B Aux User Program # 1
Start Delay Time to SD memory card Test Mode xA^3 + xB^2 + xC + D Output3 Number
[ 1] minutes 0-500 [No ] [NO ] [ 0.0000] [ 0] 0-24
(2) 113 SYSTEM SETPOINTS (1) 216 USER PREFERENCES (-) 316 TECH SCREENS (2) 426 BATTERY 1 (2) 513 AUX SETPOINTS
Pressure Transducer Load ALL settings Alarm resound timers Constant C Aux User Program # 1
Failure Engine Start from SD memory card 4Hrs 0Min 0Sec xA^3 + xB^2 + xC + D Record In Event Log
[Yes] [No] 24Hrs 0Min 0Sec [ 0.00978] [No ]
(2) 114 SYSTEM SETPOINTS (2) 217 USER PREFERENCES (-) 317 TECH SCREENS (2) 427 BATTERY 1 (2) 514 AUX SETPOINTS
Fail to start input Pressure Units Alarm Log 1/10 Constant D Aux User Program # 1
MB22 for unavailable Event Log 1/1569 xA^3 + xB^2 + xC + D Text Message Number
[No ] [bar] Pr. Log 1/25123 [- 0.05642] [ 0] 0-32
Shutdown On Low Engine Running chrg Dump Valve Volts per count Aux User Program # 1
Intake Contact Type failure alarm Delay time Engine Run Dependent
[NO ] [No] [0]s 0-999 [1.0000000] [ ]
Shutdown On Low Charger failure Pressure Minimum Amps Aux User Program # 1
Intake Pressure/Lvl delay time Transducer Shutdown in Test
[No ] [ 5]seconds 0-999 [Yes] [ 0.1] [ ]
Shutdown On Low Modbus Address Weekly Test Start Constant A Aux User Program # 1
Intake Trip Time Due Lamp Only xA^3 + xB^2 + xC + D Include in First-Up
[ 20]seconds 0-999 [ 1] 0-255 [NO] [ 0.0000] [ ]
(1) 118 SYSTEM SETPOINTS (2) 221 USER PREFERENCES (2) 321 TECH SCREENS (2) 431 BATTERY 2
Low Intake Shutdown RS485 com port Engine Running Constant B
Auto Reset Setting Speed xA^3 + xB^2 + xC + D
[Yes] [Device ] [600]rpm 200-999 [ 0.0000]
Low Intake Shutdown Modbus/Printer baud Engine Overspeed Constant C
Auto Reset Time Alarm xA^3 + xB^2 + xC + D
[ 20]seconds 0-999 [9600] [3600]rpm 1000-9999 [ 0.00978]
Pressure Switch Modbus Parity Pulses Per Constant D
Engine Start Revolution xA^3 + xB^2 + xC + D
[No ] [None] [0] 0-999 [- 0.05642]
Deluge Valve RESTART Mode Select Volts per count
Engine Start WIFI 0=US, 1=EU
[Yes] [No] [1] [1.0000000]
(2) 122 SYSTEM SETPOINTS (2) 435 BATTERY 2
High System Pressure Minimum Amps
Alarm (1)= level 2 password
[175.0]psi 999.9 (2)= level 2 password [ 0.1]
(2) 123 SYSTEM SETPOINTS (-)= no password
Engine Lockout
Latched
[NO]
(2) 124 SYSTEM SETPOINTS
Remote Start
Input Contact Type
[NO ]

The OID can view 3 main areas.
SYSTEMS STATUS. (both languages)

When the controller is switched on the OID will default to System Status screen 1 which
displays the
Fire Main Pressure.
The Start Pressure Setting.
Battery 1 and 2’s voltage and current.
SYSTEM LOGS. (both languages)

In System Logs it is possible to view 2 separate logs.
Event Logs (records alarms and system functions).
Pressure Logs (records pressure at set times).
CONFIG. (both languages)

In Config it is possible to view 5 separate areas.
System Setpoints. (both languages)
User Preferences. (both languages)
Tech Screen. (both languages)
Analog Signal. (both languages)
Auxiliary alarms. (both languages)
It may be necessary to change the Start Pressure, this can be done in System Setpoints.
To change the Start Pressure press the following pushbuttons in order.

Config button (2) once.
Button 1 (System Logs) once.
Change/Enter button once.
Buttons 1, 2 or 3 to enter the password.
Default value is 1111.
Up and Down buttons to change the digit.
Change/Enter to move to the next digit.
When the new number is complete press
Change/Enter to accept.
System Status
Check that the new Start Pressure is correct.
It may be now necessary to change the Stop Pressure, to do this press the following
pushbuttons in order.
Config button (2) once.
Button 1 (System Logs) once.
Up and Down buttons to scroll screens, go to 102.
Change/Enter button once.
Buttons 1, 2 or 3 to enter the password.
Default value is 1111.
Up and Down buttons to change the digit.
Change/Enter to move to the next digit.
When the new number is complete press
Change/Enter to accept.
System Status
Check that the new Stop Pressure is correct.
The remaining screens are not required for normal operation of the controller, if they are
required consult the Service Manual.
10. ENERGISING THE CONTROL SYSTEM.
Close all CB’s and close the AC isolator.
Visual. Power.
Auto Mode (see note).
Battery 1 Healthy
Battery 2 Healthy
Audible. Silent.
Display shows. Water Pressure.

Start Pressure.
Battery 1 Volts & Amps.
Battery 2 Volts & Amps.
NOTE. The controller will energise in the mode according to the mode switch.
11. LAMP TEST.
Press the Silence/Lamp test pushbutton for least 5 seconds, the indicators will illuminate for 2s,
and will then be extinguished for 2s. This on and off cycling procedure of the indicators will
continue while the lamp test push button is pressed, proving that the indicators can be turned
on and off.
12. RESET.
To reset an alarm, press the Reset/Esc pushbutton for at least 1 second.

13. MUTE.
To silence an alarm the Silence/Lamp Test pushbutton must be pressed and then released. The
mute facility now either silences the alarm sounder for either 4, or 24 hours depending upon
the source of the alarm. After this time period if the alarm is still present then the alarm
sounder will be activated again. For example:
These alarms have a 4 hour silence feature:

Low oil pressure, high water temperature, failed to start , engine over speed.
These alarms have a 24 hour silence feature:

Battery failure, charger failure, low fuel level, low engine temperature.
14. AC SUPPLY MONITORING.
Switching on the AC isolator will supply the Battery Charger circuit breaker CB1 and CB5
which protectS the Engine Heater circuit.
AC SUPPLY FAILURE.
Should the AC supply fail the battery chargers will be de-energised, their internal circuit senses
this and after a short delay.
Visual. AC Power Loss (due to both chargers failing).

Then after a delay of 30 seconds.
Visual. Charger 1 Failure.

Charger 2 Failure.
System Fault.
Volt free. System Failure.
Audible. Muteable.
When the AC supply is restored the AC supply alarms will clear.
15. HEATERS.
ENGINE HEATER (Option).

Engine Jacket Heater supply is protected by CB5 and when switched on will supply the engine
heater via terminals L1 & L2.
PANEL HEATER (Option).

The panel heater supply is protected by fuse F. A thermostat TH controls the panel heater.
With the thermostat TH above ambient. Heater Warms.
With the thermostat TH below ambient. Heater Cools.

Set the thermostat to 30 Deg C.

16. DC SUPPLY MONITORING.
BATTERY VOLTAGE AND CURRENT.

Battery voltage and charge current can be viewed on the LCD display mounted on the door.
BATTERY FAILURE.
If a Battery 1 is disconnected.
Visual. Battery 1 Healthy – goes out

System Fault.
Audible. Muteable, for 24 hours.
When the battery as been reconnected, the Controller must be reset for the alarms to clear.
If a Battery 2 is disconnected.
Visual. Battery 2 Healthy – goes out.

System Fault.
When the battery as been reconnected, the Controller must be reset for the alarms to clear.
If both batteries are disconnected:
Visual. Battery 1 Healthy – goes out.

Battery 2 Healthy – goes out
System Fault – on
Loss of DC power - on.
Audible. Non-Mutable.
Volt free. System Failure

Not in Auto

17. BATTERY CHARGING.
This battery charger is intended for use only in Metron Eledyne control systems. Use of an
attachment / connector not recommended or sold by Metron Eledyne may result in a risk of
fire, electric shock, or injury to persons.
Do not in any circumstances disassemble the battery charger, there are no user serviceable
parts inside. Incorrect reassembly may result in risk of electric shock or fire.
WARNING NOTICE
The performance of the battery charger is entirely automatic. No operator variables are
provided, the charger is factory preset to the required float voltage, at a maximum current of 10
Amps and NO ADJUSTMENTS MUST BE ATTEMPTED ON SITE or damage to the
batteries may result. Maintenance of batteries should be carried out in accordance with the
instructions issued by the battery manufacturer.
RISK OF EXPLOSIVE GASSES.

WORKING IN THE VICINITY OF A LEAD ACID/ NI CAD BATTERY IS DANGEROUS .
BATTERIES GENERATE EXPLOSIVE GASSES DURING NORMAL BATTERY
OPERATION.
To reduce the risk of battery explosion read this manual completely, and the battery
manufacturers data. Equipment used in the vicinity of the batteries should also be carefully
selected to reduce the risk of battery explosion.
PERSONAL PRECAUTIONS
1.Someone should be within range of your voice or close enough to come to your aid when you
work near a lead acid/ nicad battery.
2.Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or
eyes.
3.Wear complete eye protection and clothing protection. Avoid touching eyes while working
near the battery.
4.If battery acid contacts skin or clothing , wash immediately with soap and water. If acid
enters eye immediately flush with running cold water for at least 10 minutes and get medical
attention immediately.
5.NEVER smoke or allow a spark flame in the vicinity of the battery or the engine.
6.Be extra cautious to reduce the risk of dropping a metal tool onto battery, it may spark or
short the circuit battery or other electrical parts that may cause explosion.
7.Remove personal metal items such as rings, bracelets, necklaces and watches when working
with an engine battery. Such engine batteries can produce a short circuit current high enough
to weld a ring or similar, causing a severe burn.
8.NEVER charge a frozen battery.
PREPARING TO CHARGE
Clean battery terminals. Be careful to prevent corrosion from coming into contact with the
eyes. Study all battery manufacturers specific precautions such as removing or not removing
cell caps during initial charging and verify that the maximum rate of charge is not exceeded.

18. CHARGER MONITORING.
CHARGER FAILURE.
Should Charger 1 stops charging, its internal circuits will sense this and after a delay of 160
seconds.

System Fault.
If the charger starts to charge again the Charger Failure alarms will clear.
Should Charger 2 stops charging, its internal circuits will sense this and after a delay of 160
seconds.

System Fault.
If the charger starts to charge again the Charger Failure alarms will clear.
19. MANUAL MODE.
Select manual mode by using the mode selector switch.
Visual. Manual Mode.

Auto Mode goes out.
NOTE. MANUAL MODE SHOULD ONLY BE USED FOR COMMISSIONING OR

MAINTENANCE.
MANUAL START.
To start, press either ‘Crank Battery 1’ or ‘Crank Battery 2’ pushbuttons, PB1 or PB2, their
contacts will energise the start solenoids via terminals 9 or 10 cranking the engine from their
respective battery.
The battery chargers will be inhibited and the via terminal 1 the ‘Fuel Solenoid’ will be
energised
The pushbutton must be released when the ‘Engine Running’ lamp is illuminated which should
be almost immediate.
ENGINE RUNNING.
When the engine runs up to speed the speedswitch connected to the engine speed sender unit,
will energise the engine running input, terminal 2.
Visual. Engine Running.
Volt free. Engine Running.
ENGINE SHUTDOWN (MANUAL).

Pressing the Engine Stop pushbutton PB3 will result in terminal 12 the Energise To Stop
solenoid output energising, and terminal 1 the ‘Fuel Solenoid’ output de-energising.
20. AUTOMATIC MODE.
Select automatic mode by using the mode selector switch.
Visual. Auto Mode.

Manual Mode goes out
Volt Free. Automatic Mode.*
* Note:
When all power is lost to the controller then the volt free contacts will show ‘Not in Auto’
Controller is in now Standby. Manual start is inhibited.
LOW PRESSURE AUTOSTART.

Should the fire main water pressure fall to below the Engine Start Pressure set point, the
Engine Start Delay timer will be energised. When the timer times out a crank sequences will
begin, the engine will be cranked alternatively from both batteries via terminals 9 or 10 for 15
seconds.
The Engine Start Pressure can be set in System Setpoints screen 101.
The Engine Stop Pressure can be set in System Set Points screen 102.
The Engine Start Delay timer can be set in System Setpoints screen 103.
NOTE: The start pressure MUST be set to a lower value than the stop pressure.
A crank sequences begins, the engine will be cranked alternatively from both batteries via
terminals 9 or 10 for 15 seconds.
Visual. Pump on Demand.
Volt Free. Pump on Demand.
If the start signal is removed, the crank sequence will continue.

DELUGE VALVE.
Should a deluge valve signal be received at terminal 16, the Engine Start Delay timer will be
energised. When the timer times out the crank sequence will begin, the engine will be cranked
alternatively from both batteries via terminals 9 or 10 for 15 seconds.
If the start signal be removed, the crank sequence will continue.
REMOTE START.
Should a remote start signal be received at terminal 17, a crank sequence will begin (no time
delay), the engine will be cranked alternatively from both batteries via terminals 9 or 10 for 15
seconds.
Note: the remote start input can be selected for normally open or normally closed starting,
settable in screen 124.
If the start signal be removed, the crank sequence will continue.
ENGINE RUNNING.
When the engine runs up to speed the speedswitch connected to the engine speed sender unit,
will energise the engine running input, terminal 2, cranking will cease immediately..
Visual. Engine Running.
Volt free. Engine Running.
ENGINE SHUTDOWN IN AUTO.

Pressing the Engine Stop pushbutton PB3 will result in terminal 12 the Energise To Stop
solenoid output energising, and terminal 1 the ‘Fuel Solenoid’ output de-energising.
An AUTOSTART SIGNAL INHIBITS the Engine Shutdown pushbutton.
21. CRANK SEQUENCE.
Once a sequence is initiated, crank attempts occur alternately from each battery.
If the engine fuel system is held off and cranking is allowed to proceed.
Crank solenoid A energises for 15 sec’s.

Cranking ceases for 15 sec’s.
Crank solenoid B energises for 15 sec’s.

Cranking ceases for 15 sec’s.
The cycle repeats until a total of six alternate crank attempts have occurred.
BATTERY FAILURE DURING CRANKING.

As the starter motor engages, the battery voltage dips briefly to a low value and then recovers
to a higher steady value during cranking. With a poor battery, the voltage remains low. The
cranking will be transferred to the other battery.
FAILED TO START.
When the crank sequence has completed the six attempts, a Failed to start alarm will occur.
Visual. Engine Failed to Start.

System Fault.
Volt free. Failed to Start.

System Failure.
If a failed to start alarm occurs and the start signal has cleared, the controller can be reset to
return it to standby (To reset, turn the mode switch to the ‘Off’ position and press the reset
push button). If the controller is reset when a start signal remains it will repeat the crank
sequences.
Note: In addition to the above, the fuel solenoid output, energise to run on terminal 1, will
remain on for 1 hour after the failed to start or engine quit alarm is set. This feature is fitted
(and required by Factory Mutual) in case of a speed switch failure and since the engine could
actually be still running. To cancel the 1 hour fuel solenoid timer, either press the stop
pushbutton or turn the mode switch to the ‘off’ position at anytime.
22. OVERSPEED.
Should an overspeed signal be received at terminal 3 the engine will be shutdown.
Then. Engine fuel solenoid shuts off the fuel.

Engine stops.
Autostart is inhibited, but Manual start is available.
Visual. Engine Overspeed.

Available for Autostart goes out.
Volt Free. System Failure.

The controller remains latched in the ‘Overspeed’ condition until the speed switch on the
engine and the controller are reset.
23. ENGINE LUBE OIL PRESSURE LOW.
The Engine Running signal enables the low oil pressure alarm and it is delayed to allow the
pressure to rise.
After a delay.
Visual. Engine Lube Oil Pressure Low.
24. ENGINE HIGH WATER TEMPERATURE.
The Engine Running signal enables the high water temperature alarm and it is delayed to
enable the water temperature to stabilize.
Visual. Engine High Water Temperature.
25. ENGINE FUEL LEVEL LOW.
There is a 2 second on delay before the low fuel level alarm is activated, then:
Visual. Engine Fuel Level Low.
26. ENGINE LOW COOLANT TEMPERATURE.
Should the engine low coolant temperature alarm be activated, then:

Visual. Engine Low coolant temperature.
Audible. Muteable, for 24 hours..

27. ENGINE HIGH COOLING WATER TEMPERATURE.
The Engine Running signal enables the high cooling water temperature alarm and it is delayed
to enable the system to stabilize, then:
Visual. Engine high cooling water temperature.
28. ELECTRONIC ENGINES.
If the fire pump engine driver is an electronic type, then the following 2 additional alarms must
be fitted. These alarms are enabled by selecting ‘Yes’ in screen 326.
28 A) ECM Selector Switch in alternate position alarm.

Should this alarm be activated, then:
Visual. ECM selector Switch in Alt. position
28 B) Fuel Injector Malfunction alarm.

Visual. Fuel Injector Malfunction
28 C) ECM Warning.
Visual. ECM Warning
28 D) ECM Failure.
Visual. ECM Failure

29. CLOGGED WATER STRAINER.
The Engine Running signal enables the Clogged Water Strainer and it is delayed to enable the
system to stabilize, then:
Visual. Clogged Water Strainer temperature.
30. DOUBLE SKINNED FUEL TANKS.
If the fire pump set has a double skinned fuel tank, then an additional alarm must be fitted.
This alarm is enabled by selecting ‘Yes’ in screen 325.
The additional alarm is Fuel tank leak, and should this alarm be activated, then:
Visual. Fuel Tank leak
31. WEEKLY TEST START.
NFPA 20 states that the engine should be run once each week for a minimum of 30 minutes.
Set weekly start timer and stop timer can be set using screens 105 through to 109 in System
Setpoints.
When the timer activates. A crank sequence is initiated.
The engine will now run for the allotted test time and then shutdown.
32. CONTACTOR COIL FAILURE
Should the DC engine contactor coils loose continuity (either short circuit or open circuit) then,
after a short delay:
Visual. Contactor Fault
Audible. Muteable
Volt free System fault

33. ENGINE QUIT (V4.1)
If the suddenly engine stops on its own, without the controller energising the stop solenoid on
terminal 12 (either from the stop push button being pressed, auto stop timer or shutdown in test
functions) then:
Visual. System Fault
Audible. Muteable
Volt free System fault
In addition to the above, the fuel solenoid output, energise to run on terminal 1, will remain on
for 1 hour after the failed to start or engine quit alarm is set. This feature is fitted (and required
by Factory Mutual) in case of a speed switch failure and since the engine could actually be still
running. To cancel the 1 hour fuel solenoid timer, either press the stop pushbutton or turn the
mode switch to the ‘off’ position at anytime.
34. SD MEMORY CARD
The controller is equipped with an SD (Secure Digital) memory card on the motherboard to
store the Pressure log, Event log, and Auxiliary Alarm configuration information.
The SD card is located on the right hand edge of the motherboard and is removed by pressing
in on the right edge of the card to release from the card holder. When the SD card is removed,
data is still being recorded on temporary flash memory on the motherboard. Once the card is
replaced, the stored data will be written back to the SD Card. When the SD card is removed,
the LCD display will indicate that the card is missing and that is should be replaced. If the card
is not replaced within approximately 1 minute, the alarm will sound and the System Fault LED
will come on. Once the SD card is replaced, the System Fault LED will go out but the Alarm
Silence button must be pressed to silence the alarm horn. The data stored on the SD card is in
standard ASCII text format and can be read by an computer equipped with an appropriate SD
card reader. These are readily available at any electronics store, the maximum size to be used is
1 Gigabyte. The data on the SD card is in the following format:
PressXXX.txt file
This file contains a log of the water pressure, battery 1 and 2 actual voltage, and charger 1 & 2
actual output current and is stored every 15s.
Data is stored in a standard comma delimited file as follows:
07/27/07, 11:07:52, 060 12.5 12.6 0.50 2.10
Date Time Pressure Battery 2 charger current
Battery 1 Charger current
Battery 2 voltage
Battery 1 Voltage
Each file starting with “Press” contains one days worth of pressure data. XXX denotes the date
day of the pressure log.

Events.txt file
Data is stored in a standard comma delimited file as follows:
07/27/07 ,11:09:26 ,Battery2 Low Voltage, Alarm Cleared ,060 cont……
Date Time Event Action Pressure
1, 0, 0, 0, 1, 1, 0, 0, 000
Auto mode,
Engine running,
Charger 1 Fault,
Charger 2 fault,
Battery 1 OK,
Battery 2 OK,
AC power Loss
Low Fuel Level
Event Txt
The last four digits of each event is battery 1 and 2 actual voltage, and charger 1 & 2 actual
output current

35. Special modes of operation specifically for the FD4eU – Option N1
When option N1 is fitted to the FD4eU, then the diesel engine mounted speed pick up device
may be connected directly to the controller. This allows the controller to ‘see’ the actual engine
speed via an electronic module, called PC257 – speed collection board. When the controller
detects engine speed, then the status screen 1, will remove the system start pressure and instead
display the engine RPM.
To set up this function, the following screens are used:
320 Engine running Speed 300-999rpm
This tells the controller at what rpm to stop cranking the engine in automatic mode
(sometimes called crank termination speed). It is at this speed that the engine is defined as
running. This should typically be set at 600 rpm.
321 Engine Overspeed Alarm 1000-9999rpm

When the engine speed exceeds this value, then the engine overspeed alarm is set, and
the engine is automatically shutdown. It should typically be set according to NFPA 20 at the
normal engine rated speed plus 20%.
Note that for test purposes this value can be temporarily set to a lower value to verify the
operation of the engine overspeed system. However, please be sure to set the engine overspeed
parameter 321 back to the full setting when the testing is completed.
322 Pulses per Revolution 0-999

This is a very important set point, since the system uses this value along with the
number of pulses received from the engine to determine the actual RPM of the engine. Note
that if the engine is already equipped with a dedicated speed switch then this parameter 322
should be set to 0, then terminal 2 and 3 should be wired to give the engine run and overspeed
conditions.
36. DISPOSAL.
Metron Eledyne are a member of a compliance scheme under the Waste Electrical and
Electronic Equipment regulations which is applicable in all EEC countries. At the end of the
service life of the equipment the company offers to collect and dispose of this equipment in
accordance with regulations in force under the Registration Number WEE/CF0105WV.
(Equipment must be suitably packed for collection by courier if outside the UK)
Contact: Tel + 44 (0)1476 516120 Fax. + 44 (0)1476 516121 .

PART 5
CONTROL PANEL FOR JOCKEY PUMP
(TORNATECH)
Models : JP1 / JP2 / JP3 / JFA
1 2
Model #
Serial # Mfg Date:
Line Volt Phase / H

HP Ctr. Volt.
FLC Max. Pres.
Ampacity NEMA Type L1 L2 L3
LRC Amp
Options
Schema
C1
T1 T2 T3
3 4
HAND AUTO
C1 C1
T1 T2 T3 T1 T2 T3
HAND AUTO HAND AUTO HAND AUTO HAND AUTO
5 sec.
04 - 2015 1/2
8
UNIT
CUT-OUT
CUT-IN
ON TIMER
CUT-IN
OFF TIMER
CUT-OUT
9
GREEN
HAND AUTO HAND AUTO

OK
See complete IO&M on
2 sec.
tornatech.com
04 - 2015 2/2
SHORTCUTS FOR DISPLAYING VALUES
HAND AUTO HAND AUTO HAND AUTO
CUT-OUT RUN PERIOD TIMER START COUNT

(OFF TIMER)
CUT-IN SEQUENTIAL START ELAPSED TIME

TIMER (ON TIMER) METER (HOURS)
1 2
Model #
Serial # Mfg Date:
Line Volt Phase / H

HP Ctr. Volt.
FLC Max. Pres.
Ampacity NEMA Type L1 L2 L3
LRC Amp
Options
Schema
C1
T1 T2 T3
3 4
HAND AUTO
C1 C1
T1 T2 T3 T1 T2 T3
HAND AUTO HAND AUTO HAND AUTO HAND AUTO
5 sec.
04 - 2015 1/2
8
UNIT
CUT-OUT
CUT-IN
ON TIMER
CUT-IN
OFF TIMER
CUT-OUT
9
GREEN
HAND AUTO HAND AUTO

OK
See complete IO&M on
2 sec.
tornatech.com
04 - 2015 2/2
SHORTCUTS FOR DISPLAYING VALUES
CUT-OUT RUN PERIOD TIMER START COUNT

(OFF TIMER)
CUT-IN SEQUENTIAL START ELAPSED TIME

TIMER (ON TIMER) METER (HOURS)
PART 6
FLOW METER (GERAND)
GERAND ENGINEERING CO.
2300 EDGEWOOD AVE S, MINNEAPOLIS, MN 55426 952.374.1320 WWW.GERAND.COM
Fire Pump Test Meter Operating Instructions
BRASS VENT VALVES

METER
PLASTIC VENT HOSE
CONNECTING HOSE
VENTURI
VENTURI SHUT-OFF VALVE
Attached to the meter with a brass chain is an oblong metal tag with the suggested piping diagram of the
system on one side, and the following operating instructions on the reverse side:
1. Close system OSY valve “A”

2. Open by-pass valve and “B” butterfly throttle valve
3. Purge meter, located on venturi, as follows:
a) Open station shut-off valves on venturi, and vent valves attached to meter.
When a steady stream of water without air bubbles passes through the clear plastic hoses,
the meter is purged of air.
b) Close the vent valves after purging.
4. Start the fire pump, and read meter in GPM.
5. Refer to pump GPM requirement and adjust throttle valve to meet the requirement.
6.After the test, open valve “A” and close the by-pass and “B” valves.
*SPECIFY RAISED OR FLAT FACE

GERAND GPM METER - VENTURI PACKAGE
“B” - Butterfly Throttle Valve OSY or Indicating
Butterfly Bypass Valve Flow SUGGESTED
TO RESERVOIR Air Vent PIPING
OR WASTE
DIAGRAM
(2) (5)
Optional to
Pump Inlet Min. Straight Pipe Diameters same line size as Venturi
OSY Valve “A” OSY Valve

Flow
Supply from
City Main or
Reservoir To System
FIRE PUMP
Fire Pump Test Meter Installation Instructions
Materials shipped will be as follows:
– One factory calibrated direct reading GPM meter with vent valves and clear hoses assembled and
attached to the meter. The lens of the meter has an “FM Approved” sticker adhered to it as well as a
metal meter tag with the Gerand model number, maximum rated PSI and serial number.
– One calibrated Gerand venturi with an attached metal tag listing the venturi size, the pump GPM, the
meter range and the PSI rating. Adhered to the venturi is a “flow sticker” with an arrow showing the
direction of flow and the suggested minimum straight upstream and downstream pipe diameters.
– One set of 500 PSI hoses with color code ends and brass fittings to connect meter to the venturi.
– One metal installation/operation tag permanently attached to meter via brass chain.
Installation Instructions:
– The venturi must be installed in line with the flow of the system going in the same direction as the arrow
shown on the venturi. A minimum of (5 x Venturi Diameter) in straight pipe upstream and (2 x Venturi
diameter) in straight pipe downstream. The straight pipe lengths must be the same diameter as the venturi.
For example: a 6” Diameter Venturi requires 30” of 6” diameter straight pipe upstream
and 12” of 6” diameter straight pipe downstream of the venturi.
– If the system has been piped with many elbows in the same or in different planes, we suggest longer
straight runs upstream & downstream. These pipe diameters must be the same pipe size as the venturi.
– The meter is then attached via the screws to the welded bracket on the venturi.
– Once the meter is secured to the venturi, screw the ends of the hoses with no valves to the meter (red
to red; green to green). Then, thread the valve ends of the hoses to the venturi (red to red; green to green.
*SPECIFY RAISED OR FLAT FACE

GERAND GPM METER - VENTURI PACKAGE
“B” - Butterfly Throttle Valve OSY or Indicating
Butterfly Bypass Valve Flow SUGGESTED
TO RESERVOIR Air Vent PIPING
OR WASTE
DIAGRAM
(2) (5)
Optional to
Pump Inlet Min. Straight Pipe Diameters same line size as Venturi
OSY Valve “A” OSY Valve

Flow
Supply from
City Main or
Reservoir To System
FIRE PUMP
PART 7
PRV (CLAVAL)
MODEL
50B-4KG1 Globe
2050B-4KG1 Angle
Listed/Approved Fire Protection Pressure Relief Valve
• UL Listed / ULC Listed

• Factory Mutual Approved
• Fast Opening to Maintain Steady Line Pressure
• Accommodates Wide Range of Flow Rates
• Closes Gradually for Surge-Free Operation
• Adjustable Pressure Settings, Not Affected by
LISTED Pressure At Valve Discharge
The Cla-Val Model 50B-4KG1 Globe / 2050B-4KG1 Angle

Pressure Relief Valve is designed specifically to automatical-
ly relieve excess pressure in fire protection pumping sys-
tems. Pilot controlled, it maintains constant system pressure
2050B-4KG1 (Angle)
at the pump discharge within very close limits as demands
DESIGN
change. The 50B-4KG1 and 2050B-4KG1 can be supplied
UL Listed...............Sizes 3" thru 8" with optional internal and external epoxy coating of the main
ASSE
SSED
FM Approved.........Sizes 3" thru 8" valve wetted surfaces.
ULC Listed............Sizes 2” thru 10”
Type Approved
Typical Application KO Model 2050B-4KG1 Operation Sequence

Pressure Relief Valve
(Angle Pattern) At pump start, Cla-Val Relief Valve modulates to relieve
excess pump capacity, maintaining positive system pres-
sure at the pump discharge.
When fire demand slows or ceases, Cla-Val Model

50B-4KG1 opens, diverting entire pump output to dis-
charge, allowing fire pump to be stopped without causing
Fire Pump surging in the lines.
(Please note that if the Model 50B-4KG1 is to be used on

a continuous duty basis to maintain fire-system pressure,
suitable back pressure must be provided on the valve to
prevent cavitation damage. Consult the factory for details.)
Check Valve
Optional UL Listed Materials for Seawater and Severe

Service Applications:
• Nickel Aluminum Bronze (NAB) - ASTM B148 Alloy C95800
To Fire • Monel - QQ-N-288 Comp B - ASTM A494 Grade M30H
Protection System • Cast Steel - ASTM A216 Grade WCB
• 316 Stainless Steel - ASTM A743 Grades CF3M and CFM8
• Super Austenitic Stainless Steel - ASTM A351 Grade
CK3MCuN (SMO 254)
• Super Duplex Stainless Steel - ASTM A890 Grade 5A
"Fluid Control at It's Best" (CE3MN)
Specifications Dimensions
B
Sizes Globe: 2" - 10” flanged = U.L., F.M. and
Angle: 2" - 10" flanged ULC sizes
End Details 150 and 300 ANSI B16.42
Pressure Ratings Class 150 - 250 psi Max. G
= ULC sizes only
Class 300 - 300 psi Max
Water, to 180°F Max.
Model 50B-4KG1 Globe Model 2050B-4KG1 Angle
Standard Materials Main Valve Body & Cover
A H E
Ductile Iron ASTM A536 Grade 65-45-12
Standard Main Valve Trim:
Bronze Seat, Teflon Coated
Stainless Steel Stem, Dura-Kleen Stem
C
Standard Pilot Control System: C
Cast Bronze with
Stainless Steel trim
Available in the following relief
pressure ranges: D F
Adjustment Range 20-200 psi (150 Class)
100-300 psi (300 Class) We recommend providing adequate space around valve for maintenance work.
Protective epoxy resin coating
of wetted surfaces of main Valve Size (inches) 2” 2-1/2” 3” 4” 6” 8” 10”
Optional valve cast iron components Threaded Ends 9.38 11.00 12.50 --- --- --- ---
(UL listed HNFX EX2855) A 150 Flanged 9.38 11.00 12.00 15.00 20.00 25.38 29.75
300 Flanged 10.00 11.62 13.25 15.62 21.00 26.38 31.12
300 X 150 12.88 15.31 20.56 25.88 30.44
Purchase Specifications B 3.31 4.00 4.56 5.75 7.88 10.00 11.81
The Fire Pump Pressure Relief Valve shall modulate to relieve excess C 12.00 12.25 12.50 13.00 14.31 16.31 18.00
pressure in a fire protection system. It shall maintain constant pressure D 1.50 1.69 2.66 3.19 4.31 5.31 9.25
in the system regardless of demand changes. It shall be pilot controlled Threaded Ends 4.75 5.50 6.25 --- --- --- ---
and back pressure shall not affect its set point. It shall be actuated by
E 150 Flanged 4.75 5.50 6.00 7.50 10.00 12.75 14.88
line pressure through a pilot control system and open fast in order to
300 Flanged 5.00 5.88 6.38 7.88 10.50 13.25 15.56
maintain steady system pressure as system demand decreases. It shall
close gradually to control surges and shall re-seat drip-tight within 5% of Threaded Ends 3.25 4.00 4.50 --- --- --- ---
its pressure setting. The main valve shall be of the hydraulically-operat- F 150 Flanged 3.25 4.00 4.00 5.00 6.00 8.00 8.62
ed, pilot-controlled, diaphragm-type, globe or angle valve. It shall have 300 Flanged 3.50 4.31 4.38 5.31 6.50 8.50 9.31
a single, removable, teflon-coated seat, a grooved stem guided at both G & H 6.00 6.69 7.75 7.88 8.50 9.75 13.25
ends, and a resilient disc with a rectangular cross section, being con-
tained on 3 1/2 sides. No external packing glands shall be permitted and Valve Size (mm) 50 65 80 100 150 200 250
the diaphragm shall not be used as a seating surface. The pilot control Threaded Ends 238 279 318 --- --- --- ---
shall be a direct-acting, adjustable, spring-loaded, diaphragm-type valve
A 150 Flanged 234 279 305 381 508 645 756
designed for modulating service to permit flow when controlling pressure
300 Flanged 254 295 337 397 533 670 790
exceeds spring setting. This valve shall be UL Listed and Factory Mutual
approved. It shall be the Model 50B-4KG1 (globe) or Model 2050B- 300 X 150 --- --- 327 389 522 657 773
4KG1 (angle) Pressure Relief Valve as manufactured by Cla-Val Newport B 84 102 116 146 200 254 300
Beach, California. C 305 311 1318 330 363 414 457
*Special Note: D 38 43 65 81 109 135 235
The Model 50B-4KG1 Pressure Relief Valve is available with 300# ANSI Threaded Ends 121 140 159 --- --- --- ---
inlet flange and 150# ANSI outlet flange. This valve is used on higher
E 150 Flanged 121 140 152 191 254 324 378
pressure systems where 300# flange connections are required, and
300 Flanged 127 149 162 200 267 337 395
allows for adapting of a discharge cone (generally supplied with 150#
flange) to accommodate "atmospheric break" at relief valve discharge. Threaded Ends 83 102 114 --- --- --- ---
This relief valve, with 300# / 150# flanges is available on special order, F 150 Flanged 83 102 102 127 152 203 219
and is UNDERWRITERS LABORATORIES LISTED AND FACTORY 300 Flanged 89 109 111 135 165 216 236
MUTUAL APPROVED. G & H 152 170 197 200 216 248 337
Specifications: Seawater Service Option

Sizes Globe: 2" - 8" flanged Valve Capacity
Angle: 2" - 8" flanged
Consult factory for flange ratings. Valve Sizes in Inches: 2" 2 1/2" 3" 4" 6" 8" 10"
See page 1 for seawater service materials options. NFPA 20 Maximum 208 300 500 1000 2500 5000 11000
CLA-VAL
1701 Placentia Avenue • Costa Mesa CA 92627
800-942-6326 Fax: 949-548-5441 Web Site: cla-val.com E-mail: info@cla-val.com
CLA-VAL CANADA CLA-VAL EUROPE CLA-VAL UK CLA-VAL FRANCE CLA-VAL PACIFIC
4687 Christie Drive Chemin des Mésanges 1 Dainton House, Goods Station Road Porte du Grand Lyon 1 45 Kennaway Road
Beamsville, Ontario CH-1032 Romanel/ Tunbridge Wells ZAC du Champ du Périer Woolston, Christchurch, 8023
Canada L0R 1B4 Lausanne, Switzerland Kent TN1 2 DH England France - 01700 Neyron New Zealand
Phone: 905-563-4963 Phone: 41-21-643-15-55 Phone: 44-1892-514-400 Phone: 33-4-72-25-92-93 Phone: 64-39644860
Fax: 905-563-4040 Fax: 41-21-643-15-50 Fax: 44-1892-543-423 Fax: 33-4-72-25-04-17 www.cla-valpacific.com
E-mail sales@cla-val.ca E-mail: cla-val@cla-val.ch E-mail: info@cla-val.co.uk E-mail: cla-val@cla-val.fr E-mail: info@cla-valpacific.com
E-50B-4KG1/2050B-4KGL1 (R-08/2017) ©COPYRIGHT CLA-VAL 2017 Printed in USA Specifications subject to change without notice.

9750 KSB Rot Man 0001 - B - Installation and Operating Manual

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COMMENT RESPONSE SHEET

9750-KSB-ROT-MAN-0001 INSTALLATION AND OPERATING MANUAL

Queries by EMPLOYER Clarifications by KSB

9750-KSB-ROT-MAN- Add devider "PART 1 INSTALLATION AND OPERATING MANUAL OF

9750-KSB-ROT-MAN- Add devider " PART 2 INSTALLATION AND OPERATING MANUAL OF

CONTRACTOR INFORMATION EMPLOYER'S INFORMATION

Company : KSB Department :

INSTALLATION AND OPERATING MANUAL

DOCUMENT NO. : 9750-KSB-ROT-MAN-0001

PT. TRIPATRA ENGINEERS AND CONSTRUCTORS

REV. ISSUED DATE STATUS PREPARED BY REVIEWED BY APPROVED BY

A 16-Apr-19 Issued for Review IL DK RM

Mat. No.: 01424629

Original operating manual

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft, Frankenthal 20.05.2014

3 Transport/Temporary Storage/Disposal .............................................11

4 Description of the Pump (Set) ............................................................14

5 Installation at Site ...............................................................................19

5.4 Piping .............................................................................................................. 20

9 Related Documents ............................................................................51

10 EC Declaration of Conformity ............................................................58

11 Certificate of Decontamination .........................................................59

Certificate of decontamination Pump

1.2 Installation of partly completed machinery

1.3 Target group

1.4 Other applicable documents

1) If agreed upon in scope of supply

2.3 Intended use

2.4 Personnel qualification and training

2.5 Consequences and risks caused by non-compliance with this manual

2.6 Safety awareness

2.7 Safety information for the operator/user

2.8 Safety information for maintenance, inspection and installation work

2.9 Unauthorised modes of operation

3.1 Checking the condition upon delivery

Fig. 1: Transporting the pump set

Setting down the pump set

Table 4: Ambient conditions for storage

3.5 Return to supplier

4 Description of the Pump (Set)

4.1 General description

4.4 Name plate

5 ID 9972040368 Seal. SiC/Ca/EPDM 12

H 46,3 m max. IA Direkt A

29 Impeller diameter [mm] 30 Maximum starting current (only relevant for

4.5 Design details

– Motor rating 5.5 kW and above: Motor need not be removed.

4.6 Configuration and function

Fig. 3: Sectional drawing

4.7 Noise characteristics

4.8 Scope of supply

4.9 Dimensions and weights

5.1 Safety regulations

5.2 Checks to be carried out prior to installation

5.3 Installing the pump set

5.4.1 Connecting the piping

5.4.2 Permissible forces and moments at the pump nozzles

Fig. 5: Forces and moments at the pump nozzles

Forces and moments at the pump nozzles

5.5 Fitting a by-pass

5.6 Electrical connection

If a motor of a different make is used, observe the relevant operating instructions.