100 en

Montsinéry - French Guiana
HGM
Operating Manual
Order number: 9974696285 HGM 2/12

Order item number: 100
Legal information/Copyright
Operating Manual HGM
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.
© 07/02/2022
Contents
Contents
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
1.6 Key to safety symbols/markings....................................................................................................................... 7
2 Safety ...................................................................................................................................................... 8
2.1 General.............................................................................................................................................................. 8
2.2 Intended use ..................................................................................................................................................... 8
2.2.1 Prevention of foreseeable misuse....................................................................................................... 8
2.3 Personnel qualification and training............................................................................................................... 9
2.4 Consequences and risks caused by non-compliance with this manual ......................................................... 9
2.5 Safety awareness .............................................................................................................................................. 9
2.6 Safety instructions for the operator/user........................................................................................................ 9
2.7 Safety information for maintenance, inspection and installation .............................................................. 10
2.8 Unauthorised modes of operation ................................................................................................................ 10
2.9 Explosion protection ...................................................................................................................................... 10
3 Transport/Storage/Disposal ................................................................................................................ 11

3.1 Checking the condition upon delivery .......................................................................................................... 11
3.2 Transport......................................................................................................................................................... 11
3.2.1 Transporting packaged pump set components ............................................................................... 12
3.2.2 Transporting partly packaged and unpackaged pump set components........................................ 13
3.3 Storage / preservation .................................................................................................................................... 17
3.4 Return to supplier........................................................................................................................................... 19
3.5 Disposal ........................................................................................................................................................... 20
4 Description............................................................................................................................................ 21
4.1 General description ........................................................................................................................................ 21
4.2 Product information as per Regulation No. 1907/2006 (REACH)................................................................. 21
4.3 Description ...................................................................................................................................................... 21
4.4 Pump signage ................................................................................................................................................. 22
4.4.1 Name plate ......................................................................................................................................... 23
4.5 Design details.................................................................................................................................................. 24
4.6 Configuration and function........................................................................................................................... 25
4.7 Dimensions and weights ................................................................................................................................ 26
5 Installation at Site ................................................................................................................................ 27

5.1 Checklist for assembly / installation .............................................................................................................. 27
5.1.1 Alignment certificate......................................................................................................................... 29
5.2 Checks to be carried out prior to installation............................................................................................... 30
5.3 Unpacking packaged pump set components................................................................................................ 31
5.4 Removing the preservation............................................................................................................................ 32
5.5 Preparing the coupling .................................................................................................................................. 33
5.5.1 Dismantling the coupling guard ....................................................................................................... 33
5.5.2 Checking the shaft ends for run-out ................................................................................................ 33
5.5.3 Fitting the coupling hubs (keyed connection) ................................................................................. 34
5.6 Drilling the holes for fastening the feet ....................................................................................................... 36
5.7 Mounting the baseplate ................................................................................................................................ 38
5.7.1 Placing the baseplate on the foundation......................................................................................... 38
5.7.2 Mounting the baseplate on the steel structure ............................................................................... 40
5.8 Aligning the coupling .................................................................................................................................... 41
5.8.1 Checking the coupling hubs for run-out .......................................................................................... 42
5.8.2 Checking the coupling alignment..................................................................................................... 43
5.8.3 Checking the coupling alignment with consideration of thermal expansion ............................... 44
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5.8.4 Permissible displacement................................................................................................................... 46

5.9 Aligning the pump and motor ...................................................................................................................... 47
5.9.1 Aligning the pump............................................................................................................................. 47
5.9.2 Aligning the drive .............................................................................................................................. 47
5.9.3 Correcting the alignment of the pump set components................................................................. 47
5.10 Fastening the baseplate ................................................................................................................................. 48
5.10.1 Fastening the baseplate to the foundation ..................................................................................... 48
5.10.2 Fastening the baseplate to the steel structure ................................................................................ 50
5.11 Piping .............................................................................................................................................................. 51
5.11.1 Prerequisites for connecting the piping ........................................................................................... 51
5.11.2 Cleaning the pipes ............................................................................................................................. 52
5.11.3 Fitting the strainer / minimum flow control valve........................................................................... 52
5.11.4 Connecting the piping....................................................................................................................... 54
5.12 Final installation of the pump set ................................................................................................................. 55
5.12.1 Mounting the pump on the baseplate ............................................................................................. 56
5.12.2 Performing the final check................................................................................................................ 57
5.13 Preservation for standstill (optional)............................................................................................................. 57
6 Commissioning/Start-up/Shutdown................................................................................................... 58
6.1 Commissioning/Start-up ................................................................................................................................. 58
6.1.1 Checklist for commissioning/start-up................................................................................................ 58
6.1.2 Prerequisites for commissioning/start-up ......................................................................................... 61
6.1.3 Electrical connection.......................................................................................................................... 62
6.1.4 Checking the direction of rotation ................................................................................................... 63
6.1.5 Checking the rotatability of the pump rotor ................................................................................... 65
6.1.6 Installing the coupling....................................................................................................................... 65
6.1.7 Checking the shaft seal...................................................................................................................... 66
6.1.8 Priming and venting the pump......................................................................................................... 68
6.1.9 Checks prior to commissioning/start-up ........................................................................................... 69
6.1.10 Start-up and trial run......................................................................................................................... 69
6.1.11 Mounting the sound insulating hood (if applicable) ...................................................................... 71
6.2 Operating limits.............................................................................................................................................. 71
6.2.1 Ambient temperature........................................................................................................................ 72
6.2.2 Frequency of starts............................................................................................................................. 73
6.2.3 Fluid handled ..................................................................................................................................... 73
6.3 Shutdown........................................................................................................................................................ 74
6.3.1 Measures to be taken for shutdown ................................................................................................ 74
6.3.2 Work after shutdown ........................................................................................................................ 75
6.4 Returning to service ...................................................................................................................................... 77
7 Servicing/Maintenance ........................................................................................................................ 78

7.1 General information/safety regulations........................................................................................................ 78
7.2 Supervision of operation................................................................................................................................ 79
7.3 Servicing/inspection........................................................................................................................................ 80
7.3.1 Servicing plan ..................................................................................................................................... 81
7.3.2 Inspection work.................................................................................................................................. 82
7.4 Drainage/cleaning .......................................................................................................................................... 83
7.5 Dismantling the pump set.............................................................................................................................. 85
7.5.1 Removing the sound insulating hood .............................................................................................. 85
7.5.2 Dismantling the coupling .................................................................................................................. 85
7.6 Removing the pump set from the system ..................................................................................................... 87
7.6.1 Removing the piping and instruments ............................................................................................. 87
7.6.2 Removing the pump from the baseplate ......................................................................................... 88
7.7 Dismantling the pump ................................................................................................................................... 88
7.7.1 Removing the mechanical seal.......................................................................................................... 88
7.7.2 Removing the thrust bearing, discharge-side radial bearing and balancing device ..................... 90
7.8 Reassembling the pump................................................................................................................................. 91
7.8.1 Fitting the thrust bearing and discharge-side radial bearing (without using new components) .....
91
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7.8.2Fitting the thrust bearing, discharge-side radial bearing and balancing device (using new
components)....................................................................................................................................... 93
7.8.3 Installing the mechanical seal ........................................................................................................... 95
7.9 Installing the pump set in the system ........................................................................................................... 97
7.10 Spare parts stock............................................................................................................................................. 97
7.10.1 Ordering spare parts.......................................................................................................................... 97
7.10.2 Recommended spare parts stock ...................................................................................................... 98
8 Trouble-shooting................................................................................................................................ 100
8.1 Reporting faults............................................................................................................................................ 102
9 Relevant Documentation................................................................................................................... 104

9.1 Pump set........................................................................................................................................................ 105
9.1.1 Declaration of conformity ............................................................................................................... 106
9.1.2 Technical data .................................................................................................................................. 109
9.1.3 Characteristic curves ........................................................................................................................ 112
9.1.4 General arrangement drawings...................................................................................................... 114
9.1.5 Operating range for version with variable speed drive ................................................................ 116
9.1.6 Weights............................................................................................................................................. 136
9.1.7 Clearances......................................................................................................................................... 137
9.1.8 Thread sizes for dismantling / reassembly aids .............................................................................. 138
9.1.9 Tightening torques .......................................................................................................................... 139
9.2 Pump ............................................................................................................................................................. 142
9.2.1 Operating data................................................................................................................................. 143
9.2.2 Noise characteristics......................................................................................................................... 146
9.2.3 General drawings with list of components .................................................................................... 152
9.3 Coupling........................................................................................................................................................ 191
9.4 Drive .............................................................................................................................................................. 214
9.5 Minimum flow control valve........................................................................................................................ 359
9.6 Valves and equipment.................................................................................................................................. 405
9.7 Instruments ................................................................................................................................................... 411
9.8 Gear unit ....................................................................................................................................................... 487
9.9 Protective equipment................................................................................................................................... 488
Index ................................................................................................................................................... 489
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1 General
1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating 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.
KSB specialist personnel must be called in for installation, commissioning/start-up and
maintenance. KSB will only assume responsibility for faultless execution of the work
and for the safety of the personnel involved if dismantling/reassembly and
maintenance have been performed by KSB’s specialist team.
In the event of damage, immediately contact your nearest KSB service facility 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 2.3, Page 9)
1.4 Other applicable documents

Table 1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manuals, order documentation and
other product literature describing accessories and
integrated machinery components
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
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1 General
1.6 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
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.
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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 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.
▪ Comply with all the safety instructions given in the individual sections of this
operating manual.
▪ 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 and markings 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.
2.2 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.
▪ 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 (set) to handle the fluids described in the data sheet or
product literature of the pump model.
▪ Never operate the pump (set) without the fluid to be handled.
▪ 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.).
▪ Always operate the pump (set) in the direction of rotation it is intended for.
▪ 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.
2.2.1 Prevention of foreseeable misuse

▪ Never exceed the permissible application and operating limits specified in the
data sheet or product literature regarding pressure, temperature, etc.
▪ Never open the discharge-side shut-off elements further than permitted.
– The maximum flow rates specified in the product literature or data sheet
would be exceeded.
– Risk of cavitation damage
▪ Observe all safety information and instructions in this manual.
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2 Safety
2.3 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.
2.4 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
2.5 Safety awareness

In addition to the safety information contained in this operating 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
2.6 Safety instructions 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.)
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2 Safety
2.7 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 are
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.
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ 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 58)
2.8 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.
(ð Section 2.2, Page 8)
2.9 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).
Especially adhere to the sections in this manual marked with the Ex symbol and the
following sections, to
The explosion-proof status is only assured if the product is used in accordance with its
intended use.
Never operate the product outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.
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3 Transport/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 and the insurer about the damage in writing
immediately.
3.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in the specified position.
▷ Observe the information on weights, centre of gravity and fastening points.
▷ Observe the applicable local accident prevention regulations.
▷ Use suitable, approved lifting accessories.
WARNING
Lack of stability
Serious injuries due to parts tipping over!
▷ Only place the pump (set) on surfaces designed for this purpose.
▷ Comply with the requirements on the load-bearing capacity of the floor. Check
the load-bearing capacity of the floor. Consult the building drawing and
installation plan.
▷ Pay attention to the centre of gravity of the pump (set).
▷ Refer to the Table of weights for the weight of the pump, the pump set or the
packaging unit.
The pump set components are supplied in packaged, partly packaged or unpackaged
condition.
▪ Transporting packaged pump set components:
(ð Section 3.2.1, Page 12)
▪ Transporting partly packaged and unpackaged pump set components:
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3.2.1 Transporting packaged pump set components
WARNING
Improper unpacking of transport boxes
Risk of injury from falling parts and/or transport boxes tipping over
▷ Secure parts against tipping over backwards (e.g. box lids).
▷ Wear suitable protective clothing such as a safety helmet and safety shoes with
toe caps as well as safety goggles and protective gloves.
Fig. 1: Transporting the transport box

ü The weights have been checked in the packing list / table of weights.
ü Transport equipment / lifting equipment suitable for the corresponding weight
has been selected and is on hand.
ü Attention has been paid to the centre of gravity, the angle of spread α and the
permissible bending radii.
1. Attach the transporting equipment / lifting equipment in accordance with the
corresponding markings.
2. Transport the transport box to the place of installation.
3. Carefully lower the transport box at the place of installation.
4. Unpack packaged pump set components. (ð Section 5.3, Page 31)
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3.2.2 Transporting partly packaged and unpackaged pump set components
CAUTION
Improper transport
Damage to the pump components!
▷ Always protect pump components from direct contact with chains or steel
ropes.
▷ Protect add-on parts and pipes.
3.2.2.1 Transporting the pump (set)
Transport with baseplate
A A
B B
Fig. 2: Transporting the pump with baseplate (example)
A Fastening points B Transport frame
A A A A
A
A
B B B
Fig. 3: Transporting the pump set with baseplate (example)
A Fastening points B Transport frame
1. Protect add-on parts and piping against damage.
2. Attach lifting equipment to the pump and/or baseplate in accordance with the
markings.
3. Transport the pump (set) to the place of installation.
4. Carefully place down the pump (set) at the place of installation.
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Transport without baseplate

1 2
Fig. 4: Transporting the pump without baseplate (example)

1 Pump without transport frame 2 Pump with transport frame
1. Protect add-on parts and piping against damage.
2. Attach lifting equipment to the pump in accordance with the markings.
3. Transport the pump to the place of installation.
4. For pumps with transport frame, remove the transport frame from the pump.
5. Insert the marked shims between the pump feet and the baseplate.
6. Carefully place the pump on the baseplate.
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3.2.2.2 Transporting the pump rotor
DANGER
The pump rotor could slip out of the suspension arrangement
▷ Never use steel ropes or chains for transport.
▷ Use manila ropes or plastic ropes.
▷ Transport the pump rotor in a horizontal position.
Fig. 5: Transporting the pump rotor

ü The weight has been checked in the packing list / table of weights.
1. Attach lifting equipment to the pump rotor in accordance with the markings.
2. Transport the pump rotor to the place of installation.
3. Carefully place down the pump rotor at the place of installation. Protect it
against damage and secure it against rolling off.
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3.2.2.3 Transporting the accessories
CAUTION
Improper transport of strainer/filter
Damage to the strainer/filter caused by lifting tackle!
▷ Do not exert pressure on the screen and screen mesh or damage them.
▷ Transport accessories by hand. If transporting by hand is not possible due to the
weight, observe the applicable regulations.
1 2 3
4 5 6
Fig. 6: Transporting the accessories
1 Conical strainer 4 Basket strainer
2 Strainer housing 5 Y-strainer
3 Minimum flow control valve 6 Cylindrical strainer
ü The manufacturer's product literature is available.
ü The weight has been checked in the packing list / table of weights or in the
manufacturer’s product literature.
1. Attach the lifting equipment in accordance with the manufacturer's product
literature.
2. Transport the accessories to the place of installation.
3. Carefully place down the accessories at the place of installation. Protect it
against damage and secure it against rolling off.
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3.3 Storage / preservation
Storage
WARNING
Lack of stability
Serious injuries due to parts tipping over!
▷ Only place the pump (set) on surfaces designed for this purpose.
▷ Comply with the requirements on the load-bearing capacity of the floor. Check
the load-bearing capacity of the floor. Consult the building drawing and
installation plan.
▷ Pay attention to the centre of gravity of the pump (set).
▷ Refer to the Table of weights for the weight of the pump, the pump set or the
packaging unit.
WARNING
Improper storage
Impairment of the static sealing elements’ function!
Risk of burns, scalds, and cuts caused by fluid jets in the event that hot fluid
handled escapes!
▷ Never store static sealing elements together with chemicals, solvents, fuels,
acids, etc.
▷ Protect static sealing elements from light, in particular from direct sun exposure
and strong artificial light high in ultraviolet rays.
▷ Protect static sealing elements from deformation.
CAUTION
Damage during storage due to humidity, dirt or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the pump (set) or the packaged pump (set) and
accessories with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage of the pump set!
▷ Only remove caps/covers from the openings of the pump set at the time of
installation.
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
▪ Store the pump set and its components in a dry, protected room with constant
atmospheric humidity.
Table 4: Ambient conditions for storage

Ambient condition Value
Ambient temperature -20 °C to +50 °C
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Preservation
WARNING
Improper handling of materials and supplies
Risk of injury due to contact with hazardous substances!
▷ Observe the relevant safety instructions for the handling of hazardous
substances (wear safety goggles and protective gloves, for example).
Storage ≤ 12 months Standard preservation is suitable for up to 12 months of storage.
Table 5: Preservation for storage ≤ 12 months

Type of preservation Preservative To be preserved
1)
External preservation Anticorit BML3 Exposed machined parts and uncoated parts, e.g.
shaft ends, couplings and flange faces
Internal preservation Anticorit BML31) Exposed machined internal parts of the pump, e.g.
(Not applicable to pumps with casing inside, shafts, impellers and diffusers
stainless steel materials)
Storage > 12 months
WARNING
In the case of storage periods of more than 5 years, the sealing function of O-rings
may be impaired.
Risk of burns, scalds and cuts caused by fluid jets in the event that hot and
pressurised fluid handled escapes!
▷ After a storage period of more than 5 years, replace the O-rings.
▷ Check the O-rings for damage before they are fitted.
CAUTION
Anti-corrosive protection of applied preservatives wearing off
Corrosion damage, damage to the pump (set)!
▷ Replace the desiccants every 12 months.
▷ Renew the oil film of the internal bearing parts.
▷ Check the preserved surfaces. Renew the preservative if required.
No special measures are required for variants made of stainless steel materials
(material variant 4).
For variants without stainless steel materials consult KSB for the required
preservation, unless already applied in the factory.
Table 6: Preservation for storage > 12 months

Type of preservation Preservative To be preserved
2)
External preservation Tectyl 502-C Exposed machined parts and uncoated parts, e.g.
shaft ends, couplings and flange faces
Internal preservation ▪ Water/glycol mixture ▪ Exposed machined internal parts of the
▪ Contact-free desiccant pump, e.g. casing inside, shafts, impellers and
diffusers
▪ Covers and sealing elements
▪ All openings (protection against ingress of
moisture)
1 Made by Fuchs Europe Schmiermittel GmbH, Mannheim

2 Made by Valvoline GmbH, Hamburg
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Preserving the internal parts with water/glycol mixture:

1. Close the pump drain (6B).
2. Close the suction nozzle and the tapping nozzle (if any) with blind flanges.
3. Fill the pump via the discharge nozzle using a water/glycol mixture with a
mixing ratio of 1:1.
4. Close the discharge nozzle with a blind flange.
5. To prevent a separation of the fill, rotate the pump rotor by 1 or 2 rotations
once a month.
3.4 Return to supplier
WARNING
Fluids handled, 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 fluid residues.
▷ Wear safety clothing and a protective mask if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Drain the pump as per operating instructions.

2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the fluids handled by the pump leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might
ignite when coming into contact with oxygen, the pump set must also be
neutralised, and anhydrous inert gas must be blown through the pump for
drying purposes.
4. Always complete and enclose a certificate of decontamination when returning
the pump (set).
It is imperative to indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
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3.5 Disposal
WARNING
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.
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4 Description
4 Description
4.1 General description

▪ Multistage centrifugal pump in ring-section design
▪ Pumping boiler feed water and condensate in power stations and industrial
plants
4.2 Product information as per Regulation No. 1907/2006 (REACH)

For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see http://
www.ksb.com/reach.
4.3 Description
Example: HGM 3/7
Table 7: Designation key

Code Description
HG Type series group
M Type series
3 Size
7 Number of stages
HGM 21 of 492
4 Description
4.4 Pump signage
NOTE
Always observe all signs at the pump (set).
Keep signs, plates and labels in a perfectly legible condition at all times.
Immediately replace any damaged or illegible signs, plates or labels by new ones.
5
2
WEIGHT:
KSB SE & Co. KGaA

Johann-Klein-Straße 9
67227 Frankenthal
Typ Jahr
E-Nr.
Nr.
Q t/h t max. ºC
bar p2 bar 4
n 1/min
Mat. No. 01425423 ZN 3823 - 238 DE
Fig. 7: Pump signage

1 Warning sign (both sides): Hot surface
2 Information label: Weight
3 Name plate (ð Section 4.4.1, Page 23)
4 Company plate (on both sides)
5 Warning sign: Observe the instruction manual
1
Fig. 8: Baseplate signage

1 Earthing connection information plate
22 of 492 HGM
4 Description
4.4.1 Name plate
KSB SE & Co. KGaA

1 67227 Frankenthal
7
2 Typ HGM 4/5 Jahr 2019 8
3 E-Nr. 4206XXXXXXXXXXXXXXXX 9
4 Nr. 9971XXXXXX 200 / 01 10
5 Q 115 t/h t max. 75 ºC 11
6 47 bar p2 47,7 bar
n 2975 1/min
Mat. No. 01425423 ZN 3823 - 238 DE
Fig. 9: Name plate (example)

1 Type series, size / number of stages 7 Year of construction
2 Product number 8 Order item number
3 Order number 9 Consecutive number
4 Flow rate 10 Fluid temperature
5 Differential pressure (suction pressure / 11 Discharge pressure
discharge pressure)
6 Speed
HGM 23 of 492
4 Description
4.5 Design details
Design
▪ Multistage centrifugal pump in ring-section design
▪ Horizontal installation
▪ Axial inlet
▪ Pump feet at the first stage casing and last stage casing
Optional:
▪ Tapping
▪ Blind stages
Drive
▪ Electric motor
▪ Turbine
▪ Diesel engine
Shaft seal
▪ Mechanical seal
Impeller type
▪ Closed radial impeller
▪ Single-suction
Bearings
▪ Product-lubricated plain bearing
Connections
▪ Axial suction nozzle3)
▪ Discharge nozzle angled upwards from the horizontal axis by 25°. Outlet of the
fluid handled in accordance with the discharge nozzle pitch.
▪ Discharge nozzle: radial, vertically to the top
▪ Radial nozzle on casing with tapping
HGM 1, 2, 3 = 45°4) or 315°4)
HGM 4 = 60°4) or 300°4)
▪ Connecting dimensions to DIN EN or ASME
Balancing device
▪ Self-adjusting drum/disc combination where clearance and control gaps ensure
total axial thrust balancing during operation.
3 Version with 90° elbow available.

4 Position seen from the drive end. Preferably on the left; also possible on the right. Angles measured from the
vertical axis.
24 of 492 HGM
4 Description
4.6 Configuration and function

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
30 29 28 27 26 25 24 23 22 21 20 19 18 17
Fig. 10: Illustration of the high-pressure pump

1 Shaft seal housing 16 Bearing bush
2 Circulation liquid inlet 17 Spacer
3 Bearing ring carrier 18 Bearing sleeve
4 Balancing line 19 Suction stage impeller
5 Balance drum 20 Impeller
6 Piston 21 Tie bolt
7 Throttling bush 22 Stage casing
8 Discharge casing 23 Stage casing
9 Casing wear ring 24 Thrust bearing ring
10 Stage casing 25 Thrust bearing ring
11 Tapping 26 Thrust bearing ring
12 Diffuser 27 Shaft sleeve
13 Stage casing 28 Circulation liquid outlet
14 Stage casing 29 Mechanical seal
15 Suction cover 30 Shaft
Function The fluid enters the pump via the intermediate piece (17). The suction impeller (19)
accelerates the fluid handled outward. The diffuser (12) fitted in the stage casing (13)
converts the kinetic energy of the fluid handled into pressure energy. The fluid
handled is guided to the next impeller (19) via the return guide vanes of the diffuser.
This process is repeated in all stages until the fluid has passed the last diffuser. From
there, the fluid handled is pumped to the discharge casing (8), where it leaves the
pump.
A clearance gap at the casing wear ring (9) prevents any fluid from flowing back
from the stage casing into the suction area of the previous impeller. A balancing
system consisting of a piston (6) and throttling bush (7) is fitted on the rear side of
the last impeller. Together with the thrust bearing ring (24) and balance drum (5) the
balancing device provides axial thrust balancing by means of hydraulic forces.
A thrust bearing, consisting of two thrust bearing rings (25 and 26) is located on the
rear of the balance drum (5). The thrust bearing absorbs the axial thrust caused by
the inlet pressure during start-up of the pump. Behind the balancing device the fluid
area is shut off by a shaft seal housing (1), through which the shaft (30) passes. The
shaft passage through the shaft seal housing (1) is sealed by a dynamic shaft seal (29).
The shaft (30) runs in product-lubricated plain bearings. The plain bearings consist of
a piston (6), throttling bush (7), bearing sleeve (18) and bearing bush (16) and are
located in the discharge casing (8) and suction cover (15).
HGM 25 of 492
4 Description
4.7 Dimensions and weights

For the dimensions and weights of the pump (set) refer to the installation plan and
the relevant documentation.
26 of 492 HGM
5 Installation at Site
5.1 Checklist for assembly / installation
NOTE
The manufacturer’s product literature is binding for all work performed on the
pump/set
For the agreed warranty period to remain valid the checklist including the alignment
certificate for the corresponding pump set has to be completed, signed and sent to
the following address within 10 working days from the date of commissioning:
E-mail: tss-ft-engineered-pumps@ksb.com
Subject: Order number + Project name
HGM 27 of 492
Project name:
Order number
Item number
Type series
Table 8: Checklist for assembly / installation

Work required Name: Name:
Date: Date:
Step
Performed Reviewed
1 Check the pump (set) and accessories for completeness and in-
transit damage. (ð Section 3, Page 11)
2 Check the foundation as per the installation plan.
3 Align the baseplate (levelling screws / shims).
4 Version with (special) foundation bolts:
Insert the foundation bolts into the holes in the baseplate.
Version with chemical anchors:
Place the pump set with the baseplate on the foundation.
Align it. Mark and spot-drill the foundation holes.
Fasten the baseplate to the foundation.
Lift the pump set off the foundation. Drill and clean the
foundation holes. Insert the chemical anchors.
6 Install the drive and accessories (coupling, gear unit, etc).
(ð Section 5, Page 27)
7 Pre-align the pump set components. (ð Section 5.8, Page 41)
8 Grout the holes of the foundation bolts.
Allow the grouting compound to set.
Allow the grouting compound to set. Place the pump set on
the foundation. (ð Section 5.10.1, Page 48)
10 Align the pump set components. (ð Section 5, Page 27)
11 Tighten the foundation bolts / chemical anchors. Lock the
levelling screws. (ð Section 5, Page 27)
12 Grout the baseplate. (ð Section 5.10.1, Page 48)
13 Install the piping and valves. (ð Section 5.11, Page 51)
14 Check that the pipes are parallel. Document the values.
15 Precision-align the pump set components with a dial gauge
(scale 0.01 mm). Document the measured values.
16 Fasten the pump (set) to the baseplate with pins.
17 Check the variable spring hangers for proper functioning.
Remove the locking device (if any). (ð Section 5, Page 27)
28 of 492 HGM
5.1.1 Alignment certificate
Table 9: Alignment certificate: Piping connected without transmitting any stresses or strains
Service report No.:
Customer: Issued by: Qualification:
Site / Plant: Date of issue:
Signed by / Person responsible at the site:
Type series, serial number, AKZ (plant code) / KKS (power station identification Job order No. / MC:
code):
Applicable limit values Limit values for

angular misalignment s and parallel
misalignment x
(E.g. installation/operating manual,
installation plan)
s = gap caused by angular misalignment
x = parallel misalignment
s
x
Limit values
specified in the □ Installation plan, drawing number: ______________________________ smax = _______________
order
□ Installation/operating manual: ______________________________________ xmax = _______________
Deviation Suction line Discharge line Balancing line
s [mm]
x [mm]
□ The measured displacements s, x meet the applicable limit values / the limit values specified in the order for smax, xmax.
□ The applicable limit values / the limits specified in the order for smax, xmax were exceeded.
□ Suction line □ Balancing line □ _________________ □ _________________
□ Discharge line □ _________________ □ _________________ □ _________________

□ The undersigned has been informed and is personally responsible for adjusting the piping accordingly.
□ The undersigned confirms that the piping will be adjusted and that a new acceptance inspection will be carried out.
Comments
Signatures
Date: Date:
Company / Department: Company / Department:
Name / Signature: Name / Signature:
HGM 29 of 492
5.2 Checks to be carried out prior to installation
DANGER
Insufficient stability of pump set as a result of incorrect dimensioning and
fastening of the baseplate (unless included in KSB's scope of supply) or the steel
structure (not included in KSB's scope of supply).
Risk of pump set tipping over!
▷ Prior to commissioning, provide proof that the baseplate or steel structure is
adequately dimensioned to ensure the pump set’s stability, and proof of
compliance with the maximum permissible vibration level.
▷ Make sure that the vibrations do not exceed the specified limits.
WARNING
Installation on mounting surface which is unsecured and cannot support the load
Personal injury and damage to property!
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN 206-1.
▷ The mounting surface must be set, flat, and level.
▷ Observe the weights indicated.
NOTE
The specified vibration values and noise characteristics are based on proper
installation of the pump set. Improper separation of the pump set and structure /
system or an unsuitable piping layout may increase the noise level and/or vibration
level.
Before beginning with the installation check the following:

▪ The structural work required has been checked and prepared in accordance with
the installation plan.
▪ For better bonding, rough surfaces are provided in the area of the baseplate
grouting and at the side walls of the holes for the foundation bolts.
▪ Provisions for the earthing of the baseplates have been made.
▪ The place of installation and its access way have been cleared and are suitable for
transport of the pump set components. (ð Section 3.2, Page 11)
▪ Adequate alignment devices are available.
▪ A strainer is fitted upstream of the suction nozzle. KSB has been consulted about
the technical selection.
▪ A minimum flow control valve has been fitted downstream of the discharge
nozzle. KSB has been consulted about the technical selection.
Installation on a foundation
▪ The foundation has been prepared properly and the concrete has set.
▪ The foundation and the area surrounding the foundation holes are truly
horizontal and even.
▪ The site management has released the foundation and marked the centreline.
▪ For better bonding, rough surfaces are provided in the area of the baseplate
grouting and at the side walls of the holes for the foundation bolts.
Installation on a steel structure (without foundation)

▪ The baseplate is suitable for installation on a steel structure.
▪ The place of installation is horizontal and even.
▪ It has been verified that the steel structure is stable and of sufficient load-
carrying capacity.
30 of 492 HGM
5.3 Unpacking packaged pump set components
DANGER
Risk of falling when working at a great height
Danger to life!
▷ Use a sturdy scaffold.
▷ Observe the applicable local occupational safety regulations and accident
prevention regulations.
CAUTION
Open or closed connections and openings
Damage to the pump!
▷ During installation, do not open connections and openings earlier than
necessary. (All openings and connections are closed at the factory.)
▷ Prior to commissioning/start-up, check on the basis of the information given in
whether the openings and connections must be open or closed.
NOTE
In the case of damaged, wet or contaminated pump set components contact KSB.
▪ Carefully unpack the pump set components immediately prior to their

installation.
▪ Remove the pump set components from the transport frame.
▪ The operator is responsible for proper disposal of the packaging.
▪ Protect unpacked pump set components (especially instruments, power cables
and cable ducts) from dirt, moisture, spark discharge, grinding dust and other
harmful ambient influences.
▪ Store any spare parts and parts which are not immediately needed.
HGM 31 of 492
5.4 Removing the preservation
WARNING
may be impaired.
WARNING
hazard
NOTE
If the pump has been specially preserved for storage of more than 12 months or sea
transport, the necessary measures for removal of preservation prior to installation
must be carried out.
NOTE
Observe the manufacturer's instructions for application/removal of the preservative.
Internal preservation Internal preservation with water/glycol mixture:

ü A suitable container for collecting the water/glycol mixture is available.
1. Open the pump drain (6B).
ð The pump is drained.
2. Collect the drained water/glycol mixture in a container and dispose of it in
accordance with the local environmental regulations.
3. Close the pump drain (6B).
4. To remove all residues of the preservative flush the pump appropriately.
Internal preservation with a desiccant:
1. Remove the covers and sealing elements.
2. Remove the desiccant and dispose of it in accordance with the local
environmental regulations.
3. Clean the thrust bearing plate and bearing shells with suitable cleaning agents
(petrol, kerosene, diesel oil or general-purpose cleaner such as Shell
Callina 2306).
4. Carry out dismantling and reassembly work. (ð Section 7, Page 78)
5. To remove all residues of the preservative flush the pump appropriately.
External preservation ü The manufacturer's product literature is available.

1. Clean preserved external parts with suitable cleaning agents in accordance with
the manufacturer’s product literature.
32 of 492 HGM
5.5 Preparing the coupling
5.5.1 Dismantling the coupling guard
WARNING
Falling coupling parts
Risk of crushing from falling parts!
▷ Secure coupling parts against falling down.
▷ Wear safety shoes.
Fig. 11: Coupling guard

1 Bottom plate 2 Foot fastening (lock strip)
1. Remove the circulation pipes of the cooling circuit if required.
2. Undo and remove the bottom plate.
3. Undo the foot fastening.
4. Remove the coupling guard upwards.
5. Store the coupling guard if required.
5.5.2 Checking the shaft ends for run-out
Fig. 12: Checking the shaft ends for run-out

ü The manufacturer's product literature for the motor is available.
1. Turn the shafts together in the same direction by 90° to ensure the
measurement points are the same. Observe the marking between coupling hub
and shaft
ð Permissible tolerance at the pump shaft ≤ 0.05 mm. For higher values contact
KSB.
2. Permissible tolerance at the motor shaft see the manufacturer’s product
literature.
HGM 33 of 492
5.5.3 Fitting the coupling hubs (keyed connection)
WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
CAUTION
Improper dismantling
Damage to bearings and coupling parts!
▷ Always use a puller to remove the coupling hubs.
▷ Never strike the coupling hubs.
CAUTION
Improper mounting of elastomeric parts
Elastomeric parts' sealing function reduced!
▷ Never re-use elastomeric parts after they have been heated.
▷ For reassembly, always use new elastomeric parts.
Mount all coupling hubs which have not been fitted as per the manufacturer’s
product literature. Verify that the markings on the coupling parts match.
ü The manufacturer's product literature for the coupling is available.
1. Carefully clean the shaft ends and bores of the coupling hubs and check them
for dimensional accuracy.
2. Slightly debur the hub keyways and insert the key.
3. Check the protruding dimension of the key. Observe the tolerance between the
keyway and the key.
Fig. 13: Tolerance between keyway and key

4. Remove the elastomeric parts.
5. To facilitate fitting, heat up the coupling hubs uniformly to a temperature of
80 °C max.
6. Fit the coupling hubs until the shaft end and the hub face are in alignment.
34 of 492 HGM
Fig. 14: Fitting the coupling hub (example)

X Thread size see relevant documentation
7. Tighten the grub screws in accordance with the manufacturer's product
literature.
Fig. 15: Coupling hub with grub screw

A Grub screw
8. Fit the retaining ring (if any) on the coupling hub.
HGM 35 of 492
5.6 Drilling the holes for fastening the feet

If no drilled/threaded holes are provided in the baseplate for fastening the pump set
components, use the holes in the feet of the pump set components as a drilling
template.
Given the heat expansion of the pump and the corresponding displacement of the
pump feet, determine the position of fastening holes as follows:
Fig. 16: Position of foot fastening studs

1 Centre of foot (drive end) 3 Stud
2 Centre of foot (non-drive end) 4 Hole in pump foot
ü The manufacturer's product literature for the pump set components is available.
1. Place the pump set components on the baseplate in accordance with the
illustration and the manufacturer’s product literature.
2. Use the holes in the feet as a drilling template.
3. Determine the position of the holes. Pay attention to the offset between the
stud and the hole in the pump foot.
4. Lift the pump set components off the baseplate.
5. Drill the fastening holes and cut the threads.
6. Clean the holes and contact surfaces.
8. Align the coupling. (ð Section 5.8, Page 41)
9. Lightly tighten the fastening bolts.
36 of 492 HGM
Fastening the discharge-side pump foot with pins
NOTE
On pumps / pump sets with baseplate, parallel pin B is supplied fitted. If the parallel
pin B is not fitted, perform the following actions.
Fig. 17: Parallel pin of the discharge-side pump foot

B Parallel pin
1. Mark the hole position for the parallel pin (B) above the pin hole in the
discharge-side pump foot.
ð Sizes 1 to 3 = diameter 20 mm
ð Size 4 = diameter 30 mm
2. Use the holes in the feet as a drilling template.
3. Determine the position of the holes. Pay attention to the offset between the
stud and the hole in the pump foot.
4. Lift the pump set components off the baseplate.
5. Drill the fastening holes and cut the threads.
6. Clean the holes and contact surfaces.
7. Insert the parallel pin (B) into the discharge-side pump foot.
9. Align the coupling. (ð Section 5.8, Page 41)
10. Lightly tighten the fastening bolts.
HGM 37 of 492
5.7 Mounting the baseplate
DANGER
Improper transport
▷ Observe the safety regulations for transport work.
The baseplate is suitable for installation on a foundation or a steel structure. The

operator chooses the installation method.
▪ Placing the baseplate on the foundation: (ð Section 5.7.1, Page 38)
– Mounting the baseplate with foundation bolts: (ð Section 5.7.1.2, Page 39)
– Mounting the baseplate with chemical anchors: (ð Section 5.7.1.3, Page 39)
– Mounting the baseplate with special foundation bolts:
(ð Section 5.7.1.4, Page 40)
▪ Mounting the baseplate on the steel structure: (ð Section 5.7.2, Page 40)
5.7.1 Placing the baseplate on the foundation
5.7.1.1 Preparing the levelling jackscrews
Fig. 18: Preparing the levelling jackscrews (example)

1 Centreline 4 Baseplate
2 Levelling jackscrews 5 Foundation
3 Foundation holes H Maximum 47 mm / minimum 35 mm
1. Prepare the levelling jackscrews. Position them as shown in the illustration.
38 of 492 HGM
5.7.1.2 Mounting the baseplate with foundation bolts

ü The levelling screws have been prepared. (ð Section 5.7.1.1, Page 38)
1. Lift up the baseplate.
2. Insert the foundation bolts into the drilled holes in the baseplate. Screw on the
nuts until the threads protrude by approximately 10 mm.
3. Place the baseplate on the levelling screws. The foundation bolts must be
suspended freely in the foundation holes.
4. Level the baseplate using the levelling screws and a suitable tool (e.g. spirit
level) (deviation of baseplate < 0.3 mm/m). Check that the surfaces are level
lengthwise and crosswise.
5. Mount the pump set components which are not already mounted on the
baseplate in accordance with the manufacturer's product literature.
6. Again, level the baseplate using the levelling screws and a suitable tool (e.g.
spirit level) (deviation of baseplate < 0.3 mm/m). Check that the surfaces are
level lengthwise and crosswise.
5.7.1.3 Mounting the baseplate with chemical anchors

1. Lift the baseplate and place it onto the levelling screws. Position the baseplate
so that the foundation holes can be be spot-drilled.
5. Spot-drill the foundation holes.
6. Lift the baseplate.
7. Drill the foundation holes in accordance with the relevant documentation.
Clean the holes.
8. Insert the chemical anchors in accordance with the relevant documentation.
9. After the curing time of the chemical anchors, once again level the baseplate
using the levelling screws and a suitable tool (e.g. spirit level) (deviation of
baseplate < 0.3 mm/m). Check that the surfaces are level lengthwise and
crosswise.
HGM 39 of 492
5.7.1.4 Mounting the baseplate with special foundation bolts

2. Insert the special foundation bolts into the drilled holes in the baseplate. Screw
on the nuts until the threads protrude by approximately 10 mm. If the crane
hook height is insufficient, insert the special foundation bolts into the baseplate
holes from the foundation side.
baseplate in accordance with the manufacturer's product literature. If coupling
hubs are fitted on the pump set components, the marking of the coupling sides
has to match.
5. Again, level the baseplate using the levelling screws and a suitable tool (e.g.
spirit level) (deviation of baseplate < 0.3 mm/m). Check that the surfaces are
level lengthwise and crosswise.
6. Fasten the plates and nuts of the special foundation bolts to the special
foundation bolts at the bottom side of the baseplate.
The plates for the special foundation bolts must rest evenly on the foundation.
7. Tighten the nuts of the special foundation bolts to the tightening torque given
in the installation plan.
5.7.2 Mounting the baseplate on the steel structure

2. Place the baseplate on the steel structure.
3. Level the baseplate using a suitable tool (e.g. spirit level) (deviation of baseplate
< 0.3 mm/m). Check that the surfaces are level lengthwise and crosswise. If
required, insert shims to correct the alignment. The baseplate must rest fully on
its mating surfaces in the area of the connecting screws.
5. Again, level the baseplate using a suitable tool (e.g. spirit level) (deviation of
baseplate < 0.3 mm/m). Check that the surfaces are level lengthwise and
crosswise. If required, insert shims to correct the alignment. The baseplate must
rest fully on its mating surfaces in the area of the connecting screws.
40 of 492 HGM
5.8 Aligning the coupling
DANGER
Improper coupling alignment
Danger of death from parts flying off!
Overloading or destruction of coupling!
▷ Properly align the coupling.
▷ When performing alignment, take into account any thermal expansion of the
machine to be coupled.
CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷ Always check the coupling after the pump has been installed and connected to
the piping.
▷ Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
CAUTION
Increased wear due to dry running
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
The alignment begins with the pump, which is the reference point for aligning all
other pump set components.
ü The feet of the pump set components are level on the locating surfaces of the
baseplate.
ü The coupling guard has been dismantled. (ð Section 5.5.1, Page 33)
1. Align the pump set components in accordance with the manufacturer’s product
literature.
2. In the case of electric motors with axial clearance, place the rotor in the
magnetic centre as described in the manufacturer’s product literature. This rotor
position must not be altered during the full duration of alignment work.
3. Slide the pump rotor in the direction of the suction cover until it abuts
Z5D003
Fig. 19: Position of the pump rotor
HGM 41 of 492
4. Check the distance between the coupling hubs for compliance with the
installation plan, and adjust if required. If using gear couplings, fasten the
coupling sleeves wit spacer plates5) to the hubs
Fig. 20: Installing the spacer plates (example)
5.8.1 Checking the coupling hubs for run-out
Coupling hubs with outside step
Fig. 21: Run-out check with outside step (example)

1. Check the coupling hubs for run-out. Maximum permissible value = 0.05 mm.
ð If the measured value exceeds 0.05 mm, contact KSB.
Coupling hubs without outside step
Fig. 22: Run-out check without outside step (example)

1. Check the shafts for run-out. Maximum permissible value = 0.05 mm.
ð If the measured value exceeds 0.05 mm, contact KSB.
5 Included in the scope of supply
42 of 492 HGM
5.8.2 Checking the coupling alignment
CAUTION
Incorrect measurement results and damage to the alignment device
Coupling misalignment!
▷ Never turn the coupling by means of the alignment device.
Checking the coupling alignment with a dial gauge
Fig. 23: Check coupling alignment with spacer (example)

A Coupling hub used as a reference B Coupling hub to be aligned
point for alignment
A B
Fig. 24: Check coupling alignment without spacer (example)
A Coupling hub used as a reference B Coupling hub to be aligned
point for alignment
ü The manufacturer's product literature is available.
1. Perform the alignment with dial gauges in accordance with the manufacturer's
product literature.
2. Turn the coupling hubs together in the same direction by 90° to ensure the
measurement points are the same.
Checking the coupling alignment with a laser tool

Coupling alignment may also be checked with a laser tool. Observe the
documentation provided by the manufacturer of the measuring instrument.
HGM 43 of 492
5.8.3 Checking the coupling alignment with consideration of thermal expansion

The vertical centreline displacement changes due to the operating temperature of
pump and drive. To ensure smooth mechanical running of the pump set consider the
centreline displacement and align the coupling accordingly.
1. Determine the centreline displacement and height displacement in accordance
with the following illustrations.
2. Adjust and check the centreline displacement and height displacement.
Displacement established via diagram

ΔhG [mm]
1,0
0,9 TG = 100 °C
0,8
0,7 TG = 80 °C
0,6
0,5
TG = 60 °C
0,4
0,3
0,2 TG = 40 °C
0,1
200 400 600 800 1000

h G [mm]
Fig. 25: Drive centreline displacement ΔhG at operating temperature TG [°C]
Δh Change in centreline height hG Drive centreline height
G
TG Drive housing temperature during

operation
ΔhP [mm]
1,0
0,9
0,8
0,7
0,6
0,5 HGM 4
0,4 HGM 3
0,3 HGM 2
0,2 HGM 1
0,1
50 TP [°C] 100 150
Fig. 26: Pump centreline displacement ΔhP at operating temperature TP [°C]

Δh Change in centreline height TP Pump temperature during operation
P
44 of 492 HGM
Height displacement to be established at the coupling at room temperature 20 °C:

ΔhK = ΔhG - ΔhP
ΔhK a)
Pump Drive
a) ΔhK is positive.
ΔhK b)
Pump Drive
b) ΔhK is negative.
Example Drive:
Housing temperature TG at operation = 60 °C
Shaft centreline height hG = 400 mm
Pump:
Pump temperature TP at operation = 130 °C
Size = HGM 3
ΔhK = 0.18 - 0.28 = - 0.10 mm
ΔhK is negative. The drive must stand 0.10 mm higher than the pump.
-0,10
0 0
+0,10
Fig. 27: Dial gauge indication
Displacement determined via equation

ΔhK = [(TG - 20) × hM - (TP - 20) × hP] × 0.0000111
Δh Height displacement to be established [mm]
K
hG Drive centreline height [mm]

hP Pump centreline height [mm]
TG Drive housing temperature during operation [°C]
TP Pump temperature during operation [°C]
Example Drive:
Housing temperature TG at operation = 60 °C
Centreline height hG = 400 mm
Pump:
Pump temperature TP at operation = 130 °C
Shaft centreline height hP = 225 mm (HGM 3)
ΔhK = [(60 - 20) × 400 - (130 - 20) × 225] × 0.0000111
ΔhK = [16000 - 24750] × 0.0000111
ΔhK = - 0,097 mm ≈ - 0.1 mm
ΔhK is negative, i.e. the drive must stand 0.10 mm higher than the pump.
HGM 45 of 492
5.8.4 Permissible displacement
Radial displacement
Va
VR
Fig. 28: Radial displacement (example)

The radial displacement VR must not deviate more than 0.05 mm from the nominal
value, measured at a distance of 90°.
Angular misalignment
SMax.
Va
SMax. - SMIN
VW =
2
VR
SMin.
Fig. 29: Angular misalignment (example)
The permissible angular misalignment Vw is 0.05 mm max. in horizontal and vertical
direction.
Axial displacement
Refer to the installation plan and the manufacturer’s product literature for the
permissible tolerances.
46 of 492 HGM
5.9 Aligning the pump and motor
5.9.1 Aligning the pump
4
5
Fig. 30: Aligning the pump

1 Pump foot 4 Washer
2 Shims 5 Nut
3 Baseplate 6 Stud
Height correction:
ü The pump is fastened with pins at the discharge side. (ð Section 5.6, Page 36)
1. Insert shims underneath the pump.
5.9.2 Aligning the drive
NOTE
To enable the largest possible clearance for all-side alignment correction, the bolts /
threaded rods can be screwed out of the baseplate so the (nut-end) bolt thread
ends above the motor foot.
Fig. 31: Aligning the drive
Height correction
1. Insert shims underneath the drive.
Lateral correction
1. Screw bolts / threaded rods into the designated nuts (M20) on the outer contact
edges of the baseplate to correct the lateral alignment of the drive.
5.9.3 Correcting the alignment of the pump set components

1. Perform alignment corrections of the remaining pump set components in
accordance with the manufacturer’s product literature.
HGM 47 of 492
5.10 Fastening the baseplate
5.10.1 Fastening the baseplate to the foundation
5.10.1.1 Fastening the baseplate with foundation bolts
NOTE
Minimum compressive strength of the grouting compound 35 N/mm2; observe the
manufacturer’s processing instructions.
ü The baseplate has been mounted. (ð Section 5.7.1.2, Page 39)

1. Grout the foundation bolt holes with expansive concrete / expansive mortar.
Produce flowability with the help of a solvent. The grain size depends on the
foundation bolt holes to be grouted.
2. Allow the concrete / mortar to set. Observe the setting time specified by the
manufacturer.
3. Tighten the nuts of the foundation bolts to the tightening torque given in the
installation plan. (ð Section 9.1.9, Page 139)
4. Check the coupling alignment. Align the coupling if necessary.
5. Grout the baseplate. Make sure that the grouting compound bonds with the
foundation:
ð Prepare the concrete shuttering for the baseplate and foundation pedestal
up to the planned grouting height as shown in the installation plan.
ð Grout all areas of the baseplate at least 1/3 high with expansive concrete /
expansive mortar (e.g. Pagel concrete grout). The grain size depends on the
grouting height.
ð For the remaining 2/3 normal concrete (minimum compressive strength of the
grouting compound 35 N/mm2) is permissible. We recommend grouting the
baseplate completely with expansive concrete / expansive mortar. Produce
flowability with the help of a solvent. Complete grouting without major
interruptions.
6. Allow the grouting compound to set.
7. Check the nuts of the foundation bolts with a suitable tool (e.g. torque wrench).
Observe the tightening torques given in the installation plan.
8. Check the coupling alignment. Re-align the coupling if necessary.
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5.10.1.2 Fastening the baseplate with chemical anchors
NOTE

1. Tighten the nuts of the chemical anchors to the tightening torque given in the
installation plan. (ð Section 9.1.9, Page 139)
foundation:
grouting height.
interruptions.
5. Check the nuts of the chemical anchors with a suitable tool (e.g. torque
wrench). Observe the tightening torques given in the installation plan.
5.10.1.3 Fastening the baseplate with special foundation bolts
NOTE

1. Fill the holes for the special foundation bolts with dry sand.
2. Insulate the special foundation bolts in the area between the upper edge of the
foundation and the lower edge of the baseplate (e.g. with polystyrene).
foundation:
grouting height.
interruptions.
HGM 49 of 492
5. Check the nuts of the special foundation bolts with a suitable tool (e.g. torque
wrench). Observe the tightening torques given in the installation plan.
5.10.2 Fastening the baseplate to the steel structure
NOTE
The connecting screws of the steel structure only allow for minor adjustments with
shims.
NOTE
We recommend connecting the piping after the baseplate has been fastened.
ü The baseplate has been mounted. (ð Section 5.7.2, Page 40)

1. Mark the position of the connecting screws on the steel structure through the
holes in the baseplate.
2. Lift up the baseplate incl. pump set components.
3. Drill fastening holes in the marked positions. The size must match that of the
drilled holes in the baseplate.
4. Position and align the baseplate incl. pump set components.
5. Fasten the baseplate on the steel structure using connecting screws.
6. Again, level the baseplate with a suitable tool (e.g. spirit level) (accuracy
< 0.3 mm/m). Check that the surfaces are level lengthwise and crosswise. If
required, insert shims to correct the alignment. The baseplate must rest fully on
its mating surfaces in the area of the connecting screws.
7. Tighten the nuts to the tightening torque given in the installation plan.
8. Secure the baseplate to the steel structure by tack welding the 4 corners.
10. Check the nuts with a suitable tool (e.g. torque wrench). Observe the tightening
torques given in the installation plan. (ð Section 9.1.9, Page 139)
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5.11 Piping
5.11.1 Prerequisites for connecting the piping
DANGER
Improper or no earthing
Risk of personal injury from electric shock!
▷ Ensure proper earthing of the pump set and check regularly.
DANGER
Impermissible loads acting on the pump nozzles
Danger to life from leakage of hot 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.
Before connecting the piping make sure that the following requirements are met:
▪ The pump set is earthed.
▪ Equip the vent connections and drain connections with shut-off elements and
pipes that ensure the fluid handled is discharged safely.
▪ For short pipes the nominal size should be equal to or greater than the nominal
size of the pump connection. For longer pipes determine the most economical
nominal size.
▪ To prevent pressure losses (formation of air pockets), use adapters to larger
nominal sizes with a diffuser angle of approximately 8°.
▪ Installing check valves and shut-off elements is recommended.
▪ For the quantity and arrangement of existing piping, valves and instruments
refer to the installation plan.
▪ All pipes in the baseplate area have been fitted at the factory.
▪ If connecting lines are required, have them made / adjusted in accordance with
the installation plan. Offset at flange connections and pipe unions is not
permitted.
▪ Clean any pipes produced on site prior to installing them.
▪ Pipes supplied by KSB are delivered cleaned and closed. To make sure they have
not been contaminated at a later stage, check the inside of the pipes and clean
them if required. (ð Section 5.11.2, Page 52)
▪ Remove the blind flanges / covers of pump nozzles and pipe connections
immediately prior to connection. The responsibility for disposal of the parts
supplied lies with the consignee.
HGM 51 of 492
5.11.2 Cleaning the pipes
WARNING
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.
1. Blow compressed air through the pipes. If the pipes are welded with shield gas,
steam cleaning at Tmin = 110 °C is permissible.
5.11.3 Fitting the strainer / minimum flow control valve
DANGER
Improper transport
▷ Observe the safety regulations for transport work.
CAUTION
Improper transport of strainer/filter
Damage to the strainer/filter caused by lifting tackle!
▷ Do not exert pressure on the screen and screen mesh or damage them.
▷ Transport accessories by hand. If transporting by hand is not possible due to the
weight, observe the applicable regulations.
NOTE
The strainer in the inlet line is destined to stop welding beads, scale and other
impurities (that come off the piping with time) from entering the pump. It is not
destined to remove any inadmissible particles entrained in the fluid handled due to
an excessive solids content.
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Fitting the strainer
Fig. 32: Fitting the strainer (example)

ü The installation plan is available.
ü The manufacturer's product literature for the strainer is available.
1. Prior to installation, perform a visual inspection of the inlet line between
strainer and pump. If necessary, clean these areas.
2. Install the strainer in a vertical position in the inlet line as close as possible to
the pump nozzle.
3. For differential pressure monitoring in the inlet line, drill a hole into the inlet
line upstream of the strainer element and weld on the welding piece included in
the scope of supply.
Preparing the differential pressure monitoring equipment

1 2
C
A
A C H
B
B
Fig. 33: Connecting the differential pressure monitoring equipment (examples)

1 Conical strainer B Suction line of the pump
2 Y-strainer6) C Connection for the differential pressure
monitoring equipment
A Inlet line H Height (approx. 300 mm)
Installing the minimum flow control valve (optional)

ü The manufacturer's product literature for the minimum flow control valve is
available.
1. Fit the minimum flow control valve on the pump discharge nozzle in accordance
with the manufacturer’s product literature.
2. Arrange the minimum flow system in accordance with the P+I diagram (relevant
documentation).
6 Y-strainers can be installed in a horizontal or in a vertical position. The distance between the strainer and the
elbow / intermediate piece has to be at least 2 × DN.
HGM 53 of 492
5.11.4 Connecting the piping
DANGER
Impermissible load 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 piping in close proximity to the pump and connect it without
transmitting any stresses or strains.
▷ Observe the permissible forces and moments on the pump nozzle.
▷ Observe the permissible reaction forces from unbraced expansion joints.
▷ Take appropriate measures to compensate thermal expansion of the piping.
DANGER
Flange connection
NOTE
It must be possible to insert the bolts for the flange connection into and pull them
out of the respective holes without the bolts becoming jammed. If the pipes cannot
be brought into installation position with one hand, impermissibly high transverse
forces exist.
NOTE
To insert the flange seal it must be possible to prise apart the flanges of the inlet
line and the discharge line with a large screwdriver (~ 300 mm). If this not possible,
or if the flanges have to be drawn together by means of the flange bolts,
impermissibly high longitudinal forces exist.

ü The temporary holders of the piping have been removed.
ü The pipes are supported by the supports or spring hangers provided.
ü The variable spring hangers have full adjustment capabilities and are not at their
lower limit.
1. Align the holes of the flanges with those of the pump nozzles. Observe the
permissible position deviations between the flanges. Observe the information
given in the installation plan as well as the permissible nozzle forces and nozzle
moments.
2. Insert the bolts for the flange connection into the holes of the flange and pump
nozzle.
3. Tighten the flange connection bolts. Observe the tightening torques.
4. If seal-welded rings are to be used for sealing the flanges, observe the welding
plan.
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Welded joint
NOTE
The joint welds on the pump nozzles are not included in KSB’s scope of services.

ü The temporary holders of the piping have been removed.
ü The pipes are supported by the supports or spring hangers provided.
ü The variable spring hangers have full adjustment capabilities and are not at their
lower limit.
1. Align the piping with the pump nozzles. Observe the permissible position
deviations and the information given in the installation plan as well as the
permissible nozzle forces and nozzle moments.
2. Weld the welding joints and make sure that no welding particles enter the
pump. If welding particles have entered the pump, dismantle and clean the
pump.
Minimum flow line and balancing liquid line
CAUTION
Damage to the minimum flow line caused by impermissible piping layout.
Damage to the machinery!
▷ When installing the minimum flow line, observe the minimum flow diagram.
▷ Install an orifice immediately upstream of the condenser to avoid vaporisation
in the minimum flow line.
5.12 Final installation of the pump set

1. Check the coupling alignment. Re-align it if required. (ð Section 5.8, Page 41)
2. Consider height displacement and lateral displacement in accordance with the
assembly sketch.
3. Check the alignment of the pump set.
ð If connecting the piping has altered the pump set alignment, the piping has
not been connected without transmitting any stresses or strains.
ð If required, undo the bolted connections. Connect the piping without
transmitting any stresses or strains. Check the coupling alignment.
4. Record the final measurement results in the coordinate system of the alignment/
taking-over certificate of the coupling.
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5.12.1 Mounting the pump on the baseplate
Fig. 34: Fastening the pump feet (example)

1 Pump 4 Nut
2 Baseplate 5 Stud
3 Washer
1. Tighten the nuts on the discharge side. Observe the tightening torques.
2. Tighten the nuts on the suction side, so the washers can still be moved by means
of light hammer blows.
3. Lock all nuts using an additional nut.
Fastening the suction-side pump foot with pins
A B
Fig. 35: Pinning the pump feet
Table 10: Diameter of parallel pins depending on the size

Size Diameter of parallel Diameter of parallel Distance L
pin A7) pin B
[mm] [mm] [mm]
HGM 1 10 20 20
HGM 2 10 20 20
HGM 3 10 20 20
HGM 4 10 30 20
ü Parallel pin B has been fitted. (ð Section 5.6, Page 36)
1. Drill a hole for parallel pin A in accordance with the table.
2. Fit parallel pin A.
3. Fit and fasten the remaining pump set components with pins in accordance with
the corresponding manufacturer’s product literature.
7 After re-installation, bore and ream the existing hole for the parallel pin to 12 mm.
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5.12.2 Performing the final check

1. Have the tightening torques of all fastening studs and foundation bolts checked
and confirmed by the responsible site management. (ð Section 9.1.9, Page 139)
2. Have the alignment/taking-over certificate confirmed by the responsible site
management.
5.13 Preservation for standstill (optional)

If the pump set is not commissioned immediately after its installation, take the
required preservation measures: (ð Section 3.3, Page 17)
HGM 57 of 492
6 Commissioning/Start-up/Shutdown
6.1 Commissioning/Start-up
6.1.1 Checklist for commissioning/start-up
NOTE
The manufacturer’s product literature is binding for all work performed on the
pump/set
In order to ensure that the agreed warranty period remains valid, the checklist
including the alignment certificate has to be completed and signed, and sent to the
following e-mail address within 10 working days from the date of commissioning:
E-mail: tss-ft-engineered-pumps@ksb.com
Subject: Order number + Project name
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Project name
Order number
Item number
Type series
Table 11: Time of commissioning

Time of commissioning Yes No
Within 12 months from delivery
(if unknown, contact KSB.)
More than 12 months after delivery:
▪ The work has been performed by personnel authorised by KSB.
▪ The commissioning report has been attached.
Table 12: Checklist for commissioning/start-up

Work required Name: Name:
Date: Date:
Step
Performed Checked
1 Check the direction of rotation of the drive.
2 Check and document the alignment and values.
3 Fit the coupling and coupling guard.
4 Check the strainer in the inlet line. (ð Section 5.11.3, Page 52)
5 Prime and vent the pump. (ð Section 6.1.8, Page 68)
6 Prepare the pump set for operation. Check the shaft seals. Start
up the auxiliary circuits.
7 Check the instruments for proper functioning.
8 Set and check the interlocking systems.
Check the turning gear (time till engagement: from pump
standstill till start of turning gear)
9 Check the gate valve position. Check the minimum flow control
valve.
10 Start up the pump set. (ð Section 6.1.10, Page 69)
11 Fasten/affix the CE marking.
HGM 59 of 492
6.1.1.1 Alignment/taking-over certificate
Table 13: Alignment/taking-over certificate

Customer:
Place:
Site:
Type series, size: Order number:
The machinery supplied / refurbished by KSB was transferred today (date) __________________
after successful commissioning / without commissioning by the senior chief fitter / senior fitter / fitter
________________________ in perfect technical condition.
The alignment has been verified and recorded as follows:

A B
_________mm _________mm
_________mm _________mm _________mm _________mm
_________mm _________mm
A = radial
B = axial
Comments
The CE marking has been attached by: □ KSB □ Customer
Signatures
Customer: Site manager: KSB:
60 of 492 HGM
6.1.2 Prerequisites for commissioning/start-up
DANGER
WARNING
WARNING
Hot surfaces (pump and piping take on the temperature of the fluid handled).
Risk of burns!
▷ Do not touch hot surfaces.
WARNING
Unprotected, rotating parts
Risk of injury from parts flying off!
Risk of injury by rotating shafts!
▷ Operate the pump set only after all protective equipment has been fitted.
▷ Never remove any guards while the pump is running.
▷ Regularly check all guards for correct fastening.
WARNING
hazard
Before commissioning/starting up the pump set, make sure that the following
conditions are met:
▪ Installation and alignment have been performed in accordance with good
engineering practice, recorded and accepted by the operator.
▪ The drive has been checked in accordance with the manufacturer’s product
literature.
▪ All other pump set components have been checked in accordance with the
corresponding manufacturer’s product literature.
▪ All pipes have been cleaned and connected.
▪ The preservation for standstill has been removed. (ð Section 5.4, Page 32)
HGM 61 of 492
6.1.3 Electrical connection
DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained electrician.
▷ Observe regulations IEC 60364 (DIN VDE 0100) and, for explosion-proof
versions, EN 60079.
▷ The pump set's electrical equipment must comply with the general
requirements of the EN 60204-1 standard.
▷ Observe the local regulations for the power supply.
▷ Check the available mains voltage against the data on the motor name plate.
ü The manufacturer's product literature for the motor is available.

1. Check the available mains voltage against the data on the motor name plate.
2. Adjust the direction of rotation of the motor to the direction of rotation of the
pump.
3. Secure the pump set against unintentional start-up.
6.1.3.1 Installing and connecting the instruments (optional)
WARNING
Overload due to incorrectly set monitoring equipment and alarm equipment
Seal failure!
Risk of burns, scalds, cuts caused by fluid jets, and respiratory system burns by hot
and pressurised fluid handled!
▷ Connect and activate all monitoring equipment and alarm equipment installed.
▷ During operation, do not undo any screwed/bolted connections or pipe unions
and do not remove any measuring sensors.
▷ Check all instruments in accordance with the manufacturer's product literature
for correct measuring data. Adjust the instruments if required.
▷ Set the warning values and trip values in cooperation with control engineering
specialists.
▷ Regularly check that all monitoring equipment and alarm equipment are in
perfect condition.
▪ If any measuring instruments have not been supplied fitted, install and connect
them.
▪ Choose instruments with an adequate measuring range.
▪ Only remove the screw plugs immediately before the installation.
Pressure gauges
1. Insert the joint ring and screw the pipe fitting into the intended connection
point.
2. Mount the lock socket and sealing washer, screw fast the instrument holder.
3. Insert the sealing washer and screw on the lock socket.
4. Mount the shut-off valve.
5. Screw fast the pressure gauge with inserted sealing washer using a lock nut.
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Differential pressure monitoring equipment
A C A C
D D
C
B
B
C
132 139
1 2
Fig. 36: Connecting the differential pressure monitoring equipment

1 Variant with intermediate piece 132 B Suction line, pump
2 Variant with suction elbow 139 C Connection for the differential pressure
monitoring equipment
A Inlet line D Differential pressure monitoring equipment
ü The differential pressure monitoring equipment has been properly prepared.

ü The holder provided for the differential pressure monitoring equipment has
been fastened to the baseplate.
1. Fasten the differential pressure monitoring equipment (D) to the holder
provided.
2. Screw the measuring lines on at the connecting points (C) and lay them
appropriately.
3. Run the power cable in cable conduits until just before reaching the measuring
point. Have the cable connected by authorised personnel.
6.1.4 Checking the direction of rotation
DANGER
Unintentional start-up
Danger to life from unprotected rotating parts!
▷ Secure the pump (set) against unintentional start-up!
DANGER
Mistake in the electrical connections
Danger of death from electric shock!
Short circuit, motor damage or pump is running in the wrong direction!
▷ Mark the connections in the terminal box.
WARNING
Hands or objects inside the pump set
Risk of injury, damage to the pump!
▷ Never put your hands or any other objects into the pump.
▷ Check that the inside of the pump is free from any foreign objects.
HGM 63 of 492
CAUTION
Incorrect axial clearance
Damage to the bearings!
▷ In the case of electric motors with axial tolerance, if applicable, re-align the
motor shaft coupling hub as required by the actual magnetic centre. In the case
of spacer-type couplings it must be possible to mount and remove the spacer.
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.
▷ The direction of rotation of the drive must correspond to the direction given in
the installation plan.
Z6A003
1 2
Fig. 37: Checking the direction of rotation

1 Pump 2 Electric motor
ü The manufacturer's product literature for the electric motor is available.
ü The electric motor has been properly connected to the power supply.
ü The electric motor is supplied with a lubricant.
ü The coupling is not connected. Only the electric motor is rotating.
1. Carry out the following steps to verify that the motor shaft is rotating anti-
clockwise, seen from the pump.
Checking the direction of rotation with a phase-sequence indicator

The direction of rotation of the drive can optionally be checked with an
electromagnetic phase-sequence indicator. Observe the documentation provided by
the manufacturer of the measuring instrument.
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Checking the direction of rotation without a phase-sequence indicator
Fig. 38: Arrangement of spacer plates (example)

1. In the case of toothed couplings, fix the drive-end coupling sleeve on the hub
using spacer plates (supplied loose).
2. Have the electric motor started up by authorised specialist personnel.
3. Immediately switch off the electric motor when it has reached its operating
speed.
4. Check the direction of rotation.
ð If the direction of rotation is incorrect, have the connections interchanged by
authorised specialist personnel. Check the direction of rotation again.
6.1.5 Checking the rotatability of the pump rotor
Fig. 39: Rotatability of the pump rotor (example)

A Approx. 150 mm
1. In the case of toothed couplings, fix the pump-end coupling sleeve on the hub
using spacer plates (supplied loose).
2. Move the pump rotor approximately 1 mm towards the non-drive end.
3. Only rotate the pump rotor manually in the direction of rotation of the pump. If
necessary, fit a suitable tool at the coupling hub (see illustration).
ð It must be possible to rotate the pump rotor by hand.
6.1.6 Installing the coupling
WARNING
HGM 65 of 492
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.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
6.1.6.1 Installing the coupling spacer

ü The manufacturer's product literature for the coupling spacer is available.
1. Install and align the coupling spacer in accordance with the manufacturer’s
product literature.
6.1.6.2 Mounting the coupling guard
WARNING
NOTE
If the customer requests a pump (set) to be delivered without a coupling guard, the
operator must supply a coupling guard. Observe all relevant regulations for
selecting the coupling guard.
Fig. 40: Coupling guard (special design)

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

▪ Check the mechanical seal’s readiness for operation.
▪ Remove the assembly fixtures, if any.
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Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
Observe the manufacturer’s product literature.
HGM 67 of 492
6.1.8 Priming and venting the pump
DANGER
Contact with hot and pressurised fluid handled or vapour
Risk of burns, scalds and cuts caused by fluid jets!
▷ Always use an appropriate venting device.
▷ Vent the pump properly.
▷ On venting, keep your distance from the outlet.
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.
NOTE
For design-inherent reasons some unfilled volume in the hydraulic system cannot be
excluded after the pump has been primed for commissioning/start-up. However,
once the motor is started up the pumping effect will immediately fill this volume
with the fluid handled.
1. Close all drains / drain lines.

2. Open the shut-off valve in the minimum flow line.
3. Open the vent line.
4. Prime the inlet line, circulation pipes of the cooling circuit, pump and discharge
line up to the closed discharge-side gate valve, preferably with cold condensate.
NOTE
If the discharge line is equipped with a check valve and back pressure is present, the
shut-off valve in the discharge line may remain open.
5. Close the vent line.

6. Vent all pipes fitted with a pressure gauge until no more air escapes.
7. Fully open the shut-off valve in the inlet line.
8. Check whether inlet pressure is available.
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6.1.9 Checks prior to commissioning/start-up
WARNING
Leakage caused by improper fitting of pipes and/or flanges
pressurised fluid handled or steam escapes!
▷ Check all screws/bolts, screw/bolt and pipe connections as well as pipes and
flanges for leakage or damage prior to and during commissioning/start-up.
▷ Close all unused connections.
▪ The inlet tank is ready for use.

▪ The inlet line, circulation pipes of the cooling circuit, pump, heat exchanger and
discharge line have been primed and vented.
▪ The shut-off valve in the inlet line is fully open.
▪ The shut-off valve in the circulation pipe of the cooling circuit is fully open.
▪ The shut-off valve in the discharge line is closed.
▪ The tapping connection (if any) is closed.
▪ The shut-off valves in the minimum flow line are open.
▪ The temperatures measured are below the limit values.
▪ Check the pipes, flanges and pipe unions for any leakage.
6.1.10 Start-up and trial run
WARNING
Failure of components
Risk of parts flying off, burns and scalds!
▷ Access to the pump set is restricted to authorised specialist personnel only.
▷ Limit the time spent in this area to a minimum.
▷ Wear appropriate personal protective equipment, e.g. safety helmet, ear
protection, safety goggles, safety shoes and, if required, protective gloves.
▷ Regularly check the pump (set) for impermissible leakages. If necessary, initiate
immediate remedial action.
▷ Regularly measure the vibrations at the bearing housings.
WARNING
High sound pressure level > 85 dB(A) can occur during operation
Injury to the ear and hearing impairment. Hardness of hearing, tinnitus and hearing
loss can be caused!
▷ Wear ear protection.
▷ Observe the applicable local occupational health and safety regulations.
WARNING
HGM 69 of 492
WARNING
Risk of burns!
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
CAUTION
Off-design operating data
Damage to the pump set due to cavitation!
▷ The speed required for reaching the minimum head of 150 m must not be
underrun except during the start-up and stopping phase.
▷ The minimum speed n = 1500 rpm may only be underrun in the start-up and
stopping phase.
▷ The minimum permissible speed must be reached in < 5 seconds.
CAUTION
Evaporation due to inlet pressure pressure falling below the specified value.
Damage by cavitation!
▷ Observe the minimum inlet pressure specified in the operating data.
▷ Only operate the pump within the permissible temperature range specified in
the operating data.
NOTE
Temperature differences in the pump lead to deformations, which will cause
damage during operation. Strictly observe the specified temperature limits.
NOTE
Should warnings or problems occur during start-up or performance test:
1. Start up the drive in accordance with the manufacturer’s product literature.

Direct running up to nominal speed is recommended. For soft start or for
variable speed drives the minimum speed has to be reached in 5 seconds as a
maximum.
2. Open the shut-off valve in the circulation pipe.
3. If a frequency inverter is used: Increase the speed to minimum speed
n = 1500 rpm or to the speed required for reaching the minimum head of
150 m.
4. If necessary, increase the speed to reach the minimum flow rate (see data sheet).
5. Check the temperature and smooth running.
6. Check the pump pressures and differential pressures.
7. Monitor the function of the minimum flow control valve (flow noises).
8. Check the temperature at the balancing liquid line using a contact thermometer
(approx. 10 °C higher than the operating temperature).
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9. Slowly open the valve of the discharge line until it is completely open.
10. Continuously monitor the pump set’s operating behaviour.
11. Check the mechanical seals. Mechanical seals must not drip.
12. Check the temperature of the circulation liquid in the circulation pipes of the
cooling circuit.
6.1.11 Mounting the sound insulating hood (if applicable)
DANGER
Falling parts
Injury from falling parts!
▷ Use appropriate means to secure the parts, if possible.
▷ Wear personal protective equipment.
ü The manufacturer's product literature for the sound insulating hood is available.
1. Mount the sound insulating hood in accordance with the manufacturer’s
product literature.
6.2 Operating limits
DANGER
Operating a non-explosion-proof pump (set) in a potentially explosive atmosphere
Explosion hazard!
Danger to life!
▷ Only pumps / pump sets marked as explosion-proof and identified as such in the
data sheet may be used in potentially explosive atmospheres.
▷ Special conditions apply to the operation of explosion-proof pump sets to EC
Directive 2014/34/EU (ATEX). The explosion-proof status is only assured if the
product is used in accordance with its intended use.
▷ Never operate the product outside the limits in the data sheet and on the name
plate.
▷ Prevent impermissible modes of operation.
▷ Comply with the applicable local explosion protection regulations.
HGM 71 of 492
DANGER
Hot and/or pressurised fluid could escape.
Danger to life!
Cuts caused by fluid jets, burns, scalds, respiratory system burns!
▷ The fluid pressure at the discharge nozzle must not exceed the maximum
permissible pump discharge pressure.
▷ The fluid pressure at the suction nozzle must not exceed the maximum
permissible pump inlet pressure.
▷ The fluid temperature must not exceed or fall below the permissible range.
▷ Observe the minimum flow rates and maximum permissible flow rates specified
in the data sheet, (to prevent overheating damage, damage to bearings,
damage to sealing elements, cavitation damage, etc).
▷ Backflow of the fluid through the pump is not allowed. Exception: a small flow
through the pump for pre-warming
▷ The pump must only handle the fluids indicated in the data sheet.
▷ Take appropriate measures in accordance with the local regulations to avoid
exceeding or falling below the permitted application limits due to operating
errors, malfunctions or procedural errors.
▷ Only operate pumps which are in perfect technical condition. Immediately
remedy any safety-relevant faults (e.g. leakage at the pressure enclosure).
▷ Do not open the draining device and venting device during operation.
▪ Never operate the pump without the fluid to be handled.

▪ Do not throttle the pump on the suction side. Danger of cavitation damage.
▪ Make sure the strainer in the inlet line is clean.
▪ Observe the manufacturer’s supervision specifications and servicing
specifications. (ð Section 7.2, Page 79) , (ð Section 7.3.1, Page 81)
▪ Should modes of operation other than those given in the data sheets be
requested, these must be checked and approved by the manufacturer.
▪ All safety information and instructions must be observed.
▪ Observe the inlet pressure limits.
Exceeding the limits can damage the thrust bearing. Falling under the limits
causes a risk of cavitation damage.
▪ Only operate the pump in the direction of rotation indicated.
6.2.1 Ambient temperature
WARNING
Change in ambient conditions
Risk of injury from parts flying off, burns and scalds!
Freezing of fluid in the pump or piping, failure of components, escaping of hot and
pressurised fluid handled!
▷ Only operate the pump (set) in the specified ambient conditions. If changes in
ambient conditions occur, consult KSB.
72 of 492 HGM
CAUTION
Permissible ambient temperatures, fluid temperatures or bearing oil temperatures
exceeded / underrun
Destruction of pump components!
▷ Protect the bearing oil from freezing.
▷ Protect the fluid handled from freezing, or drain the pump and connected
piping during standstill.
Table 14: Permissible ambient temperatures

Permissible ambient temperature Value
Maximum +50 °C
Minimum -20 °C8)
6.2.2 Frequency of starts
CAUTION
Excessively high switching frequency
Damage to the balancing device!
▷ Do not exceed the values for the frequency of starts.
NOTE
The values indicated apply to the pump only. The frequency of starts depends on
the drive and has to be checked. See manufacturer's product literature.
The permissible number of starts per day is 5.
6.2.3 Fluid handled
6.2.3.1 Fluid temperature
CAUTION
Permissible ambient temperatures, fluid temperatures or bearing oil temperatures
exceeded / underrun
Destruction of pump components!
▷ Protect the bearing oil from freezing.
▷ Protect the fluid handled from freezing, or drain the pump and connected
piping during standstill.
Table 15: Temperature limits of the fluid handled

Permissible fluid temperature Value
Maximum +160 °C
Minimum +5 °C9)
8 For lower temperatures consult KSB.

9 For lower temperatures consult KSB.
HGM 73 of 492
6.2.3.2 Density of the fluid handled
CAUTION
Impermissibly high density of the fluid handled
Motor overload!
▷ Observe the information on fluid density in the data sheet.
CAUTION
Unsuitable fluids
Damage to the pump!
▷ The fluid handled must conform to the requirements of TRD 611 (German
Steam Boiler Regulations) for the boiler feed water of steam generators of
Group IV.
▷ Recommended total solids content 5 ppm maximum.
▷ Refer to the data sheet of the pump for the fluids handled.
6.3 Shutdown
6.3.1 Measures to be taken for shutdown
WARNING
Risk of burns!
CAUTION
Off-design operating data
Damage to the pump set due to cavitation!
▷ The speed required for reaching the minimum head of 150 m must not be
underrun except during the start-up and stopping phase.
▷ The minimum speed n = 1500 rpm may only be underrun in the start-up and
stopping phase.
▷ The minimum permissible speed must be reached in < 5 seconds.
Shutdown - Pump set remains ready for operation

1. Close the shut-off valve in the discharge line. If the discharge line is equipped
with a check valve and back pressure is present, the shut-off valve in the
discharge line may remain open.
2. Make sure the minimum flow valve works.
3. If a frequency inverter is used: Reduce the speed to minimum speed
150 m.
4. Switch off the motor, making sure it runs down smoothly to a standstill.
5. Note the run-down time.
74 of 492 HGM
Shutdown for maintenance of the pump set or prolonged standstill
WARNING
1. Close the shut-off valve in the discharge line.

2. Make sure the minimum flow valve works.
3. If a frequency inverter is used: Reduce the speed to minimum speed
150 m.
4. Switch off the motor, making sure it runs down smoothly to a standstill.
5. Note the run-down time.
6. If applicable, close the shut-off valve in the tapping line.
7. Close the shut-off valves in the minimum flow line.
8. Close the shut-off valve in the inlet line.
9. Close the remaining pipes.
6.3.2 Work after shutdown
6.3.2.1 Work after shutdown with pump set remaining ready for operation
If the period of standstill with the pump ready for operation (instant start-up) is
longer than two weeks, the pump set components such as gear unit or motor must
be protected against water ingress and humidity as described in the manufacturer’s
preservation instructions.
Every 4 to 6 weeks:
▪ Start up the pump set. (ð Section 6.1, Page 58)
▪ After approximately 10 minutes shut down the pump set.
▪ Check whether the pump rotor runs down smoothly to a standstill.
6.3.2.2 Work after shutdown for standstill - Pump not ready for operation
CAUTION
Danger of freezing!
Damage to the pump!
▷ If there is any risk of freezing or in the event of prolonged standstill, drain and
preserve the pump.
▪ Secure all valves against opening.
▪ Close all openings and supply lines.
▪ If there is any risk of freezing or in the event of standstill > 2 weeks, drain and
preserve the pump. (ð Section 7.4, Page 83)
HGM 75 of 492
6.3.2.3 Maintenance work after shutdown
DANGER
Falling parts
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.
▷ Shut off any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
DANGER
Pump too hot: Contact with hot fluid handled, damage to the O-rings causing
leakage when the pump is returned to service
Risk of injury, e.g. cuts caused by fluid jets, burns, scalds, respiratory system burns!
▷ Let the pump cool down. Pump casing temperature < 50 °C, measured at the
pump nozzles.
WARNING
Risk of injury!
▷ Always use an appropriate draining device.
▷ Drain the pump properly.
▷ On draining, keep your distance from the outlet.
WARNING
Fluids posing a health hazard
▷ Collect and properly dispose of flushing liquid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of substances posing a health
hazard.
WARNING
76 of 492 HGM
WARNING
▪ Make sure that the drive cannot be switched on.
▪ Secure all valves against opening.
▪ Open all drains and drain lines.
▪ Drain the pump, flush it with clean water (e. g. drinking water, demineralised
water), and drain the pump again. (ð Section 7.4, Page 83)
▪ Collect the fill in an appropriate container and dispose of according to the local
anti-pollution regulations.
6.4 Returning to service
WARNING
may be impaired.
For returning the equipment to service, observe the sections on commissioning/start-

up (ð Section 6.1, Page 58) .
In addition, carry out all servicing / maintenance operations before returning the
pump (set) to service. (ð Section 7, Page 78)
HGM 77 of 492
7 Servicing/Maintenance
7.1 General information/safety regulations
DANGER
WARNING
High sound pressure level > 85 dB(A) can occur during operation
Injury to the ear and hearing impairment. Hardness of hearing, tinnitus and hearing
loss can be caused!
▷ Wear ear protection.
▷ Observe the applicable local occupational health and safety regulations.
WARNING
Failure of sealing elements at the suction nozzle, discharge nozzle and other
pressurised parts
pressurised fluid handled or steam escapes!
▷ Wear safety goggles.
▷ Check the sealing elements regularly.
▷ Access to the pump is restricted to authorised specialist personnel only.
WARNING
Risk of burns!
WARNING
78 of 492 HGM
WARNING
Residual risk of component failure
Risk of parts flying off, burns and scalds!
▷ Access to the pump set is restricted to authorised specialist personnel only.
▷ Limit the time spent in this area to a minimum.
▷ Wear appropriate personal protective equipment, e.g. safety helmet, ear
protection, safety goggles, safety shoes and, if required, protective gloves.
▷ Regularly check the pump (set) for impermissible leakages. If necessary, initiate
immediate remedial action.
▷ Regularly measure the vibrations at the bearing housings.
CAUTION
Excessive density of the fluid handled
Motor overload!
▷ Observe the information on fluid density in the data sheet.
▷ Make sure the motor has sufficient power reserves.
NOTE
Only carry out the following dismantling instructions when the product is no longer
under warranty. Carrying out the maintenance work described below during the
warranty period will result in loss of warranty cover. In the event of damage during
the warranty period contact KSB.
7.2 Supervision of operation

The supervision work indicated is the recommended minimum scope. Do not exceed
the intervals; shorter intervals improve the operating reliability.
If the values deviate from the specifications or if failures occur:
Table 16: Supervision of operation

To be supervised Measure Value/condition to be met Interval
Strainer in the inlet line, Check the differential pressure Δp. Δp < 0.3 bar Weekly
differential pressure gauge
Thrust bearing / radial bearing Check for smooth running Smooth, vibration-free operation Weekly
(vibration measurement). Measure
See list of measuring points (if applicable)
manually if required.
in the relevant documentation.
Thrust bearing / radial bearing Check the clearance increase. Values: (ð Section 9.1.7, Page 137) Every 16,000 operating hours
Check the thrust bearing clearance:
Mechanical seal (433) Check the leakage. See manufacturer's product literature. See manufacturer's product
literature.
Static sealing elements Check the leakage. No leakage permitted Daily
Measuring instrument, suction Check the pressure. Value see operating data (relevant Weekly
side ps (instrument holder) documentation)
Measuring instrument, Check the pressure. Value see operating data (relevant Weekly
discharge side pd (instrument documentation)
holder)
Measuring instrument, Check the pressure. Value see operating data (relevant Weekly
tapping (instrument holder) documentation)
Coupling (for toothed Check the leakage. No leakage permitted Weekly
coupling only)
Coupling guard Check for safety. Check that the installation is contact-free. Monthly
Earthing connection Check for safety. Make sure that the connection is fitted Monthly
and marked. (ð Section 4.4, Page 22)
HGM 79 of 492
To be supervised Measure Value/condition to be met Interval

Drive See manufacturer's product See manufacturer's product literature. See manufacturer's product
literature. literature.
Thermometer (balancing Check the temperature. See operating data (relevant Weekly
liquid) documentation) and, if applicable, list of
measuring points (relevant
documentation)
7.3 Servicing/inspection
WARNING
WARNING
hazard
NOTE
All maintenance work, service work and installation work can be carried out by KSB
Service or authorised workshops. For contact details refer to the enclosed
"Addresses" booklet or visit "www.ksb.com/contact" on the Internet.
The operator ensures that maintenance, inspection and installation are performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.
Never use force when dismantling and reassembling the pump set.
▪ The pump set has been taken out of service in accordance with the instructions
(ð Section 6.3, Page 74) and prepared for maintenance
(ð Section 6.3.2, Page 75) .
▪ The spare parts required are available.
▪ Transport equipment / lifting equipment suitable for the corresponding weight
▪ Sufficient clearance and suitable tools are provided for servicing work.
▪ The drive has been secured against unintentional starting.
80 of 492 HGM
7.3.1 Servicing plan
NOTE
The intervals given in the servicing plan apply to trouble-free operation. Adjust the
intervals to the actual operating conditions, depending on the dirt accumulation,
frequency of starts, load, etc. In the case of failures and unusual operating
conditions that present electric or mechanical overloads of the pump set, perform
off-schedule servicing.
If still under warranty, servicing must be carried out by specialist personnel

authorised by KSB.
After expiry of the warranty period we recommend having work on the pump
exclusively carried out by specialist personnel authorised by KSB.
The parts required for servicing depend on the pump design. These are to be
organised in due time after consultation with KSB. Details see recommended spare
parts stock. (ð Section 7.10.2, Page 98)
KSB recommends the following regular servicing schedule:
Table 17: Overview of servicing work

Servicing work Interval
Visual inspection, as far as accessible Approx. 500 operating hours
after commissioning/start-up
Small servicing: Every two years from
▪ Check the condition of typical wear parts such as bearings, shaft seal and commissioning
balancing device. If necessary, rework or replace them.
▪ Opening the pump body is not necessary. The pump does not necessarily
need to be removed from the system.
Large servicing: Every five years from
▪ Completely dismantle the pump. Check all components. commissioning
▪ Rework or replace any worn components.
Servicing plan after commissioning/start-up and stand-by
Table 18: Overview of servicing work after commissioning/start-up and stand-by

To be serviced Measure Interval
Coupling Check condition and proper functioning. See manufacturer's product literature.
Oil fill / grease fill (if any) See manufacturer's product literature.
Pump rotor Check the axial clearance. Approximately after 8,000 operating
hours or after one year at the latest
Drive See manufacturer's product literature. See manufacturer's product literature.
Instruments 10)
See manufacturer's product literature. See manufacturer's product literature.
Mechanical seal See manufacturer's product literature. See manufacturer's product literature.
Thrust bearing / radial bearing Check the condition: In the case of exposed After 16,000 operating hours
fibres at the bearing surfaces, replace the
relevant parts.
Check the thrust bearing clearance:
Minimum flow control valve See manufacturer's product literature. See manufacturer's product literature.
Other components See manufacturer's product literature. See manufacturer's product literature.
10 If applicable
HGM 81 of 492
7.3.2 Inspection work
7.3.2.1 Checking the thrust bearing clearance
NOTE
The thrust bearing clearance only needs to be checked as part of the clearance
increase check.
If the pump is filled, an axial force of up to 4000 N is necessary, depending on the
pump size and the geodetic water column.
386.03 386.01
Fig. 41: Checking the thrust bearing clearance

1. Fit the dial gauge holder in a fixed point and place the sensing element against
the coupling face.
2. With the pump rotor touching discharge-side bearing 386.03 set the dial gauge
to position “0”.
3. Move the pump rotor until it abuts suction-side thrust bearing 386.01.
4. Read off the dial gauge and check the value. (ð Section 9.1.7, Page 137)
7.3.2.2 Maintenance of the other pump set components
Coupling
▪ See manufacturer's product literature.
Drive
Minimum flow system / minimum flow control valve

Instruments and valves

▪ Maintenance is not required. In the case of malfunction, replace the components.
82 of 492 HGM
7.4 Drainage/cleaning
DANGER
Falling parts
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.
▷ Shut off any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
DANGER
Contact with toxic, flammable, explosive or hot fluids handled
Risk of injury, e.g. chemical burns on the skin and in the eyes, poisoning and burns!
▷ Observe the relevant safety instructions, e.g. safety data sheets, for the
handling of hazardous substances (wear safety goggles, protective gloves,
protective clothing, etc., if required).
▷ Wear personal protective equipment (e.g. safety goggles, protective gloves,
protective clothing, etc).
▷ Collect and properly dispose of the flushing liquid or residues of the fluid
handled.
▷ Remove any residues of the fluid handled from the pump. Flush the pump
thoroughly.
DANGER
Pump too hot: Contact with hot fluid handled, damage to the O-rings causing
leakage when the pump is returned to service
Risk of injury, e.g. cuts caused by fluid jets, burns, scalds, respiratory system burns!
▷ Let the pump cool down: Pump casing temperature < 50 °C, measured at the
pump nozzles.
WARNING
Risk of burns, scalds and cuts caused by fluid jets!
▷ Always use an appropriate draining device.
▷ Drain the pump properly.
▷ During the draining process keep your distance from the outlet.
HGM 83 of 492
WARNING
WARNING
Fluids posing a health hazard
▷ Collect and properly dispose of flushing liquid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of substances posing a health
hazard.
WARNING
1. Make sure that the drive cannot be switched on.

2. Secure all valves against opening.
3. Open all drains and drain lines.
4. Collect the fill in an appropriate container and dispose of according to the local
anti-pollution regulations.
5. Close all drains and drain lines.
6. Fill the pump with a water/glycol mixture with a mixing ratio of 1:111). For a
standstill > 12 months perform the preservation for standstill.
7. Dismantle and store the coupling guard. (ð Section 5.5.1, Page 33)
8. Remove and store the coupling spacer in accordance with the manufacturer’s
product literature. (ð Section 7.5.2.1, Page 85)
9. To prevent a separation of the fill, rotate the pump rotor by 1 or 2 rotations
once a month. Check the fill level. Top it up if required.
ð In the case of toothed couplings, fix the pump-end coupling sleeve on the
hub using spacer plates (supplied loose).
ð Move the pump rotor towards the non-drive end by approximately 1 mm.
Rotate it by hand.
ð Only rotate the pump rotor manually in the direction of rotation of the
pump. If necessary, fit a suitable tool at the coupling hub. It must be possible
to rotate the pump rotor by hand. (ð Section 6.1.5, Page 65)
11 Provides protection against freezing down to approximately -42 °C.
84 of 492 HGM
7.5 Dismantling the pump set
7.5.1 Removing the sound insulating hood
DANGER
Falling parts
ü The manufacturer's product literature for the sound insulating hood is available.
1. If applicable, mount the sound insulating hood in accordance with the
manufacturer's product literature.
7.5.2 Dismantling the coupling
WARNING
ü The manufacturer's product literature for the coupling is available.

1. Dismantle the coupling guard (ð Section 5.5.1, Page 33)
2. Dismantle the coupling in accordance with the manufacturer's product
literature.
3. Store the coupling if necessary.
7.5.2.1 Dismantling the coupling spacer

1 2 3
Fig. 42: Marking the coupling spacer (example)

1 Coupling hub (pump) 3 Coupling hub (drive)
2 Spacer X Marking
ü The manufacturer's product literature for the coupling spacer is available.
1. Pay attention to the markings on the coupling, if any, or mark the coupling to
avoid any mixing up.
2. Dismantle the coupling spacer in accordance with the manufacturer's product
literature.
3. Store the coupling spacer.
HGM 85 of 492
7.5.2.2 Removing the coupling hub (keyed connection)
WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
WARNING
CAUTION
Improper mounting of elastomeric parts
Elastomeric parts' sealing function reduced!
▷ Never re-use elastomeric parts after they have been heated.
▷ For reassembly, always use new elastomeric parts.
CAUTION
Improper dismantling
Damage to bearings and coupling parts!
▷ Always use a puller to remove the coupling hubs.
▷ Never strike the coupling hubs.
1. Remove the retaining ring (if any) from the coupling hub.
2. Mark the coupling hub's position relative to the shaft in circumferential
direction. If no marking exists, mark the position by stamping. (Maintaining the
balancing grade for reassembly)
1 2
Fig. 43: Marking the coupling parts

1 Shaft 2 Coupling hub
3. Remove the grub screws.
4. Remove the elastomeric parts.
5. To make it easier to pull off the coupling hubs heat them up uniformly to a
temperature of 80 °C max.
6. Remove the coupling hub as shown in the figure.
86 of 492 HGM
Fig. 44: Removing the coupling hub

7. Mark and remove the keys.
8. Store the coupling hubs and keys.
7.6 Removing the pump set from the system
7.6.1 Removing the piping and instruments
WARNING
Fluid could escape when the flanged connections are opened
▷ Wear protective clothing.
▷ Collect and dispose of any liquid residues.
1. Fasten the inlet line and discharge line to temporary holders.

2. Disconnect the discharge nozzle from the discharge line. Disconnect the suction
nozzle from the inlet line.
3. If necessary, remove the minimum flow control valve.
4. If necessary, disconnect the tapping line.
5. If necessary, disconnect and remove the auxiliary lines.
6. If necessary, remove and store the measuring devices and instruments.
7. Close the openings of the dismantled pipes.
HGM 87 of 492
7.6.2 Removing the pump from the baseplate
Fig. 45: Fastening of the pump feet (example)

1 Pump 4 Nut
2 Baseplate 5 Stud
3 Washer
1. Undo the nuts.
2. Remove, mark and store the matching shims.
3. Remove and store the studs.
4. Lift the pump off the baseplate. Transport it to the dismantling place
(ð Section 3.2, Page 11) and place it down on assembly supports.
7.7 Dismantling the pump
7.7.1 Removing the mechanical seal
DANGER
Falling parts
WARNING
Damaged shaft sleeve and mechanical seals
▷ Replace damaged shaft sleeves and mechanical seals by new components.
CAUTION
Re-using bearings
Damage to the pump!
▷ Only use bearings which are in perfect condition.
▷ Never use bearings that exhibit discolouration marks or specks of rust.
▷ If the bearing surfaces show any signs of scoring or wear, the bearings (and
their mating parts if possible) must be replaced.
88 of 492 HGM
CAUTION
Incorrect dismantling
Damage to the shaft and clearance gaps!
▷ Never rotate the shaft when the bearings have been removed.
562.10 562.06
475.21
472.21 507
412.21
477.21 920.02
412.22 550.03
904.21
932.21 441
420 50-3.22
523 474.21
485.21
Z7D006
Fig. 46: Removing the mechanical seal

ü The general drawing for the mechanical seal and the manufacturer's product
literature are available.
1. Completely dismantle balancing liquid line 710, 731.
2. Remove thrower 507 from shaft sleeve 523.
3. Undo nuts 920.02. Remove nuts with discs 550.03.
4. Dismantle shaft seal housing 441, mating ring 475.21 and O-ring 412.22.
5. Undo grub screw 904.21.
6. Pull tappet 485.21 with springs 477.21, thrust ring 474.21, O-ring 412.21,
backing ring 50-3.22, circlip 932.21 and primary ring 472.21 off shaft sleeve 523.
7. Undo shaft sleeve 523 with loose shaft seal ring 420 using a suitable tool (e.g.
open-ended spanner) (left-hand thread) and pull it off the shaft.
8. Check the mechanical seal:
ð If the running surfaces are clean and undamaged, the mechanical seal can
continue to be used.
ð If the running surfaces show any signs of scoring or wear, the bearings must
be replaced. See manufacturer's product literature.
HGM 89 of 492
7.7.2 Removing the thrust bearing, discharge-side radial bearing and balancing
device
DANGER
Falling parts
CAUTION
Re-using bearings
Damage to the pump!
412.62 412.63
412.12
59-4
562.05 562.61 603
391
562.62
386.03 562.63
412.14
504
386.02
412.15 386.01
412.61
542.02
Fig. 47: Removing the thrust bearing, discharge-side radial bearing and balancing
device
1. Remove bearing ring carrier 391, thrust bearing ring 386.03, O-ring 412.12/.62
and parallel pin 562.05/.06 from shaft seal housing 441.
2. Pull balance drum 603, thrust bearing 386.02, parallel pin 562.61/.63 and O-ring
412.14/.63/.61 off the shaft using screws in accordance with the corresponding
table. .
3. Pull piston 59-4 with O-ring 412.15 off the shaft using screws in accordance with
the corresponding table .
4. Checking the bearing surfaces on the thrust bearing and radial bearing:
ð If the contact faces of thrust bearing ring 386.01/.02/.03, balance drum 603,
piston 59-4 and throttling bush 542.02 are clean and undamaged, the parts
can be re-used.
ð If the contact faces show any signs of scoring or wear, the parts must be
replaced.
90 of 492 HGM
7.8 Reassembling the pump
WARNING
Hot and/or pressurised fluid could escape.
Risk of injury (e.g. cuts caused by fluid jets, burns, scalds, respiratory system burns)!
Failure of sealing function!
▷ Prevent O-rings from coming into contact with mineral oil and grease.
▷ Only take the O-rings out of the original packaging immediately prior to fitting
them.
▷ Do not fit the O-rings in dry condition. Observe the information on auxiliary
material for assembly provided by KSB and the manufacturer's product
literature for the mechanical seal (if any).
▷ Check the O-rings for any damage before they are fitted.
▷ Always use new O-rings and gaskets.
▪ Meticulously clean the locating surfaces and sealing surface areas of all
dismantled components.
▪ Check all dismantled parts for any damage.
▪ If required, have new parts available.
▪ Prior to installation, apply the lubricants specified in work instruction UA4 28700
to the screwed/bolted connections and locating surfaces. (ð Section , Page 148)
▪ Do not damage the locating surfaces and sealing surfaces.
7.8.1 Fitting the thrust bearing and discharge-side radial bearing (without using new
components)
DANGER
Falling parts
CAUTION
Re-using bearings
Damage to the pump!
CAUTION
HGM 91 of 492
562.03
59-4
542.02
504
391
562.05
562.62 107
441
210
940.01
f
386.03
412.12
f
386.02
412.63
603
562.63
412.15
386.01
Fig. 48: Fitting the thrust bearing and discharge-side radial bearing

ü Lifting equipment suitable for the corresponding weight has been selected and is
available.
ü Coating plan / lubricant instructions have been observed.
1. Attach suitable lifting equipment to the centre of shaft 210. Lift up the shaft.
2. Slide piston 59-4 including O-ring 412.15 over shaft 210 and key 940.01.
3. Slide balance drum 603 including O-ring 412.63 and parallel pin 562.63 over
shaft 210 until it abuts against spacer ring 504.
4. Checking the thrust bearing clearance: g - (f + h) = 1±0.4 mm
5. Slide bearing ring carrier 391 with inserted O-ring 412.12, fitted parallel pin
562.05/.62 and thrust bearing ring 386.03 over the shaft until it abuts thrust
bearing ring 386.02. Fasten it in this position.
6. Install the mechanical seal. (ð Section 7.8.3, Page 95)
92 of 492 HGM
7.8.2 Fitting the thrust bearing, discharge-side radial bearing and balancing device
(using new components)
DANGER
Falling parts
CAUTION
Re-using bearings
Damage to the pump!
CAUTION
391
562.05 504 562.03
562.62 386.01
107
441 603
210
M
K
L
940.01
386.03
412.12
Fig. 49: Fitting the thrust bearing, discharge-side radial bearing and balancing device
Table 19: Adjusting dimension for the pump rotor

Size Hydraulic system Adjusting dimension A
[mm]
HGM 1 1.1 2,4 ± 0,3
HGM 2 2.1, 3.1 2,6 ± 0,3
HGM 3 4.1, 5.1 4,0 ± 0,3
HGM 4 6.1, 7.1 4,5 ± 0,3
HGM 93 of 492
Size Hydraulic system Adjusting dimension A

[mm]
HGM 4 6.2, 7.2 3,6 ± 0,3
ü Balance drum 603 and/or thrust bearing ring 386.01 are available as new
components.
ü Lifting equipment suitable for the corresponding weight has been selected and is
available.
ü Lubricant instructions have been observed. (ð Section , Page 148)
1. Attach suitable lifting equipment to the centre of shaft 210. Lift up the shaft.
2. Slide piston 59-4 including O-ring 412.15 over shaft 210 and key 940.01.
3. Use screws in accordance with the corresponding table to push thrust bearing
ring 386.01 over throttling bush 542.02 until it abuts discharge casing 107. Pay
attention to the position of parallel pin 562.03.
4. Adjust the position of the pump rotor. Move the pump rotor in the direction of
the discharge side until it abuts.
5. Move the pump rotor towards the suction side. Observe adjusting dimension (A)
(see table).
171.01
108.01 171.02 230
502 108.02 171.03 231
Fig. 50: Adjusting the position of the pump rotor

6. The position of the pump rotor must not be modified during this measurement.
Calculate the length of spacer ring 504: K - M = L
7. Shorten spacer ring 504 to the calculated dimension L. The maximum
permissible deviation from plane parallelism is 0.02 mm. If required, use a new
spacer ring 504.
8. Fit spacer ring 504 on shaft 210.
9. Coat the axial running face of balance drum 603 with the contact fluid
“engineer’s blue”. Without O-ring 412.63 slide the balance drum onto shaft 210
up to spacer ring 504.
10. In the area of shaft sleeve 523, apply Molykote G-N Plus Paste12) and a few drops
of Mobilarma 524 oil13) to the thread and locating surface of the shaft. Make
sure that the assembly aids are clean.
11. Slide shaft sleeve 523 without O-ring 412.14 onto the shaft. Tighten it with a
suitable tool (e.g. open-ended spanner) (left-hand thread). Observe the
tightening torque. (ð Section 9.1.9, Page 139)
12. For the check with the contact fluid “engineer’s blue”, move the rotor towards
the suction side and turn it slowly.
13. Move the pump rotor towards the discharge side.
12 Dow Corning Europe

13 Mobil Oil AG
94 of 492 HGM
14. Remove shaft sleeve 523 and balance drum 603.

15. At least , 3/4 of the axial running face of thrust bearing ring 386.01 have
to show a uniform print of the contact fluid. If necessary, re-machine thrust
bearing ring 386.01 on a lathe and repeat the check with contact fluid.
16. Clean the axial running faces of thrust bearing ring 386.01 and balance drum
603.
17. Slide balance drum 603 with O-ring 412.63 onto shaft 210 up to spacer ring 504.
Fasten it in this position.
18. Slide bearing ring carrier 391 with inserted O-ring 412.12, fitted parallel pin
562.05/.62 and thrust bearing ring 386.03 over the shaft until it abuts thrust
bearing ring 386.02. Fasten it in this position.
19. Install the mechanical seal. (ð Section 7.8.3, Page 95)
7.8.3 Installing the mechanical seal
DANGER
Falling parts
WARNING
Damaged shaft sleeve and mechanical seals
▷ Replace damaged shaft sleeves and mechanical seals by new components.
475.21 562.10 433 603

507 441 210 562.05 386.01
LG
902.01 904.21 412.14 412.10

550.03 420 386.02 504
412.22 523
920.02
Fig. 51: Installing the mechanical seal
Table 20: Adjusting dimension for the pump rotor

Size Observe installation dimension LG
[mm]
HGM 1 46
HGM 2 62
HGM 95 of 492
Size Observe installation dimension LG

[mm]
HGM 3 65,5
HGM 4 78,5
ü The mechanical seal has been checked to be free from contamination and
damage. If necessary, it has been replaced.
ü The general drawing for the mechanical seal and the manufacturer's product
literature are available.
ü Coating plan / lubricant instructions have been observed. (ð Section , Page 148)
ü The thrust bearing has been fitted. (ð Section 7.8.1, Page 91) ,
1. Place O-ring 412.14 into the designated groove of balance drum 603.
2. In the area of shaft sleeve 523, apply Molykote G-N Plus Paste14) and a few drops
of Mobilarma 524 oil15) to the thread and locating surface of the shaft. Make
sure that the assembly aids are clean.
3. Pull shaft sleeve 523 with O-ring 412.14 onto the shaft. Tighten it with a suitable
tool (e.g. open-ended spanner) (left-hand thread). Check that O-ring 412.14 is
seated correctly. Observe the tightening torque. (ð Section 9.1.9, Page 139)
4. Slide shaft seal ring 420 over shaft sleeve 523 until it abuts against thrust
bearing ring 386.02.
5. Slide complete mechanical seal 433 onto shaft sleeve 523.
6. Observe installation dimension LG (see table). Use grub screws 904.21 for
fastening. Observe the tightening torque. (ð Section 9.1.9, Page 139)
386.01
562.05
433 603
210 LG
523
904.21
412.14
386.02 504
Fig. 52: Installation dimension LG of the mechanical seal

7. Fit mating ring 475.21 with O-ring 412.22 in shaft seal housing 441.
8. Slide the pre-assembled shaft seal housing 441 with inserted O-ring 412.10 right
up to discharge casing 107.
ð Parallel pin 562.05 must engage into the hole provided in shaft seal housing
441.
ð Parallel pin 562.10 must engage into the respective groove of shaft seal ring
420.
9. Fasten the pre-assembled shaft seal housing 441 with discs 550.03 and nuts
920.02. Tighten nuts 920.02 in diagonally opposite sequence. Observe the
tightening torque. (ð Section 9.1.9, Page 139)
14 By Dow Corning Europe

15 By Mobil Oil AG
96 of 492 HGM
10. Slide thrower 507 over shaft 523 and check for tight fit.
11. Fit balancing liquid line 710, 731.
7.9 Installing the pump set in the system

1. Lift the pump off the assembly supports and transport it to its place of use.
2. Insert the respectively marked packs of associated shims between pump foot
and baseplate.
3. Place the pump on the baseplate.
4. Check the shaft ends for run-out. (ð Section 5.5.2, Page 33)
5. Align the pump and motor. (ð Section 5.9, Page 47)
6. Mount the pump on the baseplate. (ð Section 5.12.1, Page 56)
7. Re-install the piping and instruments that have been removed for maintenance
work. (ð Section 5.11, Page 51)
8. Install the coupling. (ð Section 6.1.6, Page 65)
9. Mount the protective equipment. (ð Section 6.1.6.2, Page 66)
7.10 Spare parts stock
7.10.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:
▪ Type series or components
▪ Size
▪ Order number
▪ Order item number
▪ Consecutive number
Refer to the name plate for all data.
Also specify the following data:
▪ Part number and description (ð Section 9.2.3, Page 152)
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)
HGM 97 of 492
7.10.2 Recommended spare parts stock
NOTE
Special tools are not required. Standard tools can generally be used.
Table 21: Recommended spare parts stock for commissioning

Part No. Description Quantity
99-9 Set of sealing elements 1
433 Mechanical seal 1
Table 22: Recommended spare parts stock for 2 years' operation to DIN 24296 (small
set of spare parts)
386 Thrust bearing ring 1
412.04 O-ring 1
16)
412.05 O-ring
42017) Shaft seal ring 1
50218) Casing wear ring 16)
50419) Spacer ring 1

523 Shaft sleeve 1
Table 23: Recommended spare parts stock for 2 years' operation to DIN 24296 (large
set of spare parts)
- Pump rotor, pre-assembled 1
386.01 Thrust bearing ring 1
412.04 O-ring 1
16)
412.05 O-ring
42017) Shaft seal ring 1
18) 16)
502 Casing wear ring
52920) Bearing sleeve 1
542.02 Throttling bush 1
545 Bearing bush 1
Table 24: Large set of spare parts

Rotating components
- Pump rotor, pre-assembled 1
16 The quantity depends on the number of stages and is provided by the selection program.
17 For cooled design only
18 Applicable for special repairs only: Impellers made of 1.4008 are levelled at the impeller neck. Casing wear rings
with smaller inside diameters are used and adapted to the diameter of the impeller neck if necessary. Impellers
made of EN-GJL-250 are generally replaced by new impellers; the corresponding casing wear rings are supplied
with finished diameters.
19 In maximum length
20 The bearing sleeve is supplied fitted on the suction-stage impeller. Additional bearing sleeves can be ordered to
be supplied but not fitted.
98 of 492 HGM

17)
420 Shaft seal ring 1
52920) Bearing sleeve 1
Stationary components
412.04 O-ring 1
16)
412.05 O-ring
50218) Casing wear ring 16)
542.02 Throttling bush 1

545 Bearing bush 1
Table 25: Set of spare parts for the pump rotor

59-4 Piston 1
210 Shaft 1
16)
230 Non-suction impeller
231 / 529 Suction-stage impeller / 1
bearing sleeve
19) 16)
504 Spacer ring
523 Shaft sleeve 1
562.61 Parallel pin 1
562.63 Parallel pin 1
603 Balance drum 1
914.01 Hexagon socket head cap 1
screw
940.01 Key 1
940.03 Key 2
940.03 Key for coupling 2
HGM 99 of 492
8 Trouble-shooting
8 Trouble-shooting
DANGER
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 service is required.
Table 26: Trouble-shooting
Problem Possible cause Remedy
Pump flow rate < specified value Pump delivers against an excessively Open the valve in the discharge line until the
high pressure. duty point is reached.
Excessively high back pressure Mount a larger impeller or larger impellers.
Increase the speed of the drive.
Check system for impurities.
Contact KSB’s service centre.
Pump and/or piping are not completely Vent / prime.
vented or primed.
Inlet line or impeller(s) clogged Remove deposits in the pump and/or piping.
Formation of air pockets in the piping Alter piping layout.
Fit a vent valve.
NPSHavailable too low (inlet) Check/alter liquid level.
Fully open the valve in the inlet line.
If resistances in the the inlet line are too high,
alter the inlet line.
Check any strainers installed.
Excessive speed of pressure fall Observe permissible speed of pressure fall.
Wrong direction of rotation Interchange two of the phases of the power
supply.
Speed is too low. Increase speed.
Increase voltage.
Wear of internal parts Replace defective internal parts.
Single-phase operation Replace defective overcurrent protection devices.
Check the cable connections.
Discharge pressure pd > specified Speed is too high. Reduce speed.
value
Alter the impeller diameter.
Damaged measuring instrument Replace the measuring instrument.
Inlet pressure ps < specified value Damaged measuring instrument Replace the measuring instrument.
Differential pressure in the strainer Dismantle and clean the strainer element.
element is too high.
Valve in the inlet line is not fully open. Open the valve.
Pressure in the inlet tank is too low. Check the inlet tank or increase the pressure.
Discharge pressure pd < specified Speed is too low. Check the drive.
value Inlet pressure is too low. Check the inlet pressure and inlet tank.
In the case of tapping, quantity tapped Throttle the tapping quantity.
is too high.
Temperature of fluid handled is too Reduce temperature.
high.
Defective minimum flow system Check the minimum flow system.
100 of 492 HGM

8 Trouble-shooting

Mechanical seal leakage Defective mechanical seal Check; replace if required.
Score marks or roughness on shaft Check shaft protecting sleeve 524 / shaft sleeve
protecting sleeve 524 / shaft sleeve 523 523. Replace it if required.
Pump set alignment Check the coupling; re-align it if required.
Pump is warped. Check piping connections and secure fixing of
pump.
Seal chamber contaminated Clean the seal chamber.
Compressive load at sealing clearance Check the installation dimensions.
too low
Excessive surface pressure at sealing Check the installation dimensions.
clearance, lack of lubricant and/or
circulation liquid
Leakage, mechanical seal > specified Mechanical seal must run in. Running-in operation of 30 minutes
value for commissioning
Leakage, mechanical seal > specified Excessive thrust bearing clearance Check the bearing clearance.
value
Check the thrust bearing clearance.
Pump temperature > specified value Pump and/or piping are not completely Vent / prime.
vented or primed.
NPSHavailable is too low (inlet) Check/alter liquid level.
Change the inlet line, if the resistances in the
inlet line are too high.
Check installed strainers; clean them if required.
Flow rate < specified value Flow rate ≥ Qmin
Pump leakage O-rings and/or metal seal faces defective Replace O-rings and/or rework metal seal faces.
Tie bolts have worked loose. Re-tighten the tie bolts.
Work instruction (relevant documentation)
Vibrations during pump operation Pump and/or piping are not completely Vent / prime.
vented or primed
Check any strainers installed.
Pump back pressure is lower than Adjust the duty point accurately by means of the
specified in the purchase order. valve in the discharge line.
In the case of persistent overloading, turn down
impeller(s) if possible.
Pump set alignment Check the coupling; re-align it if required.
pump.
Unbalance of the pump rotor Clean the pump rotor.
Balance the pump rotor.
Flow rate < specified value Flow rate ≥ Qmin
Excessive thrust bearing clearance Check the bearing clearance.
Check the thrust bearing clearance.
Excessive radial bearing clearance Have the bearing clearance checked by KSB’s
service centre.
HGM 101 of 492

8 Trouble-shooting

Vibrations during pump operation Minimum flow rate too low Check the valves in the minimum flow line.
Check the minimum flow control valve.
Excessive temperature of the Heat exchanger is dirty. Clean the heat exchanger.
circulation liquid Valve defective or closed Check or open the valve.
Cavitation noise in the pump and/or Damaged or dirty inlet line Check the inlet line.
piping Valve in the inlet line is not fully open. Open the valve.
Pressure in the inlet tank is too low. Check the inlet tank or increase the pressure.
NPSHNPSHavailable/NPSHrequired too low Check the inlet line. Change it if necessary.
Air intake at sealing elements, valves Check the piping; check the shaft seal for
and shaft seal leakage.
Pump and/or piping not completely Vent / prime.
vented
Temperature of fluid handled is too Reduce the temperature.
high.
Pump suddenly blocked. Pump rotor is mechanically blocked. De-energise, interlock and depressurise the
pump.
Fluctuating pressure / quantity of the Pump and/or piping are not completely Vent / prime.
balancing liquid vented or primed.
Check the strainers; clean them if required.
Increased axial thrust Check the casing wear rings and balancing
system. Replace them if required.
Wear of balancing device Check the rotor clearances and balancing device.
Drive overload Wear of internal parts Replace defective internal parts.
Pump back pressure is lower than Adjust the duty point accurately by means of the
specified in the purchase order. valve in the discharge line.
In the case of persistent overloading, turn down
the impeller(s) if possible.
Density or viscosity of fluid handled Contact KSB’s service centre.
higher than stated in purchase order
Speed is too high. Alter the impeller diameter.
Reduce the speed of the drive.
pump.
Supply voltage is too low. Check the cable connections.
Single-phase operation Replace defective overcurrent protection devices.
Check the cable connections.
8.1 Reporting faults
NOTE
In the event of a fault, fill in the form and send it to KSB.
102 of 492 HGM

8 Trouble-shooting
Table 27: Reporting faults

General information
Plant data
Plant: ______________________________ Contact person: ________________________
Address: ________________________________ Phone: ________________________________
Country: ________________________________ Fax: ________________________________
E-mail: ________________________________
Pump data
Pump type: ________________________________
Order number: __________________________________
Date of commissioning: ___________________________
Operating hours: ________________________________
Pump operating data
Inlet pressure: _________________ bar
Discharge pressure: _________________ bar
Flow rate: _________________ m3/h
Fluid temperature: _________________ °C
Speed: _________________ rpm
Suction-side bearing temperature: _________________ °C
Discharge-side bearing temperature: _________________ °C
Vibration values: _________________ mm/s
Show the operating data as trend curves in a diagram. Send this diagram to KSB together with the fault report.
Description of the fault
Date the fault occurred: _________________

Brief fault description:
HGM 103 of 492

9 Relevant Documentation
Table 28: Overview of relevant documentation
Section Contents See
9.1 Pump set (ð Section 9.1, Page 105)
9.2 Pump (ð Section 9.2, Page 142)
9.3 Coupling (ð Section 9.3, Page 191)
9.4 Drive (ð Section 9.4, Page 214)
9.5 Minimum flow system
9.6 Valves and equipment (ð Section 9.6, Page 405)
9.7 Instruments (ð Section 9.7, Page 411)
9.8 Gear unit (ð Section 9.8, Page 487)
9.9 Protective equipment (ð Section 9.9, Page 488)
104 of 492 HGM

9.1 Pump set

Table 29: Overview of relevant documentation for the pump set
Section Contents See
9.1.1 EU Declaration of Conformity
9.1.2 Technical data
9.1.3 Characteristic curve
9.1.4 Installation plan
9.1.5 Operating range for version with variable speed drive (ð Section 9.1.5, Page 116)
9.1.6 P+I diagram (ð Section 9.6, Page 405)
9.1.7 List of measuring points (ð Section 9.7, Page 411)
9.1.8 Clearances (ð Section 9.1.7, Page 137)
9.1.9 Thread sizes for dismantling aids / reassembly aids
9.1.10 Tightening torques (ð Section 9.1.9, Page 139)
HGM 105 of 492

9.1.1 Declaration of conformity
106 of 492 HGM

HGM 2/12
9974696285 - 100
Stefan Schäfer
Head of Development & PM HG Family
KSB SE & Co. KGaA

67227 Frankenthal (Germany)
Frankenthal, 2022-02-04
Dr. Berthold Matz

Head of Development & PM Conv. Energy
KSB SE & Co. KGaA

67227 Frankenthal (Germany)
9.1.1.1 Further information on the EU Declaration of Conformity

If any pump set components are supplied by the customer, KSB shall be provided
with the Declaration of Incorporation and the EU Declaration of Conformity,
including the operating manuals.
If the associated work procedures are not included in KSB’s scope of supply, the
following original documents bearing the company stamp shall be sent to KSB:
▪ Checklist for assembly / installation
▪ Alignment certificate / record
▪ Confirmation of readiness for operation
Send the documents to the following address:

KSB SE & Co. KGaA
Attn. Dr. Berthold Matz (Project Manager)
Johann-Klein-Strasse 9
67227 Frankenthal
The customer will be provided with the CE marking, which indicates conformity of
the pump set, together with the Declaration of Conformity of the pump set. Upon
receipt, the marking shall be attached to a cold component (e.g. coupling guard or
baseplate).
HGM 107 of 492

9.1.2 Technical data
HGM 109 of 492

Inquiry / PO. No. 82947 Page No. 5
Customer DURO DAKOVIC Date 06.10.2021
Code name Montsinéry - French Rev. 02
KSB ref No. Guiana 9974696285 Pump. HGM 2/12
Dept. / In charge TEN-222
000100 01-02 Bernd Kalnik Product No. 42042212000802130300
Pump Design
Nozzle Design DN PN Drilled acc to Position [°] *)
Inlet Flange 80 16 EN 1092-1 vertically upwards
Outlet Flange 50 100 EN 1092-1 vertically upwards
*) clockwise viewed from the driven end ( 0° = top)
Shaft Seal Manufacturer Type Material Cooling

Mech. seal KSB KB045M1-5B A2Q1EGG-BP Water cooling
Cooler KSB WA The water cooler must only be operated at
operating temperatures above 140 0C
Axial thrust balancing Hydraulically by means of Single piston
Bearing Design Lubrication Cooling

Radial Plain bearing Medium No
Pump Feet Arrangement At bottom
Noise Level Expected noise level for operating point of pump only at 1m distance 78 dB
Accessories
Balancing water pipe – returned to first pump stage
Language for plates: French
Instrumentation acc. to list of measuring points
Baseplate for pump and motor (with foundation bolts)
Intake elbow - DIN
Junction box for pump instrumentation
Pressure gauge bracket
Material
Part No. Description Material
107 Discharge casing 1.4008.09 / 1.4317
108.01 Stage casing, first stage 1.4006+QT650
108.02 Stage casing, subsequent stages 1.4006+QT650
162 Suction cover 1.4021+QT800
171 Diffuser 1.4008.09
210 Shaft C45
230 Impeller 1.4008.09
231 Suction stage impeller 1.4008.09
441 Shaft seal housing 1.4021+QT800
502 Casing wear ring RWA 350
523 Shaft sleeve 1.4021+QT800
545 Bearing bush Noricrom®
59-4 Piston 1.4021+QT800/WR 525
603 Balance drum 1.4024.09
905 Tie bolt 1.6772
Code name Montsinéry - French Guiana Rev. 02
KSB ref No. 9974696285 000100 01-02 Pump. HGM 2/12
Dept. / In charge TEN-222 Bernd Kalnik Product No. 42042212000802130300
Technical Data
Cooling water quality (recommendation)
Only cleaned water not liable to precipitation of salts causing hardness may be used as coolant.
The cooling water temperature at the outlet must not exceed 55 °C.
Cooling water requirement

Quantity Unit
Circulation 2.13 l/min
Normal Maximum
Inlet temperature [°C] 20 45
Minimum Maximum
Cooling water pressure [bar] 2 6
Spare Parts
Set of spare parts for commissioning
2 Pieces 433 Mech. seal

2 Pieces 99-9 Set of seal elements EPDM 80/A4St
Set of spare parts for 2 years of operation (Addition to commissioning)

2 Pieces 386.02 Thrust bearing ring PGK

2 Pieces 412.04 O-ring EPDM 80PEROXYD
24 Pieces 412.05 O-ring EPDM 80PEROXYD
2 Pieces 420 Shaft seal ring PTFE
2 Pieces 504 Spacer ring RWA 350
9.1.3 Characteristic curves
112 of 492 HGM

Code name Item No. Date Page
Montsignery - French Guia 1 27.8.2021 1
Project No. Revision Hydraulic

. 7193 HGM 2/12 3.1 S 3.1 N
Type - size Speed [1/min] Temperature [C] Density [kg/m3]
HGM 2/12 2982 130 934.6
900 Qmin, continuous
Qmin, thermal
H [m]
800
1: HGM 2/12 3.1 S 3.1 N

n: 2982 [1/min] 700
600 1Qmax
500
0 5 10 15 20 25 30 35 40 45 50 Q [m3/h]
140 1
120
100
P [kW]
80
60
40
0 5 10 15 20 25 30 35 40 45 50 Q [m3/h]
80
1
60
Eta [%] 40
20
0
0 5 10 15 20 25 30 35 40 45 50 Q [m3/h]
1
3.2
3.0
NPSH [m] 2.8
2.6
2.4
2.2
0 5 10 15 20 25 30 35 40 45 50 Q [m3/h]
9.1.4 General arrangement drawings
114 of 492 HGM

9.1.5 Operating range for version with variable speed drive
NOTE
If a variable speed drive is used, the minimum head Hmin must not drop below the
specified minimum.
The minimum speed nmin may only be underrun in the start-up and stopping phase.
Qmin n%
100
Hopt
100
90
II
% 80
70
50
Qopt × 1,25
60
50
Hmin = 150 m
0
0 25 Q% 50 75 100 125
Fig. 53: Operating range for version with variable speed drive
2000
1900
nmin [min-1]
1800
1700
1600
1500
1400
1 3 5 7 9 11
Pperm [bar]
Fig. 54: Minimum speed as a function of the inlet pressure
nmin Minimum speed Pperm Inlet pressure
116 of 492 HGM

Code name Item No. Date Page
Montsignery - French Guia 27.8.2021
Project No. Revision Hydraulic

. 7193 HGM 2/12 3.1 S 3.1 N
Type - size Temperature [C] Density [kg/m3]
HGM 2/12 130 934.6
Operating range diagram
Speeds 920
1: 2982 [1/min] H [m] Qmin, thermal
2: 2979 [1/min] Qmin, continuous
880
3: 2857 [1/min]
4: 2807 [1/min]
5: 2751 [1/min] 840
6: 2698 [1/min]
7: 2600 [1/min] 800
8: 2500 [1/min]
9: 2250 [1/min]
760
10: 2000 [1/min]
11: 1800 [1/min]
720
680
640
600
Qmax
560
520
480
440
400
360
320
280
240
200
0 5 10 15 20 25 30 35 40 45 50 Q [m3/h]
Minimum permissible speed 1800 [1/min]

Code name Montsignery - French Guiana Rev. 00
List of Measuring Points CD1946997

Measuring Instrument Remarks
Meas. Location of measuring point Pcs per Type Measuring Feeler Indication / Make
point No. pump range length Interlocking Drawing No.
Medium/Material Scope of Housing Diameter DIN No.
supply diameter d Ident. No.
Threaded
connect.
PI 101 Pump suction pressure 1 Pressure 0 - 6 bar Local with WIKA With
Suction nozzle gauge with 100 mm remote manome3.doc pressure
Feed pump integrated G 1/2 A transmitter ZN 16065 gauge valve
Feed water pressure 01069837 acc. to
transducer DIN 16270
KSB 0001 F
PI 102 Pump discharge pressue 1 Pressure 0 - 160 Local with WIKA With
Discharge nozzle gauge with bar remote manome3.doc pressure
Feed pump integrated 100 mm transmitter ZN 16065 gauge valve
Feed water pressure G 1/2 A 01069844 acc. to
transducer DIN 16270
KSB 0001 F
PDIA 101 Differential pressure 1 Differential - 1,0 - 0 Local with KSB With 2
Strainer pressure bar 4..20mA signal - isolating
Feed pump monitoring 90x68x27 - valves
Feed water device mm 01663186 acc. to
pumpmeter G 1/2 B DIN 16270
KSB Variant 02 (24V DC
power supply
needed)
YE 103 Shock pulse measurement 1 SPM nipple -
Driven end KSB schwin9.doc
M8 ZN 407
00129477
YE 104 Shock pulse measurement 1 SPM nipple -
Non-driven end KSB schwin9.doc
M8 ZN 407
00129477
KKS plates not included in our scope of supply

0 1 2 3 4 5 6 7 8 9
KSB SE & Co. KGaA

67227 Frankenthal
Project Name: 9974696285-Montsinery - French Guiana
KSB refrence no: 9974696285
Pos. No: 100/ 01-02
3
Client P.O No: 82947
Pump type: HGM 2/12
Type of protection IP 66
Supply voltage : - 4
Control Voltage : 24V
Date 06.10.2021
Document No. CD1947002 No. of Pages : 12

5
Please observe the connection requirement of local energy supply utilities.

Prior to commissioning, please read the operating instruction of unit.
Next page
2
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Cover Page Page No.
KSB SE & Co. KGaA
Aprr. KHERADI1 Drawing Number : CD1947002 Johann-Klein-Straße 9 1 / 12
REVISION Remark Date Name Date 06.10.2021 Order number : 9974696285 67227 Frankenthal
0 1 2 3 4 5 6 7 8 9
Table of contents KSB -Table of content
Page Page description Date Edited by 1
/1 Cover Page 06.10.2021 MISAPOO

/2 Table of contents : /1 - /12 06.10.2021 MISAPOO
/3 Revision Overview 06.10.2021 MISAPOO
/4 Technical Overview 06.10.2021 MISAPOO
/5 Differential pressure monitoring 06.10.2021 MISAPOO
/6 Pump suction, discharge pressure 06.10.2021 MISAPOO
/7 Spare terminals, X0PE 06.10.2021 MISAPOO
/8 Junction box GA 06.10.2021 MISAPOO
2
/9 Terminal diagram =+-X0PE 06.10.2021 MISAPOO
/10 Terminal diagram =+-X1 06.10.2021 MISAPOO
/11 Terminal diagram =+-X2 06.10.2021 MISAPOO
/12 Summarised Part List 06.10.2021 MISAPOO
Next page
3
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Table of contents : /1 - /12 Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
Revision overview KSB-Revision Overview-Copy
Revision name Page name Revision description Creator Date

1
REV 01 All First issue MISAPOO 06.10.2021

REV 02 All Pump meter cable changed. MISAPOO 05.01.2021
Next page
4
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Revision Overview Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
Design basis: X KSB-Standard Client specifications
Terminal Box Execution 1
Material: Customer cable entry: Color of single leads:
X Steel Sheet Cable glands Plugs

X KSB
Client
Stainless Steel Brass Stainless steel Black L1, L2, L3
Polycarbonate Polyamid X None

Light Blue N 2
Color: Wiring/conduit entry:

Green - Yellow PE
X RAL7035 X Cable glands Conduit gland
Red Control voltage AC >50V
RAL1001 Brass Stainless steel
Red - White Control voltage AC <50V

Door hinge:
X Polyamid None
Blue Control Voltage DC < 50 C 3
X Right Left KKS-Tags:
Plastic engraved Metal White Analog signals

down top
Outside-Front Outside-Back Orange External voltage

NO
Yes No Note/Type:
Door lock:
X None
Wire end ferrules: X
X Double bit insert Terminals : 4
Lead tags: X
knockouts Phoenix X Weidmuiller
Cable tags: X
Glandplate: Wago
Wiring cross-section: 0,75mm² X 1mm² 1,5mm²
X Yes No Type : ZDU2 , 5-2/3AN ZPE , 6-2/3AN
Note : The wiring will be according to KSB standard QP1606125.
Steel Sheet Additional information:
If not separately advised, the wiring of the single leads will get realized 5
with the cross-section declared here. The cross-section of the multicords is
Plastic declared in the list of material.
Next page
5
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Technical Overview Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
Client
1
KSB
JB SC1 / 6.1:2
-X1 1 2 3 4 5 6
Inside JB
On pump
-W1
Pump meter cable with plug
WH
KSB BN
BU
GY
SH
BK
3
-PM 1 1 2 3 4 5
-1 to 0 Bar
PM 10/10
PDIA 101
Wiring Connections for Pump meter as a Differential pressure 4
0.00 transmitter PM 10/10
I Colour Function
Cable 1 Brown Power Supply (-24V DC)
DP
Cable 2 White Analog output (+ active signal)
Cable 3 Blue Power Supply (+24V DC)
Cable 4 Black Analog Output (- active signal)
IN1 Probes IN2 Cable 5 Gray No function
Note : Use standard KSB cable with Plug for pump meter wiring.
Differential Pressure strainer 5
Next page
6
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Differential pressure monitoring Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
Client
1
KSB
Screen bar
SC1 / 5.7:1
SC1 / 7.1:1
JB PE / 7.1:2
-X2 1 2 3 4 ZDU 2.5-2/3AN 5 6 7 8

ZDU 2.5-2/3AN
2
Inside JB
On pump
3
-W2 -W3
ÖLFLEX® CLASSIC 110 CH ÖLFLEX® CLASSIC 110 CH
3 G 1.0 SH 3 G 1.0 SH
PE
PE
1
2
4
0...6bar GND I+ 0...160bar GND I+

4...20mA 1 2 3 4 5 6 PE 4...20mA 1 2 3 4 5 6 PE
PI 101 PI 102
do not use
do not use
do not use
do not use
do not use
do not use
do not use
do not use
I I
Wika PGT23.100
Wika PGT23.100
P P
ZN16065
ZN16065
Suction Pressure gauge with integrated Discharge Pressure gauge with integrated
pressure transducer (4-20mA output) pressure transducer (4-20mA output)
Next page
7
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Pump suction, discharge pressure Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
Client
1
KSB
JB SC1 / 6.8:2
PE / 6.8:2
-X2 9 10 11 12 -X0PE 1 2 3 4
ZDU 2.5-2/3AN
2
Inside JB
On Pump
door
mounting plate
Cabinet
3
-W4
H07V-K
1x4
GN-YE
450/750 V
4mm²
-Ground 1 4
Pump ground
Next page
8
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Spare terminals, X0PE Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
300 mm
210 mm
1
-M1
-T1 -T2
-K1
-X1
1
2
3
4
5
6
Junction Box -X2

1
2
AX 1033.000
VK4 75x37.5mm
VK4 75x37.5mm
4
5
6
300 mm
300 mm
7
8
2
1 9
10
11
12
-X0PE
-T3
VK4 75x37.5mm
3
Front View Side View Internal View / Mounting Plate
300 mm
Junction Box Details :
Manufacturer : Rittal
Type : AX 1033.000
Size : 300 X 300 X 210 mm
Material : Steel Sheet 4
Colour : -
KSB
Cable Gland : M16 X 1.5 - 4 Nos
Customer
210 mm
Terminals : ZDU2 , 5-2/3AN ZPE 6-2 / 3 AN ZPE 2.5-2/3AN

Cable entry
For Client Cable :
Cable Gland : - 5
Gland plate : Yes
Bottom View Next page

9
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Junction box GA Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
Terminal diagram F13_001
-W4
Strip
Cable name
Cable name
=+-X0PE
H07V-K 1x4Sqmm
Connection point
Connection point
Cable type
Cable type
Terminal
Jumper
2
Function text Target designation Target designation Page / column
Pump ground 1 /7.5:2
Mounting plate 2 /7.5:2
Cabinet 3 /7.6:2
Door 4 /7.6:2
Next page
10
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Terminal diagram =+-X0PE Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
-W1
Strip
Cable name
Cable name
=+-X1
plug
Pump meter cable with
Connection point
Connection point
Cable type
Cable type
Terminal
Jumper
2
Differential pressure monitoring BN -PM1 1 1 -X1 /5.3:2
WH -PM1 2 2 -X1 /5.3:2
BU -PM1 3 3 -X1 /5.3:2
BK -PM1 4 4 -X1 /5.3:2
GY -PM1 5 5 -X1 /5.4:2
SH -W1 6 -X2 4:1 /5.4:2
Next page
11
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Terminal diagram =+-X1 Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
-W3
-W2
Strip
Cable name
Cable name
=+-X2
ÖLFLEX® CLASSIC 110 CH
ÖLFLEX® CLASSIC 110 CH
Connection point
Connection point
Cable type
Cable type
Terminal
Jumper
2
Suction pressure gauge 1 1 1 -X2 /6.2:2
2 2 2 -X2 /6.2:2
3
PE PE 3 -X1 6:1 /6.3:2
SH -W2 4 -X2 /6.3:2
Discharge pressure gauge 1 1 5 -X2 /6.5:2
2 2 6 -X2 /6.5:2 3
3
6
PE PE 7 -X2 /6.6:2
SH -W3 8 -X2 /6.5:2
9 -X2 /7.2:2
10 -X2 /7.2:2
11 -X2 /7.2:2
12 -X2 /7.2:2
Next page
12
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Terminal diagram =+-X2 Page No.
KSB SE & Co. KGaA
0 1 2 3 4 5 6 7 8 9
Summarised Part List

Description Part No. Make Qty Device Tag Order No 1
Pressure gauge with electrical output signal PGT23.100 Wika 2

Cable - ÖLFLEX® CLASSIC 100 300/500V 3G x 1.0 LAPP.10035057 LAPP 2
End bracket ZEW 35/2 WEI.8630740000 Weidmüller 6 8630740000
Terminal marking EM 8/30 WEI.1806120000 Weidmüller 3 1806120000
Partition plate (terminal) ZAP/TW7 WEI.1706110000 Weidmüller 6 1706110000
Terminal marking DEK 5 GW L WEI.0522761032 Weidmüller 22 0522761032
PE terminal ZPE 6-2/3AN WEI.1771360000 Weidmüller 4 1771360000
Feed-through terminal block ZDU 2.5-2/3AN WEI.1706010000 Weidmüller 15 1706010000
2
Terminal rail TS 35X7.5/LL 2M/ST/ZN WEI.0514500000 Weidmüller 1 -K1 0514500000
PE terminal ZPE 2.5-2/3AN WEI.1706090000 Weidmüller 3 -K1 1706090000
Compact enclosures AX 300x300x210mm RIT.1033000 Rittal 1 -M1 1033000
SKINTOP ST-M 16x1,5 RAL 7001 SGY LAPP.53111010 LAPP 4 -M1 53111010
SKINTOP GMP-GL-M 16x1,5 RAL 7001 SGY LAPP.53119010 LAPP 4 -M1 53119010
Cable conduit HG-DC13 Double Slit HG-DC13 Double Slit HellermannTyton 1 -M1
Power and control cables - H07V-K 1X4 GNYE LAPP.4520003 LAPP 1 -M1 4520003
Pump meter PM 10/10-Differential pressure measurement PM 10/10 KSB 1 -PM 1
Pump meter power supply cable with plug 01146983 KSB 1 -PM 1
Cable tray VK4 75X37.5 17332691610 Rehau 3 -T1...-T3 3
Remark-As per stock availability,material from equivalent supplier shall be used. Next page
Prep. MISAPOO Customer Name : DURO DAKOVIC Page Description : Summarised Part List Page No.
KSB SE & Co. KGaA
Start-up and shut down a pump set
Important note: The following chapters are only a quick summary, and does not
supersede the KSB OM (Operating Manual) or of the suppliers OM´s and
specifications.
It is essential to consider the safety instructions of the OM.
List of contents
1. General activities before starting a feed water pump

1.1. Start requirements
1.2. Periodical checks
2. Commissioning
3. Start-up of Pump
4. Shut down of feed water pump to operational standby.
5. Start-up of feed water pump from operational standby.
6. Shut down of feed water pump without operational standby.
Rev 0/ 24.09.2021
1. General activities before starting a feed water pump
1.1 Start requirements

Before each start of the pump make sure that:
- Pump set has been filled and vented
- The valves in the minimum flow pipe are open
- Direction of rotation of the motor checked
- During the start up the minimum speed must be achieved quickly (< 5 s).
For start-up, operation and shutdown, the instructions given in the OMM of the pump set
have to be considered.
No sudden/ rapid falling of suction pressure (particularly when pump is under hot conditions)
has to be ensured by plant operator.
1.2 Periodical checks

Ensure strainer is cleaned regularly
There is no big change in vibrational behavior of the pump set
Pump set bearing temperatures are stable
No big fall in discharge and tapping pressure of the pump
There is no undue noise for the equipment
All auxiliary equipments, valves and instruments are working properly
Required spare parts are on stock
Maintenance of equipments is carried out as specified / recommended by the manufacturer
2. Commissioning
Prior to commissioning make sure that:
Installation and alignment of the entire pump set (devices / systems related to feed water
system such as minimum flow, oil supply unit etc.) have been performed and recorded
according to the manufacturer’s specifications and have been accepted by the operating
company.
All auxiliary equipment and instruments have been installed and checked for proper
functioning according to the manufacturer’s specifications.
Rev 0/ 24.09.2021
3. Start-up of Pump following steps to be followed
• All auxiliary systems are in operation as per requirement. (e.g. Cooling water system)
For more details refer P & I diagram
• In case of pressure oil lubrication sufficient oil pressure is available, including allowable
oil temperature.
• Oil level in bearing housing / oil tank is adequate above minimum level.
• Sufficient grease is applied for grease lubricated parts (motor, coupling, etc.)
• Discharge line is closed (If a check valve is installed in discharge line, the discharge valve
may remain open, provided that back pressure available).
• Tapping line must be closed in case of tapping nozzle is provided on the pump.
• Pump is not running in reverse rotation
• Minimum flow line is open.
• Suction line is open
• Sufficient NPSH is available
• Ensure strainer is cleaned periodically
• Switch off Space heater of the main motor (if applicable)
• VOITH auxiliary oil pump on and scoop tube in minimum position (if applicable)
• Ensure there are no alarm and trip signals.
If all above points are met then the motor is ready to start
Adjust the feed water flow to operating point according to procedural method of operator.
Qmax limits to be considered. The pumps should not run outside the permissible operating
range.
4. Shut down of feed water pump to operational standby

Following steps to be followed
• Reduce speed to minimum allowable speed in case of variable speed driver
• Minimum flow line is open.*
• Ensure minimum flow valve is working.
• Discharge line is closed (If a check valve is installed in discharge line, the discharge line
may remain open, provided back pressure available).
• Ensure that the auxiliary oil pump is working if applicable
• Stop the motor
• Wait until the pump comes to standstill.
• All auxiliary systems are in operation as per requirement. (e.g. Cooling water system)*
• In case of Pressure oil lubrication sufficient oil pressure is available including allowable
oil temperature.
• Ensure the valves in warm up lines are open (if applicable)
Rev 0/ 24.09.2021
• Switch on the space heater of the main motor(if applicable)
• Ensure that the scoop tube of variable speed coupling is at minimum position (if applicable)
• Pump is ready for operational standby see chapter 5
*These points are necessary to ensure standby operation of pump
5. Start-up of feed water pump from operational standby

Pump is ready for operation according to chapter 4
• Open the discharge line and back pressure is available.
Adjust the feed water flow to operating point according to procedural method of operator.
Qmax limits to be considered
• Open the tapping line (if applicable) and back pressure is available.
• Pump is not running in reverse rotation
• Switch off space heater of the main motor (if applicable)
• Ensure there are no alarm and trip signals
If all above points are met then the motor is ready to start
Adjust the feed water flow to operating point according to procedural method of operator
Qmax limits to be considered. The pumps should not run outside the permissible operating
range.
6. Shut down of feed water pump without operational standby

• Reduce speed to minimum allowable speed in case of variable speed driver

• Minimum flow line are open.
• Ensure minimum flow line is working.
• Discharge line is closed (If a check valve is installed in discharge line, the discharge valve
may remain open, provided back pressure available).
• Ensure that the auxiliary oil pump is working (if applicable)
• Stop the motor
• Wait until the pump comes to standstill.
• After 10 minutes of shutdown, switch off the auxiliary systems like cooling water, oil
supply pump (if applicable) etc.
• Close the valves in warm up lines (if applicable)
Rev 0/ 24.09.2021
9.1.6 Weights
NOTE
Some pump set components weigh > 25 kg. Check the indicated weights.
▪ Pump weight: See sign at the stage casing.

▪ Pump set weight: See installation plan (relevant documentation).
▪ Weights of pump set components: See relevant documentation.
Table 30: Weights of individual components

Part No. Description Material variants Material variants
1-4 5 and 11
[kg] [kg]
107 Discharge casing 55 60
108.11/.13 Stage casing 33 52
441 Shaft seal housing 26 26
- Pump rotor 4 stages 38 38
Each additional 4,5 4,5
stage
Table 31: Pump weight

Number of Pump weight (without fill) Pump fill
stages Material variants Material variants
1-4 5 and 11
[kg] [kg] [kg]
4 349 344 10,3
5 381 377 12,4
6 413 410 14,6
7 444 443 16,8
8 476 475 19,0
9 507 509 21,2
10 539 542 23,4
11 570 575 25,6
12 602 608 27,8
13 633 641 30,0
14 665 674 32,2
15 696 707 34,4
16 728 740 36,6
17 759 773 38,8
18 791 806 41,0
136 of 492 HGM

9.1.7 Clearances
9.1.7.1 Clearances
S1
2
Fig. 55: Clearance between bearing sleeve and bearing bush
S3 S2
2 2
Fig. 56: Clearance between impeller and casing wear ring / diffuser
Table 32: Clearance between bearing sleeve and bearing bush, impeller and casing wear ring / diffuser
Diametral clearance in as-new condition
S1 Max. S2 Max. S3 Max.
clearance S1 GG GS clearance S2 GG GS clearance S3
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
0,18 - 0,222 0,27 0,3 - 0,4 0,4 - 0,5 0,9 0,3 - 0,386 0,45 - 0,53 1,0
9.1.7.2 Clearance of the discharge-side bearing unit
Table 33: Clearance of the discharge-side bearing unit

S4 Max. clearance S4
[mm] [mm]
0,18 - 0,222 0,27
HGM 137 of 492

9.1.7.3 Thrust bearing clearances
0,8 - 2,5 S4
2
S5
Fig. 57: Thrust bearing clearance
Table 34: Thrust bearing clearance

S5 Max. clearance S5
[mm] [mm]
1 ± 0,4 2,5
9.1.7.4 Total theoretical axial clearances
Sa2 Sa1
Fig. 58: Total theoretical axial clearances
Table 35: Total theoretical axial clearances

Hydraulic system Sa1 + Sa2
Impeller material
Grey cast iron Chrome steel
[mm] [mm]
2.1 4,5 - 6,0 4,5 - 6,0
3.1 4,5 - 6,0 4,5 - 6,0
9.1.8 Thread sizes for dismantling / reassembly aids
Table 36: Thread sizes for dismantling / reassembly aids

Part No. Description Thread size
107 Discharge casing M16
108.02 Stage casing -
108.11/.13 Stage casing M12
162 Suction cover M20
138 of 492 HGM

Part No. Description Thread size

171.03 Diffuser (last stage) M8
386.01 Thrust bearing ring M8
386.02 Thrust bearing ring -21)
386.03 Thrust bearing ring -22)
391 Bearing ring carrier M8
545 Bearing bush M6
59-4 Piston M6
603 Balance drum M8
- Shaft end, coupling side M12
9.1.9 Tightening torques
NOTE
The tightening torques exclusively apply to the bolts/screws included in the scope of
supply.
Prerequisites 1. The threads of the screw/bolt and nut are not damaged.
2. The threads and bearing surfaces of the screws/bolts and nuts are level, and have
been deburred and cleaned thoroughly.
3. The threads move smoothly.
4. The washers are level, and have been deburred and cleaned thoroughly.
Pump
Table 37: Tightening torques for screws/bolts fastening pump components, pump feet and baseplate
Part No. Thread size Material Tightening torque MA
[Nm]
523 - - 100
901.01 M20 5.6 150
904.21 (mechanical seal) - - 10
914.01 M24 C3-80 400
920.02 M16 8 100
Fastening of pump feet (discharge side) - - 190
Baseplate fastening 23)
M20×400 - 70
Flange connection Table 38: Tightening torques for flange connection (discharge nozzle and tapping
nozzle)
Nominal diameter DN Nominal pressure PN Tightening torque MA
[mm] [bar] [Nm]
25 64 80
100 80
12024) 80
50 64 160
100 240
24)
120 240
65 64 140
80 64 250
100 140
21 Remove with a lever tool.

22 Remove with a wire (diameter 4 mm).
23 Foundation bolts, chemical anchors, special foundation bolts
24 Maximum pressure for flange with nominal pressure PN 160 or Class 900
HGM 139 of 492


[mm] [bar] [Nm]
80 12024) 250
100 64 240
100 350
12024) 350
Table 39: Tightening torques for flange connection (discharge nozzle and tapping
nozzle)
[inch] [Class] [Nm]
1 600 80
24)
900 240
2 600 80
900 240
2 1/2 600 140
900 240
3 600 140
900 240
4 600 240
900 490
Table 40: Tightening torques for flange connection (suction nozzle)

Nominal diameter DN Nominal pressure, pressure Tightening torque MA
class PN
[mm] [bar] [Nm]
65 16 70
80 16 50
125 16 70
150 16 130
Table 41: Tightening torques for flange connection (suction nozzle)

Nominal diameter DN Nominal pressure, pressure Tightening torque MA
class PN
[inch] [Class] [Nm]
2 1/2 300 90
3 300 90
5 300 120
6 300 120
Tie bolts (905 / 920.01) 1. For the number of required scale graduation marks (grooves on the nut) refer to
the table. The marks are also stamped on the pump in the area of the discharge
nozzle.
2. Grease the threads in accordance with the lubricant instructions.
3. Pre-tighten the tie bolt to 30 Nm.
4. Tighten the nuts in accordance with the scale graduation marks specified in the
table.
140 of 492 HGM

Table 42: Scale graduation marks for tie bolts (905 / 920.01)

Number of stages Scale graduation marks
Tie bolt (number × thread size)
8 × M40×1,5
4 6
5 7
6 9
7 10
8 11
9 12
10 13
11 14
12 15
13 16
14 18
15 19
16 20
17 21
18 22
HGM 141 of 492

9.2 Pump
Operating Data
Noise Characteristics
Lubricant Instructions
General Drawings with List of Components
Coating Procedure
142 of 492 HGM

9.2.1 Operating data
HGM 143 of 492

Pump type Horizontal ring-section pump

Pump size / stages HGM 2/12 Quantity 2
Drive Motor with frequency converter (1 x working + 1 x spare)
Operating Data P52396 / P52397
Application/Medium handled: Boiler feed water
Conditioning AF Alkaline composition with salt-free water
pH value at 25°C >9.0 O2 contents mg/l <= 0.1
Operating point Design 1
Unit Design point to ISO 9906 / 2B Qmin, thermal
Operating temperature °C 130 130

Density kg/dm3 0.935 0.935
Pressure in inlet vessel bara 2.701
NPSH available m 5.78
bar 0.53
NPSH required at Qs **) m 2.243
bar 0.206
Pressure at suction nozzle bar a 3.231
Mass flow rate at disch. t/h 29.53
Capacity m3/h 31.6*** 10.74
Total head m 823.25*** 886.51
bar 75.45 81.25
Pump discharge pressure bar a 78.7
Efficiency *) % 62***
Pump input power kW 106.22
Pump speed 1/min ~ 2982 ~2982
Direction of rotation clockwise as viewed from the driven end
ADDITIONAL DATA
Nozzle discharge pressure at Q=0, coldwater Pump discharge nozzle
bar a (+/- 3 %) 87.8
Permissible minimum operating speed 1/min 1800
*) Efficiency improvement acc. to Karassik

**) without strainer loss
***) Warranty data
Pump design temperature 160°C

Code name Montsinéry - French Rev. 02
KSB ref No. Guiana 9974696285 Pump. HGM 2/12
Dept. / In charge TEN-222
000100 01-02 Bernd Kalnik Product No. 42042212000802130300
Operating Data
Operating point Normal Design 2 Minimal 1 Minimal 2
Unit
Operating temperature °C 130 130 130 130
Density kg/dm3 0.935 0.935 0.935 0.935
Pressure in inlet vessel bara 2.701 2.701 2.701 2.701
NPSH available m 6.03 6.03 6.17 6.41
bar 0.553 0.553 0.566 0.588
NPSH required at Qs **) m 2.091 2.231 1.98 1.92
bar 0.192 0.204 0.181 0.176
Pressure at suction nozzle bar a 3.254 3.254 3.267 3.289
Mass flow rate at disch. t/h 23.55 23.55 17.66 20.56
nozzle
Capacity m3/h 25.2 25.2 18.9 22****
Overall head m 783.09 856.28 742.95 705.1
bar 71.77 78.48 68.09 64.62
Pump discharge pressure bar a 75 81.7 71.4 67.9
Efficiency *) % 58.36 57.56 52.27 56.39
Pump input power kW 86.06 95.41 68.43 70.03
Pump speed 1/min ~2857 ~2979 ~2751 ~2698
Operating point Minimal 3

Unit
Operating temperature °C 130
Density kg/dm3 0.935
Pressure in inlet vessel bara 2.701
NPSH available m 6.41
bar 0.588
NPSH required at Qs **) m 2.038
bar 0.187
Pressure at suction nozzle bar a 3.289
Mass flow rate at disch. t/h 20.56
Capacity m3/h 22****
Overall head m 765.93
bar 70.2
Pump discharge pressure bar a 73.5
Efficiency *) % 55.59
Pump input power kW 77.19
Pump speed 1/min ~ 2807
Direction of rotation clockwise as viewed from the driven end
*) Efficiency improvement acc. to Karassik **) without strainer loss
****) Case Minimal (8.3 m3/h (7,79 t/h) towards the boiler)
achieved in conjunction with the manual bypass of the minimum flow valve:
pump flow at discharge nozzle 22 m³/h
=> 8.3 m³/h (7,79 t/h) (towards the boiler) + 13.7 m³/h (= through the manual bypass)
9.2.2 Noise characteristics
146 of 492 HGM

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

Operating point - pump: Q [m3/h] H [m] P [kW]
Design 1 31.6 823.25 106.22
It. Pump set component Description N LpA LS LWA
[1/min] [dB] [dB] [dB]
1 Pump HGM 2/12 ~ 2982 78 14 92
2 Motor Siemens Motor ~ 2982 77 14 91
Total of items 1/2 79 16 95
Air-borne sound octave spectr. in 63 Hz 125 Hz 250 Hz 500Hz 1000 2000 4000 8000
for item 1/2 70 70 70 73 76 76 72 68
Lubricants to Be Used for Assembly of HGM Pumps
1. General
The dash-and-dot line on the attached drawings divides the pump into a wetted area
(coming into contact with the pumped medium) and a non-wetted area.
2. Application Instructions
2.1 Wetted Area
2.1.1 Wetted O-rings (EPDM material) may only be handled with oil-free hands. To facilitate
fitting, they shall be coated very sparingly with the silicon grease Unisilkon L250L from
Klüber Lubrication.
2.1.2 To facilitate assembly, running surfaces, inside radial bearings, and the wetted shaft
area shall be coated with the above-mentioned silicon grease or with slushing oil
Anticorit BML3 from FUCHS DEA Schmierstoffe GmbH + Co. KG.
2.1.3 Thrust Bearing

2.1.3.1 Variant 60 PLN (see page 3)
The thrust bearing components and the insert ring shall be coated thinly with the
(O-ring-compatible) slushing oil Anticorit BML3 from FUCHS DEA Schmierstoffe GmbH
+ Co. KG.
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
Attention The axial bearing faces on the double drum and on the thrust
bearing components must not be coated with lubricants.
–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
2.1.3.2 Variant FVW / Noricrom® (see page 4)

After checking the thrust bearing plate and balance drum with the contact fluid
“engineer's blue", the running surfaces of the two bearing components shall be coated
thinly with Molykote G-N Plus Paste from Dow Corning Europe or metal-free
assembly paste from DEPAC GmbH. The other surfaces shall be smeared with
Anticorit BML3 from FUCHS DEA Schmierstoffe GmbH + Co. KG.
2.1.4 The thread zone of the hexagon socket head cap screw for fastening the suction stage
impeller shall be coated with Molykote G-N Plus Paste from DOW Corning Europe
or with a metal-free assembly paste from DEPAC GmbH.
The screw head base shall be protected against picking up by means of a metal-
free assembly paste from DEPAC. Surplus paste shall be removed after assembly.
BENENNUNG / DENOMINATION
08 Üeberarb. 24.04..2020 Barthel Work instruction

INDEX ÄNDERUNG DATUM/DATE NAME
ALTERATION
STELLE/DEPARTMENT NR. / NO. BLATT-NR.
Q-MANAGEMENT SHEET-NO
NORM/STANDARD UA
UA4 28700 EN 1
GEPR/APPROVED SCHUTZVERMERK DIN 34-1-D COPYRIGHT DIN 34-1-E
24.04.2020 Barthel
BEARB/PREPARED ERS. FÜR / REPLACES ENTST. AUS / ORIGINAT. FROM von / of
23.04.2020 Cicak
DATUM/DATE NAME 4
2.1.5 Shaft protecting sleeve
Prior to assembly, debur the thread of the shaft protecting sleeve (if necessary),
especially the start and end of the thread. Then check the thread for any swarf. Take care
to remove all swarf. Also clean the locating surface.
Prior to applying assembly aids, once again check for utmost cleanliness of the thread
and of the shaft's locating surface.
Check the shaft protecting sleeve and the corresponding shaft section for flawless
machining quality.
Apply Molykote G-N Plus paste made by Dow Corning Europe and a few drops of
Mobilarma 524 oil made by Mobil Oil AG to the thread and the locating surface on the
shaft. Verify that the assembly aids are clean.
During assembly, also check for smooth rotation. If rotation is sluggish, remove the shaft
protecting sleeve and clean all contact areas. Then start again with the above procedure.
In general, observe the following:

Prior to major assembly work, e.g. replacing the balance drum, protect the free shaft
section by covering it with adhesive tape. Any shaft damage could lead to problems when
mounting the shaft protecting sleeve.
2.2 Non-wetted Area

Non-wetted screws/bolts shall be coated with Molykote G-N Plus Paste from Dow
Corning Europe or with a metal-free assembly paste from DEPAC.
The keys on the coupling hub fit shall be treated with the same agents.
No lubricants shall be used on the fitting surfaces of coupling shaft journal and coupling
hub.
Otherwise, the shrink-fit connection would lose part of the contact friction required.

ALTERATION
NORM/STANDARD UA
UA4 28700 EN 2
24.04.2020 Barthel
23.04.2020 Cicak
DATUM/DATE NAME 4

ALTERATION
NORM/STANDARD UA
UA4 28700 EN 3
24.04.2020 Barthel
23.04.2020 Cicak
DATUM/DATE NAME 4

ALTERATION
NORM/STANDARD UA
UA4 28700 EN 4
24.04.2020 Barthel
23.04.2020 Cicak
DATUM/DATE NAME 4
9.2.3 General drawings with list of components
152 of 492 HGM

List of components HGM 2/12
Schutzvermerk ISO 16016
Copyright to ISO 16016
En accord avec ISO 16016
Auftrags-Nr. / Pos. Serien-Nr. Name Stellenkurzz. Datum
Order number / item. Serial number Name Dept. code Date
N° de commande / Pos. N° de fabrication Nom Sigle Date
9974696285 / 100 CD1946999 Sudhanshu TEN-222 30.09.2021
Teile-Nr. ME Menge/Einh. Bennennung Werkstoff
Part number Quantity/unit Description Material
Repère Quant./Pompe Désignation Matériaux
97-2 GENERAL DRAWING PUMP UG1476722

PLAN D’ENSEMBLE POMPE
97-2 GENERAL DRAWING MECHANICAL SEAL UG1735920
PLAN D’ENSEMBLE GARNITURE
MÉCANIQUE
1M.1 PRESSURE MEASURING INSTRUMENT
CONNECTION
MESUREUR DE PRESSION RACCORD
1M.2 PRESSURE MEASURING INSTRUMENT
CONNECTION
MESUREUR DE PRESSION RACCORD
6B.1/2 PUMPED LIQUID DRAIN
LIQUIDE POMPÉ VIDANGE
6D.4 PUMPED LIQUID VENTING
LIQUIDE POMPÉ DÉGAZER
7E.1 COOLING LIQUID INLET
LIQUIDE DE REFROIDISSEMENT
ENTRÉE
7E.4 COOLING LIQUID INLET
ENTRÉE
7A.1 COOLING LIQUID OUTLET
SORTIE
7A.4 COOLING LIQUID OUTLET
LIQUIDE DE REFROIDISSEMENT SORTIE
8B LEAKAGE LIQUID DRAIN
LIQUIDE D’ÉGOUTTAGE VIDANGE
14E BALANCE LIQUID INLET
LIQUIDE D’ÉQUILIBRAGE ENTRÉE
14A BALANCE LIQUID OUTLET
LIQUIDE D’ÉQUILIBRAGE SORTIE
26M.1 VIBRATION MEASUREMENT
CONNECTION
MESURAGE DE VIBRATIONS RACCORD
107 PC 1 DISCHARGE CASING DN 50 1.4008
CORPS DE
REFOULEMENT
108.01 PC 1 STAGE CASING 95/ 320X 57,8 1.4006+QT650
CORPS D'ETAGE
Seite 1 von 5
9974696285 / 100 CD1946999 Sudhanshu TEN-222 30.09.2021
108.02 PC 9 STAGE CASING 95/ 321X 75 1.4006+QT650

CORPS D'ETAGE
108.03 PC 1 STAGE CASING 95/ 320X 75 1.4006+QT650
CORPS D'ETAGE
139 PC 1 SUCTION ELBOW HGM 2 P250GH
COUDE D'ENTREE
162 PC 1 SUCTION COVER 146/ 405X 70 1.4021+QT800
FOND D'ASPIRATION
171.01 PC 1 DIFFUSER DIA 290/231 1.4008
DIFFUSEUR
171.02 PC 10 DIFFUSER DIA 290/231 1.4008
DIFFUSEUR
171.03 PC 1 DIFFUSER DIA 290/232 1.4008
DIFFUSEUR
210 PC 1 SHAFT 50X1101 C45+SH+SR
ARBRE
230 PC 11 IMPELLER 230X 6,5-13 1.4008.09
ROUE
231 PC 1 IMPELLER, SUCTION 230X 6,5-13 1.4008.09
STAGE
ROUE ASPIRATRICE
386.01 PC 1 THRUST BEARING RING 104/ 150X 32 RWA 350
GRAIN FIXE DE BUTEE
386.02 PC 1 THRUST BEARING RING 70/ 100X 12 PGK
GRAIN FIXE DE BUTEE
386.03 PC 1 THRUST BEARING RING 69/ 100X 12 NORICROM1.4475
GRAIN FIXE DE BUTEE
391 PC 1 BEARING RING CARRIER 70/ 165X 18 1.4021+QT800
SUPPORT GRAIN FIXE DE
BUTEE
411.01 PC 1 SEALING RING A 21 X 26 A4
JOINT D'ETANCHEITE
411.04 PC 1 SEALING RING A 33 X 39 A4
JOINT D'ETANCHEITE
412.01 PC 1 O-RING 136,00X 4,00- EPDM 80 PEROXIDE
JOINT TORIQUE N-B

JOINT TORIQUE N-B
Seite 2 von 5
9974696285 / 100 CD1946999 Sudhanshu TEN-222 30.09.2021

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B

JOINT TORIQUE N-B
420 PC 1 SHAFT SEAL RING 55/ 78X 30 PTFE

BAGUE D'ETANCHEITE
D'ARBRE
433 PC 1 MECHANICAL SEAL-KSB KB045M1-5B AQ1EGG
GARNITURE MECANIQUE-
KSB
441 PC 1 SHAFT SEAL HOUSING 46/ 240X 141 1.4021+QT800
CORPS DE LA
GARNITURE MECANIQUE
504 PC 1 SPACER RING 39/ 50X 16,5 RWA 350
BAGUE-ENTRETOISE
507 PC 1 THROWER S 40 ST
DEFLECTEUR
Seite 3 von 5
9974696285 / 100 CD1946999 Sudhanshu TEN-222 30.09.2021
515.01 PC 1 TAPER LOCK RING 390X 390X 60 S355J2+N

BAGUE DE SERRAGE
515.02 PC 1 TAPER LOCK RING 395X 390X 60 S355J2+N
BAGUE DE SERRAGE
523 PC 1 SHAFT SLEEVE 36/ 59X 135 1.4021+QT800
CHEMISE D'ARBRE
542.02 PC 1 THROTTLE BUSH 83/ 120X 70 NORICROM1.4475
DOUILLE DE LAMINAGE
545 PC 1 BEARING BUSH 120/ 155X 59 NORICROM1.4475
COUSSINET
550.01 PC 8 WASHER 20-200 HV ST
RONDELLE
550.02 PC 16 WASHER 25X 44X 4- ST+PHR
RONDELLE 300HV
550.03 PC 8 WASHER 17X 30X 3- ST+PHR

RONDELLE 300HV
562.01 PC 1 PARALLEL PIN 5 M 6X 10 1.4305

GOUPILLE CYLINDRIQUE
562.03 PC 1 PARALLEL PIN 6 M 6X 12 A4
59-4 PC 1 PISTON 50/ 83X 70 1.4021-PWK
PISTON
603 PC 1 BALANCE DRUM 39/ 153X 59 1.4024.09
PISTON D'EQUILIBRAGE
720 PC 1 SPECIAL PIPE PART 20/ 45X 65 1.4571
PIECE FACONNEE
Seite 4 von 5
9974696285 / 100 CD1946999 Sudhanshu TEN-222 30.09.2021
731.01 PC 1 PIPE UNION EW 25S-G 1.4571

RACCORD FILETE
731.02 PC 1 PIPE UNION DS 25B 1.4571
RACCORD FILETE
901.01 PC 8 HEXAGON HEAD SCREW M20 X 55 5.6
VIS A TETE HEXAGONALE
902.01 PC 8 STUD M 16 X110 5.8
GOUJON
903.01 PC 1 SCREW PLUG E G 1/2 A A4
BOUCHON FILETE
905 PC 8 TIE BOLT HM24X1,5X 1.6772
TIRANT D'ASSEMBLAGE 860
914.01 PC 1 HEXAGON SOCKET HEAD M24 X 60 C3-80

CAP SCREW
VIS A TETE CYLINDRIQUE
920.01 PC 16 HEXAGON NUT BM 24X1,5 1.7709+QT
ECROU HEXAGONAL ATR
920.02 PC 8 HEXAGON NUT M16 8 +A2A

ECROU HEXAGONAL
940.01 PC 13 PARALLEL KEY A 5X 3X 25 1.4057+QT800+C
CLAVETTE
940.03 PC 1 PARALLEL KEY 10X 8X 90 C45+C
CLAVETTE
Seite 5 von 5
KSB Mechanical Seal
5A / 5B
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual 5A / 5B
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 30/08/2021

Contents
Contents
1 General.................................................................................................................................................... 4
1.1 Principles ........................................................................................................................................................... 4
1.2 Target group..................................................................................................................................................... 4
1.3 Other applicable documents............................................................................................................................ 4
1.4 Symbols ............................................................................................................................................................. 4
1.5 Key to safety symbols/markings....................................................................................................................... 5
2 Safety ...................................................................................................................................................... 6
2.1 General.............................................................................................................................................................. 6
2.2 Intended use ..................................................................................................................................................... 6
2.3 Personnel qualification and training............................................................................................................... 6
2.4 Consequences and risks caused by non-compliance with this manual ......................................................... 6
2.5 Safety awareness .............................................................................................................................................. 7
2.6 Safety information for the user/operator ....................................................................................................... 7
2.7 Safety information for maintenance, inspection and installation ................................................................ 7
2.8 Unauthorised modes of operation .................................................................................................................. 7
3 Transport/Storage/Disposal .................................................................................................................. 8
3.1 Checking the condition upon delivery ............................................................................................................ 8
3.2 Transport........................................................................................................................................................... 8
3.3 Storage/preservation ........................................................................................................................................ 8
3.4 Return to supplier............................................................................................................................................. 9
3.5 Disposal ............................................................................................................................................................. 9
4 Description............................................................................................................................................ 11
4.1 General description ........................................................................................................................................ 11
4.2 Product information as per Regulation No. 1907/2006 (REACH)................................................................. 11
4.3 Designation..................................................................................................................................................... 11
4.4 Materials ......................................................................................................................................................... 11
4.5 Design details.................................................................................................................................................. 12
4.6 Configuration and function........................................................................................................................... 13
5 Installation/Dismantling ...................................................................................................................... 15

5.1 Permissible aids............................................................................................................................................... 15
5.2 Prerequisites.................................................................................................................................................... 15
5.3 Installing the mechanical seal........................................................................................................................ 16
5.4 Removing the mechanical seal ...................................................................................................................... 17
5.5 Tightening torques......................................................................................................................................... 17
6 Operation.............................................................................................................................................. 19
6.1 Safety instructions for operation................................................................................................................... 19
6.2 Emissions ......................................................................................................................................................... 19
6.3 Operating limits.............................................................................................................................................. 20
7 Maintenance......................................................................................................................................... 21
7.1 Maintenance/inspection................................................................................................................................. 21
8 Trouble-shooting.................................................................................................................................. 22
9 Related Documents .............................................................................................................................. 23
9.1 Dimensions...................................................................................................................................................... 23
9.1.1 5A........................................................................................................................................................ 23
9.1.2 5B ........................................................................................................................................................ 24
10 Certificate of Decontamination........................................................................................................... 26

Index ..................................................................................................................................................... 27
5A / 5B 3 of 30
1 General
1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
The order number and order item number of the pump clearly identify the
mechanical seal via the corresponding material number in the pump's parts list and
serve as identification for all further business processes.
In the event of damage, immediately contact your nearest KSB service facility to
maintain the right to claim under warranty.
For any queries: contact.ksbglrd@ksb.com
1.2 Target group

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents

Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
in which the mechanical seal is installed.
General assembly drawing1) Description of the mechanical seal as part of the
sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.4 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. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
1974.81/06-EN
1 If agreed to be included in the scope of supply
4 of 30 5A / 5B
1 General
1.5 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.
1974.81/06-EN
5A / 5B 5 of 30
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 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.
▪ Comply with all the safety instructions given in the individual sections of this
operating manual.
▪ 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 and markings 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
– Fitting direction
▪ The operator is responsible for ensuring compliance with all local regulations not
taken into account.
2.2 Intended use

▪ This product must only be operated within the limit values stated in the technical
product literature for the ambient temperature, fluid handled, speed, density,
pressure, temperature and in compliance with any other instructions provided in
the operating manual or other applicable documents.
2.3 Personnel qualification and training

▪ All personnel involved must be fully qualified to install, operate, maintain and
inspect the product 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 product must always be supervised by specialist technical
personnel.
2.4 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.
1974.81/06-EN
▪ 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
6 of 30 5A / 5B
2 Safety
2.5 Safety awareness

In addition to the safety information contained in this operating 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
2.6 Safety information for the user/operator

▪ 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 of hazardous fluids (e.g. explosive, toxic, hot) so as to avoid any
danger to persons and the environment. Observe all legal requirements.
▪ The design of mechanical seals always produces a small amount of leakage.
▪ Higher leakage may occur especially in the running-in phase. The leakage must
be drained off in a controlled way
2.7 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the mechanical seal require 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 are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪ Only carry out work on the mechanical seal when the shaft is not rotating.
For mechanical seals installed in pump sets:
▪ 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.
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ 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.
▪ Observe the relevant sections of the corresponding pump operating manual.
2.8 Unauthorised modes of operation

Never operate the mechanical seal outside the limits stated in the data sheet and in
this operating manual.
1974.81/06-EN
The warranty relating to the operating reliability and safety of the mechanical seal
supplied is only valid if the mechanical seal is used in accordance with its intended
use.
Any damage caused by dry running shall be excluded from the warranty.
5A / 5B 7 of 30
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
CAUTION
Improper transport
Damage to the mechanical seal!
▷ Only transport the mechanical seal in suitable packaging.
▷ Observe the weights, symbols and instructions indicated on the packaging.
▷ Use suitable, approved lifting accessories.
KSB’s standard packaging is suitable for dry transport ,e.g. by truck, rail, air. Special
packaging can be provided if specified in the contractual agreement.
CAUTION
Removing transport locks too early
Damage to previously locked components during transport!
▷ If transport locks are fitted, do not remove them too early.
3.3 Storage/preservation
CAUTION
Improper storage
Damage due to humidity, vermin, corrosion and contamination!
▷ Avoid outdoor storage.
▷ Observe, check and record the storage conditions.
▷ Regularly check the packaging for any damage.
▷ Regularly check the humidity indicator of shrink-wrapped objects. The relative
humidity should be < 50 %.
▷ If the relative humidity indicated for shrink-wrapped objects > 50 %, have the
equipment repacked by the manufacturer.
CAUTION
Improper storage
Impairment of O-rings' sealing function!
▷ Do not store O-rings together with chemicals, solvents, fuels, acids, etc.
1974.81/06-EN
▷ Protect O-rings from light, in particular from direct sun exposure and strong
artificial light high in ultraviolet rays.
8 of 30 5A / 5B
CAUTION
Wet, contaminated or damaged openings and connections
Risk of embrittlement! Damage to elastomers!
▷ Only open screw plugs and connections at the mechanical seal at the time of
installation.
▷ Avoid opening screw plugs, connections and similar before that time.
We recommend taking the following measures for storing the mechanical seal:
For storing the mechanical seal observe standards ISO 2230 and DIN 7716.
Store the mechanical seal in its original packaging, placed on a level surface in a dry,
protected room with constant conditions that meet the following requirements:
▪ Relative humidity < 65 %
▪ Temperature between 15 °C and 25 °C
▪ Moderately vented atmosphere
▪ Dust-free and vermin-free
If properly stored indoors, the equipment is protected for a maximum of 36 months.
New mechanical seals are supplied by our factory duly prepared for storage.
3.4 Return to supplier

1. Remove the used mechanical seal from the system.
2. Always flush and clean the mechanical seal, particularly if it has been used for
handling noxious, explosive, hot or other hazardous fluids.
3. If the mechanical seal has handled fluids whose residues could lead to corrosion
damage in the presence of atmospheric humidity or could ignite upon contact
with oxygen, the mechanical seal must also be neutralised and dried with
anhydrous inert gas.
4. Always complete and enclose a certificate of decontamination when returning
the mechanical seal. Always indicate any safety measures and decontamination
measures taken.
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
hazard
1974.81/06-EN
1. Dismantle the mechanical seal.

Collect greases and other lubricants during dismantling.
2. Separate and sort the mechanical seal materials, e.g. by:
- Metals
- Plastics
- Greases and other lubricants
5A / 5B 9 of 30
3. Dispose of materials in accordance with local regulations or in another

controlled manner.
1974.81/06-EN
10 of 30 5A / 5B
4 Description
4 Description
4.1 General description

▪ KSB mechanical seal
Mechanical seal for installation in pump sets and other rotating machinery in
accordance with the manufacturer's instructions.
4.2 Product information as per Regulation No. 1907/2006 (REACH)

For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see https://
www.ksb.com/ksb-en/About-KSB/Corporate-responsibility/reach/ .
4.3 Designation
Example: KU065M1-5A-RA
Table 4: Designation key

Code Description
K Version
K Short overall length
N Standard overall length
S Special overall length
U Type
U Unbalanced
B Balanced
065 Nominal diameter
M Direction of rotation
M Bi-directional with multi-spring arrangement
S Bi-directional with single spring
L Direction of rotation anti-clockwise
R Direction of rotation clockwise
1 Anti-twist lock of mating ring
0 Without lock
1 With lock
5A Type series, type
5A Type U, without shaft shoulder
5B Type B, with shaft shoulder
RA Mating ring protected against axial displacement
RA With protection against axial displacement
2)
- Without protection against axial displacement
4.4 Materials
▪ Depending on the application
▪ See product literature of the pump
1974.81/06-EN
▪ Selection of suitable material variant on request
2 Blank
5A / 5B 11 of 30
4 Description
4.5 Design details
Design
▪ Mechanical seal in modular design
▪ To EN 12756
▪ Single mechanical seal or as combination (tandem arrangement (API Plan 52) or
back-to-back arrangement (API Plan 53))
▪ Dynamic type
▪ Bi-directional
▪ Axial movability +/- 2.5 mm
▪ Torque transmission via cup point grub screws
▪ Multi-spring arrangement
5A:
▪ Unbalanced
5B:
▪ Balanced
1974.81/06-EN
12 of 30 5A / 5B
4 Description
4.6 Configuration and function
5A-1) 5A - RA)
161 477 474 412.53 412.52 500

471
562
475
5AF)
210
485
5AN)
500 485
904 485 932 472 475
5B-1) 5B-RA)
161 904 474 412.53 412.52 500

471
562
475
210
5BF)
485
5B-RC)
412.52
477 485 932 472 475 472 475
Fig. 1: Sectional drawing 5A-1, 5A-RA, 5AF, 5AN, 5B-1, 5B-RA, 5BF, 5B-RC
1974.81/06-EN
161 Casing cover 477 Spring for mechanical seal

210 Shaft 485 Torque-transmitting element
412.52/.53 O-ring 500 Ring
471 Seal cover 562 Parallel pin
472 Primary ring 904 Grub screw
474 Thrust ring 932 Circlip
475 Mating ring
5A / 5B 13 of 30
4 Description
Design Mechanical seal for installation in pump sets and other rotating machinery in
accordance with the manufacturer's instructions.
Type series 5A-1 with nominal diameter d1 and installation dimension L1K is
equivalent to version K (short design) and type U (unbalanced) in accordance with
EN 12756.
Type series 5B-1 with nominal diameter d1 is equivalent to version K (short design)
and type B (balanced) in accordance with EN 12756.
Type series 5A-RA/5B-RA with nominal diameter d1 and installation dimension L1K is
equivalent to version K (short design) and type U (unbalanced) / type B (balanced) in
accordance with EN 12756, but with mating ring locked against axial displacement.
Type series 5AF/5BF is equipped with a pumping device at the torque-transmitting
element. With the exception of d3, its installation dimensions comply with EN 12756.
Type series 5AN with nominal diameter d1 and installation dimension L1N is
equivalent to version N (normal design) and type U (unbalanced) in accordance with
EN 12756.
Type series 5A-OM with nominal diameter d1 and installation dimension L1S complies
with installation in accordance with EN 12756 and type U (unbalanced), but with
special overall length S for specific use in OMEGA pumps.
Type series 5B-RC with nominal diameter d1 and installation dimension L1S is based
on EN 12756 and equivalent to type B (balanced), but with special overall length S
and a coolable mating ring.
Type series 5B-HP with nominal diameter d1 and installation dimension L1K is
equivalent to version K (short design) and type B (balanced) in accordance with
EN 12756, but with a special primary ring design for high-pressure applications.
Function Primary ring 472, which is the axially movable seal ring, is pressed to mating ring 475
by springs 477. O-rings 412.52 and 412.53 are fitted for secondary sealing. Parallel pin
562, which is fitted in seal cover 471, transmits the friction torque and prevents
mating ring 475 from rotating with the primary ring. Thrust ring 474 engages
primary ring 472 and torque-transmitting element 485, causing them to rotate with
shaft 210 without hindering the axial movability of primary ring 472. Torque-
transmitting element 485 is connected to shaft 210 via grub screws 904. The axial
movability of primary ring 472 compensates for wear and thermal expansion. The
primary ring and the mating ring remain in constant contact. Together with torque-
transmitting element 485, circlip 932 holds together the assembly comprising primary
ring 472, springs 477, thrust ring 474, and O-ring 412.52. This assembly rotates with
shaft 210. Versions with protection against axial displacement of mating ring 475
have a ring 500 clamped between seal cover 471 and casing cover 161; an adjusted
mating ring 475 is used in this case. Versions without protection against axial
displacement do not have ring 500 fitted.
1974.81/06-EN
14 of 30 5A / 5B
5 Installation/Dismantling
NOTE
Priority shall be given to the installation instructions and/or installation sequence in
the documents of the pump set into which this mechanical seal is to be installed.
This also applies to the dismantling instructions and/or dismantling sequence.
5.1 Permissible aids
CAUTION
Impermissible cleaning agents
Damage to the seal faces at the mechanical seal!
▷ For removing minor contamination use only paper tissues and ethyl alcohol.
▷ Do not use dirty cleaning cloths or cleaning cloths that leave behind lint.
CAUTION
Impermissible assembly aids
Sealing elements made of ethylene propylene diene rubber perishing or swelling
up!
▷ Never let sealing elements come into contact with mineral oil base lubricants.
▷ Use permissible lubricants only.
▷ Verify that the assembly aids are silicon-free.
▪ Lubricants3)
– Permanent lubricants, such as non-mineral grease (Klüber Asonic HQ 72-102)
are used for elastomers that do not serve to transmit the torque. Examples
are mating rings with an anti-twist lock or primary rings that move axially
relative to the pump components.
– Non-permanent lubricants such as a soap solution, for example, are used for
elastomers that serve as a sealing element and, in addition, transmit the
torque. An example would be a mating ring without anti-twist lock.
▪ Recommended cleaning agent for seal faces and grub screws: ethyl alcohol
▪ Thread-locking agent: Loctite, No. 243
▪ Open-ended wrench, ring spanner, socket wrench (cleaned, no impact tools)
▪ Torque wrench (cleaned)
5.2 Prerequisites
▪ Chamfered ends to EN 12756
▪ Installation dimensions to DIN EN 12756, except 5A-OM, 5B-RC (pump-specific
installation dimensions);
▪ Surface roughness of pump components to DIN EN 12756
▪ Shaft run-out to ISO 5199:
1974.81/06-EN
– Shaft diameter ≤ 50 mm: 0.05 mm max.

– Shaft diameter 50 to 100 mm: 0.08 mm max.
– Shaft diameter > 100 mm: 0.10 mm max.
▪ Face run-out of the shaft in relation to the vertical connection surface of the
casing:
3 Lubricants must be compatible with all fluids used. They must not be aggressive to the secondary sealing
elements.
5A / 5B 15 of 30
– Shaft speed ≤ 750 rpm: 0.2 mm max.

– Shaft speed > 750 rpm to 1000 rpm: 0.15 mm max.
▪ Permissible centre offset between the pump casing and the shaft:
– Max. 0.2 mm for seals without pumping ring
– Max. 0.1 mm for seals with pumping ring
▪ The seal faces are clean and have not been touched with fingers.
▪ The mechanical seal is in proper condition and complete.
▪ The elastomers are free from any contamination, cracks, softening, hardening,
stickiness and discolouration.
▪ The mechanical seal has been placed down on a clean and level surface.
5.3 Installing the mechanical seal

The rules of sound engineering practice and the pump manufacturer's general
provisions apply. Tidiness and cleanliness are essential for proper execution of the
installation work.
CAUTION
Use of grease or other permanent lubricants
Torque transmission impeded / overheating of and damage to the pump!
▷ Never use grease or other permanent lubricants for fitting the torque-
transmitting elements of a mechanical seal.
▷ Use soft soap to reduce any friction caused during assembly.
▷ Never coat the mechanical seal faces with grease or oil.
Example of an installation sequence for KSB pumps:

ü The operating manual for the pump is on hand.
ü The pump and/or machinery has been prepared in accordance with the
manufacturer's instructions for installing the mechanical seal.
ü Any corrosion or wear has been removed.
ü The mechanical seal and assembly aids are on hand.
ü The installation of the mechanical seal is carried out in accordance with the
installation drawing.
ü The back pull-out unit of the pump has been placed in a clean and level assembly
area.
ü The original mechanical seal is fully assembled and undamaged.
NOTE
If any installation instructions or an installation sequence are specified in the
product literature of the pump/machinery into which the mechanical seal is to be
installed, they must be observed.
1974.81/06-EN
1. Clean the seal faces with a suitable paper tissue and ethyl alcohol.
2. Wet O-ring 412.52 and the corresponding surface at the pump casing with
permanent lubricant (e.g. Klüber Asonic HQ 72).
3. Position O-ring 412.52 on mating ring 475.
4. Mark the position of the groove on the rear side of mating ring 475 with anti-
twist lock in a suitable place (not in the seal face area). Align the groove with
parallel pin 562 in seal cover 471.
16 of 30 5A / 5B
5. Press O-ring 412.52 together with mating ring 475 into the seat in the casing. If
necessary, use a spacer sleeve and elastic intermediate element to protect the
seal faces.
6. Check the seal face for any damage. Clean the seal face again if required.
7. For version 5A-RA or 5B-RA insert ring 500 between casing cover 161 and seal
cover 471.
8. Connect seal cover 471 with casing cover 161.
9. Check that the mating ring is properly seated (face run-out/perpendicular to
shaft 210).
10. Wet O-ring 412.53 and the corresponding surface at the shaft / shaft protecting
sleeve with a suitable, permanent lubricant.
11. Guide the rotating seal assembly onto shaft 210.
12. Observe/verify installation dimension L1K.
13. Degrease grub screws 904. Apply a drop of thread-locking agent. Screw the
grub screws into torque-transmitting element 485.
14. Tighten the grub screws with a torque wrench. Observe the installation
dimension and tightening torque.
NOTE
Do not re-use cup point grub screws!
Used grub screws must be replaced by new cup point grub screws.
ð Cup point grub screws must not be re-used. Repeated tightening can impair
the reliability of force transmission.
15. Carry out the installation instructions given in the operating manual of the
pump/machinery.
5.4 Removing the mechanical seal

The rules of sound engineering practice and the pump manufacturer's general
provisions apply. Tidiness and cleanliness are essential for proper execution of the
installation work.
Example of a dismantling sequence for KSB pumps:
ü The operating manual for the pump is on hand.
ü The mechanical seal is accessible.
ü The components have been placed down and secured in a horizontal position.
NOTE
If any dismantling instructions and/or a dismantling sequence are specified in the
product literature of the pump/machinery into which the mechanical seal is to be
installed, they must be observed.
1. Loosen grub screws 904. Pull the rotating assembly of the mechanical seal off
the shaft / shaft protecting sleeve.
2. Carefully remove seal cover 471, including mating ring 475 and O-ring 412.52.
3. Jointly remove O-ring 412.52 and mating ring 475 from seal cover 471.
1974.81/06-EN
4. Carry out further dismantling instructions given in the operating manual of the
pump/machinery.
5.5 Tightening torques

Table 5: Tightening torques
Thread [Nm]
M6 (threaded length ≤ 6mm) 5
M6 (threaded length > 6mm) 7
5A / 5B 17 of 30
Thread [Nm]
M8 15
M10 30
1974.81/06-EN
18 of 30 5A / 5B
6 Operation
6 Operation
6.1 Safety instructions for operation
CAUTION
Air intake via the seal faces
Dry running of the seal and consequential seal failure!
▷ For single seals the pressure in the seal chamber of the pump must always be
higher than the ambient pressure.
CAUTION
Unsuitable fluid to be sealed off
Damage to the machinery!
▷ Take appropriate measures to ensure that the fluid to be sealed off at the
mechanical seal is in liquid condition no matter what the operating status of
the pump. This applies in particular when starting up and stopping the pump.
▷ If the fluid to be sealed off forms deposits while the pump set cools down or
during standstill of the pump set, the seal chamber must be flushed through
with a clean liquid. The quantity and type of flushing liquid has to be defined
by the operator for the specific material combination of the mechanical seal.
CAUTION
Excessive rise in temperature
Dry running or damage to the elastomers, incrustations at the seal faces, etc.
▷ Shut down the pump as described in the operating manual.
NOTE
If the operating limits indicated are observed and the instructions given in this
manual are complied with, the mechanical seal can be expected to give trouble-free
operation. If the values during operation are not within the specified limits, the
mechanical seal must be removed from the system and sent to KSB for inspection.
6.2 Emissions
WARNING
Incorrect handling of the fluid to be sealed off
Risk of injury!
▷ If the fluid to be sealed off and/or the buffer fluid have to meet the
requirements of the German Hazardous Substances Regulations, the regulations
on handling hazardous substances (safety data sheets to Directive 91/155/EEC)
and the accident prevention regulations must be heeded.
1974.81/06-EN
NOTE
If a reduction in leakage cannot be observed or if other failures occur, the
mechanical seal must be shut down, removed from the system and sent to KSB for
inspection.
5A / 5B 19 of 30
6 Operation
NOTE
Any leakage must be drained off in a controlled way and safely disposed of.
Components which may come into contact with the seal leakage must either be
corrosion-resistant or must be adequately protected.
▪ For physical and technical reasons a mechanical seal cannot be leak-free.

▪ Leakage can be either in liquid or gaseous form. Its aggressiveness corresponds to
that of the fluid to be sealed off.
▪ The quantity of leakage is influenced by several factors:
– Seal selection
– Manufacturing tolerances
– Operating statuses
– Smooth running of the pump
▪ In the running-in phase of the mechanical seal higher leakage can occur.
6.3 Operating limits
NOTE
Always observe the operating limits in the product literature and the other
applicable documents.
NOTE
The following values are limits that depend on the seal face materials and
elastomer materials. As the characteristics influence each other, operation at
minimum/maximum limits is not possible for all characteristics at the same time.
Table 6: Operating limits (nominal diameter, sliding velocity, maximum pressure to be sealed off and temperature
limits depending on the material combination and fluid)
Type series Nominal diameter v4) Max. pressure to be sealed off T5)
Min. Max. Carbon/SiC SiC/SiC SiC/TC Min. Max.
[mm] [mm] [m/s] [bar] [bar] [bar] [°C] [°C]
5A 28 100 20 25 16 16 -50 +220
5B 28 100 20 606) 20 20 -50 +220
Table 7: Maximum temperature of the buffer fluid for mechanical seal 5A/5B as

double seal (back-to-back, tandem)
Buffer fluid Maximum temperature of the buffer
fluid
[°C]
Oil-based fluid 60
Water-based fluid 80
NOTE
1974.81/06-EN
Take appropriate measures (e.g. cooling the reservoir) to ensure that the buffer
fluid does not exceed the temperature limits.
4 Sliding velocity
5 Fluid temperature
6 Valid for type series 5B-HP only
20 of 30 5A / 5B
7 Maintenance
7 Maintenance
7.1 Maintenance/inspection
NOTE
The operator is responsible for conducting checks.
▪ The mechanical seal is low in maintenance. Replace wear parts as necessary.

▪ Proper operation includes regular checks of temperature and leakage (drainage)
of the mechanical seal.
▪ When a system maintenance inspection or pump maintenance inspection is
conducted, the mechanical seal should also be inspected. The seal faces should be
reworked and all elastomer joint rings and springs should be replaced by new
ones. KSB is available for inspecting the mechanical seal.
1974.81/06-EN
5A / 5B 21 of 30
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.
NOTE
Prior to conducting any work on the mechanical seal during the warranty period
contact the manufacturer. KSB Service will be pleased to help you. Non-compliance
with this instruction will lead to forfeiture of any and all rights to claims for
damages.
NOTE
For any failures you cannot remedy or whose cause cannot be identified, contact
the responsible KSB service centre.
What to do in the event of a fault/malfunction

▪ Determine and document the nature of the fault/malfunction.
▪ Monitor the development of leakage quantity. If necessary, shut down the pump
as described in the operating manual.
A steady flow of leakage indicates mechanical seal damage.
Maintenance work, service work and installation work by KSB Service

▪ KSB Service GmbH | Service Center Pegnitz
E-mail: service-center.pegnitz@ksb.com
▪ KSB Service LLC | Service Center Abu Dhabi
E-mail: ksb@ksb.ae
Contact for general queries:

▪ E-mail: LPC_Mechanical.Seals@ksb.com
Further contact addresses:

▪ https://www.ksb.com/en-global/contact
1974.81/06-EN
22 of 30 5A / 5B
9 Related Documents
9 Related Documents
9.1 Dimensions
9.1.1 5A
1) l5×20° 2) l5×20°
l6
e
Ø d7
Ø ds
Ø d7
3,5
Ø d3
Ø d6
Ø d9
Ø d6
Ø d8
Ø d8
Ø d1
l7 l4
l4 l7
l3
l1 K
l9
l8 l9
Ø d10
Fig. 2: Dimensions 5A
1 5A without seat lock 2 5A-RA with seat lock
Table 8: Dimensions 5A [mm]

d1 d37) d6 d7 d8 d9 d10 ds e l1K8) l3 l4 l5 l6 l7 l8 l9
H11 H8 +/- 0,5 + 0,5
028 42 37 43 3 48 M6 × 6 47 4 42,5 32,5 10 2 5 9 6 17.5
030 44 39 45 50 49
032 46 42 48 53 51
033 47 42 48 53 51 6.5
035 49 44 50 60 54
038 54 49 56 4 62 M6 × 8 59 6 45 34 11 6 18.5
040 56 51 58 65 61
043 59 54 61 67 65 6
045 61 56 63 70 66
048 64 59 66 72 69
050 66 62 70 75 71 47,5 36 11,5 2,5 19
053 69 65 73 77 75
055 71 67 75 86 76 7.5
058 78 70 78 88 M6 × 10 83 52,5 41 6
060 80 72 80 91 85
063 83 75 83 93 88 8.5
065 85 77 85 96 M8 × 10 95
1974.81/06-EN
068 88 81 90 98 93 40 12,5 7 20
070 90 83 92 103 95 60 47,5
075 99 88 97 108 M8 × 12 105 10
7 To determine the safety distance between rotating and stationary components these dimensions are
recommended as maximum dimensions.
8 The mechanical seal manufacturer may supply a mechanical seal shorter than the dimension indicated. Any
differences in length should be compensated by means of a spacer which should also be supplied by the
manufacturer of the mechanical seal.
5A / 5B 23 of 30
9 Related Documents
d1 d37) d6 d7 d8 d9 d10 ds e l1K8) l3 l4 l5 l6 l7 l8 l9

H11 H8 +/- 0,5 + 0,5
080 104 95 105 4 120 M8 × 12 109 6 60 47 13 3 7 9 10 20.5
085 109 100 110 125 114
090 114 105 115 130 119 65 52 12
095 119 110 120 135 124
100 124 115 125 140 129
110 143 128.2 140.3 - M10 × 16 148 - 67 15 2 10 12 24.5
130 163 146.2 158.3 - 168 10.3
9.1.2 5B
1) 2) 3)
l5×20°
l5×20° l6
Ø d10 l6 e
Ø d3
Ø d7
Ø ds
Ø d7
l8 3 3,5
Ø d2
Ø d8
Ø d9
Ø d6
Ø d6
Ø d1
l4
Ø d8
l4 l7 l7
l2
l 1K
l9
R1 l9
.6
Fig. 3: Dimensions 5B
1 5B without seat lock 2 5B-RA with seat lock 3 5B-RC with cooled mating
ring
Table 9: Dimensions 5B [mm]

d1 d2 d39) d6 d7 d8 d10 d1s e l1K10) l2 l3 l4 l5 l6 l7 l8 l9
h6 H11 H8 +/- 0,5 +/- 0,5 + 0,5
028 33 47 37 43 3 M6 × 6 51 4 50 20 40 10 2 5 9 6,5 17,5
030 35 49 39 45 54
033 38 54 42 48 M6 × 8 59
035 40 56 44 50 61
038 43 59 49 56 4 65 6 52,5 23 41,5 11 6 6 18,5
040 45 61 51 58 66
043 48 64 54 61 69
045 50 66 56 63 71
048 53 69 59 66 75
050 55 71 62 70 76 57,5 25 46 11,5 2,5 7,5 19
1974.81/06-EN
053 58 78 65 73 M6 × 1 83 6
055 60 80 67 75 0 85
9 To determine the safety distance between rotating and stationary components these dimensions are
recommended as maximum dimensions.
10 The mechanical seal manufacturer may supply a mechanical seal shorter than the dimension indicated. Any
differences in length should be compensated by means of a spacer which should also be supplied by the
manufacturer of the mechanical seal.
24 of 30 5A / 5B
9 Related Documents
d1 d2 d39) d6 d7 d8 d10 d1s e l1K10) l2 l3 l4 l5 l6 l7 l8 l9

h6 H11 H8 +/- 0,5 +/- 0,5 + 0,5
058 63 83 70 78 4 M6 × 1 88 6 62,5 25 51 11,5 2,5 6 9 8,5 19
0
060 65 85 72 80 M8 × 1 95
063 68 88 75 83 0 93
065 70 90 77 85 95
070 75 99 83 92 M8 × 1 105 70 28 57,5 12,5 7 10 20
075 80 104 88 97 2 109
080 85 109 95 105 114 57 13 3 20,5
085 90 114 100 110 119 75 62 12
090 95 119 105 115 124
095 100 124 110 120 129
100 105 129 115 125 134
1974.81/06-EN
5A / 5B 25 of 30
10 Certificate of Decontamination
10 Certificate of Decontamination
Type: ................................................................................................................................
Order number /
Order item number11): ................................................................................................................................
Delivery date: ................................................................................................................................
Application: ................................................................................................................................
11)
Fluid handled : ................................................................................................................................
Please tick where applicable11):
⃞ ⃞ ⃞ ⃞ ⃞
Corrosive Oxidising Flammable Explosive Hazardous to health
R
⃞ ⃞ ⃞ ⃞ ⃞
Seriously hazardous to Toxic Radioactive Bio-hazardous Safe
health
Reason for return:11): ................................................................................................................................

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 and 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 intermediate piece 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
1974.81/06-EN
11 Required field
26 of 30 5A / 5B
Index
Index
C
Certificate of Decontamination 26
D
Design 12
Designation 11
Disposal 9
E
Event of damage 4
K
Key to safety symbols/markings 5
O
Other applicable documents 4
P
Personnel 6
Q
Qualification 6
R
Return to supplier 9
S
Safety 6
Safety awareness 7
Specialist personnel 6
T
Tightening torques 17
Training 6
W
Warnings 5
Warranty claims 4
1974.81/06-EN
5A / 5B 27 of 30
(05094048)
1974.81/06-EN
KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com
Coating Procedure
Quality Class according to ZN 35 – 4 ES2N
Type Permissible Surface Primer Intermediate coat

temperature preparation
range
Product name Colour type and film Product Colour type and film
thickness [µm] name thickness [µm]
A -30 to +150 [°C] Sand-blasting SikaCor Zinc R 2-component zinc SikaCor EG1 2-component epoxy resin
-22 to +302 [F] SA 2.5 dust, water-thinned 1 x approx. 60 – 70
shortly to +180 [°C] /+356 [°F] **) 1 x max. 40
B -30 to +200 [°C] Sand-blasting - - Aqua-Air 2-K 2-component epoxy
-22 to +392 [F] SA 2.5 Epoxyprimer compound, water-thinned
99600 1 x max. 60
Type Permissible Finish coat Applications

temperature
range
Product name Colour type and film Colour
thickness [µm]
A -30 to +150 [°C] SikaCor EG5 2-component RAL 5002 Marine / industrial
-22 to +302 [F] polyurethane Ultramarine blue atmospheres
shortly to +180 [°C] /+356 [°F] **) 1 x max. 40
B -30 to +200 [°C] Aqua-Air 2-K Pur 2-component RAL 5002 Marine / industrial
-22 to +392 [F] Topcoat 99500 polyurethane binder Ultramarine blue atmospheres
1 x max. 40
**) Colour deviations / -changes possible at high temperatures
Coating Type and Colour

Item Coating type RAL No.
Pump B RAL 5002
Baseplate A RAL 5002
Balancing water pipe, pressure gauge line N/A stainless steel
Min. flow control valve B RAL 5002
Motor Manufacturer's standard RAL 7030
Strainer body B RAL 5002
Preservation for pump removed from system (indoor storage). Period and measures.
Storage of pump < 12 months
Pump is preserved after performance test
(Anticorit 87, Fuchs Mineralölwerke GmbH)
9.3 Coupling
Data Sheet
Operating Manual
HGM 191 of 492

Shaft Couplings
Pump - motor
Manufacturer TSCHAN
Type / size NOR-MEX H 148-82
Coupling type Flexible coupling
Mass 20.6 kg
Quantity 2
Spacer for Shaft distance 180 mm
Retaining ring No
Lubrication None
Max. bore 65 mm
Spacer plates Not necessary
Coupling guard Sheet steel
Balancing quality Q 2,5
BAWN 007-GBR-1
10/2008
Assembly
Assembly and
and operating
operating instructions
instructions TSCHAN®
Flexible
Elastic coupling
coupling
®
- 
RINGFEDER POWER TRANSMISSION GMBH

Werner-Heisenberg-Straße 18, D-64823 Groß-Umstadt, Germany · Phone: +49 (0) 6078 9385-0 · Fax: +49 (0) 6078 9385-100
TSCHAN GmbH
E-mail: sales.international@ringfeder.com
Zweibrücker Straße 104 D-66538 Neunkirchen-Saar
Telefon: +49(0) 6821 866 0 Telefax: +49(0) 6821 883 53 www.tschan.de
Content
Chapter Page
1 Notes on safety................................................................................................................. 2
2 Function............................................................................................................................ 3
2.1 Appropriate Use......................................................................................................... 3
3 Marking of the coupling..................................................................................................... 3
4 Storage ............................................................................................................................. 4
5 Construction ..................................................................................................................... 5
6 Technical data .................................................................................................................. 6
7 Assembly .......................................................................................................................... 7
7.1 Pay attention before the assembly ............................................................................ 7
7.2 Finished borehole ...................................................................................................... 8
7.3 Installing coupling ...................................................................................................... 9
8 Adjusting coupling .......................................................................................................... 11
8.1 Angular misalignment ∆Kw ....................................................................................... 12
8.2 Radial displacement ∆Kr .......................................................................................... 12
8.3 Axial displacement................................................................................................... 13
9 Operation........................................................................................................................ 14
9.1 Sense of rotation test............................................................................................... 17
10 Maintenance .................................................................................................................. 19
10.1 Wear Inspection on the Buffer Ring......................................................................... 19
10.2 Wear limit of elastic buffers...................................................................................... 20
10.3 Changing the elastic intermediate ring .................................................................... 20
11 Waste Disposal .............................................................................................................. 21
1 Notes on safety
The present assembly and operating instruction (AOI) constituents a part of the coupling
supply. Always keep the AOI near the coupling well accessible.
The German version of this manual is the predominant and binding version.
Make sure that all persons charged with the assembly, operating, service, and maintenance
have read and understood the AOI and follow all the points:
- Avert hazards for body and live of the user and third parties.
- Ensure the operating safety of the coupling.
- Avoid the loss of use and environmental impairment through false handling.
In the case of transport, mounting, dismounting and maintenance, attention is to be paid to

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

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

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

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

5 Construction
1 Pan-head screw DIN 912

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

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

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

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

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

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

7.3 Installing coupling
• Take out the elastic intermediate ring

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

coupling!
• Mount the hubs so that the shaft

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

against unintentional touching of free rotating parts.
To avoid sparks coverings in stainless steel should be used.
IP2X.
The covering is to be so designed that it does not deposit dust
onto the coupling parts.
The covering must not touch the coupling or influence it in its
function.
In the case of use of accessories and spare parts, which were not originally manufactured by
TSCHAN GmbH, no liability or guarantee will be accepted for any resulting damage.
11 Waste Disposal
The waste disposal has to occur according to the specific regulations of the respective user
country.
9.4 Drive
Data Sheet
Dimension Drawing
Circuit Diagram
Torque Chart
Operating Manual
214 of 492 HGM

Operating and Installation Data
Rated-
-power PN 132 kW Connection D/Y
-voltage UN 400/690 V Class of rating S1
-frequency fN 50 Hz Absolute altitude <1000 m ab.s.l.
-current IN 220/128 A Coolant temperature 40 °C
-speed nN 2988 1/min Therm. class (designed/util.) 155 (F) / 130 (B)
-torque MN 422 Nm
Power factor cosι 0,9
Standard: IEC/EN 60034-1

Tolerances: IEC/EN 60034-1
Calculated Start-Up Data
Motor voltage U/UN 1 0,8
Locked-rotor torque MA/MN 3,1 1,9

Locked-rotor current IA/IN 10,5 8,2
Breakdown torque MK/MN 4,0 2,5
Calculated Partial Load Data
P/PN 1,25 1 0,75 0,5 0,25

cos ι 0,91 0,90 0,88 0,83 0,64
γ (%) 95,9 96,2 96,1 95,5 92,7
v20210517
Responsible dept. Technical reference Created by Approved by Project
DI MC LVM EU MF-FRE SCM EN TRA 188987 JANIK, DAVID JANIK, DAVID

Document type Document state Customer
Electrical Data Sheet released

s Title Document no.
3~ Asynchronous motor with Squirrel Cage Rotor

unrestricted 1LE1604-3AA23-4AH4-Z Rev. Date of issue Language Sheet
© SIEMENS AG 2021 LIAZ 3487915/1 2021-09-23 en 1/1

2021-09-22 Janus
Released
Operating and Installation Data
Rated-
-power PN 132 kW Connection D/Y
-voltage UN 400/690 V Class of rating S1
-frequency fN 50 Hz Absolute altitude <1000 m ab.s.l.
-current IN 220/128 A Coolant temperature 40 °C
-speed nN 2988 1/min Therm. class (designed/util.) 155 (F) / 130 (B)
-torque MN 422 Nm
Power factor cosι 0,9
Standard: IEC/EN 60034-1

Tolerances: IEC/EN 60034-1
6 12
5 10
4 8
M/MN 3 6 I/IN
2 4
1 2
0 0
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
n/nS
M/MN at UN M/MN at 80 % UN I/IN at UN I/IN at 80 % UN
v20210517
Responsible dept. Technical reference Created by Approved by Project
DI MC LVM EU MF-FRE SCM EN TRA 188987 JANIK, DAVID JANIK, DAVID

Document type Document state Customer
Starting Data M=f(n), I=f(n) released

s Title Document no.
3~ Asynchronous motor with Squirrel Cage Rotor

unrestricted 1LE1604-3AA23-4AH4-Z Rev. Date of issue Language Sheet
© SIEMENS AG 2021 LIAZ 3487915/1 2021-09-23 en 1/1

Introduction 1
Safety information 2
3
SIMOTICS GP, SD, DP Description
Preparing for use 4

Low-Voltage Motors
1LE1, 1FP1/3, 1PC1/3 shaft height 5
63 ... 315 Assembly
Electrical connection 6
Operating Instructions
Commissioning 7
Operation 8
Maintenance 9
Spare parts 10
Disposal 11
Service & support A
Technical data B
Quality documents C
07/2020
A5E38483075A
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG Document order number: A5E38483075A Copyright © Siemens AG 2008 - 2020.

Digital Industries Ⓟ 07/2020 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 Introduction ........................................................................................................................................... 9
1.1 About these instructions ...................................................................................................... 9
1.2 Compiling personal documents ............................................................................................ 9
2 Safety information ............................................................................................................................... 11
2.1 Information for those responsible for the plant or system ................................................... 11
2.2 The 5 safety rules............................................................................................................... 11
2.3 Qualified personnel............................................................................................................ 12
2.4 Safe handling .................................................................................................................... 12
2.5 Electromagnetic fields when operating electrical power engineering installations ............... 14
2.6 Electrostatic sensitive devices............................................................................................. 14
2.7 Electromagnetic compatibility ............................................................................................ 15
2.8 Interference immunity ....................................................................................................... 15
2.9 Influence on the line power supply through a strongly irregular torque............................... 15
2.10 Interference voltages when operating the converter ........................................................... 16
2.11 Special designs and construction versions .......................................................................... 16
3 Description........................................................................................................................................... 17
3.1 Area of application............................................................................................................. 17
3.2 Rating plates ...................................................................................................................... 18
3.3 Installation ........................................................................................................................ 20
3.3.1 Cooling and ventilation ...................................................................................................... 20
3.3.1.1 General.............................................................................................................................. 20
3.3.1.2 Machines with a fan........................................................................................................... 21
3.3.1.3 Machines without a fan (optional)...................................................................................... 21
3.3.2 Bearings ............................................................................................................................ 22
3.3.3 Balancing........................................................................................................................... 22
3.3.4 Types of construction/method of installation ...................................................................... 22
3.3.5 Degree of protection .......................................................................................................... 24
3.3.6 Environmental conditions .................................................................................................. 24
3.3.7 Optional built-on and built-in accessories ........................................................................... 25
3.3.8 Terminal box...................................................................................................................... 25
3.3.9 Paint finish ........................................................................................................................ 25
4 Preparing for use ................................................................................................................................. 27
4.1 Safety-related aspects to consider when configuring the plant............................................ 27
4.2 Observing the operating mode........................................................................................... 27
4.3 Machines without final paint coating.................................................................................. 27
1LE1, 1FP1/3, 1PC1/3 shaft height 63 ... 315

Operating Instructions, 07/2020, A5E38483075A 3
Table of contents
4.4 Delivery ............................................................................................................................. 28

4.5 Transport and storage ........................................................................................................ 28
4.5.1 Safety instructions for transport ......................................................................................... 28
4.5.2 Transport........................................................................................................................... 30
4.5.3 Storage.............................................................................................................................. 31
4.5.4 Securing the rotor .............................................................................................................. 33
4.5.5 Commissioning after storage ............................................................................................. 35
4.5.5.1 Insulation resistance and polarization index ....................................................................... 35
4.5.5.2 Lubricating the rolling bearings .......................................................................................... 35
4.5.5.3 Regreasing rolling bearings after storage periods of up to two years ................................... 35
4.5.5.4 Releasing the rotor shipping brace before commissioning................................................... 35
4.6 Ensure adequate cooling .................................................................................................... 36
4.7 Interlock circuit for anti-condensation heating.................................................................... 38
4.8 Noise emission .................................................................................................................. 38
4.9 Voltage and frequency fluctuations during line operation ................................................... 38
4.10 Rotational speed limit values .............................................................................................. 39
4.11 System-inherent frequencies.............................................................................................. 39
4.12 Electromagnetic compatibility ............................................................................................ 39
4.13 Converter operation........................................................................................................... 40
4.13.1 Parameterizing the converter ............................................................................................. 40
4.13.2 Converter input voltage ..................................................................................................... 41
4.13.3 Reducing bearing currents during operation with converter (low voltage)........................... 41
4.13.4 Insulated bearings for converter operation ......................................................................... 43
4.13.5 Tandem operation ............................................................................................................. 44
4.13.6 Speed limits for converter operation .................................................................................. 44
5 Assembly ............................................................................................................................................. 45
5.1 Safety instructions for installation ...................................................................................... 45
5.2 Preparing for installation.................................................................................................... 46
5.2.1 Requirements for installation ............................................................................................. 46
5.2.2 Insulation resistance .......................................................................................................... 47
5.2.2.1 Insulation resistance and polarization index ....................................................................... 47
5.2.2.2 Checking the insulation resistance and polarization index of the winding ........................... 47
5.3 Installing the machine ....................................................................................................... 50
5.3.1 Preparing the assembly area .............................................................................................. 50
5.3.2 Lift the machine to where it will be mounted and position it............................................... 50
5.3.3 Machines with type of construction IM B15, IM B9, IM V8 and IM V9................................... 51
5.3.4 Foot mounting................................................................................................................... 51
5.4 Aligning and fixing the machine......................................................................................... 52
5.4.1 Measures for alignment and mounting............................................................................... 52
5.4.2 Flatness of the supporting surfaces for conventional motors............................................... 53
5.4.3 Machine frame mounting feet (special design) ................................................................... 53
5.5 Installing the machine ....................................................................................................... 53
5.5.1 Preconditions for smooth, vibration-free operation............................................................. 53
5.5.2 Aligning the machine to the driven machine and mounting ................................................ 54
5.5.2.1 Selecting bolts ................................................................................................................... 54

4 Operating Instructions, 07/2020, A5E38483075A
Table of contents
5.5.2.2 Horizontal types of construction with mounting feet .......................................................... 54

5.5.2.3 Horizontal types of construction with flange....................................................................... 55
5.5.2.4 Vertical types of construction with flange ........................................................................... 55
5.5.3 Removing the rotor shipping brace..................................................................................... 56
5.5.4 Recommended alignment accuracy .................................................................................... 56
5.5.5 Mounting the drive output elements .................................................................................. 56
6 Electrical connection ........................................................................................................................... 61
6.1 Safety instructions for the electrical connection.................................................................. 61
6.2 Connecting the machine .................................................................................................... 62
6.2.1 Terminal box...................................................................................................................... 63
6.2.1.1 Circuit diagram inside the terminal box cover ..................................................................... 63
6.2.1.2 Direction of rotation .......................................................................................................... 64
6.2.1.3 Terminal marking............................................................................................................... 64
6.2.1.4 Cable entry ........................................................................................................................ 64
6.2.1.5 Versions ............................................................................................................................ 65
6.2.1.6 Protruding connection cables ............................................................................................. 65
6.2.1.7 Connecting protruding cables ............................................................................................ 65
6.2.1.8 Connection with/without cable lugs ................................................................................... 65
6.2.1.9 Minimum air clearances ..................................................................................................... 66
6.2.2 Cable glands ...................................................................................................................... 66
6.2.2.1 Mounting position of sheet metal nuts in screw-type connections ...................................... 67
6.3 Tightening torques ............................................................................................................ 68
6.3.1 Cable entries, sealing plugs and thread adapters ................................................................ 68
6.4 Connecting the grounding conductor ................................................................................. 68
6.4.1 Minimum surface area of grounding conductor .................................................................. 68
6.4.2 Grounding connection type................................................................................................ 69
6.5 Connecting a temperature sensor / anti-condensation heater.............................................. 70
6.5.1 Connecting optional integrated devices and equipment ..................................................... 70
6.6 Conductor connection........................................................................................................ 71
6.6.1 Type of conductor connection ............................................................................................ 71
6.6.2 Connecting aluminum conductors...................................................................................... 72
6.7 Connecting converters ....................................................................................................... 72
6.8 Final checks ....................................................................................................................... 73
7 Commissioning .................................................................................................................................... 75
7.1 Measures before commissioning ........................................................................................ 75
7.1.1 Checks to be carried out prior to commissioning ................................................................. 75
7.1.2 Mechanical and electrical check ......................................................................................... 76
7.1.3 Converter operation........................................................................................................... 77
7.1.4 Insulation resistance and polarization index ....................................................................... 77
7.1.5 Testing the cooling of the machine .................................................................................... 77
7.1.6 Commissioning an external fan .......................................................................................... 78
7.1.7 Further documents ............................................................................................................ 79
7.1.8 Setpoint values for monitoring the bearing temperature..................................................... 79
7.2 Switching on ..................................................................................................................... 79
7.2.1 Test run ............................................................................................................................. 80

Table of contents
8 Operation............................................................................................................................................. 83
8.1 Safety instructions for operation ........................................................................................ 83
8.1.1 Safety instructions relating to ventilation and cooling......................................................... 86
8.1.1.1 Safety instruction for forced ventilation (option) ................................................................ 86
8.1.1.2 Safety instructions when operating machines with fan ....................................................... 86
8.1.1.3 Machines with fan for the textile industry........................................................................... 86
8.2 Switching on the machine ................................................................................................. 87
8.3 Deactivating ...................................................................................................................... 87
8.4 Switching on again after an emergency switching-off......................................................... 87
8.5 Stoppages ......................................................................................................................... 87
8.5.1 Avoidance of damage to rolling bearings during stoppages ................................................ 89
8.5.2 Decommissioning the machine .......................................................................................... 89
8.5.3 Re-commissioning the machine.......................................................................................... 89
8.6 faults ................................................................................................................................. 89
8.6.1 Inspections in the event of faults........................................................................................ 89
8.6.2 Electrical faults .................................................................................................................. 90
8.6.3 Mechanical faults............................................................................................................... 91
8.6.4 Rolling bearing faults ......................................................................................................... 91
8.6.5 Faults at the external fan ................................................................................................... 92
9 Maintenance........................................................................................................................................ 93
9.1 Preparation and notes ........................................................................................................ 93
9.1.1 North American market (optional)...................................................................................... 93
9.1.2 Touch up any damaged paintwork ..................................................................................... 94
9.2 Inspection and maintenance .............................................................................................. 94
9.2.1 Safety instructions for inspection and maintenance ............................................................ 94
9.2.2 Inspections in the event of faults........................................................................................ 95
9.2.3 First inspection after installation or repair........................................................................... 96
9.2.4 General inspection ............................................................................................................. 97
9.2.5 Assessing the rolling bearings ............................................................................................ 97
9.2.6 Maintenance intervals........................................................................................................ 98
9.2.7 Re-greasing ....................................................................................................................... 99
9.2.8 Cleaning ............................................................................................................................ 99
9.2.9 Cleaning the fan cover of machines for the textile industry ............................................... 100
9.2.10 Drain condensate............................................................................................................. 100
9.2.11 Insulation resistance and polarization index ..................................................................... 101
9.2.12 Servicing the external fan ................................................................................................ 101
9.3 Corrective maintenance ................................................................................................... 102
9.3.1 Rolling bearings ............................................................................................................... 103
9.3.1.1 Bearing bushes ................................................................................................................ 104
9.3.1.2 Installing bearings ........................................................................................................... 104
9.3.2 Mounting dimension "x"................................................................................................... 106
9.3.3 Fan.................................................................................................................................. 106
9.3.3.1 Mounting fans ................................................................................................................. 109
9.3.3.2 Mounting the fan cover ................................................................................................... 109
9.3.4 Canopy; mounting a rotary pulse encoder under the canopy............................................. 109
9.3.5 Tightening torques .......................................................................................................... 110
9.3.6 Screw lock washers .......................................................................................................... 110

Table of contents
9.3.7 Links ................................................................................................................................ 110

9.3.8 Reassembly: Miscellaneous information ........................................................................... 110
9.3.9 Optional add-on units ...................................................................................................... 110
9.3.9.1 Mounting a brake ............................................................................................................ 111
9.3.10 O-ring seal ....................................................................................................................... 111
10 Spare parts ......................................................................................................................................... 113
10.1 Parts order ....................................................................................................................... 113
10.2 Data matrix code on the machine..................................................................................... 113
10.3 Ordering data .................................................................................................................. 113
10.4 Determining the spare parts via the Internet..................................................................... 114
10.5 Replacing rolling bearings ................................................................................................ 114
10.6 Parts groups definition ..................................................................................................... 114
10.7 Ordering example ............................................................................................................ 115
10.8 Machine parts .................................................................................................................. 116
10.9 Standardized parts ........................................................................................................... 118
10.10 Exploded drawings .......................................................................................................... 119
10.10.1 1LE, 1PC shaft heights 63 ... 71 aluminum ....................................................................... 119
10.10.2 1LE, 1PC, 1FP shaft heights 80 ... 160 aluminum .............................................................. 120
10.10.3 1LE, 1PC shaft heights 180 ... 200 aluminum ................................................................... 121
10.10.4 1LE, 1PC shaft heights 71 ... 90 cast iron .......................................................................... 122
10.10.5 1LE, 1PC, 1FP shaft heights 100 ... 200 cast iron............................................................... 123
10.10.6 1LE, 1PC shaft heights 225 ... 315 cast iron ...................................................................... 124
11 Disposal.............................................................................................................................................. 125
11.1 RoHS - restricting the use of certain hazardous substances................................................ 125
11.2 Information according to Article 33 of the REACH regulation ............................................ 125
11.3 Preparing for disassembly ................................................................................................ 126
11.4 Dismantling the machine ................................................................................................. 126
11.5 Disposal of components ................................................................................................... 126
A Service & support ............................................................................................................................... 129
A.1 Siemens Industry Online Support ..................................................................................... 129
A.2 Further documents .......................................................................................................... 130
B Technical data.................................................................................................................................... 131
B.1 Tightening torques .......................................................................................................... 131
B.1.1 Tightening torques for screw and bolt connections........................................................... 131
B.1.2 Terminal board and grounding ......................................................................................... 132
B.1.3 Terminal boxes, end shields, grounding conductors, sheet metal fan covers ..................... 132
B.1.4 Additional connecting terminals for monitoring equipment and anti-condensation
heating ............................................................................................................................ 132
C Quality documents ............................................................................................................................ 133
C.1 Quality documents SIMOTICS in SIOS ............................................................................... 133

Table of contents
Index .................................................................................................................................................. 135

Introduction 1
1.1 About these instructions
These instructions describe the machine and explain how to handle it, from initial delivery to
final disposal of the equipment. Keep these instructions for later use.
Read these operating instructions before you handle the machine and follow the instructions
to become familiar with its design and operating principles and thus ensure safe, problem-
free machine operation and long service life.
Safety instructions and handling-related warning notes are provided in these instructions.
When carrying out any activity at or with the machine, carefully comply with all of these
notes for your own safety, to protect other people and to avoid material damage.
Please contact the Service Center if you have any suggestions on how to improve this
document.
Text format features

You can find the following text format features in these instructions:
1. Handling instructions are always formatted as a numbered list. Always perform the steps in
the order given.
• Lists are formatted as bulleted lists.
– Lists on the second level are hyphenated.
Note
The note provides you with additional information about the product itself, handling the
product - and the relevant documentation.
1.2 Compiling personal documents

On the Internet pages in Industry Online Support you have the possibility of compiling
personal documents using the function Documentation
(https://support.industry.siemens.com/My/ww/en/documentation)
Using the "Documentation" function, from Product Support manuals, you can compile your
own "Documentation". However, you can also include other Product Support content such as
FAQs or characteristics in the documentation that you compile.
In the "Documentation" function, you have the option of creating your own compiled
documents in your own structure and managing them. You can delete or shift individual
chapters or topics. Further, using the note function you can import your own content. The
compiled "documentation" can be exported as PDF, for example.

Introduction
1.2 Compiling personal documents
Using the "Documentation" function, you can efficiently compile your own plant or system
documentation. The "Documentation" compiled in a specific language can also be
automatically exported in one of the other available languages.
The full functionality is only available for registered users.

Safety information 2
2.1 Information for those responsible for the plant or system
This electric machine has been designed and built in accordance with the specifications
contained in Directive 2014/35/EU ("Low-Voltage Directive") and is intended for use in
industrial plants. Please observe the country-specific regulations when using the electric
machine outside the European Community. Follow the local and industry-specific safety and
setup regulations.
The persons responsible for the plant must ensure the following:
• Planning and configuration work and all work carried out on and with the machine is only
to be done by qualified personnel.
• The operating instructions must always be available for all work.
• The technical data as well as the specifications relating to the permissible installation,
connection, ambient and operating conditions are taken into account at all times.
• The specific setup and safety regulations as well as regulations on the use of personal
protective equipment are observed.
Note
Use the services and support provided by the local service center for planning, installation,
commissioning and service work.
2.2 The 5 safety rules

To ensure your own personal safety as well as to avoid material damage, always comply with
the safety-relevant instructions when carrying out any work. Also carefully comply with the 5
safety rules according to EN 50110-1 "Working in a no-voltage state" in the specified
sequence.
5 safety rules
1. Disconnect the system.
Also disconnect the auxiliary circuits, for example, anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
4. Ground and short-circuit.
5. Provide protection against adjacent live parts.
To energize the system, apply the measures in reverse order.

Safety information
2.3 Qualified personnel
2.3 Qualified personnel

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

Workplace safety depends on the attentiveness, care, and common sense of the personnel
who install, operate, and maintain the machine. In addition to the safety measures cited, as a
matter of principle, the use of caution is necessary when you are near the machine. Always
pay attention to your safety.
Also observe the following to prevent accidents:
• General safety regulations applicable in the country where the machine is deployed.
• Manufacturer-specific and application-specific regulations
• Special agreements made with the operator
• Separate safety instructions supplied with the machine
• Safety symbols and instructions on the machine and its packaging
Danger as a result of stationary parts under voltage (live parts)

Live parts represent a hazard. Touch protection against active (live) parts is no longer
guaranteed if covers are removed. The minimum clearance and creepage distances may be
violated when coming close to live parts. Touching or coming close to them can result in
death, serious injury or material damage.
• Ensure that all live parts are suitably covered.
• Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules" (Page 11).
Risk of injury due to rotating parts

Rotating parts are dangerous. Touch protection against rotating parts is no longer guaranteed
if covers are removed. Touching rotating parts can result in death, serious injury or material
damage.
• Ensure that all rotating parts are reliably covered.
• Switch off and disconnect the machine first if you want to remove covers. Observe the "5
safety rules" (Page 11).
• Only remove covers when the rotating parts have come to a complete standstill.

Safety information
2.4 Safe handling
Risk of burns due to hot surfaces

Individual machine parts can become hot in operation. Burns can result when coming into
contact with these parts.
• Never touch machine parts during operation.
• Allow the machine to cool before starting work on the machine.
• Check the temperature of parts before touching them. If required, wear suitable
protective equipment.
Health hazard due to chemical substances

Chemical substances required for the setup, operation and maintenance of machines can
present a health risk.
• Observe the product information provided by the manufacturer.
Flammable substances hazard

Chemical substances required for the setup, operation and maintenance of machines may be
flammable. These substances can ignite if handled incorrectly. They can cause burns and
property damage.
• Observe the product information provided by the manufacturer.
Noise emissions
During operation, the machine's noise emission levels can exceed those permitted at the
workplace, which can cause hearing damage.
• Ensure that nobody is in the area of increased noise emissions during machine operation.
• Take steps to reduce noise so that the machine can be operated safely within your system.
The following measures may help to reduce noise.
– Covers
– Noise insulation
– Hearing protection measures
Prevention of hearing damage

If the permissible sound pressure level is exceeded, hearing damage can occur when
operating three-phase motors at their rated power.
The permissible sound pressure level is 70 dB (A).

Safety information
2.5 Electromagnetic fields when operating electrical power engineering installations
2.5 Electromagnetic fields when operating electrical power

engineering installations
Electrical power equipment generate electromagnetic fields during operation. Potentially
lethal malfunctions can occur in medical implants, e.g. pacemakers, in the vicinity of
electrical power equipment. Data may be lost on magnetic or electronic data carriers.
• Protect the personnel working in the plant by taking appropriate measures, such as
erecting identifying markings, safety barriers and warning signs and giving safety talks.
• Observe the nationally applicable health and safety regulations.
• It is forbidden for people with pacemakers to be close to the machine.
• Do not carry any magnetic or electronic data media.
2.6 Electrostatic sensitive devices
Material damage due to electrostatic discharge

Electronic modules contain components that can be destroyed by electrostatic discharge.
These components can be damaged or destroyed if they are not handled correctly. To protect
equipment against damage, follow the instructions given below.
• Only touch electronic modules if you absolutely have to work on them.
• The body of the person concerned must have been electrostatically discharged and
grounded immediately before any electronic modules are touched.
• Electronic modules should not be brought into contact with electrically insulating
materials, such as:
– Plastic film
– Plastic parts
– Insulating table supports
– Clothing made of synthetic fibers
• Always place electrostatic sensitive devices on conductive bases.
• Always pack, store and transport electronic modules or components in conductive
packaging, such as:
– Metallized plastic or metal containers
– Conductive foam material
– Domestic aluminum foil

Safety information
2.7 Electromagnetic compatibility
The ESD protective measures required for components that can be destroyed due to
electrostatic discharge are shown in the following drawings:
a = conductive floor sur- b = ESD table c = ESD shoes

face
d = ESD overall e = ESD wristband f = cabinet ground connection
Electromagnetic compatibility
This machine is designed in accordance with IEC/EN 60034, and when used as specified, it
complies with the requirements of European Directive 2014/30/EU regarding Electromagnetic
Compatibility.
2.8 Interference immunity

By selecting suitable signal cables and evaluation units, ensure that the interference
immunity of the machine is not diminished.
2.9 Influence on the line power supply through a strongly irregular

torque
A strongly irregular torque, for example with the drive of a reciprocating motor, forces a non-
sinusoidal motor current. The emerging harmonics can have an impermissible influence on
the line power supply via the connection lines.

Safety information
2.10 Interference voltages when operating the converter
2.10 Interference voltages when operating the converter
Interference voltages when operating the converter

When a converter is in operation, the emitted interference varies in strength depending on
the converter (manufacturer, type, interference suppression measures undertaken). On
machines with integrated sensors (e.g. PTC thermistors), interference voltages caused by the
converter may occur on the sensor lead. This can cause faults which can result in eventual or
immediate death, serious injury or material damage.
• Comply with the EMC information provided by the manufacturer of the converter. This is
how you prevent the limit values stipulated by IEC/EN 61000-6-2 .... IEC/EN 61000-6-4 for
the drive system (consisting of the machine and converter) from being exceeded.
• You must put appropriate EMC measures in place.
2.11 Special designs and construction versions

Before carry out any work on the machine, determine the machine version.
If there are any deviations or uncertainty, contact the manufacturer, specifying the type
designation and serial number (see the rating plate), or contact the Service Center
(Page 129).

Description 3
3.1 Area of application
WARNING
Risk of explosion
This machine is not designed for use in hazardous areas. An explosion can occur if the
machine is operated in these areas. This can result in death, serious injury or material
damage.
• Never operate this machine in hazardous areas.
The rotating electrical motors of this series are used as industrial drives. They are designed for
a wide range of drive applications both for line operation as well as in conjunction with
frequency converters.
They are characterized by their high power density, extreme robustness, long service life and
outstanding reliability.
Correct and intended use of the machines

These machines are intended for industrial installations. They comply with the harmonized
standards of the series EN / IEC 60034 (VDE 0530). It is prohibited to use these motors in
hazardous zones if the marking on the motor rating plate does not explicitly permit line or
converter operation. If other/more wide-ranging demands (e.g. protection so that they
cannot be touched by children) are made in special cases – i.e. use in non-industrial
installations – these conditions must be ensured by the customer.
Note
Machine directive
Low-voltage motors are components designed for installation in machines in accordance with
the current Machinery Directive. Commissioning is prohibited until it has been absolutely
identified that the end product is in conformance with this Directive. Comply with standard
EN / IEC 60204-1.
Use of machines without CE marking

Machines without CE marking are intended for operation outside the European Economic
Area (EEA). Do not use any machines without a CE marking in the EEA!

Description
3.2 Rating plates
Note
IE2 marking
Since January 1, 2017, according to REGULATION (EC) No. 640/2009, low-voltage motors
with power ratings above 0.75 kW up to 375 kW – and with efficiency IE2 – have this label.
This is mandatory within the European Economic Area (EEA). Customers are solely
responsible in ensuring the correct use.
When connecting the machine to a converter, carefully observe the rules and notes in
Chapter "Connecting a converter."
Use of machines without EAC marking

EAC machines are appropriately marked on the rating plate, and are intended for operation
within the Eurasian customs union.
Within the Eurasian customs union, do not use machines without the appropriate EAC
marking.
Operating a machine with a converter
Implement all machines of the overall machine-converter system according to UL-File
E227215 assuming that the machines are only to be operated with a converter and are
supplied with UL certificate.
The company operating the equipment is responsible for implementing this in the actual
application.
3.2 Rating plates
Rating plate
The rating plate shows the identification data and the most important technical data. The
data on the rating plate and the contractual agreements define the limits of proper usage.
Data on the rating plate
Item Description Item Description

General data Electrical data
1 Type of machine 31 Electrical data
2 Machine type 33 Rated voltage V
3 Serial number (incl. date of manufacture 34 Winding connections
YY.MM )
4 Standards 35 Frequency Hz
5 Additional details (optional) 36 Rated power kW

Description
3.2 Rating plates
Item Description Item Description

6 Customer data (optional) 37 Rated current A
7 Country of origin 38 Power factor cosφ
8 Production location 39 Rated speed rpm
9 Identification number of testing agency 40 Efficiency class
(optional)
10 Regulations (optional) 41 Efficiency
49 Company logo 42 Torque Nm (optional)
52 Marine regulation 43 Bemessungsleistung hp (optional)
53 Machine family type 44 Service factor (optional)
Mechanical data 45 Starting current ratio (optional)
11 Frame size 46 Operating mode (optional)
12 Type of construction 47 NEMA data (optional)
13 Degree of protection 48 Anti-condensation heating (optional)
14 Machine weight kg 50 CODE: Motor code number for converter parame-
terization (optional)
15 Temperature class 51 Converter data
16 Ambient temperature range (optional)
17 Installation altitude (only if higher than 1000
m)
18 Vibration severity grade
19 Bearing sizes
20 Relubrication data/specifications (optional)
21 Brake data (optional)
22 Mechanical speed limit
24 Feather key arrangement

Description
3.3 Installation
3.3 Installation
The regulations and standards used as the basis for designing and testing this machine are
stamped on the rating plate. The machine design basically complies with the following
standards:
Table 3- 1 Applicable general regulations
Feature Standard EAC

Dimensioning and operating behavior EN / IEC 60034-1 GOST R IEC 60034-1
Procedure for determining the losses and the effi- EN / IEC 60034-2-1 GOST R IEC 60034-2-1
ciency of rotating electrical machines and inspections EN / IEC 60034-2-2 GOST R IEC 60034-2-2
EN / IEC 60034-2-3 GOST IEC 60034-2-3
Degree of protection EN / IEC 60034-5 GOST IEC 60034-5
Cooling EN / IEC 60034-6 GOST R IEC 60034-6
Type of construction EN / IEC 60034-7 GOST R IEC 60034-7
Terminal designations and direction of rotation EN / IEC 60034-8 GOST 26772
Noise emission EN / IEC 60034-9 GOST IEC 60034-9
Integrated thermal protection EN / IEC 60034-11
Starting characteristics of rotating electrical machines EN / IEC 60034-12 GOST R IEC 60034-12
Vibration severity grades EN / IEC 60034-14 GOST IEC 60034-14
Efficiency classification of three-phase squirrel-cage EN / IEC 60034-30-1 GOST IEC 60034-30-1
induction motors
IEC standard voltages IEC 60038 GOST R IEC 61800-1
3.3.1 Cooling and ventilation
3.3.1.1 General
The machines of this series have a closed primary (internal) cooling circuit and an open
secondary cooling circuit (surface cooling). The surface cooling varies depending on the
version.

Description
3.3 Installation
3.3.1.2 Machines with a fan
Self-ventilation (standard): Cooling method IC 411 according to EN / IEC 60034-6

Located at the ND end of the stator housing is an air intake cowl that guides the external air
on its way to the motor. The external air is drawn in through openings in the air intake cowl
and flows axially across the outer cooling ribs of the motor frame. The fan wheel for the
external flow of cooling air is attached to the machine shaft.
The fan wheels are bidirectional.
Check the cooling effect below rated speed in the case of frequent switching or braking – or
if the speed is controlled continually below the rated speed.
Forced ventilation (optional): Type of cooling IC 416 in accordance with EN / IEC 60034-6
Cooling that does not depend on the speed is achieved by means of a unit that is
independent of the motor operating state (forced ventilation). This unit is closed to the
outside by a fan cover. It has its own main drive with fan impeller which creates the cooling
air flow required for cooling the motor.
3.3.1.3 Machines without a fan (optional)
Surface cooling by free convection: Cooling method IC 410 according to EN / IEC 60034-6
Figure 3-1 IC410

Description
3.3 Installation
Surface cooling by relative movement of cooling air: Cooling method IC 418 according to
EN / IEC 60034-6
Figure 3-2 IC418
3.3.2 Bearings
To support the machine shaft and maintain its position in the non-moving part of the
machine, DE and NDE rolling bearings are used. One end performs the function of a locating
bearing that transfers axial and radial forces from the rotating machine shaft to the non-
moving part of the machine. The opposite end is implemented as a floating and support
bearing to allow thermal expansion inside the machine and transfer radial forces.
The nominal (theoretical) service life of the bearings according to ISO 281 is at least 20,000
hours when the permissible radial/axial forces are complied with, and the machine is
operated on 50 Hz line supplies. However, the achievable useful life of the bearings can be
significantly longer in the case of lower forces (e.g. operation with self-aligning couplings).
Rolling bearings with permanent lubrication are maintenance-free.
The machine is equipped with grease-lubricated rolling bearings.
• In the standard version, the bearings of machines up to shaft height 250 are permanently
lubricated.
• The bearings of machines from shaft height 280 and above are equipped with a
relubrication system.
3.3.3 Balancing
As standard, the machine is designed with vibration severity level A. The rotor is dynamically
balanced with a half feather key (code "H").
Vibration severity level B can be ordered as option, and stamped on the rating plate.
See also
Mounting the drive output elements (Page 56)
3.3.4 Types of construction/method of installation

The type of construction of the machine is stated on the rating plate.

Description
3.3 Installation
Table 3- 2 Type of construction
Basic type of construc- Diagram Other methods of Diagram

tion code installation
IM B3 (IM 1001) IM V5 (IM 1011)
IM V6 (IM 1031)
IM B6 (IM 1051)
IM B7 (IM 1061)
IM B8 (IM 1071)

IM B5 (IM 3001) IM V1 (IM 3011)
IM V3 (IM 3031)

IM B14 (IM 3601) IM V18 (IM 3611)
IM V19 (IM 3631)

Description
3.3 Installation
Basic type of construc- Diagram

tion code
IM B35 (IM 2001)
IM B34 (IM 2101)
3.3.5 Degree of protection

The machine has a type of protection as stamped on the rating plate, and can be installed in
dusty or humid environments.
3.3.6 Environmental conditions

Limit values for the standard version
Relative humidity for ambient temperature Tamb Max. 55 %

40 °C
Ambient temperature -20 °C to +40 °C
Installation altitude ≤ 1000 m
Air with normal oxygen content, usually 21 % (V/V)
The standard machines are not suitable for use in corrosive atmospheres, atmospheres with a
high salt content, or outdoor applications.
Limit values for the special versions
If the environmental conditions are different from the details listed here, then the values on
the rating plate or in the catalog will apply.

Description
3.3 Installation
3.3.7 Optional built-on and built-in accessories

Machines can be equipped with the following integrated components/devices:
• Temperature sensors integrated in the stator winding in order to monitor the temperature
and protect the stator winding from overheating.
• Anti-condensation heating for machines whose windings are subject to a risk of
condensation due to the climatic conditions.
Machines can be equipped with the following mounted components/devices:
• Brake
• Rotary pulse encoder
• External fan (forced ventilation)
• Measuring nipple for SPM shock pulse measurement for bearing monitoring
• Backstop
Note
Further documents
Observe all of the other documents provided with this machine.
Supplementary devices
Depending on the order, various supplementary devices can be installed or mounted. These
include sensors for bearing temperature monitoring or winding monitoring, for example.
3.3.8 Terminal box

As an option, additional connecting terminals are available in the terminal box for monitoring
equipment. For larger machines, an additional terminal box can be optionally mounted. You
can see the number of available terminals in the circuit diagrams.
3.3.9 Paint finish
Paint finish
The machine is painted according to the instructions in your order.

Description
3.3 Installation

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

A number of residual risks are associated with the machine. These are described in the
chapter titled "Safety information" (Page 11) and in related sections.
Take appropriate safety precautions (covers, barriers, markings, etc.) to ensure the machine is
operated safely within your plant.
4.2 Observing the operating mode

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

For machines, which are only delivered with primer, you must paint them to comply with the
applicable guidelines for the specific application. The primer alone does not provide adequate
corrosion protection.
Please contact the Service Center for recommendations relating to the paint finish.

Preparing for use
4.4 Delivery
4.4 Delivery
Checking the delivery for completeness

The drive systems are put together on an individual basis. When you take receipt of the
delivery, please check immediately whether the items delivered are in accordance with the
accompanying documents. Siemens will not accept any claims relating to items missing from
the delivery and which are submitted at a later date.
• Report any apparent transport damage to the delivery agent immediately.
• Report any apparent defects/missing components to the appropriate SIEMENS office
immediately.
Archive the safety and commissioning notes provided in the scope of delivery as well as the
optionally available operating instructions so that these documents are always easily
accessible.
The rating plate optionally enclosed as a loose item with the delivery is provided to enable
the motor data to be attached on or near the machine or installation.
4.5 Transport and storage
4.5.1 Safety instructions for transport

Observe the following when carrying out any work on the machine:
• Comply with the general safety instructions (Page 11).
• Comply with the applicable national and sector-specific regulations.
• When using the machine within the European Union, comply with the specifications laid
down in EN 50110-1 regarding safe operation of electrical equipment.
The information required to correctly attach, lift and transport the machine - such as weight,
center of gravity and attachment points - is provided here:
• Machine dimension drawing and the associated explanations or the technical data
• Transport data
• Rating plate and lifting plate, if available
• Shipping parts list
• Packaging

Preparing for use
Danger when incorrectly lifting and transporting

Danger of death, serious injury, or substantial material damage caused by tipping or falling
transported goods. Comply with the following safety instructions:
• All work must be performed with due caution and care.
• Comply with any notes in the shipping papers.
• Carefully comply with all of the handling information and markings on the packages
whenever transporting and putting the equipment into storage according to ISO 780.
• Only use suitable and adequately dimensioned lifting equipment, transport equipment
and industrial trucks.
Danger due to incorrect attachment and lifting

• Ensure that suitable lifting equipment is available.
• Only hoist the goods using the designated hoisting points and/or at marked positions. The
attachment points are not dimensioned for additional loads.
• Use suitable strap guiding or spreading devices.
• If not specified otherwise in the transport data, always transport the machine in the
position associated with its specific type of construction.
Danger due to damaged attachment points

• Carefully check the attachment points provided on the machine, e.g. attachment eyes,
lifting lugs or ring bolts for possible damage. Replace any damaged attachment points.
• Before using, carefully ensure that the attachment points are correctly attached.
Danger when incorrectly transporting the motor suspended from cables or ropes
If you transport the motor suspended from cables or ropes, the cables or ropes can break, e.g.
as a result of damage. Further, if not adequately attached, the motor can swing. This can
result in death, serious injury, or material damage.
• Use additional, suitable lifting equipment for transport and during installation.
• Two cables alone must be able to carry the complete load.
• Prevent the lifting equipment from sliding by appropriately securing it.
• When using 2-cable lifting equipment, ensure that the maximum angle of inclination is
≤45° according to ISO 3266 (DIN 580).
• Align the eyebolts so that the cables used for lifting are aligned with the planes of the
eyebolts.

Preparing for use
Danger when incorrectly lifting and transporting

The motor can slide or topple over if it is not correctly lifted or transported. This can result in
• Use all the lifting eyes on the machine.
• When using the lifting eyes on the machine, do not attach any additional loads or weight.
The lifting eyes are only designed for the weight of the machine itself.
• Any eyes that are screwed in must be tightly fastened.
• Eyebolts must be screwed in right up to their supporting surface.
• Comply with the permissible eyebolt loads.
• When necessary, use suitably dimensioned lifting equipment, for example hoisting slings
(EN1492-1) and webbing load restraints (EN12195-2).
Danger if the machine falls

The attachment points on the machine are designed for the weight of the machine only. If a
machine set is lifted and transported at a single machine, this can fracture the attachment
point. The machine or machine set may fall. This can result in death, serious injury or material
damage.
• Do not lift machine sets by attaching lifting tackle to the individual machines.
• Use only the equipment provided, e.g. the openings or lugs on the base plates, for
transporting machine sets. Note the maximum capacity of the lifting lug.
• Never remain under or in the immediate vicinity of the machine when it is lifted.
WARNING
Danger to life as a result of a machine falling
If the lifting gear or load handling attachments were to fail, the machine could fall. This
can result in death, serious injury or material damage.
• In order to gain easy and safe access to the underside of the machine, place it in a
secure and raised position.
Note
When lifting the machines for transport, only lift them in a position that corresponds to their
basic construction type.
The type of construction of the machine is stated on the rating plate.
4.5.2 Transport
If any transport locks are in place, remove them before commissioning. Store the transport
locks or disable them. Use the transport locks when transporting the motors again or
reactivate the transport locks.

Preparing for use
The machines are packed in different ways depending on how they are transported and their
size. If not otherwise contractually agreed, the packaging corresponds to the packing
guidelines according to ISPM (International Standards for Phytosanitary Measures).
Comply with the graphic symbols provided on the packaging. Their meaning is as follows:
This way Fragile Protect Protect Center of Hand hooks Attach

up goods against against gravity forbidden here
moisture heat
4.5.3 Storage
Storing outdoors
NOTICE
Damage to the motor
Damage can occur if incorrectly stored.
Take all precautions to protect the motor under extreme climatic conditions, e.g. salt-laden
and/or dusty, moist/humid atmospheres.
Choose a dry storage location which is safe from flooding and free from vibration. Repair any
damage to the packaging before putting the equipment into storage if this is necessary to
ensure proper storage conditions. In order to ensure protection against ground moisture,
locate machines, equipment and crates on pallets, wooden beams or foundations. Prevent
equipment from sinking into the ground. Do not impede air circulation under the stored
items.
Covers or tarpaulins used to protect the equipment against the weather must not come into
contact with the surfaces of the equipment. Use wooden spacer elements to ensure that air
can circulate freely around the equipment.
Storing indoors
The storage rooms must provide protection against extreme weather conditions. They must
be dry, free from dust, frost and vibration and well ventilated.
Bare metal surfaces

For transport, the bare surfaces (shaft ends, flange surfaces, centering edges) should be
coated with an anti-corrosion agent which will last for a limited amount of time (<6 months).
Apply suitable anti-corrosion measures for longer storage times.

Preparing for use
Condensation drain hole

Open any condensation drain holes to drain the condensation depending on the
environmental conditions, every six months at the latest.
Storage temperature
Permissible temperature range: -20 °C to +50 °C
Maximum permissible air humidity: 60%
For machines that have a special design regarding the ambient temperature in the operating
state or the installation altitude, other conditions could apply regarding the storage
temperature. In this case, refer to the machine rating plate for data on the ambient
temperature and installation altitude.
Storage time
Turn the shaft once every year to avoid bearing brinelling. Prolonged storage periods reduce
the useful life of the bearing grease (aging).
Open bearings
• For open bearings, e.g. 1Z, check the status of the grease when stored for longer than 12
months.
• Replace the grease if it is identified that the grease has lost its lubricating properties or is
polluted. The consistency of the grease will change if condensation is allowed to enter.
Closed bearings
• For closed bearings, replace the DE and NDE bearings after a storage time of 48 months.
NOTICE
Storage
The motor can be damaged if you use it or store it unprotected outdoors.
• Protect the motor against intensive solar radiation, rain, snow, ice and dust. Use a
superstructure or additional cover, for example.
• If required, contact the service center, or technically coordinate outdoors use.

Preparing for use
4.5.4 Securing the rotor

Depending on the version, the machine is fitted with a rotor shipping brace. This protects the
bearings against damage due to shock and vibration during transport or storage.
NOTICE
Motor damage due to vibrations
Not using the rotor shipping brace can cause damage to the machine if it is jolted during
transport or storage. Material damage can result.
• If the machine is fitted with a rotor shipping brace, this should always be used when
transporting the machine. The rotor shipping brace must be attached during the
transport.
• Protect the motor against strong radial shocks and vibration when storing, as the rotor
shipping brace cannot completely absorb these forces.
• Do not remove the rotor shipping brace until you are ready to push on the output
element.
• If the customer already has mounted parts, such as a coupling or belt pulley, the
bearings can be damaged during transport. In this case, make sure that the customer
uses a rotor shipping brace.
• For machines with a vertical type of construction:
– Do not remove the rotor shipping brace until the machine is in a vertical position.
– If a machine has to be transported in a horizontal position, the rotor must be fixed in
position before the machine is turned onto its side. Vertical machines can be supplied
in the horizontal position from the manufacturing plant.

Preparing for use
Alternative rotor bracing

• If you transport the machine after the output element has been pulled on, then you must
axially fix the rotor in another way.
① Sleeve ② Shaft screw and washer

Figure 4-1 Axial fastening of the rotor
Thread in the shaft extension Tightening torque

M16 40 Nm
M20 80 Nm
M24 150 Nm
M30 230 Nm
Tightening torques for other rotor shipping brace types

• The thread in the shaft extension indicates the rotor weight. This indirectly specifies the
required preload force when axially fastening the rotor.
Thread in the shaft extension Preload

M16 13 kN
M20 20 kN
M24 30 kN
M30 40 kN
Axial preload force for other rotor shipping brace types
Storing the rotor locking device

Store the rotor locking device in a safe place. It must be remounted if the machine is removed
and shipped on further.

Preparing for use
4.5.5 Commissioning after storage
4.5.5.1 Insulation resistance and polarization index

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

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

• For machines with regreasing systems, briefly lubricate both bearings after commissioning
with the machine running as a precautionary measure.
• Grease type, grease quantity and relubrication intervals for the regreasing system are
stamped on the rating plate attached to the machine.
4.5.5.4 Releasing the rotor shipping brace before commissioning

If one is being used, release the rotor shipping brace before commissioning.

Preparing for use
4.6 Ensure adequate cooling
WARNING
Overheating and failure of the motor
Death, severe injury or material damage can occur if you do not carefully observe the
following points.
• Do not obstruct ventilation.
• Prevent the air expelled by neighboring equipment from being immediately sucked in
again.
• For vertical types of machine construction with the air intake from above, protect the air
intakes from the ingress of foreign bodies and water.
• If the shaft extension is facing upwards, liquid must be prevented from entering by
moving along the shaft.
WARNING
Damage caused by small parts falling in
Material damage and injury can occur if the fan is destroyed and therefore the motor
overheats.
• For types of construction with the shaft extension facing downwards, prevent small parts
from falling into the fan cover by providing suitable covers.
• Ensure that the cooling air flow is not reduced as a result of covers and that the
minimum air clearances are maintained.
For machines with external fans, install an interlock circuit that prevents the main machine
being switched on if the external fan is not operational.
Table 4- 1 Air guidance
Incorrect Correct

Preparing for use
Incorrect Correct
Minimum dimension "x" for the distance between neighboring modules and the air intake of the ma-
chine
Table 4- 2 Minimum dimension "x" for the distance between adjacent modules and the air intake of
the machine
Shaft height x
mm
63 ... 71 15
80 ... 100 20
112 25
132 30
160 40
180 ... 200 90
225 ... 250 100
280 ... 315 110
355 140

Preparing for use
4.7 Interlock circuit for anti-condensation heating
4.7 Interlock circuit for anti-condensation heating

If the anti-condensation heating is operated while the machine is running, this can increase
the temperatures inside the machine.
• Install an interlock circuit that switches off the anti-condensation heating once the main
machine is switched on.
• Only switch on the anti-condensation heating after the motor has been switched off.
Comply with the data stamped on the plate of the anti-condensation heating, if available.
4.8 Noise emission

Prevention of hearing damage
If the permissible sound pressure level is exceeded, hearing damage can occur when
operating three-phase motors at their rated power.
The permissible sound pressure level is 70 dB (A).
4.9 Voltage and frequency fluctuations during line operation

Unless otherwise stated on the rating plate, the permissible voltage/frequency fluctuation is
corresponds to Zone B in IEC / EN 60034-1. Permissible fluctuations that go beyond this are
indicated on the rating plate – or for some versions, on a supplementary plate.
Operate the machine in continuous operation in Zone A. Prolonged operation in Zone B is not
recommended:
• Exceeding the permissible tolerances for voltage and frequency can lead to an
impermissibly high temperature rise of the winding. This can result in long-term damage
to the winding.
• Limit exceptions of this sort with regard to the values that arise, how often, and for how
long they occur.
• Where possible and within a reasonable time take corrective actions such as reducing the
power. In this way you can avoid that the service life of the machine is reduced as a result
of thermal aging.

Preparing for use
4.10 Rotational speed limit values
4.10 Rotational speed limit values
Danger as a result of resonance within certain speed ranges

At over-critical speeds, machines encounter resonance within certain speed ranges. Such
vibrations can reach impermissibly high levels. This can result in death, serious injury or
material damage.
• The controller must ensure that those speed ranges are blocked when the converter is in
operation. Please note the data on the blocked speed ranges specified in the Electrical
Data.
• The blocked speed ranges must be run through rapidly.
Machine damage due to excessively high speeds

Excessive rotational speed can lead to serious damage to the machine. This can result in
• Avoid operation above the permissible speed by using the appropriate control function.
• Observe the speeds stamped on the rating plate and in the Electrical Data.
4.11 System-inherent frequencies

Excessively high vibration levels and system resonances can damage the machine set.
• Configure and match the system consisting of the foundation and machine set in such a
way that no system resonances can arise and result in the permissible vibration levels
being exceeded.
• The vibration values according to DIN ISO 10816-3 must not be exceeded.
Note
If the torque levels are very unequal (e.g. when a reciprocating compressor is being driven), a
non-sinusoidal machine current will be induced whose harmonics can have an impermissible
effect on the supply system and cause impermissible interference emissions as a result.

Preparing for use
4.13 Converter operation
Note
Converter
• If operated with a frequency converter, the emitted interference varies in strength,
depending on the design of the converter (type, interference suppression measures,
manufacturer).
• Avoid that the specified limit values stipulated for the drive system (consisting of the
motor and converter) are exceeded.
• You must observe the EMC information from the manufacturer of the converter.
• The most effective method of shielding is to conductively connect a shielded machine
supply cable to the metal terminal box of the machine (with a metal screw connection)
over a large surface area.
• On machines with integrated sensors (e.g. PTC thermistors), disturbance voltages caused
by the converter may occur on the sensor cable.
When used in accordance with their intended purpose, and operated on a line supply with
characteristics according to EN 50160, the enclosed machines comply with the requirements
of the EC Directive regarding electromagnetic compatibility.
Immunity to interference
The machines fulfill the requirements of interference immunity in conformity with EN /
IEC 61000-6-2. For machines with integrated sensors, e.g. PTC thermistors, the operating
company must ensure sufficient interference immunity by selecting a suitable sensor signal
cable (possibly with shielding, connected in the same way as the machine feeder cable) and a
suitable evaluation unit.
When operating the machines from a converter at speeds higher than the rated speed,
carefully comply with the mechanical speed limits (safe operating speed EN / IEC 60034-1).
4.13.1 Parameterizing the converter

• If the design of the motor requires connection to a particular converter type, the rating
plate will contain corresponding additional information.
• Correctly parameterize the converter. Parameterizing data can be taken from the machine
rating plates.
You can find parameter data here:
– In the operating instructions for the converter.
– In the SIZER engineering tool
– In the SINAMICS Configuration Manuals.
– For explosion-protected machines, also in the declaration of compliance with the order
2.1.

Preparing for use
• Do not exceed the specified maximum speed limit nmax. You can either find this on the
rating plate nmax or on the supplementary plate for converter operation as the highest
speed.
• Check that the machine is cooled sufficiently for commissioning purposes.
4.13.2 Converter input voltage

The insulation system of SIMOTICS machines always complies with the requirements of stress
category C (IVIC C = high stress). If voltage peaks higher than those specified according to
IVIC C can occur, contact the Service Center.
• For a line supply voltage (converter input voltage) up to max. 480 V, and when controlled
from a SINAMICS G/SINAMICS S converter with uncontrolled/controlled infeed: Comply
with the guidelines for configuring motor and converter.
• For line voltages (converter input voltages) higher than 480 V, motors, which are ordered
for converter operation, have an appropriate insulation system.
• Operation with a converter from another manufacturer: Comply with the permissible
voltage peaks according to IEC 60034-18-41 in accordance with stress category C,
dependent on the particular line voltage (converter input voltage) and the motor
insulation system.
NOTICE
Material damage caused by an excessively high supply voltage
The insulation system will be damaged if the supply voltage is too high for the insulation
system. This can completely destroy the machine.
• Comply with the peak voltages as laid down in the guidelines above.
4.13.3 Reducing bearing currents during operation with converter (low voltage)
Taking the following actions will reduce the bearing currents:
• Ensure that the contacts are made over a large area. Solid copper cables are not suitable
for high-frequency grounding because of the skin effect.
• Install the equipotential bonding conductor in parallel with the motor cable, as close as
possible and avoid creating any loops.
Equipotential bonding conductors:

Use equipotential bonding conductors:
• between motor and driven machine
• between motor and converter
• between the terminal box and the RF grounding point at the motor enclosure.

Preparing for use
Selecting and connecting the cable:

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

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

Preparing for use
4.13.4 Insulated bearings for converter operation

If the machine is controlled from a low-voltage converter, depending on the machine type,
an insulated bearing can be fitted at the NDE.
An insulated speed encoder can be optionally mounted.
Comply with the information provided on the machine plates relating to bearing insulation
and possible jumpers.
① Driven machine ④ Insulated bearings

② Motor ⑤ Insulated tachometer fitting
③ Coupling
Figure 4-2 Schematic representation of a single drive
NOTICE
Bearing damage
The bearing insulation must not be bridged. Bearing currents can damage bearings.
• Do not bridge the bearing insulation for subsequent installation work, such as the
installation of an automatic lubrication system or a non-insulated vibration sensor.
• Where necessary, contact the Service Center.
If you connect 2 motors in series in "tandem operation", install an insulated coupling between
the motors.
① Driven machine ④ Insulated bearings

② Motor ⑤ Insulated tachometer fitting
③ Coupling ⑥ Insulated coupling
Figure 4-3 Schematic representation of a tandem drive

Preparing for use
NOTICE
Bearing damage
Bearing currents can flow if the coupling between the motors of the tandem drive is not
insulated. This can damage the DE bearings of both motors.
• Use an insulated coupling to couple the motors.
4.13.5 Tandem operation

If you connect two motors in series in "tandem operation", locate a coupling between the
motors; this coupling should satisfy the Directive 2014/34/EU or the regulations that apply in
the country where the equipment is installed.
4.13.6 Speed limits for converter operation

Observe the information on the rating plate regarding the speed limits for converter
operation.

Assembly 5
5.1 Safety instructions for installation
Injury and material damage caused by inappropriate fastening material

If screws of an incorrect property class have been selected or if they have been fastened to an
incorrect tightening torque, they may break or become loose. This will cause the machine to
move, which could damage the bearings. The rotor could smash into the machine enclosure
and machine parts could be flung out of place. This can result in death, serious injury or
material damage.
• Comply with the required property classes for screwed connections.
• Tighten the screwed connections to the specified tightening torques.
Injury and material damage caused by incorrect machine alignment

If the machine has not been properly aligned, this will mean the fastening parts are subjected
to stress/distortion. Screws may become loose or break, the machine will move, machine
parts could be flung out of place. This can result in death, serious injury or material damage.
• Carefully align the machine to the driven machine.
Material damage caused by improper handling

Mounting parts such as temperature sensors or speed sensors are attached to the machine
and could be ripped off or destroyed as a result of improper handling. This could lead to
machine malfunctions, extending even to total loss of the machine.
• Where necessary, use suitable steps when performing installation work on the machine.
• Do not stand on cables or attachments during installation. Do not use attachments as
steps.

Assembly
5.2 Preparing for installation
Loss of conformity with European directives

In the delivery state, the machine corresponds to the requirements of the European
directives. Unauthorized changes or modifications to the machine lead to the loss of
conformity with European Directives and the loss of the associated warranty.
5.2.1 Requirements for installation

The following requirements must be satisfied prior to starting installation work:
• Staff have access to the operating and installation instructions.
• The machine is unpacked and ready for mounting at the installation location.
• Measure the insulation resistance of the winding before starting any installation work. If
the insulation resistance lies below the specified value, take appropriate remedial
measures. These remedial measures may necessitate the machine being removed again
and transported.
Note
Note also the technical data on the rating plates on the motor enclosure.
NOTICE
Damage to the motor
To avoid material damage, before commissioning, check whether the correct direction of
rotation of the machine has been set on the customer side, e.g. by decoupling from the
driven load.
Damage to mounted parts and components as a result of high temperatures

The motor components get very hot during operation. High temperatures can damage parts
mounted by customers, such as cables manufactured out of materials that are not heat
resistant.
• Temperature-sensitive parts must not come into contact with or be attached to
components mounted on the machine.
• Only use heat-resistant mounting parts. The connecting cables and cable entries must be
suitable for the particular application.

Assembly
5.2.2 Insulation resistance
5.2.2.1 Insulation resistance and polarization index

"Testing the insulation resistance and polarization index" (Page 47)
5.2.2.2 Checking the insulation resistance and polarization index of the winding
WARNING
Hazardous voltage at the terminals
Hazardous voltages are sometimes present at the terminals during and immediately after
measurement of the insulation resistance or polarization index of the winding. Contact with
these can result in death, serious injury or material damage.
• If power cables are connected, ensure that a line voltage cannot be applied.
• Discharge the winding after measurement until the risk is eliminated, e.g. using the
following measures:
– Ground the terminals until the recharge voltage drops to a non-hazardous level.
– Attach the connection cable.

Assembly
Measure the insulation resistance

1. Follow the instructions in the Operating Manual of the insulation measuring instrument
used.
2. Ground other windings, integrated winding temperature sensors and, if applicable, other
mounted and installed components.
3. If power cables are connected, ensure that a line voltage cannot be applied.
If no power cables are connected, this reduces the effect of the I/O devices on the
measurement.
4. Measure the winding temperature and the insulation resistance of the winding in relation to
the machine enclosure. The winding temperature should not exceed 40 °C during the
measurement.
5. Convert the measured insulation resistances in accordance with the formula to the
reference temperature of 40 °C. This thereby ensures that the minimum values specified can
be compared.
6. Read out the insulation resistance one minute after applying the measuring voltage.
7. Discharge the winding after measurement, e.g. by doing the following:
– Connect the terminals to the ground potential until the recharge voltage drops to a
non-hazardous level
– Attach the connection cable.
Limit values for the winding insulation resistance

The following table specifies the measuring voltage and limit values for the insulation
resistance. These values correspond to the recommendations of IEC 60034-27-4 and
IEEE 43-2000.
Table 5- 1 Insulation resistance of the winding at 40 °C
UN Umeas RC
V V MΩ
U ≤ 1000 500 ≥5
1000 ≤ U ≤ 2500 500 (max. 1000) 100
2500 12000 5000 (max. 10000)
Urated = rated voltage, see the rating plate

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

Assembly
Conversion to the reference temperature

When measuring at winding temperatures other than 40 °C, convert the measured value to
the reference temperature of 40 °C according to the following equations from IEC 60034-27-
4 and IEEE 43-2000.
RC Insulation resistance converted to 40° C reference temperature

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

used as the basis.
• The insulation resistance halves every time the temperature rises by 10 K.
• The resistance doubles every time the temperature falls by 10 K.
For a winding temperature of approx. 25° C, the minimum insulation resistances are 20 MΩ
(U ≤ 1000 V) or 300 MΩ (U > 1000 V). The values apply for the complete winding to ground.
Twice the minimum values apply to the measurement of individual assemblies.
• Dry, new windings have an insulation resistance of between 100 ... 2000 MΩ, or possibly
even higher values. An insulation resistance value close to the minimum value could be
due to moisture and/or dirt accumulation. The size of the winding, the rated voltage and
other characteristics affect the insulation resistance and may need to be taken into
account when determining measures.
• Over its operating lifetime, the motor winding insulation resistance can drop due to
ambient and operational influences. Calculate the critical insulation resistance value
depending on the rated voltage by multiplying the rated voltage (kV) by the specific
critical resistance value. Convert the value for the current winding temperature at the time
of measurement, see above table.
Measuring the polarization index

1. To determine the polarization index, measure the insulation resistances after one minute
and ten minutes.
2. Express the measured values as a ratio:
Polarization index = Rinsul 10 min / Rinsul 1 min
Many measuring devices display these values automatically following the measurement.
Measuring the polarization index is not helpful for insulation resistances > 5000 MΩ, and is
therefore not included in the assessment.
R(10 min) / R(1 min) Assessment

≥2 Insulation in good condition
<2 Dependent on the complete diagnosis of the insulation

Assembly
5.3 Installing the machine
NOTICE
Damage to insulation
If the critical insulation resistance is reached or undershot, this can damage the insulation
and cause voltage flashovers.
• Contact the service center.
• If the measured value is close to the critical value, you must subsequently check the
insulation resistance at shorter intervals.
Limit values of the anti-condensation heating insulation resistance

It is not permissible that the insulation resistance of the anti-condensation heating with
respect to the machine enclosure falls below 1 MΩ when measured at 500 V DC.
5.3.1 Preparing the assembly area

1. Prepare a suitable assembly area (e.g. assembly stands). Make sure that the assembly area
has sufficient clearance from the floor for the DE shaft end. The necessary data is provided
in the machine dimension drawing.
2. Refer to the shipping documents to check that all motor components are available for
assembly.
5.3.2 Lift the machine to where it will be mounted and position it

• For vertical installation, use all the eyebolts provided and when necessary, hoisting straps
according to DIN EN 1492-1 and/or lashing straps according to DIN EN 12195-2 to stabilize
the position.
• Prevent foreign bodies from falling into the fan cover. For vertical machine installation
with the shaft end facing downwards, attach a protective canopy.
• If the shaft extension is facing upwards, the user must prevent liquid from moving along
the shaft and entering the motor.
• Clean bare metal surfaces with anti-corrosion agent using white spirit to ensure proper
installation and / or machine mounting.
• Do not obstruct the ventilation. Do not draw in the hot discharged air directly – also from
adjacent equipment.

Assembly
• Avoid exposing them to direct, intense solar radiation, rain, snow, ice, or also dust for
extended periods. Attach a covering structure or an additional cover when using or storing
outdoors.
• Do not exceed the permissible axial and radial forces.
5.3.3 Machines with type of construction IM B15, IM B9, IM V8 and IM V9
Types of construction without bearings on the drive side

These machines do not have their own bearing system for the machine shaft at the drive end
(DE). The machine shaft is accepted by the (hollow) shaft or coupling of the system or driven
machine.
• Using the centering edge, the machine is aligned with respect to enclosures, flanges or
driven machines.
• Note that the temperature of the motor and motor shaft increases during operation. The
thermal expansion of the machine shaft must be compensated by the customer by
applying suitable measures.
Use the spring washers provided to locate the NDE bearing without any play.
NOTICE
Damage to the motor
Material damage can occur if the following notes are not carefully observed:
• The IM B3 bearing shield with integrated distance ring mounted at the drive end (DE) is
only used transport lock. A warning label is attached to this bearing shield.
• The spacer ring is not a roller bearing.
• Remove the bearing shield and the spacer ring.
• Remove the transport lock before commissioning.
5.3.4 Foot mounting
Note
Only authorized retrofit partners must be employed to relocate the bolted on mounting feet
at the machine enclosure.
After attaching the mounting feet, you must note the following in order to avoid stressing
and deforming the machine.
• Ensure that the foot mounting surfaces are aligned in one plane and are parallel to the
machine shaft.
• Post-machine the foot mounting surfaces or use thin shims, for example.

Assembly
5.4 Aligning and fixing the machine
• Professionally touch up damaged painted surfaces.

• Observe the information provided in Chapter Aligning and mounting (Page 52)
5.4 Aligning and fixing the machine

Observe the following when aligning and mounting:
• Ensure a flat and uniform contact surface for foot and flange mounting.
• When mounting on the wall, support the machine from below, e.g. using a bracket, or
bolt it.
• Precisely align the machine when couplings are used.
• Ensure that the mounting surfaces are clean and free of any dirt.
• Remove any anti-corrosion protection using white spirit.
• Avoid installation-related resonances with the rotating frequency and twice the line
frequency.
• Note any unusual noise when the rotor is manually turned.
• Check the direction of rotation with the motor uncoupled.
• Avoid rigid couplings.
• Repair any damage to the paint, this must be done immediately and correctly.
5.4.1 Measures for alignment and mounting

The following measures are required in order to compensate any radial offset at the coupling
and to horizontally adjust the electrical machine with respect to the driven load:
• Vertical positioning
For vertical mounting positions, avoid deforming the machines by placing shims under the
mounting feet. Keep the number of shims low; only use a few stacked shims.
• Horizontal positioning
To position the machine horizontally, shift it sideways on the foundation and ensure that
the axial position is maintained (angularity error).
• When positioning the motor, ensure that a uniform axial gap is maintained around the
coupling.
• Smooth running
Preconditions for smooth, vibration-free operation:
– Stable foundation design free of any shock or vibration.
– A precisely aligned coupling.
– A well-balanced drive output element (coupling, belt pulleys, fans, ...)
Maintain the maximum permissible vibration values in operation according to ISO 10816-
3.

Assembly
Avoid inadmissible vibration caused by imbalance, for example (drive output element),
external vibration or any resonance over the complete speed range.
It may be necessary to completely balance the machine with the drive output element or
the system resonance frequency must be shifted.
• Foot mounting/flange mounting
– Use the specified thread size laid down in EN 50347 when flanging the machine to a
foundation or a machine flange.
– Mount the machine at all the foot or flanged holes provided. The choice of fixing
elements depends on the foundation and is the plant operator's responsibility. Comply
with the required property classes for screwed connections and materials for fixing
elements.
– Select the correct screw length for IM B14 flanges.
– Ensure that the screw heads are in full contact with the flange surface. Use additional
flat washers (ISO 7093), especially for elongated foot mounting holes.
5.4.2 Flatness of the supporting surfaces for conventional motors
Shaft height Flatness

[mm]
≤ 132 0.10
160 0.15
≥ 180 0.20
5.4.3 Machine frame mounting feet (special design)

Please note that when the terminal box is mounted at the NDE (option H08), dimension C can
deviate from EN 50347.
To comply with dimension C according to EN 50347, for machines with double or triple holes
at the NDE, use the appropriate screw bore.
5.5.1 Preconditions for smooth, vibration-free operation

Preconditions for smooth, vibration-free operation:
• Stable foundation design
• Precise alignment of the machine

Assembly
• Correct balancing of parts to be fitted to the shaft end.

• Vibration values in compliance with ISO 10816-3
5.5.2 Aligning the machine to the driven machine and mounting
5.5.2.1 Selecting bolts

• Unless specified otherwise, use fixing screws with at least strength class 8.8 to ISO 898-1
to ensure that the machine is securely mounted and to transmit the torque-generated
forces.
• When selecting the bolts and the design of the foundation, take into account the
maximum forces occurring in the case of a fault such as short circuit or system transfers in
phase opposition, etc.
Request the foundation force values from the Service Center if required.
See also
Tightening torques for screw and bolt connections (Page 131)
5.5.2.2 Horizontal types of construction with mounting feet

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

Assembly
5.5.2.3 Horizontal types of construction with flange

The standard flange is provided with a centering. The choice of fit for the mating flange on
the driven machine is the system manufacturer's or the plant operator's responsibility.
If the machine is not fitted with a standard flange, align the machine to suit the driven
machine.
Procedure
The machine axis must be horizontal when it is lifted and the flange must be parallel to the
mating flange, so as to avoid seizing and stressing. Otherwise damage to the centering will
result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw three studs into tapped holes spaced about 120° apart around the driven machine
flange. The studs act as positioning aids.
3. Position the machine so that its axis is aligned with that of the driven machine, but not yet
quite touching. Advance the machine slowly towards the driven machine; advancing too
quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Move the machine fully up against the mating flange so that it is fully in contact.
6. Fix the machine using the flange fixing bolts, finishing by replacing the studs.
5.5.2.4 Vertical types of construction with flange

The standard flange is provided with a centering. The choice of fit for the mating flange on
the driven machine is the system manufacturer's or the plant operator's responsibility.
If the machine is not fitted with a standard flange, align the machine to suit the driven
machine.
Procedure
The machine axis must be vertical when it is lifted and the flange must be parallel to the
mating flange, so as to avoid seizing and stressing. Otherwise damage to the centering will
result.
1. Grease the centering flange with assembly paste to make the process easier.
2. Screw in two studs into tapped holes on opposite sides of the driven machine flange. The
studs act as positioning aids.
3. Lower the machine slowly toward the driven machine and into the centering, so that the
flanges do not quite touch. Lowering too quickly risks damaging the centering.
4. If necessary, rotate the machine into the right position so that the clearance holes in the
flange are central to the tapped holes.
5. Lower the machine completely onto the mating flange so that it is fully in contact; then
remove the studs.
6. Fix the machine using the flange fixing bolts.

Assembly
5.5.3 Removing the rotor shipping brace

If a rotor shipping brace is attached to the machine, remove it at the last possible moment,
for example, when you are ready to push on the output or drive element.
Storing the rotor locking device

Store the rotor locking device in a safe place. It must be remounted if the machine is removed
and shipped on further.
5.5.4 Recommended alignment accuracy

The alignment accuracy required depends essentially on the configuration of the overall
machine train. Observe the required alignment accuracy of the coupling manufacturer in all
cases when aligning the machine.
Table 5- 2 Recommended alignment accuracy
Speed Parallel offset Angular offset

rpm mm mm per 100 mm coupling diameter
750 0.09 0.09
1500 0.06 0.05
3000 0.03 0.025
5.5.5 Mounting the drive output elements

The rotor is dynamically balanced. For shaft extensions with feather keys, the type of
balancing is specified using the following coding on the face of the drive end of the shaft
extension and on the rating plate:
• "H" means balancing with a half feather key (standard)
• "F" means balancing with a whole feather key
• "N" means balancing without a featherkey.
Figure 5-1 DE balancing type

Assembly
WARNING
Risk of injury due to Incorrect installation or removal
The feather key may be flung out if the motor is operated without drive output elements,
such as coupling, etc. Carefully comply with the required measures.
This can result in death, serious injury or material damage.
• The general touch protection measures for drive output elements must be observed.
• Only operate the machine with the drive output element mounted.
• Drive output elements may only be pulled on or pulled off with the correct equipment.
• The feather keys are only locked against falling out during shipping. For test operation or
when commissioning without drive output element, carefully secure the feather key
using a suitable locking element. When doing this, take into account the type of machine
balancing.
Pulling on drive output elements

• Requirements:
– The coupling and/or the drive output element must be appropriately dimensioned for
the operating case at hand.
– Observe the coupling manufacturer's instructions.
– Make sure that the balancing type of the drive output element correctly matches the
type of balance of the rotor.
– Use only ready drilled and balanced drive output elements. Check the hole diameters
and the balancing status before pulling them on. Thoroughly clean the shaft extension.
• Pulling on:
– Heat up the drive output elements to expand them before pulling them on. Select the
temperature difference for the heating process to suit the coupling diameter, fit and
material. Observe the coupling manufacturer's instructions.
– Drive output elements may only be pulled on or pulled off with the correct equipment.
The drive output element must be pulled on in one continuous operation via the front
thread holes in the shaft or pushed on by hand.
– Do not use a hammer, as this will damage the bearings.

Assembly
Withdrawing drive output elements
Mounting drive output elements

Only transfer radial or axial forces specified in the catalog to the motor bearings via the shaft
extension.
You can obtain the permissible values for axial and radial forces by contacting the Service
Center (Page 129) or by referring to the machine catalog.
Shaft extensions with feather key

The feather key data for the shaft and drive output element must match and indicate the
correct type of balancing. The drive output element must be correctly mounted.
The balance quality corresponds to vibration severity grade "A" for the complete machine;
vibration severity grade "B" is possible as an option. To ensure the required balance quality, it
must be ensured that the feather key data on the hub and machine shaft match in the case of
a shorter or longer drive output element.
• If the drive output element is shorter than the feather key with balancing type "H", then
you must machine off the section of feather key protruding from the shaft contour and
drive output element in order to maintain the balance quality.
• If the drive output element is longer than the feather key, when balancing the coupling,
take into account that the feather key does not take up all of the coupling slot.

Assembly
The following applies to all four-pole machines with a frequency ≥ 60 Hz:

• The feather key must be shortened if the coupling hub is shorter than the feather key.
• The center of gravity of the coupling half should be within the length of the shaft end.
• The coupling used must be prepared for system balancing.
Align the offset at the coupling between electrical machines and the driven machines so that
the maximum permissible vibration values according to ISO 10816-3 are not exceeded.

Assembly

Electrical connection 6
6.1 Safety instructions for the electrical connection
Hazardous voltages on electrical connections

Dangerous voltages can arise on electric motors. Death, injury or material damage can occur.
Observe the following safety information before connecting up the motor:
• Only qualified personnel should carry out work.
• Carefully follow the 5 safety rules (Page 11).
• Disconnect the machine from the power supply and take measures to prevent it being
reconnected. This also applies to auxiliary circuits.
• Check that the machine really is in a no-voltage condition.
• Ensure that there is a safe and reliable protective conductor connection before starting
any work.
• If the incoming power supply system displays any deviations from the rated values in
terms of voltage, frequency, curve form or symmetry, such deviations will increase the
temperature and influence electromagnetic compatibility.
• Operating the machine on a line supply system with a non-grounded neutral point is only
permitted over short time intervals that occur rarely, e.g. the time leading to a fault being
eliminated (ground fault of a cable, IEC/EN 60034-1).
Material damage as a result of connection parts coming loose

If you use fixing elements made from the wrong material or apply the wrong tightening
torque, this could impair current transfer or cause connecting parts to become loose. This
could result in material damage to the machine or even in total failure, which could in turn
lead indirectly to material damage to the system.
• Tighten the screwed connections to the specified tightening torques.
• Observe any specifications regarding the materials from which fixing elements must be
made.
• When performing servicing, check the fastenings.

Electrical connection
6.2 Connecting the machine
See also
Tightening torques (Page 131)
Note
Service Center
If you require support when electrically connecting up the machine, please contact the
Service Center (Page 129).

Take the following criteria into account when selecting the connecting cables:
• Rated current
• Rated voltage
• If required, service factor
• System-dependent conditions, such as ambient temperature, routing type, cable cross-
section as defined by required length of cable, etc.
• Configuration notes
• Requirements according to IEC/EN 60204-1
• Dimensioning for bundled cable routing, e.g. according to DIN VDE 0298 Part 4 or
IEC 60364-5-52
• Carefully comply with the information provided in EN / IEC 60034-1 (VDE 0530-1)
regarding operation at the limits of A and B zones, especially in respect of temperature
increase and deviation of the operating data from the rated data stamped on the rating
plate. Do not exceed these limits. Do not use machines in zone B that are marked for zone
A.
• Connect up so that a permanently safe electrical connection is guaranteed (no protruding
wire ends); use the assigned cable-end fittings (e.g. cable lugs, end sleeves).
Connect up the line supply voltage and arranged the disconnecting link in accordance
with the circuit diagram provided in the terminal box.
• Select the connecting cables in accordance with DIN VDE 0100 taking into account the
rated current and the installation-specific conditions – e.g. ambient temperature, routing
method etc. - according to DIN VDE 0298 and/or EN / IEC 60204-1.
The technical specifications stipulate the following that have to be taken into account with
respect to the motor connection:
• Direction of rotation
• The number and arrangement of the terminal boxes.
• The circuit and connection of the motor winding

6.2.1 Terminal box
DANGER
Hazardous voltage
Electric motors have high voltages. When incorrectly handled, this can result in death or
severe injury.
Switch off the machine so that it is in a no-voltage condition before you open the terminal
box.
NOTICE
Damage to the terminal box
If you incorrectly carry out work on or in the terminal box, this can result in material
damage. You must observe the following to avoid damaging the terminal box:
• Ensure that the components inside the terminal box are not damaged.
• It must be ensured that there are no foreign bodies, dirt or moisture in the terminal box.
• Close the terminal box using the original seal so that it is dust tight and water tight.
• Use O-rings or suitable flat gaskets to seal entries in the terminal box (DIN 42925) and
other open entries.
• Please observe the tightening torques for cable entries and other screws.
See also
6.2.1.1 Circuit diagram inside the terminal box cover

Data on the connection and connecting the machine winding can be found in the circuit
diagram in the cover of the terminal box.

6.2.1.2 Direction of rotation

The standard motors are suitable for clockwise and counter-clockwise rotation.
For defined directions of rotation (direction of rotation arrow), appropriately connect the line
power cables.
• If you connect the line cables with phase sequence L1, L2, L3 at U, V, W or according to
NEMA at T1 T2 T3 , then the machine rotates in the clockwise direction.
• If you interchange 2 connections, e.g. L1, L2, L3 at V, U, W or according to NEMA at
T2 T1 T3, then the machine rotates counterclockwise.
Direction of According to IEC According to NEMA
rotation
Line feeder cables - L1 L2 L3 L1 L2 L3
Terminal connec- Clockwise U V W T1 T2 T3
tion rotation
Terminal connec- Counter- V U W T2 T1 T3
tion clockwise
rotation
Direction of rotation of the motor when viewing the DE
6.2.1.3 Terminal marking

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

Screw the screw-type connection into the housing or fasten with a nut.
Note
The screw-type connections must have been matched to the connecting cables used
(diameter armoring, braid, shield).
For the screw-type connections, comply or exceed the requirements relating to IP degree of
protection (water and dust) - as well as the temperature range in operation stamped on the
rating plate.

6.2.1.5 Versions
The terminal box can be turned 4x90 degrees on the terminal base of the machine's housing.
6.2.1.6 Protruding connection cables
WARNING
Risk of short-circuit and voltage hazard
A short circuit can occur if connecting cables are clamped and crushed between parts of the
enclosure and the cover plate.
This can result in death, severe injury and material damage.
• During disassembly and particularly when installing the cover plate, make sure that the
connecting cables are not clamped between enclosure parts and the cover plate.
CAUTION
Damage to connecting cables that are freely led out
You must observe the following note to avoid damaging connecting cables that are freely
led out:
• It must be ensured that there are no foreign bodies, dirt, or moisture in the terminal base
of the machine enclosure.
• Use O-rings or suitable flat gaskets to seal entries in cover plates (DIN 42925) and other
open entries.
• Seal the terminal base of the machine enclosure using the original seal of the cover plate
to prevent dust and water from entering.
• Please observe the tightening torques for cable entries and other screws.
6.2.1.7 Connecting protruding cables

In the case of connection cables brought out of the machine, no terminal board is installed on
the terminal base of the machine housing. The connection cables are directly connected to
stator winding terminals at the factory.
The connection cables are color-coded or labeled. The customer directly connects individual
cables in the control cabinet for their system in accordance with the labeling.
6.2.1.8 Connection with/without cable lugs

In the case of terminals with terminal clamps, distribute the conductors in such a way that
the clamping heights on both sides of the fillet are about the same. This method of
connection requires that you must bend a single conductor in a U shape or use a cable lug.
The same applies to the inner and outer terminals of the ground conductor.
When connecting up using cable lugs, select their size corresponding to the required cable
cross-section and the stud size. An inclined arrangement is only permitted provided the
required air clearances and creepage distances are carefully maintained.

Remove insulation from the ends of the conductors so that the remaining insulation almost
reaches the cable lug.
Note
The direct contact between the cable lug surfaces and the contact nuts or contact screws
ensure that the connection can conduct current.
6.2.1.9 Minimum air clearances

After proper installation, verify that the minimum air clearances between non-insulated parts
are maintained. Be aware of any protruding wire ends.
Table 6- 2 Minimum air clearance dependent on rms value of the alternating voltage Urms
Rms value of the alternating voltage Urms Minimum air clearance

mm
≤ 250 V 3.0
≤ 500 V 3.0
≤ 630 V 5.5
≤ 1000 V 8.0
Values apply at an installation altitude of up to 2000 m.
When determining the required minimum air clearance, the voltage value in the table may be in-
creased by a factor of 1.1, so that the rated input voltage range is taken into account during gen-
eral use.
6.2.2 Cable glands
Cable glands with (sheet metal) nuts (EN 50262)
① Nut
② O ring

Cable glands with reductions and (sheet metal) nuts (EN 50262)
① Nut
② O ring
6.2.2.1 Mounting position of sheet metal nuts in screw-type connections
② O ring
③ Mounting position of metal-sheet
nuts
Cable glands with connecting thread in the terminal box (EN 50262)
② O ring


Note the information in Chapter Tightening torques (Page 131).
6.3.1 Cable entries, sealing plugs and thread adapters

Note the following when mounting:
• Avoid damaging the cable jacket.
• Adapt the tightening torques to the cable jacket materials.
Observe the documentation for tightening torques of the cable entries and sealing plugs for
direct mounting at the machine as well as additional glands (e.g. adapters).
6.4 Connecting the grounding conductor

The machine's grounding conductor cross-section must comply with EN / IEC 60034-1.
Please also observe installation regulations such as those specified in EN / IEC 60204-1.
Basically, there are two ways of connecting a grounding conductor to the machine.
• Internal grounding with a connection in terminal box at the location intended for this
purpose and marked accordingly.
• External grounding with connection at the stator housing at the locations intended for
this purpose and marked accordingly.
6.4.1 Minimum surface area of grounding conductor
Table 6- 3 Minimum cross-sectional area of grounding conductor
Minimum cross-section of the phase conductor Minimum cross-section of the associated

for installation grounding connection
S
[mm²]
[mm²]
S ≤ 25 S
25 < S ≤ 50 25
S > 50 0.5 S

6.4 Connecting the grounding conductor
6.4.2 Grounding connection type
Type of enclosure grounding Conductor cross-

section
mm²
Connection of an individual conductor under … 10

the external grounding bracket.
… 25
Connection is made using a DIN cable lug under
the external grounding bracket. DIN 46 234
Internal ground terminal

When making connections, ensure the following:
• Ensure that the connecting surface is bare and is protected against corrosion using a
suitable substance, e.g. acid-free Vaseline.
• Arrange the flat washer and spring washer under the bolt head.
• Locate the cable lug under the clamping bracket.
• Use the terminals designated for the grounding conductor in the terminal box.
• Observe the tightening torque for the locking screw.
External ground terminal

When making connections, ensure the following:
• Ensure that the connecting surface is bare and is protected against corrosion using a
suitable substance, e.g. acid-free Vaseline.
• Position the cable lug between the contact bracket and the grounding bracket; do not
remove the contact bracket pressed into the enclosure!
• Arrange the flat washer and spring washer under the bolt head.
• Use the marked connection location for the grounding conductor on the stator housing.
• Observe the tightening torque for the locking screw.

6.5 Connecting a temperature sensor / anti-condensation heater
6.5 Connecting a temperature sensor / anti-condensation heater
WARNING
Hazard due to electric shock
The installation of the temperature sensors for the winding monitoring with respect to the
winding is implemented according to the requirements for basic insulation. The
temperature sensor connections are located in terminal boxes, safe to touch, and have no
protective separation. This is the reason that in the case of a fault, a hazardous voltage can
be present at the measuring sensor cable. When touched, this can result in death, severe
bodily injury and material damage.
• When connecting the temperature sensor to external temperature monitoring devices,
when required, apply additional measures to fully comply with the requirements set out
in IEC 60664-1 or IEC 61800-5-1 "Hazard due to electric shock".
6.5.1 Connecting optional integrated devices and equipment

In addition to the current-dependent overload protective device located in the connecting
cables, use the optionally available integrated devices and equipment, for example,
temperature sensors, anti-condensation heating.
Depending on the terminal box version, connect the auxiliary circuits to the terminal box.
Terminal block connection

6.6 Conductor connection
6.6 Conductor connection

Cross-sections that can be connected depending on the size of the terminal (possibly reduced
due to size of cable entries)
Table 6- 4 Max. conductor connection
Shaft height Max. connectable conductor cross-section

[mm²]
63 ... 90 1.5
2.5 with cable lug
100 ... 112 4.0
132 6.0
160 ... 180 16.0
200 25.0
225 35.0 with cable lug
250 ... 280 120.0
315 240.0
6.6.1 Type of conductor connection
Terminal board Conductor

cross-
section
[mm²]
Connection with cable lug
DIN 46 234
Bend down the cable lug for the
connection. ... 25
Connection of an individual con-

ductor with terminal clamp
... 10
Connection of two conductors of

approximately the same thickness
with terminal clamp
... 25
① Connecting bar
② Line supply cable
③ Motor connecting cable
④ Cover plate

6.7 Connecting converters
6.6.2 Connecting aluminum conductors

If you are using aluminum conductors, then comply with the following:
• Use only cable lugs that are suitable for connecting aluminum conductors.
• Immediately before inserting the aluminum conductor, remove the oxide layer from the
contact areas on the conductor and/or the mating piece. Do this using a brush or file.
• Then grease the contact areas immediately using neutral Vaseline. This prevents a new
oxide layer from forming.
NOTICE
Aluminum flow due to contact pressure
Aluminum flows following installation due to the contact pressure. The connection using
clamping nuts can loosen as a result. The contact resistance increases, obstructing the
current from being conducted. This can result in fire and material damage to the
machine – or even in total failure, as well as material damage to the plant or system due
to machine failure.
• Retighten the clamping nuts after approximately 24 hours and then again after
approximately four weeks. Make sure that the terminals are de-energized before you
tighten the nuts.
6.7 Connecting converters
NOTICE
Material damage caused by an excessively high supply voltage
Material damage can occur if the supply voltage is too high for the insulation system.
• Observe the values in the following tables.
SIMOTICS machines can be operated with SINAMICS G converters and SINAMICS S converters
(uncontrolled and controlled infeed) when maintaining the permissible peak voltages.
The insulation system of SIMOTICS machines corresponds to the specifications laid down in
IEC 60034-18-41 according to voltage stress category C (IVIC C = high stress).
Table 6- 5 Maximum voltage peaks at the motor terminals for line (DOL) motors, converter operation possible
Rated motor voltage Maximum peak voltage at the motor terminals

V Ûphase-to-phase Ûphase-to-ground DC link UDC
Vpk Vpk V
≤ 500 V 1500 1100 750

6.8 Final checks
Table 6- 6 Maximum voltage peaks at the motor terminals for motors specifically designed for converter operation (e.g.
VSD 10)
Rated motor voltage Maximum peak voltage at the motor terminals

V Ûphase-to-phase Ûphase-to-ground DC link UDC
Vpk Vpk V
≤ 500 V 1600 1400 750
> 500 V to 690 V 2200 1500 1080
Depending on the step height, the voltage rise times for the individual voltage steps in the
line-to-ground voltage at the motor end of the cable must not fall below the following values.
Table 6- 7 Rise times as a function of voltage level
Step height Minimum rise time tr

V ns
900 100
1050 200
1260 400
See also
Further documents (Page 130)
6.8 Final checks

Before closing the terminal box/terminal base of the machine enclosure, check the following:
• Establish the electrical connections in the terminal box in accordance with the information
in this documentation.
• Maintain the air clearances between non-insulated parts as described in Chapter Minimum
air clearances. (Page 66)
• Avoid protruding wire ends.
• In order not to damage the cable insulation, freely arrange the connecting cables.
• Connect the machine corresponding to the specified direction of rotation.
• Keep the inside of the terminal box clean and free from trimmed-off ends of wire.
• Ensure that all seals and sealing surfaces are undamaged and clean.
• Correctly and professionally close unused openings in the terminal boxes. Observe the
information in this documentation.
• Observe the information on torques in this documentation.
See also

6.8 Final checks

Commissioning 7
Note
Service Center
Please contact the Service Center if you require commissioning support.
7.1 Measures before commissioning
7.1.1 Checks to be carried out prior to commissioning

The following list of checks to be performed prior to commissioning does not claim to be
complete. It may be necessary to perform further checks and tests in accordance with the
specific situation on-site.
Once the system has been correctly installed, you should check the following prior to
commissioning:
• The machine is undamaged.
• The machine has been properly installed and aligned.
• The output transmission elements are set correctly for their type,
e.g. alignment and balancing of couplings, belt forces in the case of a belt drive, tooth
forces and tooth-flank backlash in the case of geared output, radial and axial clearance in
the case of coupled shafts.
• All fixing screws, connection elements, and electrical connections have been tightened to
the specified tightening torques.
• The operating conditions match the data provided in accordance with the technical
documentation, such as degree of protection, ambient temperature, etc.
• Moving parts, for example the coupling, move freely.
• All touch protection measures for both moving and live parts have been implemented.
• Screwed-in lifting eyes are removed after installation or secured to prevent them from
becoming loose.

Commissioning
• Before commissioning, attach the covers to guarantee the correct air guidance.
• Ensure that all condensation drain holes are always located at the lowest part of the
machine.
Second shaft extension

If the second shaft extension is not used:
• Carefully secure the feather key to prevent it from being thrown out, and for balancing
type "H" (standard type), ensure its weight is reduced to approximately 60 % of the
original value.
• Using covers, carefully secure the unused shaft extension so that it cannot be touched.
Risk of losing the IP degree of protection as a result of damaged shaft sealing rings
This can result in death, serious injury, or material damage.
• Replace damaged components immediately.
7.1.2 Mechanical and electrical check

• Rotate the rotor to ensure that it does not touch the stator.
• Ensure that the bearing insulation is not bridged/jumpered.
• Using the appropriately designed and adjusted control and speed monitoring functions
ensure that the permissible speeds specified on the rating plate cannot be exceeded.
• Ensure that any supplementary equipment used to monitor the motor is correctly
connected and is functioning.
• Carefully check the grounding and potential bonding connections.
• Connect the machine corresponding to the specified direction of rotation.
• Using the appropriate open-loop control and speed monitoring functions, carefully ensure
that no higher speeds can be achieved than are permitted and specified in the technical
data. For this purpose, compare the data on the rating plate or, if necessary, the system-
specific documentation.
• Comply with the minimum insulation resistances.
• Comply with the minimum air clearances.
• Correctly connect possibly available machine monitoring devices and equipment - and
carefully ensure that they are functioning correctly.
• Check the correct functioning of the brakes or backstops.
• Set the values for "Alarm" and "Shutdown" at the monitoring devices.
• Carefully ensure that temperature-sensitive parts and components, e.g. cables are not in
contact with the machine enclosure.

Commissioning
7.1.3 Converter operation
Converter operation
• If the motor design requires connection to a specific converter type, carefully check the
supplementary data on the rating plate/supplementary plate.
• Ensure that the converter is correctly parameterized. Depending on the design, you will
find some parameterization data on the rating plate of the machine. Further information
is provided in the converter documentation. If necessary, contact the Service Center.
• Check that the supplementary equipment and devices to monitor the machine are
correctly connected and are functioning correctly.
• In continuous operation, carefully ensure that the motor cannot exceed the specified
upper speed limit nmax or fall below the lower speed limit nmin.
The permissible acceleration time to the limit speed nmin depends on the parameter
assignment.
7.1.4 Insulation resistance and polarization index

"Testing the insulation resistance and polarization index" (Page 47)
7.1.5 Testing the cooling of the machine
Cooling
• Check that the machine cooling is available for commissioning.

Commissioning
See also
Preparing for use (Page 27)
7.1.6 Commissioning an external fan

The external fan ensures that the machine is cooled irrespective of the machine speed or
direction of rotation. The external fan is only suitable for one direction of rotation.
Checks before the first test run

Before the first test run, carry out the following checks:
• The external fan is correctly fitted and aligned.
• The rotor runs freely.
• All of the retaining elements and electrical connections are securely tightened.
• The grounding and equipotential bonding connections to the mains have been correctly
made.
• The air flow is not impeded or shut off by flaps, covers or similar.
• If the cooling air is in open circulation, it has only weak, chemically abrasive properties
and a low dust content.
• All protection measures have been taken to prevent accidental contact with moving or live
parts.
Performing the test run

1. Switch the external fan motor on and off briefly.
2. Compare the direction of rotation of the external fan with the specified direction of rotation.
The direction of rotation of the external fan is indicated with an arrow on the fan cover
specifying the direction of rotation or with a terminal designation on the rating plate of the
external fan unit.
Depending on the version, the fan impeller is visible through the air inlet opening in the
fan cover on the external fan motor.
3. If the direction of rotation is wrong, then interchange two line cables in the external fan
motor terminal box.
Note
Use these operating instructions for motors with external fans.

Commissioning
7.2 Switching on
7.1.7 Further documents
Note
Further documents
7.1.8 Setpoint values for monitoring the bearing temperature
Prior to commissioning
If the machine is equipped with bearing thermometers, set the temperature value for
disconnection on the monitoring equipment before the first machine run.
Table 7- 1 Set values for monitoring the bearing temperatures before commissioning
Set value Temperature

Alarm 115 °C
Shutting down 120 °C
Normal operation
Determine the maximum operating temperature of the bearings Toperation taking into account
the temperature, bearing load and influences of the plant on the motor in °C. Set the values
for shutdown and warning corresponding to the operating temperature Top.
Table 7- 2 Set values for monitoring the bearing temperatures
Set value Temperature

Alarm Toperation + 5 K ≤ 115 °C
Shutting down Toperation + 10 K ≤ 120 °C
7.2 Switching on
Measures for start-up

After installation or inspections, the following measures are recommended for normal start-
up of the machines:
• Start the machine without a load. To do this, close the circuit breaker and do not switch
the machine off prematurely. Switching the machine off again while it is starting up and
still running at slow speed should be kept to a bare minimum, for example for checking

Commissioning
7.2 Switching on
the direction of rotation or for checking in general. Allow the machine to run to a
standstill before switching it back on again.
• Check mechanical operation for noise or vibration at the bearings or end shields.
• If the machine is not running smoothly or is emitting abnormal noises, switch it off, and
determine the cause of the fault as it runs down.
• If mechanical operation improves immediately after the machine is switched off, then the
cause is magnetic or electrical, e.g. voltage imbalance, magnetic imbalance. If mechanical
operation does not improve immediately after switching the machine off, then the cause
is mechanical, e.g. an imbalance in the electrical machines or in the driven machine,
inadequate alignment of the machine set, operation of the machine with the system
resonating (system = machine + base frame + foundations etc.).
• If the machine runs perfectly in terms of its mechanical operation, switch on any cooling
devices present and continue to monitor the machine for a while as it idles.
• If it runs perfectly, connect a load. Check that it runs smoothly.
Read off and document the values for voltage, current, and power.
Where possible, read off corresponding values for the driven machine and document
them as well.
• Monitor the bearing temperature, winding temperature, etc. until the system reaches a
steady state.
Document these, provided this is possible with existing measuring instruments.
NOTICE
Destruction of the machine
The machine can be destroyed if the vibration values are not strictly complied with.
• In operation, maintain vibration values in accordance with DIN ISO 10816-3.
7.2.1 Test run

After installation or inspection, carry out a test run:
1. Start up the machine without a load. To do this, close the circuit breaker and do not switch
off prematurely. Check whether it is running smoothly.
Switching the machine off again while it is starting up and still running at slow speed
should be kept to a bare minimum, for example for checking the direction of rotation or
for checking in general.
Allow the machine to run down before switching it on again.
2. If the machine is running smoothly and evenly, switch on the cooling equipment. Continue
to observe the machine for a while in no-load operation.

Commissioning
7.2 Switching on
3. If it runs perfectly, connect a load.
NOTICE
Thermal overload of motors connected directly to the line supply
In addition to the load torque, the ramp-up (accelerating) time is essentially influenced
by the moment of inertia to be accelerated. While ramping up when connected to the
line supply, the inrush (starting) current is a multiple of the rated current. This can result
in thermal overload. This can damage the motor.
As a consequence, when ramping up, observe the following:
• Monitor the ramp-up time and number of consecutive starts.
• Comply with the limit values and/or ramp-up conditions specified in the catalog or the
order documentation.
4. During the test run, check and document the following:

– Check whether it is running smoothly.
– Document the voltage, current and power values. As far as possible, document the
corresponding values of the driven machine.
– If this is possible using the available measuring equipment, check the bearing and
stator winding temperatures until they have reached steady-state values.
– Check the machine for noise or vibrations on the bearings or bearing shields as it runs.
5. In case of uneven running or abnormal noise, switch off the machine. As the machine runs
down, identify the cause.
– If the mechanical operation improves immediately after the machine is switched off,
then the cause is magnetic or electrical.
– If the mechanical running does not improve immediately after switching the machine
off, then the cause is mechanical.
- Imbalance of the electrical machine or the driven machine
- The machine set has not been adequately aligned
- The machine is being operated at the system resonance point. System = motor, base
frame, foundation, ...
NOTICE
Serious damage to the machine
If the vibration values in operation are not maintained in accordance with DIN ISO
10816-3, then the machine can be mechanically destroyed.
• During operation, observe the vibration values in accordance with
DIN ISO 10816-3.

Commissioning
7.2 Switching on

Operation 8
Hazardous voltages at the machine

Electrical machines have hazardous voltage levels. Contact with these can result in death,
serious injury or material damage.
Operating the machine on a line supply system with a non-grounded neutral point is only
permissible for short periods of time that occur rarely, e.g. the time leading to a fault being
eliminated. Cable ground fault EN / IEC 60034-1.

damage.
• Carefully ensure that all of the covers are closed while operational.
• First switch off and disconnect the machine if you must remove covers. Carefully comply
with the "5 safety rules".
• Only remove the covers when the rotating parts have come to a complete standstill.

Operation

guaranteed if covers are removed. The minimum air and creepage distances may be fallen
below (violated) when coming close to active parts. Touching or coming close can result in
• Carefully ensure that all of the covers are closed while operational.
• First switch off and disconnect the machine if you must remove covers. Carefully comply
with the "5 safety rules".
• When the machine is in operation, the terminal boxes must remain closed at all times.
Terminal boxes may be opened only when the machine is stopped and in a no-voltage
condition.
Faults in operation
Any changes with respect to the normal condition can indicate that the machine is not
functioning correctly.
• Higher power consumption, temperatures or vibration levels.
• Unusual noise or smells.
• Monitoring devices respond.
These changes can cause faults which can result in eventual or immediate death, serious
injury or material damage.
• Immediately inform the service personnel.
• If you are in doubt, immediately switch off the machine, carefully observing the system-
specific safety conditions.
Corrosion damage as a result of condensation

Humidity can condense inside the machine if the machine and/or ambient temperatures
fluctuate, for intermittent operation or load fluctuations.
Condensation can accumulate. Moisture can have a negative impact on the winding
insulation or result in damage, such as corrosion.
• Ensure that any condensation can freely flow away.
• If available, remove the screw plugs to drain the water depending on the ambient and
operating conditions.
• If available, reinsert the screw plugs.
If the motor is equipped with drain plugs, then the water can drain away by itself.

Operation
Risk of burn injuries as a result of hot surfaces

Individual machine parts can become hot in operation. Burns can result when coming into
contact with these parts.
• Never touch machine parts during operation.
• Allow the machine to cool down before starting work.
Hazardous substances
Chemical substances required for the setup, operation and maintenance of machines can
present a health risk. Poisoning, skin damage, cauterization of the respiratory tract, and other
health damage may result.
• Read the information in these operating instructions and the product information supplied
by the manufacturer.
• Observe the relevant safety regulations and wear the personal protective equipment
specified.
Substances that can be easily ignited and are flammable
Chemical substances required for the setup, operation and maintenance of machines may be
flammable. Burns and other damage to health and material may result.
• Read the information in these operating instructions and the product information supplied
by the manufacturer.
• Observe the relevant safety regulations and wear the personal protective equipment
specified.
Damage to the machine or premature bearing failure

The bearings can be damaged if the following is not observed.
• It is absolutely crucial that you maintain the permissible vibration values according to ISO
10816-3 to avoid damage to the machine or even its destruction.
• Under all circumstances maintain the minimum radial load of cylindrical rolling bearings of
50 % corresponding to what is specified in the catalog.
• Take the appropriate measures to reduce bearing currents. Comply with the information
in Chapter Converter operation.
Overheating as a result of the anti-condensation heating

If the anti-condensation heating is operated while the machine is operational, this can
increase the temperatures inside the machine and cause material damage.
• Install an interlock circuit that switches off the anti-condensation heating once the main
machine is switched on.
• Only switch on the anti-condensation heating after the motor has been switched off.
Comply with the data stamped on the plate of the anti-condensation heating, if available.

Operation
8.1.1 Safety instructions relating to ventilation and cooling
8.1.1.1 Safety instruction for forced ventilation (option)

Forced ventilation (optional): Type of cooling IC 416 in accordance with EN / IEC 60034-6
WARNING
Risk of burning
Operating the machine without external fan results in overheating. This may result in death,
personal injury and material damage.
• Never commission the machine without an external fan.
8.1.1.2 Safety instructions when operating machines with fan
CAUTION
Risk of injury when touching the fan
There is a risk of injury at machines equipped with a fan cover (e.g. on machines in the
textile industry), as the fan is not completely touch protected.
• Do not touch the rotating fan.
• Do not put your fingers into the larger air discharge openings.
• Prevent manual intervention by using suitable measures, e.g. appropriate housings or a
protective grating.
8.1.1.3 Machines with fan for the textile industry

In order to guarantee an essentially unobstructed flow of cooling air containing fluff, remains
of materials or similar dirt, machines used in the textile industry have a larger air discharge
cross-section between the edge of the cover and the cooling ribs of the machine frame.
These machines have a warning sticker on the fan cover.

Operation
8.2 Switching on the machine
8.2 Switching on the machine

1. If at all possible, run the machine without load and check that it is running smoothly.
2. If it runs perfectly, connect a load.
NOTICE
Thermal overload of motors connected directly to the line supply
In addition to the load torque, the ramp-up (accelerating) time is essentially influenced
by the moment of inertia to be accelerated. While ramping up when connected to the
line supply, the inrush (starting) current is a multiple of the rated current. This can result
in thermal overload. This can damage the motor.
As a consequence, when ramping up, observe the following:
• Monitor the ramp-up time and number of consecutive starts.
• Comply with the limit values and/or ramp-up conditions specified in the catalog or the
order documentation.
3. If this is possible using the available measuring equipment, check the bearing and stator
winding temperatures.
8.3 Deactivating
Commission any devices provided for protection against condensation after switching off the
machine.
Do not immediately switch off the separately-driven (external) fan after switching off the
machine. First wait for the machine to cool down. This will prevent the accumulation of
residual heat.
8.4 Switching on again after an emergency switching-off

• Check the machine before recommissioning the driven machine after an Emergency Off.
• Eliminate all the causes that have led to the emergency off
8.5 Stoppages
The stoppage is a shutdown for a period of time, during which the machine is stopped but
remains at the location of use.
Under normal ambient conditions, e.g. the stationary machine is not exposed to any
vibration, no increased level of corrosion, ... then the following measures are required.

Operation
8.5 Stoppages
Longer non-operational periods

• For longer non-operational periods (> 1 month), either operate the machine or at least
turn the rotor regularly, approximately once per month.
• If attached, remove the rotor shipping brace before you turn the rotor.
• Carefully comply with the information in Section "Switching on" before switching on to
recommission the motor.
NOTICE
Restricted motor function
If not used for longer periods of time, material damage or complete motor failure can occur.
If the motor is out of service for a period of more than 12 months, then environmental
effects can damage the motor.
• Apply suitable corrosion protection, preservation, packaging and drying measures.
Switching on the anti-condensation heating, if available

Only switch on the anti-condensation heating after the motor has been switched off. Comply
with the data stamped on the plate of the anti-condensation heating, if available.
Taking the machine out of service

Detailed information on how to take the machine out of service is provided in Chapter
Preparing for use (Page 27).
Lubricating before recommissioning
NOTICE
Dry running bearings
Bearings can be damaged if they do not have sufficient grease.
• Re-grease the bearings if they have been out of service for more than one year. The shaft
must rotate so that the grease can be distributed in the bearings. Follow the instructions
on the lubricant plate.
• More information can be found in Chapter Rolling bearings (Page 103).

Operation
8.6 faults
8.5.1 Avoidance of damage to rolling bearings during stoppages

Extended stoppages at the identical or almost identical resting position of the rotor in the
rolling bearings can result in damage, such as brinelling or corrosion.
• During stoppages, regularly start up the machine for a brief period once a month. As a
minimum, turn the rotor several times.
If you have uncoupled the machine from the driven machine and secured the rotor with a
rotor shipping brace, then remove this before turning the rotor over or starting up the
machine.
Make sure that the resting position of the rotor after the rotor has been turned over is
different from its previous position. Use the fitted key or the coupling halves as reference
markers.
• When recommissioning, carefully comply with the information in Chapter "Commissioning
(Page 75)".
8.5.2 Decommissioning the machine

• Record the decommissioning steps. This log will be useful upon recommissioning.
• If the machine is going to be out of service for longer than six months, then take the
necessary measures for preservation and storage. Otherwise, the machine could be
damaged as a result of not being operated.
8.5.3 Re-commissioning the machine

When you re-commission the machine, proceed as follows:
• Study the record made when the machine was decommissioned, and reverse the
measures that were taken for conservation and storage.
• Perform the measures listed in Chapter "Commissioning (Page 75)".
8.6 faults
8.6.1 Inspections in the event of faults

Natural disasters or unusual operating conditions, such as overloading or short circuit, are
faults that overload the machine electrically or mechanically.
Immediately perform an inspection after such faults.
Correct the cause of the fault as described in the respective remedial measures section.
Repair any damage to the machine.

Operation
8.6 faults
8.6.2 Electrical faults
Note
If you are operating the motor with a converter, the operating instructions of the converter
must also be observed if electrical faults occur.
Table 8- 1 Electrical faults
↓ Motor fails to start

↓ Motor accelerates sluggishly
↓ Rumbling noise during startup
↓ Rumbling noise during operation
↓ High temperature rise during no-load operation
↓ High temperature rise with load
↓ High temperature rise of individual winding sections
Possible causes of faults Remedial measures
X X X X Overload Reduce the load.
X Interrupted phase in the supply cable Check the switches and cables.
X X X X Interrupted phase in the feeder cable Check the switches and cables.
after switching on
X Mains voltage too low, frequency too Check the power supply conditions.
high
X Mains voltage too high, frequency too Check the power supply conditions.
low
X X X X X Stator winding incorrectly connected Check the winding connection in the terminal
box.
X X X X Winding short circuit or phase short Determine the winding resistances and insula-
circuit in stator winding tion resistances. Carry out repair work after
consultation with the manufacturer.
X Incorrect direction of rotation Check the connection.

Operation
8.6 faults
8.6.3 Mechanical faults

Table 8- 2 Mechanical faults
↓ Grinding noise
↓ Radial vibrations
↓ Axial vibrations
X Rotating parts grind Establish the cause and realign the parts.
X Rotor or coupling not balanced. Disconnect the rotor or coupling and rebalance.
If the machine has two shaft ends, and a transmission element is only
fitted to one end, secure the fitted key at the other end to prevent it
from being thrown out. If the rotor has balance type "H" (standard
type), the fitted key must be cut back to roughly half of its length.
X Rotor out of round, shaft bent Consult the manufacturing plant.
X X Poor alignment Align the machine set; check the coupling. (1)
X Coupled machine not balanced Rebalance the coupled machine.
X Shocks from coupled machine Investigate the coupled machine.
X X Uneven running of gear unit Fix the gearing.
X X Resonance of the overall system Stabilize the foundation following consultation.
comprising motor and foundation
X X Changes in foundation Establish the cause of the changes and eliminate them if necessary;
realign the machine.
(1) Take any changes into account when warming up the machine.
8.6.4 Rolling bearing faults

Damage to rolling bearings can be difficult to detect in some cases. If in doubt, replace the
rolling bearing. Use other bearing designs only after consulting the manufacturer.
Table 8- 3 Rolling bearing faults
↓ Bearing overheats
↓ Bearing "whistles"
↓ Bearing "knocks"
X High coupling pressure Align the machine more accurately.
X Belt tension too high Reduce the drive belt tension.
X Bearing contaminated Clean or replace the bearing. Check the seals.
X High ambient temperature Use a suitable high-temperature grease.
X X Insufficient lubrication Grease the bearings as instructed.
X X Bearing canted Contact the service center.
X X Insufficient bearing play Contact the service center.
X Excessive bearing play Contact the service center.
X X Bearing corroded Replace the bearing. Check the seals.
X Too much grease in bearing Remove surplus grease.
X Wrong grease in the bearing Use the correct grease.
X Friction marks on raceway Replace the bearing.
X Brinelling or scoring Replace the bearing. Avoid any vibration at standstill

Operation
8.6 faults
8.6.5 Faults at the external fan

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

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

Maintenance 9
Through careful and regular maintenance, inspections, and overhauls you can detect faults at
an early stage and resolve them. This means that you can avoid consequential damage.
Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals can be specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).
Note
Please contact the service center, if you require support with service, maintenance or repair.
9.1 Preparation and notes
9.1.1 North American market (optional)

When making changes or repairs, maintain the corresponding design standards! These
machines are labeled on the rating plate with the following markings.
Underwriters Laboratories
Canadian Standard Association
Canadian Standard Association Energy Efficiency Verification

Maintenance
9.2 Inspection and maintenance
9.1.2 Touch up any damaged paintwork

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

guaranteed if covers are removed. The minimum air and creepage distances may be fallen
below (violated) when coming close to active parts. Touching or coming close can result in
• Take the machine out of operation.
• Switch off the machine and ensure that it is in a no-voltage condition. Carefully comply
with the "5 safety rules" (Page 11).
• Only open the terminal box when the motor is stationary and in a no voltage condition.

damage.
• Before carrying out any repair work on the machine, take it out of operation, and carefully
lock it out so that it cannot be switched on again.
• Only remove the covers when the rotating parts have come to a complete standstill.

Maintenance
Risk of burn injuries due to hot surfaces

In operation, the temperature of individual machine parts can increase - and only decrease
slowly after switching off. You can burn yourself if you touch hot surfaces.
• Allow the machine to cool before starting any maintenance and service work on the
machine.
Danger when cleaning using compressed air

When cleaning parts of the machine using compressed air, loose parts or particles of dirt can
be flung around and cause injury.
• Installed suitable extraction measures.
• Wear personal protective equipment, such as protective glasses, gloves, overall.
• Ensure that personnel not involved in the work are not in the danger area.
Damage if the machine is not maintained

The machine can be damaged if it is not appropriately maintained. This can cause faults
which can result in eventual or immediate death, serious injury or material damage.
• Maintain the machine at the specified maintenance intervals.
Damage from foreign bodies in the machine

Foreign bodies such as dirt, tools or loose components can be left by accident inside the
machine after maintenance is performed. These can cause short circuits, reduce the
performance of the cooling system or increase noise in operation. They can also damage the
motor.
• Ensure that no foreign bodies are left in or on the motor.
• Securely attach all loose parts once you have completed the work.
• Carefully remove any dirt.
9.2.2 Inspections in the event of faults

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

Maintenance
Note
Inspection specifications
• Carefully comply with the relubrication intervals for rolling bearings that deviate from the
inspection intervals.
• When servicing a three-phase machine, it is generally not necessary to dismantle it. The
machine only has to be dismantled if the bearings are to be replaced.
9.2.3 First inspection after installation or repair

Perform the following checks after approximately 500 operating hours or at the latest six
months after commissioning:
Table 9- 1 Checks after assembly or repair
Check When the At stand-

motor is still
running
The electrical parameters are maintained. X
The permissible bearing and winding temperatures are not exceeded X
(Page 79).
The smooth running characteristics and machine running noise have not X
deteriorated.
The foundation has no cracks or indentations. (*) X X
(*) You can perform these checks while the motor is running or at a standstill.
Additional tests may also be required according to the system-specific conditions.
NOTICE
Machine damage
When carrying out the inspection, if you detect any impermissible deviations from the
normal state, you must rectify them immediately. They may otherwise cause damage to the
machine.

Maintenance
9.2.4 General inspection

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

motor is still
running
The electrical parameters are maintained X
The permissible bearing temperatures are not exceeded X
The smooth running characteristics and machine running noise have not X
deteriorated
The foundation has no cracks or indentations. (*) X X
The machine is aligned within the permissible tolerance ranges X
All the fixing bolts/screws for the mechanical and electrical connections X
have been securely tightened
All the potential connections, grounding connections and shield supports X
are correctly seated and properly bonded
The winding insulation resistances are sufficiently high X
Any bearing insulation is fitted as shown on the plates and labels X
The CABLES and insulating parts and components are in good condition and X
there is no evidence of discoloring
(*) You can perform these checks while the motor is at standstill or, if required, while running.
NOTICE
Machine damage
When carrying out the inspection, if you detect any impermissible deviations from the
normal state, you must rectify them immediately. They may otherwise cause damage to the
machine.
9.2.5 Assessing the rolling bearings

To assess the rolling bearings, it is generally not necessary to dismantle the machines. The
motor only has to be dismantled if the bearings are to be replaced.
The state of a rolling bearing can be assessed by analyzing the bearing vibration. The
measured values provide an indication and can be assessed by specialists. In this case, please
contact the Service Center.

Maintenance
9.2.6 Maintenance intervals

Please note the following in order to identify faults at an early stage, rectify them and avoid
follow-on damage:
• Maintain the machine regularly and carefully.
• Inspect the machine.
• Motors must be allocated a revision/inspection number after inspection.
NOTICE
Motor failure
Material damage can occur if the machine develops faults or is overloaded.
• Immediately inspect the machine if faults occur.
• An immediate inspection is especially necessary, if the three-phase motor is
excessively stressed, either electrically or mechanically (e.g. overload or short-circuit).
The machines are equipped with permanently lubricated rolling bearings. The machine may
be equipped with a regreasing device.
CAUTION
Skin irritations and eye inflammations
Many greases can cause skin irritations and eye inflammations.
• Follow all safety instructions of the manufacturer.
Measures, intervals and deadlines

Measures after operating period intervals or deadlines have elapsed:
Operating situations and characteristics can vary widely. For this reason, only general
maintenance intervals are specified here. Maintenance intervals should therefore be
scheduled to suit the local conditions (dirt, starting frequency, load, etc.).
Table 9- 3 Operating period intervals
Measures Operating period intervals Intervals

Initial inspection After 500 operating hours After 1/2 year at the latest
Relubrication (optional) See the lubricant plate
Clean Depending on the degree of pollution
Main inspection Approximately every 16000 operating After two years at the latest
hours
Drain condensate Depending on the climatic conditions

Maintenance
9.2.7 Re-greasing
For machines with regreasing system, relubrication intervals, grease quantity and grease
grade are provided on the lubricant plate. Additional data can be taken from the main
machine rating plate.
Grade of grease for standard motors (IP55) UNIREX N3 - ESSO.
Note
It is not permissible to mix different types of grease.
Prolonged storage periods reduce the useful lifetime of the bearing grease. Check the
condition of the grease if the equipment has been in storage for more than 12 months. If the
grease is found to have lost oil content or to be contaminated, the machine must be
immediately relubricated before commissioning. For information on permanently-greased
bearings, please refer to the section titled Rolling bearings (Page 103).
Procedure
To relubricate the rolling bearings, proceed as follows:
1. Clean the grease nipples at the drive end and non-drive end.
2. Press-in the specified grease and amount of grease according to the data stamped on the
lubrication plate.
– Please observe the information on the rating and lubricant plates.
– Regreasing should be carried out when the motor is running (max. 3600 rpm).
The bearing temperature can rise significantly at first, and then drops to the normal value
again when the excess grease is displaced out of the bearing.
WARNING
Rotor can fall out
If the machine is in a vertical position, the rotor can fall out while work is being performed
on the locating bearing. This can result in death, serious injury or material damage.
Support or relieve the rotor when carrying out work with the machine in a vertical position.
9.2.8 Cleaning
Cleaning the grease ducts and spent grease chambers

The spent grease collects outside each bearing in the spent grease chamber of the outer
bearing cap. When replacing bearings, remove the spent grease.
Dismantle the bearing cartridges to replace the grease in the lubrication duct.

Maintenance
Cleaning the cooling air ducts

Regularly clean the cooling air ducts through which the ambient air flows.
The frequency of the cleaning intervals depends on the local degree of fouling.
Damage to the machine when cleaning with compressed air or water jets
• Do not direct compressed air or water jets in the direction of the shaft outlet or machine
openings.
• Avoid direct impact of compressed air and water jets on sealing elements of the machine.
9.2.9 Cleaning the fan cover of machines for the textile industry
Regularly remove fluff balls, fabric remnants, and similar types of contamination from the fan
cover of machines for the textile industry (particularly at the air passage opening between
the fan cover and cooling fins of the machine enclosure) to ensure that the cooling air can
flow without obstruction.
9.2.10 Drain condensate

If there are condensation drain holes present, open these at regular intervals, depending on
climatic conditions.
WARNING
Hazardous voltage
The winding can be damaged if objects are introduced into the condensation holes
(optional). This can lead to death, serious injury or material damage.
Note the following to maintain the degree of protection:
• Switch off the machine so that it is in a no-voltage condition before you open the
condensation drain holes.
• Close the condensation drain holes, e.g. using T-plugs, before commissioning the
machine.
NOTICE
Reduction of the degree of protection
If condensation drain holes are not closed, then this can result in material damage to the
motor.
In order to maintain the degree of protection, after the condensation has been drained, you
must close all of the drain holes.

Maintenance
9.2.11 Insulation resistance and polarization index

"Testing the insulation resistance and polarization index"
9.2.12 Servicing the external fan
WARNING
Injury caused by rotating parts or live (under voltage) parts
Live electrical parts are dangerous. Contact with them can cause death, serious injury or
material damage.
• Before carrying out any maintenance work on the external fan, disconnect it from the
mains, particularly before opening the terminal box.
• Make sure that the device cannot be switched back on.
Servicing the external fan

However, dirt and dust deposits on the impeller and the motor, particularly in the gap
between the impeller and the inlet nozzle can impair its function.
• Remove the dirt and dust deposits regularly; the intervals depend on how dirty the
surrounding area is.
• Make sure that the impeller is cleaned evenly, as irregular deposits can lead to an
imbalance.
• The full air flow can only be achieved when air can freely flow through the impeller.

Maintenance
9.3 Corrective maintenance
• There must be a clearance of at least 1 x air intake diameter in the axial direction.
• A uniform gap must be maintained between the impeller and the air intake assembly.
Servicing the external fan motor

• Perform an occasional visual inspection of the external fan motor and check it electrically
and mechanically every time the rolling bearings are replaced.
• Replace the permanently lubricated rolling bearing on the external fan motor after
40,000 operating hours or five years at the latest.

If the motor has to be transported, please observe the information and instructions in the
"Transport (Page 28)" chapter.
Note
Before commencing removal, you should mark how each of the fastening elements has been
assigned, as well as how internal connections are arranged. This simplifies subsequent
reassembly.
Avoid damaging the windings protruding out of the stator enclosure when assembling the
end shield.
If possible, assemble the machine on and alignment plate. This ensures that the mounting
feet surfaces are all on the same plane.
Sealing measures
1. Apply the necessary liquid sealant, e.g. Fluid-D, Hylomar, to the centering edge.
2. Check the terminal box seals, and if required, replace these.
3. Repair any damage to the paint, also to screws/bolts.
4. Take the necessary measures to ensure compliance with the applicable degree of protection.
5. Do not forget the foam rubber cover in the cable entry. Completely seal the holes, and
ensure that cables do not come into contact with sharp edges.
See also
Terminal boxes, end shields, grounding conductors, sheet metal fan covers (Page 132)

Maintenance
9.3.1 Rolling bearings

Refer to the rating plate or the catalog for the designations of the bearings being used.
Bearing lifetime
Prolonged storage periods reduce the useful lifetime of the bearing grease. For permanently
lubricated bearings, this reduces the bearing service life.
We recommend that the grease is replaced after a storage time of 12 months. Replace
greased bearings also in the case of closed bearings (suffix 2Z or 2 RS). After 4 years in
storage, generally replace all rolling bearings and grease.
Replacing bearings
Recommended interval after which bearings are to be replaced under normal operating
conditions:
Table 9- 4 Bearing replacement intervals
Ambient temperature Principle of operation Bearing replacement intervals

40 °C Horizontal coupling operation 40 000 h
40 °C With axial and radial forces 20 000 h
• Do not reuse bearings that have been removed.

• Remove the dirty spent grease from the bearing shield.
• Replace the existing grease with new grease.
• Replace the shaft seals when the bearings are replaced.
• Slightly grease the contact surfaces of the sealing lips.
Note
Special operating conditions
The operating hours are reduced, e.g.
• When machines are vertically mounted.
• High vibration and surge loads
• Frequent reversing operation
• Higher ambient temperatures.
• High speeds etc.

Maintenance
① Heat up 80 ... 100 °C
9.3.1.1 Bearing bushes

Protect the bearings against the ingress of dirt and moisture.
When fitting the bearing cartridges, observe the specified screw tightening torques
(Page 132).
9.3.1.2 Installing bearings
Sealing the bearings

Note the following details:
• Shaft sealing rings are used to seal machines at the rotor shaft.
– For V rings, comply with the assembly dimension.
• Use the specified bearings.
• Ensure that the bearing sealing disks are in the correct position.
• Insert the elements for bearing preloading at the correct end.
• Fixed bearings can have a locking ring or bearing cover.
• Seal the bearing cap screws with the appropriate gaskets or with grease.
• Do not interchange the position of the bearing covers (DE and NDE or inner and outer).

Maintenance
Danger as a result of rotor falling out

If the motor is in a vertical position, the rotor can fall out while work is being performed on
the locating bearing. This can result in death, serious injury or damage.
• Support or unload the rotor when carrying out work with the machine in a vertical
position.
Installing rolling bearings

• Extreme caution and attention to cleanliness are vital when installing rolling bearings.
Observe the correct assembly sequence of the components.
• Attach all components with the specified tightening torques (Page 131).
• For individually mounted angular contact ball bearings, carefully comply with the
installation position corresponding to the permissible direction of force.
• Angular contact ball bearings arranged in pairs must always be installed in strict
compliance with the manufacturer's specifications.
• Always use angular contact ball bearings of the same type.
Note
For further information about mounting the rolling bearing, please refer to the catalog or the
information provided by the rolling bearing manufacturer.
Procedure
1. Replace the damaged components.
2. Remove any dirt from the components. Remove any grease and the remains of sealant or
liquid threadlocker.
3. Prepare the bearing seats:
– Lightly oil the inner ring seat.
– Grease the outer ring seat with a solid lubricant such as Altemp Q NB 50.
– Press the inner bearing cover onto the shaft.
4. Warm up the rolling bearing.
5. Push the inner ring of the warmed up rolling bearing onto the shaft. Avoid any blows that
might damage the bearing.
6. Ensure that the rolling bearing is resting against the shaft shoulder or the 2nd bearing.

Maintenance
7. Fill the bearing to the top with the specified lubricating grease as stamped on the lubricant
plate.
8. Warm up the grease slinger (if one is available), and push it onto the shaft.
9. Depending on the particular version, fix the bearing with a locking ring or shaft nut.
10.Support the rotor when installing the bearing housing or bearing end shield.
11.Use a suitable sealant when assembling.
12.Assemble the bearing shield or bearing housing together with the bearing shield.
13.Install the outer bearing cover (if one is available).
14.Install the sealing elements:
9.3.2 Mounting dimension "x"

Mounting dimension "x" of V rings
Shaft height x
mm
63 ... 71 4.5 ±0.6 Standard design
80 ... 112 6 ±0.8
132 ... 160 7 ±1
180 ... 225 11 ±1
250 ... 315 13.5 ±1.2
Special design
• Extreme caution and attention to the correct positioning are vital during installation and
assembly.
• Make sure the sealing surface is free of dirt and damage.
• Lightly grease the sealing lips.
9.3.3 Fan
NOTICE
Destruction of the fan
Material damage can occur by forcefully removing the fan from the shaft.
Take care not to damage the snapping mechanisms on fans that are equipped with these.

Maintenance
Plastic fan
• Correctly expose the breakout openings provided in the fan plate.
• Heat up the fans to a temperature of approximately 50° C around the area of the hub.
• Use a suitable tool to pull off the fan (puller).
• Locate the arms of the pulling tool in the breakout openings and slightly tension the
pressure screw of the tool.
• For fans with snapping mechanisms, simultaneously release the two snap-in lugs of the
fan from the annular shaft groove.
Keep the snap-in lugs in this position.
• Uniformly withdraw the fan from the shaft by turning the pressure screw of the pulling
tool.
• Do not apply any hammer blows to avoid damaging the rotor shaft, the fan and the
bearings.
• Order the appropriate new parts if damaged.
Metal fan
• Shaft height 63: Release the two M4 clamping screw so that the fan can rotate freely on
the shaft.
• Shaft heights 71...90: Release the M5 set screw so that the fan can rotate freely on the
shaft.
• Shaft height 100...355: Remove the locking ring.
• Use a suitable tool to pull off the fan (puller).
• Locate the arms of the pulling tool in the openings in the fan in the vicinity of the hub.
• Alternatively, place the pulling tool at the outer edge of the fan plate.
• Uniformly withdraw the fan from the shaft by turning the pressure screw of the pulling
tool.
• Do not apply any hammer blows to avoid damaging the rotor shaft, the fan and the
bearings.
• Order the appropriate new parts if damaged.

Maintenance
Plastic fan cover

Shaft height 80 ... 160
1. Carefully release the snap openings of the cover one after the other from the lugs.
2. Do not insert the lever directly under the lug, as otherwise it could break.
3. Take care to not damage the catch mechanism. Order the appropriate new parts if
damaged.
Shaft height 180 ... 200

1. Carefully release the first snap opening of the cover.
2. For machines with type construction B3, select the snap opening in the area of the machine
mounting feet.
3. Insert the lever at the edge of the cover close to the lug. ①
4. Carefully release 2 other snap openings together and then withdraw the cover. ②
5. Take care to not damage the catch mechanism. Order the appropriate new parts if
damaged.
Canopy
Canopies with spacer bolts or with screwed mounting brackets

Forcibly removing or separating can destroy the distance bolts, the connecting elements of
the mounting bracket or the fan cover.
• Release the fixing screw on the outer surface of the canopy.
• Under no circumstances remove the spacer bolts or the mounting bracket – or forcibly
separate them from one another or the cover.

Maintenance
Canopies with welded support brackets

• Release the fixing screws at the contact location (canopy foot - riveting nut) at the outer
surface of the cover mesh.
9.3.3.1 Mounting fans

• Take care not to damage the snapping mechanisms on fans that are equipped with these.
• To ensure this, the fans should be heated to a temperature of approximately 50 °C around
the area of the hub.
• If any damage is caused, request new parts.
9.3.3.2 Mounting the fan cover

Incorrectly mounting covers with snap mechanism
Avoid injury caused by touching the rotating fan or material damage caused by partial or
complete release of the cover while the machine is operational.
• Carefully ensure that all 4 snap openings of the cover completely engage in the associated
snap-in lugs.
Plastic fan cover shaft heights 80 ... 200
• Align the cover with the line marked on the edge of the cover with the middle enclosure
rib as extension to the terminal box base.
• Center the cover by axially moving on the snap-in lugs of the enclosure or the bearing
shield cams.
• First engage 2 snap openings positioned next to one other, then carefully press the cover
into position with the two openings situated opposite these using the snap-in lugs, and
snap it into place.
• Attach the cover using all 4 of its snap-in lugs by applying axial pressure to the reinforced
edge of the cover in the area of the cover mesh.
• If required, use a rubber hammer and apply it once or several times to the edge of the
cover in the axial direction. When doing this, take care not to damage or destroyed the
mesh of the cover.
• When fitting the cover, do not overextend it (you could break it).
9.3.4 Canopy; mounting a rotary pulse encoder under the canopy

Canopy, encoder under the canopy
For screwed canopies, insert the fastening screws through the holes on the outer surface of
the canopy.
Tighten the fastening screws with a torque of 3 Nm ±10 %.

Maintenance
9.3.5 Tightening torques

Note the information in Chapter Tightening torques (Page 131).
9.3.6 Screw lock washers

Nuts or bolts that are mounted together with locking, resilient and/or force-distributing
elements (e.g., safety plates, spring-lock washers, etc.) must be refitted together with
identical, fully functional elements.
Locking and sealing elements must always be replaced!
9.3.7 Links
• Replace any corroded screws.
• Take care not to damage the insulation of live parts.
• Document the position of any rating and supplementary plates that have been removed.
• Avoid damaging the centering edges.
9.3.8 Reassembly: Miscellaneous information

• Position all rating and supplementary plates as in the original state.
• Where relevant, fix electric cables.
• Check the tightening torques of all screws, as well as those of screws that have not been
released.
9.3.9 Optional add-on units
Note
Further documents
You can find additional operating instructions here:Service & support (Page 129)

Maintenance
9.3.9.1 Mounting a brake
Table 9- 5 Assigning standard brakes for 1LE1 machines
Shaft height Brake type Tightening torque for the

manual release lever
Nm
63 INTORQ BFK 458-6 2LM8 005-1NA10 2.8
71 INTORQ BFK 458-6 2LM8 005-2NA10
80 INTORQ BFK 458-8 2LM8 010–3NA10
90 INTORQ BFK 458-10 2LM8 020–4NA10 4.8
100 INTORQ BFK 458-12 2LM8 040–5NA10
112 INTORQ BFK 458-14 2LM8 060–6NA10 12
132 INTORQ BFK 458-16 2LM8 100–7NA10
160 INTORQ BFK 458-20 2LM8 260–8NA10 23
180 INTORQ BFK 458-20 2LM8 315–0NA10
200 INTORQ BFK 458-25 2LM8 400–0NA10 40
225 INTORQ BFK 458-25 2LM8 400–0NA10
Precima FDX 30
250 Pintsch Bubenzer KFB 63
Precima FDX 30
Precima FDX 40
Precima FDX 40
9.3.10 O-ring seal

If O-ring seals are present, you should check that they are in perfect condition and that the O-
ring seals are properly seated in the grooves between the components. Replace damaged O-
ring seals.
O-ring seals can be present on the following components, for instance:
• Adapters, tapers
• Entries, glands
• Bearing seals
• End shield seals
• Terminal box sealing
• etc.

Maintenance

Spare parts 10
10.1 Parts order
In addition to the exact part designation, please specify the machine type and the serial
number of the machine in all orders for spare parts and repair parts. Ensure that the part
designation is the same as that in the parts list, and make sure you also use the associated
part number.
When spare and repair parts are ordered, the following details must be provided:
• Designation and part number
• Order number and serial number of the machine
The machine type and serial number can be found on the rating plate.
See also
Spares On Web (https://www.sow.siemens.com/)
10.2 Data matrix code on the machine
Data matrix code

A data matrix code may be provided on machines manufactured in Europe. You can retrieve
the following information from the data matrix code:
• Machine type
• Serial number
• Customer material number, if ordered as option Y84
• Using the Data Matrix code and the App "SIMOTICS Digital Data", you can access the
technical data, spare parts and operating instructions for your motor.
10.3 Ordering data
Note
The graphical representations in this chapter show schematic diagrams of the basic versions.
They are used for spare parts definitions. The supplied version may differ in details from these
representations.

Spare parts
10.4 Determining the spare parts via the Internet
10.4 Determining the spare parts via the Internet
You can use "Spares on Web" to determine the order numbers for motor
spare parts quickly and easily.
Spares on Web (https://www.sow.siemens.com/?lang=en).
See also
Guide for Spares on Web (https://www.weblogx.siemens.de/SoWHilfe_HS/motors/en/)
10.5 Replacing rolling bearings
Rolling bearings
When ordering rolling bearings, in addition to the bearing identification code, the
supplementary specifying code is also necessary for the bearing version. Both of these codes
are stamped on the lubricant plate and specified in the motor documentation, or can also be
taken from the installed bearings.
Always replace the rolling bearings with the identical bearings.
If insulated rolling bearings are fitted, use insulated rolling bearings of the same type as spare
parts. This will prevent any bearing damage being caused by bearing currents.
10.6 Parts groups definition

A distinction is made between the following groups of parts:
Spare parts
Spare parts are machine parts that can be ordered during the production time - and for a
further 5 years after discontinuation of production. These parts should be replaced only by
authorized service or modification partners.
Repair parts
Repair parts are machine parts that can only be supplied during the active production of the
machine (until the product discontinuation). Repair parts are parts used for the repair or
modification of the current products. These parts should be replaced only by authorized
service or modification partners.

Spare parts
10.7 Ordering example
Standardized parts
Standardized parts are machine parts that can be commercially obtained with the necessary
dimensions, materials and surface finish. A detailed list can be found in Chapter
"Standardized parts".
Other parts
Other parts are small parts required to complete the exploded drawing. These parts cannot be
supplied as individual spare or repair parts. Delivery as assembled units, for example as
complete terminal box, is possible on request.
Delivery obligations for replacement machines and repair parts

The following delivery obligations apply to replacement machines and repair parts after
production has been phased out.
• For up to 3 years after the delivery of the original machine, in the event of total machine
failure, Siemens will supply a comparable replacement machine with regard to the
mounting dimensions and functions; it is possible that this will involve a new series.
• If a replacement machine is supplied within the 3 year period, this does not mean that the
warranty restarts.
• Replacement machines delivered after the active production of the machine series are also
identified as spare motors on the rating plate.
• Spare parts are available only on request for these spare motors. Repair or replacement is
not possible.
• After a period of 3 years (after the delivery of the original machine), it is only possible to
repair these machines, depending on the availability of the spare parts required.
• After the delivery of the original motor, spare parts will be available for up to 5 years. For
an additional period of 5 years, Siemens provides information about spare parts, and
when required, provides documentation.
10.7 Ordering example
End shield, drive end 1.40 End shield

Machine type * 1LE1002-1DB43-4AA0
Ident: No. * E0605/0496382 02 001
* corresponding to the rating plate

Take the type and serial number from the rating plate and the machine documentation.
When replacing rolling-contact bearings, in addition to the bearing identification code, the
replacement code for the bearing version is required. Both of these codes are specified on the
rating plate and in the machine documentation. They are also shown on the installed
bearings.
The graphical representations in this chapter show schematic diagrams of the basic versions.
They are used for spare part definitions. The supplied version may differ in details from these
representations.

Spare parts
10.8 Machine parts
10.8 Machine parts
Part Description Part Description

1.00 DE bearings Terminal box, complete
1.30 Bolt 5.43 Entry plate
1.31 Spring lock washer 5.44 Terminal box top side
1.32 Bolt 5.45 Enclosure
1.33 Nut 5.46 Bolt
1.40 End shield 5.47 Bolt
1.43 Shaft sealing ring 5.48 Spring lock washer
1.44 Bearing cover DE, inner 5.49 Self-tapping screw
1.45 Bolt (bearing cover) 5.51 Nut
1.46 Cover ring 5.52 Cable gland
1.47 O ring 5.53 Screw plug
1.48 Self-tapping screw 5.54 O ring
1.49 Bolt 5.55 Nut
1.50 Flanged nut 5.60 Terminal board screw
1.56 Spacer washer 5.61 Bolt
1.58 Spring washer 5.62 Spring lock washer
1.60 Roller bearing 5.63 Mounting rail
1.61 Spring band for end shield hub 5.64 Spring lock washer
1.63 Condensation drain plug 5.65 Bolt
1.65 Grease nipple 5.68 Screw plug
1.67 Bearing cover NDE, outer 5.69 O ring
1.68 Grease slinger (optional) 5.70 Terminal clamp
1.69 Compression spring 5.72 Contact bracket
3.00 Rotor, complete 5.76 Terminal plate / contact bracket
3.02 Locking ring 5.78 Washer
3.03 Locking ring 5.79 Bolt
3.38 Featherkey 5.81 Self-tapping screw
3.88 Featherkey for fan 5.82 O ring
4.00 Stator, complete 5.83 Seal
4.04 Eyebolt 5.84 Terminal box cover
4.07 Housing foot 5.85 Terminal box cover including seal (optional bolt)
4.08 Housing foot, left 5.88 Spring lock washer
4.09 Housing foot, right 5.89 Bolt
4.10 Spring lock washer 5.90 The top side of the terminal box can be rotated 4 x 90
degrees, complete
(for subsequent mounting)
4.11 Bolt 5.91 Bolt
4.12 Nut 5.92 Terminal box cover
4.18 Rating plate 5.93 Seal
4.19 Self tapping screw or slotted pin 5.94 Bolt
4.20 Cover 5.95 Terminal box top side
4.30 Contact bracket 5.96 Screw plugs
4.31 Grounding bracket 5.97 Nut

Spare parts
10.8 Machine parts
Part Description Part Description

4.35 Disk 5.98 Sheet metal nut
4.37 Terminal board 5.99 Adapter plate
4.38 Spring lock washer 6.00 Bearings, NDE
4.39 Grounding screw (self-tapping screw) 6.02 Locking ring
4.40 Disk 6.03 Bearing cover NDE, inner
5.00 Terminal box, complete 6.10 Rolling bearing
5.02 spacer 6.11 Spring band for end shield hub
5.03 Seal 6.12 Locking ring
5.04 Seal 6.20 End shield
5.06 Mounting rail 6.23 Shaft sealing ring
5.08 Spacer sleeve 6.25 Lubrication sleeve
5.09 Bolt 6.27 Bearing cover NDE, outer
5.10 Complete terminal board 6.29 Bolt
5.11 Terminal block 6.30 Bearing cover NDE, inner
5.13 Link rail 6.31 Flanged nut
5.15 Plug 6.65 Grease nipple
5.16 Spring lock washer 6.66 Screw
5.18 Spring lock washer 6.67 Rubber bush
5.19 Bolt 6.72 Grease slinger
5.21 Screw (drilled) 7.00 Ventilation system, complete
5.24 Bolt 7.04 Fan
5.27 Clamp 7.12 Locking ring
5.28 Upper saddle terminal 7.40 Fan cover
5.29 Lower saddle terminal 7.41 bracket
5.36 Spring lock washer 7.48 Washer
5.37 Spring lock washer 7.49 Bolt
5.42 Terminal box housing, including seal
Tools for mounting and withdrawing roller bearings; fans and output transmission elements cannot be supplied.

Spare parts
10.9 Standardized parts
10.9 Standardized parts
Table 10- 1 Purchase standard parts according to dimensions, material and surface properties through normal commercial
channels.
No Standard Picture No Standard Picture

3.02 DIN 471 1.32 DIN 939
6.02
7.12
6.12 DIN 472

1.49 EN ISO 4017
4.11
4.39
4.04 DIN 580 5.60
5.61
5.65
5.89
7.49
DIN 582
1.60 DIN 625 1.30 EN ISO 4762

6.10 1.45
4.11
5.19
5.46
5.47
5.49
5.60
6.29
6.66
3.38 DIN 6885 5.09 EN ISO 7045
5.91
5.94
1.33 EN ISO 4032 5.24 EN ISO 7049

4.12
4.14
5.55
5.51 EN ISO 4035 4.05 EN ISO 7089

7.48

Spare parts
10.10 Exploded drawings
10.10.1 1LE, 1PC shaft heights 63 ... 71 aluminum

Spare parts
10.10.2 1LE, 1PC, 1FP shaft heights 80 ... 160 aluminum

Spare parts
10.10.3 1LE, 1PC shaft heights 180 ... 200 aluminum

Spare parts
10.10.4 1LE, 1PC shaft heights 71 ... 90 cast iron

Spare parts
10.10.5 1LE, 1PC, 1FP shaft heights 100 ... 200 cast iron

Spare parts
10.10.6 1LE, 1PC shaft heights 225 ... 315 cast iron

Disposal 11
Protecting the environment and preserving its resources are corporate goals of the highest
priority for us. Our worldwide environmental management system to ISO 14001 ensures
compliance with legislation and sets high standards in this regard. Environmentally friendly
design, technical safety and health protection are always firm goals even at the product
development stage.
Recommendations for the environmentally friendly disposal of the machine and its
components are given in the following section. Be sure to comply with local disposal
regulations.
Country-specific legislation
The machine uses materials that can be recovered or recycled. Correctly separating materials
helps to simply recycle important materials.
• When disposing of the machine or of waste that is created during the individual phases of
its life cycle, please observe the statutory requirements applicable in the country of use.
• Please contact your local authorities for more information about disposal.
11.1 RoHS - restricting the use of certain hazardous substances

In compliance with RoHS ("Restriction of certain Hazardous Substances" ) we replace
substances that are damaging to the environment by those that are not based on state-of-
the-art technology. In doing so, safety in operation and handling will take priority at all times.
11.2 Information according to Article 33 of the REACH regulation

This product contains one or several subproducts in which the following substance –
belonging to the "list of candidates" – exists in a concentration exceeding 0.1 percent by
weight.
• CAS No. 7439-92-1, lead
Based on the currently available information, we assume that this substance does not
represent any risk when correctly used, including its disposal.

Disposal
11.3 Preparing for disassembly
11.3 Preparing for disassembly

Disassembly of the machine must be carried out and/or supervised by qualified personnel
with appropriate expert knowledge.
1. Contact a certified waste disposal organization in your vicinity. Clarify what is expected in
terms of the quality of dismantling the machine and provision of the components.
2. Carefully follow the 5 safety rules (Page 11).
3. Disconnect all electrical connections and remove all cables.
4. Remove all liquids such as oil and cooling liquids. Collect the liquids separately and dispose
of them in a professional manner.
5. Detach the machine fixings.
6. Transport the machine to a suitable location for disassembly.
See also
Corrective maintenance (Page 102)
11.4 Dismantling the machine

Dismantle the machine using the general procedures commonly used in mechanical
engineering.
WARNING
Machine parts can fall
The machine is made up of heavy parts. These parts are liable to fall during dismantling.
This can result in death, serious injury or material damage.
• Before you release any machine parts, secure them so that they cannot fall.
11.5 Disposal of components
Components
The machines consist mainly of steel and various proportions of copper and aluminum.
Metals are generally considered to be unlimitedly recyclable.
Sort the components for recycling according to whether they are:
• Iron and steel
• Aluminum

Disposal
• Non-ferrous metal, e.g. windings

The winding insulation is incinerated during copper recycling.
• Insulating materials
• Cables and wires
• Electronic waste
Process materials and chemicals

Sort the process materials and chemicals for recycling according to whether they are for
example:
• Oil
• Grease
• Cleaning substances and solvents
• Paint residues
• Anti-corrosion agent
• Coolant additives such as inhibitors, antifreeze or biocides
Dispose of the separated components according to local regulations or via a specialist
disposal company. The same applies for cloths and cleaning substances which have been
used while working on the machine.
Packaging material
• If necessary, contact a suitable specialist disposal company.
• Wooden packaging for sea transport consists of impregnated wood. Observe the local
regulations.
• The foil used for water-proof packaging is an aluminum composite foil. It can be recycled
thermally. Dirty foil must be disposed of via waste incineration.

Disposal

Service & support A
A.1 Siemens Industry Online Support
Technical questions or additional information
If you have any technical queries or you require additional information,

please contact Technical Support
(https://support.industry.siemens.com/cs/ww/en/sc/4868).
Please have the following data ready:
• Type
• Serial number
You can find this data on the rating plate.
Contact person
If you wish to request on-site service or order spare parts, please contact
your local office. This office will contact the responsible service center on
your behalf. You can find your contact person in the relevant contact da-
tabase:
www.siemens.com/yourcontact (www.siemens.com/yourcontact)
Siemens Support for on the move
With the "Siemens Industry Online Support" App, you can access more
than 300,000 documents for Siemens Industry products – any time and
anywhere. The App supports you in the following areas:
• Resolving problems when executing a project
• Troubleshooting when faults develop
• Expanding a system or planning a new system
Further, you have access to the Technical Forum and other articles that our
experts have drawn-up:
• FAQs
• Application examples
• Manuals
• Certificates
• Product announcements and many more
The app is available for Apple iOS, Android and Windows Phone.

Service & support
A.2 Further documents
A.2 Further documents

These operating instructions can also be obtained at the following Internet site:
http://support.industry.siemens.com (Page 129)

Technical data B
B.1 Tightening torques
B.1.1 Tightening torques for screw and bolt connections
Bolt locking devices

• Refit nuts or bolts that are mounted together with locking, resilient, and/or force-
distributing elements with identical, fully-functional elements when re-assembling.
Always renew keyed elements.
• When screwing together threads secured with a liquid adhesive, use a suitable medium
such as Loctite 243.
• Always use suitable securing devices or removable adhesives (e.g., Loctite 243) when
installing fixing bolts with a clamping length of less than 25 mm. The clamping length is
taken as the distance between the head of the bolt and the point at which the bolt is
screwed in.
Tightening torques
The bolted connections with metal contact surfaces, such as end shields, bearing cartridge
parts, terminal box parts bolted onto the stator frame, should be tightened to the following
torques, depending on the thread size:
Table B- 1 Tightening torques for bolted connections with a tolerance of ±10 %.
Thread M5 M6 M8 M10 M12 M16 M20 M24

∅
Nm 5 8 20 40 70 170 340 600
The tightening torques stated above apply to screws with property class 8.8, A4-70 or A4-80
according to ISO 898-1, however only to bolts screwed into components made from
materials with the same or higher property class, e.g. cast iron, steel or cast steel.
Non-standard tightening torques

Different tightening torques for electrical connections and bolted connections for parts with
flat seals or insulating parts are specified in the relevant sections and drawings.

Technical data
B.1 Tightening torques
B.1.2 Terminal board and grounding
Table B- 2 Tightening torques for electrical connections on the terminal board and grounding
Thread ∅ M 3.5 M4 M5 M6 M8 M 10 M 12 M 16
min 0.8 0.8 1.8 2.7 5.5 9 14 27
Nm Max. 1.2 1.2 2.5 4 8 13 20 40
B.1.3 Terminal boxes, end shields, grounding conductors, sheet metal fan covers
If no other tightening torques are specified, then the values in the following table apply.
Table B- 3 Tightening torques for screws on the terminal box, end shields, screw-type grounding conductor connections
Thread ∅ M 3.5 M4 M5 M6 M8 M 10 M 12 M 16 M20

Nm min 0.8 2 3.5 6 16 28 46 110 225
max 1.2 3 5 9 24 42 70 165 340
Table B- 4 Tightening torques for self-tapping screws on the terminal box, end shields, screw-type grounding conductor
connections, sheet metal fan covers
Thread ∅ M4 M5 M6
Nm min 4 7.5 12.5
max 5 9.5 15.5
B.1.4 Additional connecting terminals for monitoring equipment and anti-

condensation heating
Table B- 5 Tightening torques for monitoring equipment and anti-condensation heating
Main terminal box 0.4 Nm

EN 60999-1: 2000 table 4 III
Auxiliary terminal box min 0.6 Nm max 0.8 Nm

Quality documents C
C.1 Quality documents SIMOTICS in SIOS
You can find the quality documents here:

https://support.industry.siemens.com/cs/ww/de/ps/13310/cert
(https://support.industry.siemens.com/cs/ww/en/ps/13310/cert)

Quality documents
C.1 Quality documents SIMOTICS in SIOS

Index
Disposal, 126
Disposal
" Chemicals, 127
Components, 126
"Siemens Industry Online Support" App, 129
Drive output element, 57
A E
Aligning, 55
Electrical faults, 90
Aluminum conductors, 72
Electromagnetic compatibility, 15
Anti-condensation heating, 38
Electromagnetic fields, 14
Insulation resistance, 50
Emergency off, 87
Assembly
Emitted interference, 14
Rolling bearing, 105
Equipotential bonding conductor, 41
Axial force, 58
ESD guidelines, 14
Axial gap, 54
External fan, 36
Commissioning, 78
Maintenance, 101
B Test run, 78
Balancing type, 56
Bearing currents
Reduction, 41 F
Bearing insulation, 43
faults
Bearing shipping brace, 35
Mechanical, 91
Bearing temperature
Faults
Monitoring, 79
Cooling system, 92
Set values, 79
Electric, 90
Blocked speed ranges, 39
Inspection, 89, 95
Bolt locking device, 131
Rolling bearings, 91
Faults in operation, 84
Fixing, 61
C Flammable substances, 13
Centering flange, 55 Foundation forces, 54
Circuit diagram, 63 Frequency fluctuation, 38
Common-mode filters, 42
Connecting cables
Selection of, 62 G
Cooling system
General inspection, 97
faults, 92
Grounding system
Correct usage, 18
Meshed, 42
Coupling, 44
H
D
Hazardous substances, 13
Damping cores, 42
Hearing damage, 13
Data matrix code, 113
Hot surfaces, 13
Disassembly

Index
I Polarization index, 35, 47, 77, 101

Measuring, 49
Inspection
Positioning, 54
Faults, 89, 95
Precision alignment, 54
Installation
Preload
Initial inspection, 96
Rotor bracing, 34
Insulated bearings, 43
Preparations for assembly, 46
Insulated coupling, 43
Property class, 54
Insulation resistance, 35, 47, 77, 101
Measuring, 48
Interference immunity, 15
Q
Interference voltages, 16 Qualified personnel, 12
Interlocking circuit
External fan, 36 R
Radial force, 58
Rating plate, 18
L REACH regulation, 125
Limit speed, 41 Re-commissioning, 89
Live parts, 12 Regreasing system, 35
Repair
Initial inspection, 96
M Repair parts, 114
Residual risks, 27
Machine
Restriction of certain Hazardous Substances, 125
Aligning to the driven machine, 54
RF grounding point, 41
Securing, 54
RoHS, 125
Machine expansion, 54
Rolling bearing
Maintenance
Assembly, 105
Maintenance intervals, 93
Rolling bearings
Mechanical faults, 91
faults, 91
Minimum air clearances, 66
Inspection, 97
Replacement, 114
Rotating parts, 12
N Rotor shipping brace, 33
Noise emissions, 13 Remove, 56
O S
On-site service, 129 Safety instructions
Operating mode, 27 Flammable substances, 13
O-ring seals, 111 Hazardous substances, 13
Over-critical machine, 39 Hot surfaces, 13
Overspeed, 27 Live parts, 12
Rotating parts, 12
Selection of bolts, 54
P Siemens Industry Online Support
App, 129
Paint finish, 25
SIMOTICS Digital Data, 113
Paint system, 94
Spare parts, 114, 129
Paintwork damage, 94
Spares on Web, 114

Index
Standard flange, 55
Standardized parts, 115
Stoppages, 87
Rolling bearings, 89
Supplementary devices, 25
Switching on, 80, 87
System resonances, 39
T
Tandem operation, 43
Technical Support, 129
Terminal marking, 64
Test run, 80
Tightening torques, 61
Bolted connection, 131
V
Vibration values, 39, 81
Voltage fluctuations, 38

9.5 Minimum flow control valve
Data Sheet
Dimensional Drawing
Automatic Recirculation Valve
Item List
Operating Manual
HGM 359 of 492

Data Sheet
Order 4012576.1 Rev. 0 prev. Order No.

Customer KSB SE & Co. KGaA/108590 Data Sheet No. DB4012576.1
Order No. 4505755339 Quantity 2
Project Montsignery
Tag No. / KKS No. P52396;P52397
Type TDM086FV-005T-CS PUMP PROTECTION VALVE
Valve Design
Connection Size Class Standard Schedule Surface
P Inlet DN 50 PN 100 EN 1092-1 B1
R Outlet DN 50 PN 100 EN 1092-1 B1
B Bypass DN 25 PN 100 EN 1092-1 B1
above A Start-Up DN 25 PN 100 EN 1092-1 B1
Installation P-R vertical
Painting Customer Painting Specification
Certificates no Certificate
Design Data
Design Temp. 160,00 °C Design Pressure 87,00 bar g
Material
Body 1.0460 Internals Cr>13% Gaskets EPDM-02
Medium
Medium Boiler feed water
Operating Temp. min. 130,00 °C max. 130,00 °C
S.G. min. 0,935 t/m³ max. 0,935 t/m³
Operating Data
Case 1 Case 2 Case 3
QM m³/h 10,74
HM m 886,51
Q100 m³/h 31,6 22,00 22,00
H100 m 823,3 705,1 765,9
Qmax
Hmax
H0
QA m³/h 13,7
HA m 885,00
pv bar g 2,23
pN bar g 6,8
DpBypass bar 76,71
kv-Bypass 1,19
RPM
Remarks
The bypass back pressure (PN) is assumed.
All other data is taken from valve inquiry datasheet, pump curve and pump datasheet. Please check and confirm the design and
operating data.
Start-Up connection: above check valve

Pump speed (RPM): case 1: 2982 1/min; case 2: 2698 1/min; case 3: 2807 1/min
Case minimal (our case 2)
Pump discharge flow: 22m³/h; process flow: 8,3m³/h; 13,7m³/h through manual bypass
Special painting acc. to ZN 35.1 ES2N B - RAL 5002

Revision Date Description Name
0 24.09.2021 Anlage/creation Weiss
SCHROEDAHL GmbH
Alte Schönenbacher Str. 4 · 51580 Reichshof-Mittelagger
Telefon +49 2265 9927-0 · Telefax +49 2265 9927-927
eMail: schroedahl@circor.com · www.schroedahl.com Version 1.07 / 20.03.2019
FREILAUF-RÜCKSCHLAG-VENTIL-MASSBLATT
AUTOMATIC-RECIRCULATION-VALVE-DIMENSION-DRAWING
Anlage: Kom-Nr.: Stück:
Project: Montsignery Work-no.:
4012576.1 Quantity: 2
Best.-Nr.: Typ:
Order-no.: 4505755339 Type:
TDM086FV-005T-CS
Anlagenkennzeichen: Gehäusewerkstoff: Gewicht:
P52396;P52397 Body material: 1.0460 kg 56
Item-no.: Weight:
P = Pumpenseite
Einbaulage P-R: vertikal P = pump end
Installation P-R: vertical
R = Rohrleitung
R = pipeline end
B = By-Pass Seite
B= by-pass end
A = Anfahrseite
A = Start up
DN 50 PN 100 EN 1092-1 B1
300 mm
DN 25 PN 100 EN 1092-1 B1
DN 25 PN 100 EN 1092-1 B1
110 mm
DN 50 PN 100 EN 1092-1 B1
193 mm 193 mm
Zust./Index Datum/Date Änderung/Revision Bearb./Draw. Gepr./Checked
A 24.09.2021 Erstellung Koehler

SCHROEDAHL GmbH
Alte Schönenbacher Str. 4 · 51580 Reichshof-Mittelagger
eMail: schroedahl@circor.com · www.schroedahl.com
Telefon +49 2265 9927-0 · Telefax +49 2265 9927-927
P = Pumpenseite
193 mm 193 mm P = pump end
DN 50-PN 100-EN 1092-1-B1- R = Rohrleitung
R = pipeline end
B = By-Pass Seite
B = by-pass end
A = Anfahr-Seite
A = Start up
Einbaulage: vertikal
Installation: vertical
300 mm
DN 25-PN 100-EN 1092-1-B1-
DN 25-PN 100-EN 1092-1-

B1-
110 mm
DN 50-PN 100-EN 1092-1-B1-

Anlage: Auftrags-Nr.:
Montsignery 4505755339
Project: Order-no.:
Anlagenkennzeichen: Kom-Nr.:
P52396;P52397 4012576.1
Item-no.: Work-no.:
Für diese Zeichnung Maßstab Gewicht:
behalten wir uns alle
Allgemeintoleranzen
Scale
- Weight:
General tolerance
Rechte vor! Stückzahl Gehäusewerkst
DIN EN 558 - 1 2 1.0460
All rights reserved! Quantity Body material:
Datum Name
Date Name Freilauf-Rückschlag-Ventil
Bearb
Draw.
Koehler Automatic Recirculation Valve
Gepr. Typ:
Check. Type: TDM086FV-005T-CS
Bl 1
Änderung Datum Bear Gep

SZ-4012576.1 von 1
Rev.
Revision Date Draw.Check. Ers. für: Ers. durch:
STÜCKLISTE
ITEM-LIST Seite/Page: 1/1
Anlage: Kom-Nr.:
Project:
Montsignery
Work-No.:
4012576.1
Kunde: Typ:
Customer:
KSB SE & Co. KGaA Type: TDM086FV-005T-CS
Anlagenkennzeichen: Stückzahl:
Item-No.:
P52396;P52397
Quantity:
2
Pos. Stk. Benennung Werkstoff Bemerkung
Pos. Quant. Description Material Remark
01 1 Unterteil Lower body 1.0460
02 1 Oberteil Upper body 1.0460
03 2 Führungssteg Stem guide 1.4408
04 1 Führung Guide 1.4021
06 1 Schraubenfeder Spring 1.4310
07 1 Kegel kpl. Check valve cpl. 1.4404
08 1 Futterblech Liner 1.4300
09 1 Seitenstutzen Bypass 1.0460
09.1 1 Seitenstutzen Bypass 1.0460
10 1 Vortexbuchse Vortex socket 1.4122
10.1 1 Vortexbuchse Vortex socket 1.4122
11 1 Steuerkopf Control head 1.4122
12 1 Vortexkegel Vortex plug 1.4122
13 1 Hebel Lever 1.4313
14 1 Lagerbolzen Pivot pin 1.4021
15 1 Entlastungsbuchse Relief bushing 1.4122
16 1 Entlastungskolben Relief piston 1.4122
18 1 Anfahr-Vortexkegel Start-up vortex plug 1.4122
19 1 Halter Holder 1.4122
20 1 Splint Pin 1.4300
21 1 Gewindering Threaded ring 1.4122
23 1 Düse Nozzle 1.4122
23.1 1 Düse Nozzle 1.4122
25 1 Stift Pin A2
26 16 Stiftschraube Stud bolt 1.7709
27 4 Stiftschraube Stud bolt 1.7709
27.1 4 Stiftschraube Stud bolt 1.7709
28 16 Sechskantmutter Hexagon nut 1.7218
29 4 Sechskantmutter Hexagon nut 1.7218
29.1 4 Sechskantmutter Hexagon nut 1.7218
30 1 O-Ring O-Ring EPDM-02
31.1 2 O-Ring O-Ring EPDM-02
33.1 1 Glyd-Ring Glyd-ring PTFE/CARBON
85.1 1 Typenschild Nameplate ALU
Zust./Index Datum/Date Änderung/Revision Bearb./Draw. Gepr./Checked

0 24.09.2021 Erstellung Koehler
1
2
3
Schroedahl GmbH
Alte Schönenbacher Str.4 - 51580 Reichshof - Mittelagger
Telefon (02265) 99 27 -0 - Telefax (02265) 99 27 947
© SCHROEDAHL GmbH, D-51580 Reichshof-Mittelagger
email: schroedahl@circor.com Internet: http://www.schroedahl.de
Installation, maintenance, assembly and
operating manual for minimum flow valves of Page 1 of 41
type TDM

operating manual for minimum flow
valves of type TDM
BA-TDM-01-EN
Version: 05.2017
type TDM
Content
1 General.........................................................................................................................................4
1.1 Customer service and procedure when servicing .......................................................................................... 4
1.2 About this manual .......................................................................................................................................... 4
1.3 Applicability of this operating manual ........................................................................................................... 5
1.3.1 Applicable documents............................................................................................................................................ 5
1.4 Subject to change........................................................................................................................................... 5
1.5 Warranty/guarantee ...................................................................................................................................... 5
2 Explanation of symbols and safety instructions .............................................................................6
2.1 Explanation of symbols .................................................................................................................................. 6
2.2 Notes on dangers and warnings .................................................................................................................... 7
2.3 Safety instructions ......................................................................................................................................... 8
3 Packing .........................................................................................................................................9
4 Transport and storage ................................................................................................................ 10
5 Description and technical data .................................................................................................... 11
5.1 Intended Use ................................................................................................................................................ 11
5.2 Structure of the valve type TDM .................................................................................................................. 11
5.3 Functioning of the valve type TDM .............................................................................................................. 13
5.4 General notes regarding operation of the valve .......................................................................................... 15
5.5 Normal operational requirement ................................................................................................................ 16
5.6 Special operational requirement ................................................................................................................. 16
5.7 Valve with start-up side ............................................................................................................................... 17
5.8 Identification of the valve ............................................................................................................................ 19
6 Installation of the valve in the plant ............................................................................................ 20
6.1 Please observe before the installation in the pipeline! ............................................................................... 20
6.2 Installation of the valve................................................................................................................................ 24
6.2.1 Valve with flanges ................................................................................................................................................ 24
6.2.2 Valve with welding ends ...................................................................................................................................... 24
7 Pickling and flushing ................................................................................................................... 24

8 Disassembly ................................................................................................................................ 25
8.1 Valves with flanges....................................................................................................................................... 25
8.2 Valves with welding ends ............................................................................................................................. 25
9 Disassembly and assembly of the valve and the bypass ............................................................... 26
9.1 General assembly and disassembly information ......................................................................................... 26
9.2 Disassembly and inspection of the TDM valve ............................................................................................ 28
type TDM
9.3 Disassembly and inspection of the bypass trim ........................................................................................... 29

9.4 Assembly of the bypass trims ...................................................................................................................... 29
9.5 Assembling the valve ................................................................................................................................... 29
9.6 Disassembly of the start-up connection ...................................................................................................... 30
9.7 Assembly of the start-up connection ........................................................................................................... 30
9.8 Assembly tightening torques in Nm for expansion bolts and stud bolts (item 26, item 27, and item
27.1) .......... ……………………………………………………………………………………………………………………………………………………….31
10 Commissioning ........................................................................................................................... 33
11 Maintenance .............................................................................................................................. 34
12 Inspections and inspection schedules .......................................................................................... 35
12.1 Inspections ................................................................................................................................................... 35
12.2 Inspection schedules .................................................................................................................................... 35
13 Causes and remedies in the event of failures ............................................................................... 36
Appendix .......................................................................................................................................... 41
A.1 Form for the malfunction ................................................................................................................................. 41
type TDM
1 General
1.1 Customer service and procedure when servicing
Please contact for additional information:
SCHROEDAHL GmbH
Alte Schoenenbacher Str. 4
51580 Reichshof-Mittelagger
Tel.: +49-2265-9927-0
Fax: +49-2265-9927-927
E-Mail: schroedahl@circor.com
Internet: http://www.schroedahl.de
In the event of malfunctions, please fill out the form attached in the Annex and send to the following
contact person of SCHROEDAHL:
SCHROEDAHL GmbH
-After Sales Service-
Alte Schoenenbacher Str. 4
51580 Reichshof-Mittelagger
Tel.: +49-2265-9927-0
Fax: +49-2265-9927-927
E-Mail: schroedahl_service@circor.com
Internet: http://www.schroedahl.de
Information regarding the technical data of the valve can be found on the nameplate
(see Chapter 5.8 Identification of the valve).
INFORMATION
1.2 About this manual

General:
This manual applies to installation, maintenance, assembly and operation, unless otherwise agreed. Please refer to the
conditions agreed in the purchase order in this connection.
The manual contains basic instructions to be followed for transportation, storage, assembly, commissioning, operation,
maintenance and repair. This manual is therefore mandatorily to be read before transportation, storage, installation,
commissioning, operation, maintenance and repair by the qualified personnel as well as the assigned operator and
must be available at the place of operation.
Also please note in particular the rules and the operating instructions given together with the danger, warning and
information symbols. Your non-compliance can lead to damage to the valve as well as slight and heavy injury to
persons. If any questions arise after reading through the manual, then please contact the manufacturer or the
associated local Sales personnel.
type TDM
1.3 Applicability of this operating manual

This manual applies to valves of the series given on the cover sheet. The conformity of the above type designations with
the nameplate of the valve should be ensured before beginning any action and spare part order.
The rules, guidelines and notes given in this operating manual apply to delivery to the EU. Operators outside the EC, in
their sole responsibility, must consider the listed rules as a basis for safe handling and assess their implementation
against the rules applicable for the erection site.
1.3.1 Applicable documents

This operating manual always includes the standard documents of the valve, such as:
 Data sheet
 Sectional drawing
 Parts list
 Dimension sheet
These order-related documents are supplied along with each purchase order.
1.4 Subject to change

The rules, guidelines and notes mentioned in this operating manual correspond to the status of information at the time
of the order and are not subject to amendment service. The operator is responsible and obliged to apply them in their
latest and valid versions. In principle, the product suitability for a new version cannot be hereby derived.
1.5 Warranty/guarantee
The scope and period of a warranty have been specified especially in the "General Terms and Conditions of Sale" or in
the contract. The latest version, applicable at the time of delivery, is valid. The details given in this manual are used only
to specify the products, and no properties are assured.
Unless special conditions have been agreed upon in the order, our warranty is for 1 year, but limited to 24 months after
shipment outside EU.
The manufacturer accepts no liability for, or the warranty excludes, damages or breakdowns due to:
 Non-compliance with this installation, maintenance, assembly and operating manual.
 Damages that have obviously occurred during commissioning due to pollution or unusual operating manner.
 The pressure reduction units and seals subject to wear.
 Unsuitable or improper application as well as during unintended use.
 Faulty assembly, maintenance, incorrect commissioning or to improper operation.
 System-related vibrations of the plant that can arise under certain conditions during pump switching
operations, quick shut-off etc.
 Improper operating manner (deviating from the operating data in the data sheet).
 Incorrect or careless handling of the valve.
 Damages caused by components that do not belong to the valve itself.
 Contaminations in the medium (if different from the planned operating conditions).
 Use by inadequately qualified assembly, operating and/or maintenance personnel.
 Unauthorised reworks.
 Changes or reworks on the valve, which are improper or carried out without the prior approval of the
manufacturer.
type TDM
 Use of unapproved spare parts and accessories.
The trim parts and seals of the valve are considered as wear parts.
NOTE
Our warranty covers only the return and the replacement of faulty material or products.
NOTE
2 Explanation of symbols and safety instructions

This installation, maintenance, assembly and operating manual specifically focuses on dangers, risks and safety-relevant
details by means of an emphatic display.
Notes on dangers and warnings in the text describe rules of conduct, whose non-compliance can lead to serious injuries
or death of users or third parties or to property damage of the plant or the environment. They should be followed
without fail and marked with a warning triangle.
However, the observance of notes and details is equally indispensable to avoid breakdowns that can directly or
indirectly cause damages to personnel or property.
The following dangers, warnings and notes do not take into account any additional regional, local or company-specific
safety regulations and it is the responsibility of the operator himself to add them.
2.1 Explanation of symbols
Death, serious bodily injury or substantial property damage will occur, if the relevant precautions
are not taken.
DANGER
There is a threat of property damages or harmful environmental influences in the event of non-
compliance with warning.
WARNING
Is a reference to a possible advantage in the case of compliance with the recommendation.

NOTE
Gives useful tips and suggestions.

INFORMATION
type TDM
2.2 Notes on dangers and warnings
The valve is under pressure and usually at high temperature during operation.
DANGER Non-compliance can result in death, serious bodily injuries or substantial property damages.
The valve can also still contain the medium in a pressure-free condition.
Protection measures should be taken from the safety data sheets of the manufacturer of the medium.
Warning: Serious injuries possible!
DANGER
Suitable protective clothing is required for assembly and maintenance work.
As for their danger potential, valves should be treated equivalent to pressure containers. Therefore,
the standards, guidelines, accident-prevention regulations, reliability regulation, plant-specific safety
regulations corresponding to planning, installation, operation, testing, assembly and maintenance , the
relevant site regulations and the technical documents concerning the valve must be followed.
DANGER
Amended requirements or additions are also applicable at the time of installation and must be
complied with.
The valves should only be operated within their limits of design and layout. These limits should be
taken from the nameplate. They should be operated only within their specified performance limits (see
technical data). No modifications must be carried out on the valve without the approval of the
manufacturer. In particular, the values for the pressure rating, the design pressure, the design
temperature and test pressure must not be exceeded, since it may otherwise lead to overloading of the
DANGER valve.
Only those media must be used, against which the materials are resistant and whose application has
been planned for this. Dirty media or applications of the valve outside the specified values can lead to
component damages.
Assembly and maintenance work can only be carried out when the plant has been shut off and the
valve is without pressure and has cooled down. Please also follow the plant-specific guidelines.
DANGER
Avoid any contact with the valve during operation as there is a risk of trapping or crushing due to the
valve spindle procedure.
DANGER
Do not mount or operate the valve and do not carry out any adjustments on it, if the valve or the
supply lines have been damaged.
WARNING
The plant should be commissioned again only after completion of the installation and maintenance
work.
WARNING
type TDM
2.3 Safety instructions
Prerequisite for the installation, operation and maintenance of this valve is the engagement of qualified
personnel. It concerns the personnel who are familiar with the installation, commissioning, operation
and maintenance of the valve because of their technical training and experience. During the guarantee
period, these works must be carried out by SCHROEDAHL personnel or by the plant personnel with a
report to Schroedahl. The operator has the responsibility for it and monitoring of personnel must be
NOTE done by him. If the operator does not possess the required specialised knowledge, then a specialist
company should be engaged. Any person entrusted with one of the measures described in this
operating manual must have read and understood this manual.
Use appropriate tools and devices for installation, maintenance and assembly.
Use of spare parts should correspond to the parts list given in the order. These should be procured
exclusively from SCHROEDAHL or from our authorised dealers.
NOTE After completion of the installation, maintenance or repair, test the correct function of the valve and
check that there is no leakage in the connecting lines.
The valve should be regularly subjected to a safety check in accordance with the company-specific
safety regulations and statutory requirements. In this case, especially the pressurised components and
connecting elements should be checked for wear and corrosion.
NOTE
If the valve uses fluids that are harmful to the people or the environment, then the operator should fix
a warning note very close to the valve.
NOTE
Use of the valve other than as intended is not permitted.

NOTE
The valves should only be operated within their limits of design and layout.
NOTE
No modifications must be carried out on the valve without the consent or approval of the
manufacturer.
NOTE
For installation, operation, maintenance and assembly of the valve, the currently applicable standards,
guidelines, accident-prevention regulations, reliability regulation, plant-specific safety regulations, site
NOTE regulations and technical documents should be followed.
type TDM
3 Packing
 The valves should be sent from the works in a dry and good condition.
The port holes should be closed with plastic caps or such like.
 Depending on the size on a pallet, the valve is shipped in a skid-carton or a wooden crate. The warnings on the
packing must be followed. Special packing and conservation for larger periods of time must be indicated
separately in the purchase order.
 Transportation, unloading and lifting of the delivery unit must be carried out with the required caution as well
as using tools that correspond to the weight and the dimensions.
 Check the packaging for integrity at the time of delivery.
 Check the scope of supply for completeness.
 Check whether the identification of the valve on the name plate (see Chapter 5.8 Identification of the vale)
corresponds to your order.
 In the case of damage, incomplete or incorrect delivery, contact your forwarding agent, the person engaged
for transportation or us.
We accept no liability for damages resulting from improper transportation, loading or unloading.
NOTE
type TDM
4 Transport and storage
Improper transportation can cause property damages to a significant extent.

WARNING
Appropriate transportation and lifting devices must be used. For weights, see dimension sheet.
WARNING
The valve should be protected against external force (impact, shock, vibration, etc.).
WARNING
During transportation and intermediate storage, the following points should be respected.
 The valve should be stored in a dry, clean, well-ventilated and safe place until the assembly.
 The transportation and storage temperature should be between -10 °C and +50 °C. When stored below -10 °C,
our winter inerting regulations must be observed.
 Any damage to the corrosion protection (painting) should be immediately rectified.
 If the storage is to be done for a longer period of time (longer than 6 months), special packing and
conservation must be specially planned by you.
 Keep the valve using the factory protective measures (foils, boxes, pallets, etc.)
 The flange plugs must be removed only at the place of operation.
 Installation position, dimensions and weight of the valve should be documented in the dimension sheet and
complied with.
 In the case of valves with a weight of over 25 kg, it is necessary to ensure that mounting lugs and lifting tools
are available above the mounting location to a sufficient height.
type TDM
5 Description and technical data
5.1 Intended Use
The valves should only be operated within their limits of design and layout. These limits should be
taken from the nameplate. They should be operated only within their specified performance limits
(see technical data). In particular, the values for the pressure rating, the design pressure, the design
temperature and test pressure must not be exceeded, since it may otherwise lead to overloading of
DANGER the valve.
Only those media must be used, against which the materials are resistant. Dirty media or
applications of the valve outside the specified values can lead to component damages.
In the piping system, the usual flow velocities for continuous operation should not be exceeded.
Operating conditions such as vibration, pressure surges, cavitation and ingredients of solid
materials (in particular abrasive materials) in the medium must be clarified with the manufacturer
WARNING
in advance.
5.2 Structure of the valve type TDM

The minimum quantity valve, or the automatic recirculation valve (ARV), consists of the lower housing and upper
housing (item 01 and item 02) with the respective main attachment flanges. The bypass outlet (item 09) and optionally
even the manual start-up (item 09.1), see Chap. 5.7, are arranged horizontally on opposite sides. In the interior there is
the non-return plug (item 07), as well as the mechanically operating control and throttle section (items 10-16, 21, 23,
31-36).
The standard housing materials are carbon steel, stainless steel or duplex steel.
The selection of the housing materials depends on the design pressure, the design temperature and the medium. The
standard trim parts are manufactured from stainless steel with a chromium content of at least 13%. Other materials for
housing and trim parts are possible on request. The selection of the seal materials depends on the medium and the
temperature.
The valves of the type TDM are available in standard sizes from DN 25 (1") up to DN 300 (12") and pressure ratings of
PN 10 to PN 400 or class 150 to class 2500. Special sizes or special pressure ratings are possible on request.
Flanges conform to EN or ASME standards. Flanges in accordance with other standards and regulations (e.g. ISO, BS, JIS,
NF) as well as connections with welding ends are also possible on request.
type TDM
Housing
Item Description
01 Lower body
02 Upper body
03 Valve stemguide
04 Guide bolt
06 Spring
07 Non-return plug assembly
07.1 Non-return plug
07.2 Stem
08 Liner or venturi ring
09 Bypass branch
25 Guide Pin
26 Stud bolt
27 Stud bolt
28 Hexagon Nut
29 Hexagon Nut
30 O-ring
Figure 1 Sectional drawing and parts list of the valve type TDM (example)
Bypass Type TDM

Item Description
10 Vortex bushing
11 Control head
12 Vortex Plug
13 Lever
14 Pivot pin
15 Relief Bushing
16 Relief Piston
21 Threaded Ring
23 Orifice plate / nozzle
31 O-ring
32 O-ring
33 O-ring
33.1 Glyd ring
34 O-ring
34.1 Glyd ring
35 O-ring
35.1 Glyd ring
36 O-ring
Figure 2 Sectional drawing and parts list of the bypass type TDM (example)
type TDM
5.3 Functioning of the valve type TDM

This automatic recirculation valve is a flow-actuated valve, which automatically maintains the minimum flow required
for the reliability of the pump and thus protects the centrifugal pumps against overheating, loss of stability and
cavitation. The design TDM, which consists of several vortex-pressure reduction stages is independent of the
temperature, to a differential pressure from 20 bar up to 230 bar. As soon as the main delivery flow falls below a
certain value, then the valve opens its bypass so far, that always the required minimum delivery of the pump is
bypassed, even if the main delivery flow is zero.
By the main delivery flow to the process, the non-return plug (item 07), item numbers of the components, see page 11,
is brought to a certain vertical position and its position changes depending on the pump flow. The non-return plug (item
07) transmits this movement to the control lever (item 13) of the bypass system. The movement of the lever (item 13)
is transmitted via a control piston (item 16) to the multi-stage vortex plug (item 12). The highly pressure-reduced
minimum delivery flow is thereby modulated by way of the bypass outlet via numerous pressure-reduction stages to
the feed tank.
The opening of vortex plug (item 12) increases linearly, as the non-return plug (item 07) goes to the closed position.
When the non-return plug (item 07) is fully closed the entire minimum quantity is passed through the bypass (item 10-
16, 21, 23, 31-36). Conversely, the bypass (item 10-16, 21, 23, 31-36) is completely closed and the full pump flow is fed
to the system if the non-return plug (item 07) is in the uppermost position. As a result of this modulated control, the
sum of delivery flow and minimum volume remains approximately constant.
The spring-loaded non-return plug (item 07) designed as a control unit, has such a high natural frequency, that the
dreaded water hammering is avoided. It dampens pulsations because of its throttling effect on the main flow and
stabilises unstable pump characteristics in the partial load range.
type TDM
Minimum quantity delivery

flow
Main delivery
flow
Figure 3 TDM valve with closed non-return plug and open bypass
Main delivery flow
Figure 4 TDM valve with open non-return plug and closed bypass (switch point)
Main delivery flow
Figure 5 TDM valve with open non-return plug in maximum flow level and closed bypass
type TDM
5.4 General notes regarding operation of the valve

In general, unless otherwise agreed, the automatic pump protection valve is designed for a normal operational
requirement of the process volume flow from 40% to 100%.
In the high-pressure range above 120 bar bypass differential pressure, the required pressure in the bypass return line is
to be 4 bar higher than the pressure of the liquid in the saturation state for the operating medium Water 1) and
mixtures thereof. Any conditions differing from this must be agreed upon.
The operating conditions considered in the valve design are documented in the order through associated data sheet.
Pressure loss P/R in bar

Main flow m³/h
Valve lift in %
Minimum quantity flow Process flow R
Pump flow P Pressure loss P-R
Figure6 Characteristic curve of a minimum quantity valve of the type TDM

1) Water includes: distilled water, demineralised water, sea water condensate and similar
type TDM
5.5 Normal operational requirement

The valve is normally used in a load range between 40% and 100% of the rated flow. The automatic recirculation valve
is mainly used in the limited start-up and withdrawal operations and it assumes here the modulating bypass control.
The maximum differential pressure between the valve TDM and the bypass system is up to 230 bar.
If the order documents and the data sheet do not specify any operational requirement, then the normal operational
requirement is presumed and considered. Any deviating condition must be explicitly agreed upon.
Delivery head H - Flow Q [in %]

Delivery head H B) Special operational requirement
180%
160%
Operating point at the
140% maximum flow
P100 [Q100; H100]
120%
100%
80% Operating point at Bypass (valve) switch
minimum flow point SP
60%
[QM; HM]
40%
20% A) Normal operational requirement
0%
0% 20% 40% 60% 80% 100% 120% 140%
Flow Q
Figure 7 Normal and special operational requirement
5.6 Special operational requirement

For applications in the full load range from 0% to 100% in the process flow, any special design characteristics, which can
affect the valve functioning, must be verified before placing purchase order. This operational requirement must be
specified in the purchase order and confirmed through the data sheet. In the case of this operational requirement, an
enhanced requirement arises with respect to the valve design and the bypass back pressure.
If no high back pressure can be ensured for the valve during the plant operation, then the use of a back pressure
controller of the type BPV is necessary, because it must be ensured at any point of time that the bypass back pressure
in the bypass return line is always 4 bar higher than the pressure of the liquid in the saturation condition.
For the above reason, the special operational requirement does not allow the use of a simple orifice plate for pressure
accumulation. The level of the required pressure in the return line is specified at the time of placing the order and can
differ from the above-mentioned general requirement of 4 bar. Deviating conditions must be explicitly agreed.
type TDM
5.7 Valve with start-up side

Depending on the plant design or additional requirements, the valve may require an additional start-up side. A variety
of options can be selected for the start-up/heating side (A).
Option A Option B
B-TDM
Figure 8 Valve type TDM with different manual start-ups A1-A5 (left) and B-TDM (right)
type TDM
Option A:
A commonly used option is that low-pressure fluid flows through the start-up as shown in (Fig. 8) are required to the
process/boiler or to the neighbouring pumps/systems for the heating process.
Additional connection options (on request):
A1: Start-up/warm-up above check valve (direction of flow from lower part item 01 to start-up item 09.1)
A2: Start-up/warm-up below check valve (direction of flow from lower part item 01 to start-up item 09.1)
A3: Warm-up above check valve (direction of flow from start-up item 09.1 to lower part item 01)
A4: Warm-up below check valve (direction of flow from start-up item 09.1 to lower part item 01)
A5: Degassing system (direction of flow lower part item 01 to start-up item 09.1)
Option B:
Depending on the operating and commissioning conditions of the plant (dirt, certain load cases, etc.), special trim parts
can be selected for the bypass. The valve is then supplied with the integrated optional bypass set. The original trim
parts for the bypass are included here (must be installed after the commissioning).
type TDM
5.8 Identification of the valve

The specific technical data of the valve are mentioned on the nameplate. The nameplate is fixed on each valve housing
and should not be removed. The identification includes at least the following details:
 Name of the manufacturer
 Nominal width
 PN designation
 Maximum allowable pressure PS
 Maximum allowable temperature TS
 Test pressure PT
 Material
 Order number (serial number)
 Type of valve
 Year of manufacture
 CE marking (if necessary and possible)
Specific valve data are indicated on the valve nameplate as per sample below:
Figure 9 Example of a nameplate of the type TDM
In the case of spare part deliveries, basically the order number (serial number), the type and the part number from the
parts list should be mentioned.
If within an order item several valves are supplied, then the nameplates should be additionally marked with a serial
number beginning with "1". This ensures that the corresponding valves can be related.
type TDM
6 Installation of the valve in the plant
6.1 Please observe before the installation in the pipeline!
The valve must be installed when the pipeline is in a cooled condition.

Valves, which are operated with high or low temperatures (T > 60 °C or T < 0 °C), must be protected
against accidental contact.
DANGER
The valve should be installed in the pipeline according to the flow arrows marked on the housing.
It should be ensured that the flange pads and the seals are clean and free of damages, before
tightening the bolts with the torque wrench for the appropriate tightening torque.
Use only the provided bolts and seals of the manufacturer for installation of the valve in the plumbing
WARNING
system.
Remove flange covers, if present.

WARNING
The inner parts of the valve and the pipeline must be free of foreign particles.
WARNING
Installation position of the valve with respect to the flow should be correctly maintained; see
identification on the valve.
WARNING
For assembly work, appropriate transportation and lifting devices must be used. For weights, see
catalogue sheet.
WARNING
In order to avoid damages to the flange pads and/or bolts, the valve assembly must be mounted in the
plumbing system without stress.
NOTE
The valve should be installed as close as possible to the discharge flange of the centrifugal pump,
preferably directly on the pump discharge flange. If this is not possible, the distance between the pump
outlet and valve inlet should not exceed 3 m, in order to avoid frequency shocks caused by pressure
NOTE pulsation of the medium.
In the case of indirect assembly on the pump discharge flange, the valve requires at the inlet a straight
stretch of at least 2 x DN (no bends).
NOTE
type TDM
Unless agreed by a separate specification, the following should be considered prior to installation of the valve:
 The valve is generally installed in a vertical position upwards in the flow direction and directly on the outlet
flange of the pump. The recommended installation position is the vertical main passage, but also horizontal
installation is possible on request. The bypass line should also be horizontal in the case of horizontal mounting.
 For high pressure applications from PN 64/class 300, a straight outlet stretch of at least 3 x DN is
recommended at the bypass connection.
 Removal of the protective caps.
 Installation position, dimensions and weight of the valve should be documented in the dimension sheet and
complied with.
 In the case of valves with a weight of over 25 kg, it is necessary to ensure that mounting lugs and lifting tools
are available above the mounting location to a sufficient height.
 Prior to installation, the details of materials, pressure and temperature should be compared with the design
and operating conditions of the plumbing system.
 Verification of identification on the nameplate with the operating data of the system. Any mismatch may lead
to significant damages of valves, for which the manufacturer shall not be liable.
 Check that sufficient space (hoist for assembly, etc.) is available at the installation location for easy installation
and removal.
 Check that the pipeline has been flushed and cleaned before installation. If not, the manufacturer accepts no
liability for the resulting damages.
 Check that the distance between pipe ends matches the valve length.
 Plumbing system must be correctly installed so that mechanical stresses (e.g., forces and moments from
pipeline expansions during the operation, vibrations, etc.) do not act on the valve housing during installation
and operation.
 Pipeline forces can be applied by the valve only to the extent, as they were considered by the specified
pressure classes (flange geometry) and selection of material while planning the pipe system. Additional
requirements need a special confirmation.
type TDM
Figure 10 Typical representation of the handling options when installing the valve
type TDM
Valve installation:
To the
process
Placement of BPV
Straight pipe section ≥ 3 x NPS or orifice plate -> As
near as possible to
the tank
Bypass line
ARV Tank
1) Optimum distance: zero!

Pump
2) Maximum 3 m considering a
straight pipe section of ≥ 2 x DN
No elbows at the valve inlet!
Figure 11 Schematic representation of the installation conditions for the pump protection valve
To prevent low frequency shocks caused by pulsation of the medium, the distance between pump
outlet and valve inlet should not exceed 3 m. Also a straight inlet pipe stretch should be provided.
Deviations should be clarified with the manufacturer.
NOTE
The recommended filter at the pump outlet should have a maximum mesh size of 0.3 to 0.5 mm.
During commissioning we recommend a smaller filter mesh size (e.g. 0.1 mm).
NOTE
type TDM
6.2 Installation of the valve

6.2.1 Valve with flanges
The sealing surfaces of the attachment flanges must be clean and without damages.
Flange gaskets must be mounted centrally and should not constrict the flow space.
The flanges should be carefully aligned before bolting. All provided flange holes must be used for the flange
attachment. The bolts must be tightened according to the specifications given in the plumbing plan.
6.2.2 Valve with welding ends
It is pointed out that the valves are welded by qualified personnel with appropriate tools and according
to established engineering practices. The responsibility rests with the plant operator.
NOTE
The welding process should be chosen according to the specifications given in the plumbing plan.
While welding the valve, the valve housing must not be used to test the welding electrode or the polarity.
During the welding process and any subsequent heat treatment required, the trim parts must be removed. If
elastomeric seals are provided between the upper body and the lower body, and for the bypass housing, then they
must be removed.
7 Pickling and flushing
The materials used in the valve are in general suitable for pickling. In practice, during pickling and flushing, impurities
and foreign objects pass through the valves. This may result in damages to the trim parts.
During the flushing operation, the trim parts of the valve may be damaged by foreign objects.
Therefore, we recommend to replace the trims with appropriate protective inserts prior to pickling or flushing.
After pickling and flushing, the valve must be cleaned and the seals must be replaced.
Any foreign object, which remains in the valve after pickling or flushing, may damage the valve.
NOTE
type TDM
8 Disassembly
The valve must be without pressure, drained and in cooled condition.

DANGER
Notes given in the corresponding dimension sheet must be followed
8.1 Valves with flanges

1. Suspend the valve, but do not lift.
2. Remove the flange bolts.
3. Remove the valve from the pipeline.
4. Store the valve in a protected condition.
The flange sealing surfaces of the valve must not be damaged during the removal of the pipeline and
must be closed with suitable plastic caps or such like.
NOTE
8.2 Valves with welding ends

For valves with welding ends, the housing cannot be removed. This requires a mechanical destruction of the connection
of housing and pipeline or the plumbing system allows a displacement of the pipe parts (responsibility of the plant
operator).
type TDM
9 Disassembly and assembly of the valve and the bypass
9.1 General assembly and disassembly information

Due to the high precision and close tolerances, maximum cleanliness and proper handling should be ensured. Any
contamination or damage puts the proper operation in jeopardy.
No special tools are required for the assembly or disassembly of the valve.
Before disassembling the valve, the valve must be without pressure, drained and in cooled condition!
Also, remember that the piping on the bypass unit is part of the high-pressure stage!
DANGER
Before beginning any work ensure the following:
 Work correctly and safely according to the applicable regulations as well as the warnings and
notes in this operating manual.
 Valves are pressure equipment! Any improper opening of the valve may endanger your health!
The plant must be without pressure and dry before the disassembly.
 The pump must be switched off and secured against switching on again.
 Block the pipeline upstream and downstream of the valve.
 Remove the pressure from the pipe section.
 Allow the valve to cool to room temperature.
 Find out from the safety data sheet about the contents of the line and properly drain all
hazardous and/or groundwater-endangering media from the blocked pipe section.
WARNING
 Ensure the personal protective equipment prescribed in the safety data sheet.
 Immediately wipe away leakages and/or collect larger amounts or residues of medium in
suitable containers.
 Always properly dispose of residues of medium (only in the case of hazardous media) in
accordance with the Law on Waste. Never allow leakages/residues of medium seep into the
sewerage system.
type TDM
Remove flange covers, if present.

WARNING
The interiors of the valve and the pipeline must be free of foreign particles.
WARNING
Installation position of the valve with respect to the flow should be correctly maintained; see
identification on the valve.
WARNING
For assembly work, appropriate transportation and lifting devices must be used. For weights see
dimension sheet.
WARNING
Special safety regulations and risk analyses must be performed before any maintenance, so that risks to
humans and the environment are excluded!
WARNING
Please also refer to films on maintenance on our website:

www.schroedahl.com
INFORMATION http://schroedahl.com/en/media-services/maintenance-movie/TDM/
type TDM
9.2 Disassembly and inspection of the TDM valve
Before disassembling the valve, the valve must be without pressure, drained and in cooled condition!
Also, remember that the piping on the bypass unit is part of the high-pressure stage!
WARNING
The pipeline system must be ventilated after prior emptying in the case of corrosive, combustible,
aggressive or toxic media.
WARNING
Please check before dismantling that sufficient spare parts and seals are available!
NOTE
Spare parts have a delivery time of 12 weeks or more!

NOTE
Procedure for removal:
1. Depressurise the system!
2. Remove the valve from the system (pump pipelines).
3. Loosen the hexagon nuts (item 29) and disassembly of the bypass housing (item 09).
4. Carefully lift out the bypass internals using a screwdriver or an assembly lever, which is set at the collar of the
control head (item 11) and the lower part (item 01).
5. Separate the upper body (item 02) from the lower body (item 01) after loosening the hexagon nuts (item 28).
Observe the preload of the spring (item 06)!

WARNING
6. The non-return plug (item 07) and spring (item 06) can then be removed from the lower body (item 01).
Inspection:
1. Clean all parts and check for any damages.
2. In case of damages to the seating areas, the components must be replaced with new ones.
3. Replace the o-ring (item 30).

type TDM
9.3 Disassembly and inspection of the bypass trim
Occasionally, and because of contamination of the fluid, a complete disassembly of the bypass trim
may be required!
In the case of each revision, the bypass trim is checked for its proper condition. If there are visible
WARNING damages, then the bypass trim must be disassembled and the affected parts should be replaced!
In case of doubt, the complete bypass assembly (items 10-16, 21, 23, 31-36) should be replaced and the
disassembled bypass trim should be sent to the factory for repair!
NOTE All seals (item 31-36) and glyd-rings (item 33.1, 34.1 and 35.1) should be replaced!
Inspection:
1. Check the contact area of the vortex plug (item 12) and the contact area of the vortex bushing (item 10) for
any damages.
2. In the case of damages, the valve plug (item 12) and the vortex bushing (item 10) should always be replaced as
a unit.
3. The orifice plate or nozzles (item 23 must be checked for damage.
9.4 Assembly of the bypass trims
The bypass trim is assembled in the reverse order compared to that described earlier in Chapter 9.3.
9.5 Assembling the valve
Procedure for assembly:
1. Replace the non-return plug (item 07) with the spring (item 06) in the lower body (item 01).
2. Pre-assemble parts of the bypass (items 10, 23, 32 and 36) on the bypass housing (item 09).
3. Carefully slide the parts of bypass (items 11-16, 21, 25, 31, 33-35) in the lower body (item 01) and ensure that
the control lever (item 13) is inserted in the slot of the taper stem (item 07.2).
4. Fit the bypass housing (item 09) with pre-assembled parts of the bypass on to the lower body (item 01) and
fasten using the hexagon bolts (item 27)/the hexagon nuts (item 29).
5. Tighten the hexagon bolts (item 27)/hexagon nuts (item 29) evenly with the required torque (see Chap. 9.8)
using a torque wrench.
6. Carefully set the upper body (item 02) on the lower body (item 01) and fasten using the hexagon bolts (item
26)/the hexagon nuts (item 28).
7. Tighten the hexagon bolts (item 26)/hexagon nuts (item 28) evenly with the required torque (see Chap. 9.8)
using a torque wrench.
type TDM
9.6 Disassembly of the start-up connection
Manual start-up connection type

TDM
Item Description
09.1 Bypass housing (start-up)
10.1 Vortex bushing
18 Start-up vortex plug
19 Holder
20 Cotter
23.1 Orifice plate or nozzle
27.1 Stud bolt
29.1 Hexagon Nut
31.1 O-ring
32.1 O-ring
36.1 O-ring
Figure 12 Manual start-up connection type TDM with parts list
Procedure for removal:
1. Loosen the hexagon nuts (item 29.1)

2. Remove the bypass housing (item 09.1)
3. Remove cotter (item 20) and unscrew start-up vortex plug (item 18).
Inspection:
1. In the case of damage to the start-up vortex plug (item 18) or the vortex seat (item 10.1), the complete start-
up connection including orifice plate or nozzle (item 23.1) must be replaced.
2. The O-rings (item 31.1, 32.1 and 36.1) should be always replaced.
9.7 Assembly of the start-up connection

1. The start-up insert is assembled in the reverse order compared to that described earlier in Chapter 9.6.
2. Tighten the hexagon bolts (item 27.1)/hexagon nuts (item 29.1) evenly with the required torque (see Chap.
9.8) using a torque wrench.
type TDM
9.8 Assembly tightening torques in Nm for expansion bolts and stud bolts (item 26, item
27, and item 27.1)
If no data have been indicated on assembly tightening torque for expansion bolts or shoulder studs in the drawings
accompanying the order, then the tables below apply.
Expansion bolts or shoulder studs should be tightened only in the unpressurised and cool condition of
the valve with the appropriate tightening torque according to Table 1 and Table 2, respectively.
NOTE
Bolt material
Thread size 8.8 1.7225 1.7709 1.4923
M12 44 60 37 40
M16 117 133 98 107
M20 229 260 190 208
M24 395 448 329 359
M27 576 654 480 523
M30 805 915 671 732
M33 1,089 1,237 907 990
M36 1,381 1,569 1,150 1,255
M39 1,840 2,091 1,533 1,673
M42 2,250 2,216 1,875 2,045
M45 2,876 2,833 2,397 2,615
M48 3,423 3,371 2,853 3,112
M64 8,442 8,314 7,035 7,674
Table 1 Assembly tightening torques in Nm for expansion bolts (item 26, item 27 and item 27.1)
type TDM
Bolt material
Thread size 8.8 1.7225 1.7709 1.4923
M12 66 89 55 60
M16 162 184 135 147
M20 316 360 264 288
M24 547 621 455 497
M27 801 910 668 728
M30 1,086 1,234 905 987
M33 1,478 1,680 1,232 1,344
M36 1,899 2,158 1,582 1,726
M39 2,457 2,792 2,048 2,234
M42 3,040 2,994 2,533 2,764
M45 3,795 3,737 3,162 3,450
M48 4,566 4,497 3,805 4,151
M64 11,058 10,890 9,215 10,053
Table 2 Assembly tightening torques in Nm for stud bolts (item 26, item 27 and item 27.1)
type TDM
10 Commissioning
The valve is commissioned subsequent to commissioning of the pump. When the pump starts, the prescribed amount
of minimum flow automatically flows through the bypass of the valve when the main shut-off valve in the main line is
closed. By actuating the shut-off valve in the main line the opening and closing of the bypass can be controlled. The
switch point is acoustically perceptible (use a stethoscope or a screwdriver to hear the flow) or check the flow from the
flow and pressure readings in the plant.
If the minimum flow is sent through the bypass during start-up of the plant over a period of time, the technically high-
quality control elements can be exposed to increased wear. In order to avoid this, a so-called start-up trim can be
installed in the start-up phase, which however has higher tolerances and a lower control quality. Therefore, the
modulating bypass control described in Section 5.3 has not been provided.
If a manual start-up connection has been installed on the valve, the minimum volume flow through this unit can be
achieved for specific start-up conditions. While using the manual start-up side, the normal bypass side is closed
downstream by the shut-off valve, but the shut-off valve on the start-up side is opened beforehand. The automatic
bypass unit is protected by this procedure during commissioning, because the fluid might be contaminated, or might
contain foreign objects, which can damage the valve.
The valves must not be operated outside the permissible fields of application. The limits of usage can
be found on the nameplate.
WARNING
Residues in pipelines and valves (such as dirt, welding beads, etc.) cause leakages or damages.
WARNING
When operating at high (> 50 °C) or low (< 0 °C) temperatures of the media, there is risk of injury when
touching the valve. If necessary, put up warnings or make insulation protection!
WARNING
Before each commissioning, after reworks and repairs, proper completion of all installation works must
be ensured.
WARNING
If the valve is operated with other operating data, then increased wear of the parts should be expected,
depending on the variation in the design data.
In the case of changed operating data, we recommend to consult the manufacturer, so that the valve
NOTE can be specifically set to the operating conditions.
After commissioning, an inspection of the valve is recommended, in order to ensure that there are no
damages to the valve!
NOTE
type TDM
11 Maintenance
The valve of the type TDM has been so designed, that no special maintenance is required. It is confined to cleaning of
trim parts during regular maintenance of the pump or similar plant components and regular replacement of seals, at
least every 2 years. When disassembling the valve, it is to be ensured that new set of seals are used.
The valve should be checked regularly.
We recommend a maintenance after commissioning and periodic changing of the seals, at least every 2 years. In
addition, we recommend to maintain a bypass set in stock.
The valve is under pressure and usually at high temperature during operation.
Non-compliance can result in death, serious bodily injuries or property damages.
 Assembly and maintenance work can only be carried out when the plant has been shut off and
the valve is without pressure and has cooled down.
DANGER
 The plant should be commissioned again only after completion of the installation and
maintenance work
The valve can also still contain the medium in a pressure-free condition.
Protection measures should be taken from the safety data sheets of the manufacturer of the medium!
Warning: Serious injuries possible!

DANGER
Suitable protective clothing is required for assembly and maintenance work.
Servicing and maintenance works must be carried out only by qualified personnel!
NOTE
Standard spare parts have a delivery time of 12 weeks or more!

NOTE
The operator is responsible for compliance with the safety regulations applicable at the place of
erection!
NOTE
type TDM
12 Inspections and inspection schedules
12.1 Inspections
The valve has been designed and manufactured, such that maximum quality and service friendliness is achieved. This
results in a lower need for care and maintenance of the valve.
The valve should be regularly subjected to a safety check in accordance with the company-specific
safety regulations and statutory requirements. In this case, especially the pressurised components and
connecting elements should be checked for wear and corrosion.
NOTE
Necessary checks before commissioning and after significant changes in the plant and repetitive checks should be
carried out by the operator as required by the national regulations.
A test of valve performance can be performed ideally with the original pump. The Kv/Cv value testing can be performed
on our test bench and certified.
Please contact SCHROEDAHL for additional information.
12.2 Inspection schedules

We recommend inspection of the valve according to the Table below during the regular maintenance of the pump or
pump systems, when plant is not operating, or at the latest every 2 years.
Inspection
Components Items Measures
time
Housing 01 02 09 09.1*) Inspection
Internal parts 03 03.1**) 04 06 07 08 Inspection
10 10.1*) 11 12 13 14 Maintenance
of the pump Check and
Bypass internal
15 16 18*) 19*) 20*) 21 or pump replace if
parts
systems necessary
23 23.1*) 25
Expansion screws or
/ shank screws or when the
26 27 27.1*) 28 29 29.1*) Inspection
and hexagonal plant is not
nuts operating
30 31 31.1*) 32 32.1*) or
Seals/ Glyd-rings 33 33.1 34 34.1 every 2 years Replacement
35 35.1 36 36.1*)
Guiding rings**) 41 42 Inspection
*) For valves with start-up / heating side
**) For valves from size TDM13...

Table 3 Test intervals for the components of the valve type TDM
type TDM
13 Causes and remedies in the event of failures

In the case of failures or improper operation it is to be checked whether assembly and adjustments have been carried
out and completed in accordance with this operating manual.
Before beginning any work ensure the following:
 Work correctly and safely according to the applicable regulations as well as the warnings and
notes in this operating manual.
 Valves are pressure equipment! Any improper opening of the valve may endanger your health!
The plant must be without pressure and dry before the disassembly.
 The pump must be switched off and secured against switching on again.
 Block the pipeline upstream and downstream of the valve.
 Remove the pressure from the pipe section.
WARNING  Allow the valve to cool to room temperature.
 Find out from the safety data sheet about the contents of the line and properly drain all
hazardous and/or groundwater-endangering media from the blocked pipe section.
 Ensure the personal protective equipment prescribed in the safety data sheet.
 Immediately wipe away leakages and/or collect larger amounts or residues of medium in
suitable containers.
 Always properly dispose of residues of medium (only in the case of hazardous media) in
accordance with the Law on Waste. Never allow leakages/residues of medium seep into the
sewerage system.
For troubleshooting, follow the safety instructions in Chapter 2.3.!

NOTE
If the measures below do not lead to a satisfactory result, the manufacturer/supplier must be contacted.
type TDM
Defects No. Possible causes Measures

1.1  Flange covers (transportation  Remove flange covers
1. No flow protection) not removed (transportation protection)
2.1  Contaminated strainer (dirt trap)  Clean or replace the strainer
2.2  Blockage in the plumbing system  Check the plumbing system
2.3  Valve designed for 40% - 100%  Communicate operating data

operating condition, but and duration of operation of the
operation below 40% or plant to the manufacturer, in
occasionally below 40% during order to verify that the
the start-up and shut-down parameters agree with the
design data of the valve. In the
case of deviation of operating
data and design data of the
valve, they will be modified and
adapted by the manufacturer
2.4  Wear or damage of the valve or  Replacement of the valve or the

the bypass unit due to vapour bypass unit
and condensation shocks and
cavitation
2. Low valve flow

type TDM
2.5  Back pressure in the bypass line  At high pressures in the bypass
set incorrectly or too low or BPV line, the pressure must be about
(back pressure controller) is 4 bar higher than the vapour
defective pressure of the medium (water).
Increase in temperature (15 °C
to 20 °C) of the medium due to
the pump must be taken into
account
 Increase the pressure in the

tank or move BPV directly (as
close as possible) to the tank
 Investigation of the vapour

content after the BPV and the
arrangement of the pipe to the
tank
 Checking the dimensions of the

BPV with existing operating data
of the plant by the
manufacturer
2.6  The valve not installed in  Install the valve in the direction
direction of flow of flow
3.1  Non-return plug (item 07) does  Remove foreign objects in the
not close fully seating area. If there is
corrosion or wear, remove the
valve and send or request for
manufacturer's service
3.2  Valve seat at the lower body  Replace the valve or rework the
(item 01) or non-return plug sealing surfaces of the valve
(item 07) damaged due to seat in the lower body (item 01)
foreign objects (grinding) and replace the non-
3. Leakage of valve return plug (item 07)
seat 3.3  Too small back pressure 𝑃𝑁  See para. 2.5
type TDM
4.1  Incorrect tightening torque of  Check tightening torques of the

stud bolts/hexagon nuts (item stud bolts/hexagon nuts (item
26 and item 28) or too small 26 and item 28) (see chapter
pressing force on the seal (item 9.8) and, if necessary, retighten
30) it with the correct tightening
4. Leakage between torque (using torque wrench)
upper part (item 2)
and lower part (item 1) 4.2  Uneven seal pressure  Set a uniform gap by tightening
the nuts in the correct sequence
(through torque wrench)
4.3  Damaged seal (O-ring, item 30)  Replacement of damaged seal

(O-ring, item 30)
5.1  Incorrect tightening torque of  Check tightening torques of the

stud bolts/hexagon nuts (item stud bolts/hexagon nuts (item
27 and item 29) or too small 27 and item 29) (see chapter
pressing force on the seal (item 9.7) and, if necessary, retighten
30) it with the correct tightening
5. Leakage between torque (using torque wrench)
lower body (item 1)
and bypass housing 5.2  Uneven seal pressure  Set a uniform gap by tightening
(item 9) the nuts in the correct sequence
(through torque wrench)
5.3  Damaged seals (O-rings, item 31)  Exchange of damaged seals (O-
on the control head rings, item 31) on the control
head
6.1  Inner parts of the bypass or the  Inner parts of the bypass or the
complete bypass (items 10-16, complete bypass (items 10-16,
21, 23, 31-36) worn out and/or 21, 23, 31-36) must be checked
6. Bypass of the valve defective due to and replaced if worn. In
debris/impurities addition, a filter/strainer with
is leaking maximum mesh width of 0.5
mm should be included
7.1  The plumbing system or medium  Inspection of pipeline and valve,

not clean, possibly happens whether contaminants are
during commissioning present and clean accordingly.
In the case of contaminated
water, an additional filter (max.
mesh size 0.5 mm) should be
7. Functional failure or installed
jamming of the valve
7.2  High wear or damage to the  Replacement of the valve or
valve and/or bypass unit worn components on the valve
f
type TDM
8.1  Cavitation on the TDM bypass  Check the back pressure and, if
unit necessary, increase
8.2  Minimum quantity of the pump  Inform the manufacturer

too low
8.3  Dirty filter/strainer  Clean or replace the

filter/strainer
8.4  Operating data of the system do  Correct the operating data and
not match with those given in forward the new operating data
the data sheet to manufacturer
8.5  Damaged trim parts  Inspection of the valve: clean or

replace trim parts
8. Oscillations,
vibrations and
8.6  Distance between pump outlet  Reduce the distance between
pressure surges in the and valve inlet > 3 m pump outlet and valve inlet (< 3
valve m)
8.7  Bend in inlet pipe stretch  Straight inlet pipe stretch (avoid
bend)
8.8  Pump characteristic not stable  Check operation of the pump

due to unforeseen pump and stabilise pump
switching operations or quick characteristic
shut-downs of the pump
8.9  Back pressure is too low and not  Forward to the manufacturer
stable the details of arrangement of
the pipes in the main and
bypass lines for checking
Table 4 Causes and measures for malfunctions of the valve type TDM
type TDM
Appendix
A.1 Form for the malfunction

Meldung zur Betriebsstörung / Failure Report
Achtung Im Falle einer Störung ist dieses Formular ausgefüllt an Ihren Ansprechpartner bei
Schroedahl zu senden.
Attention In the case of a failure please fill out this report and send it back to your Schroedahl
contact partner.
Allgemeine Information / General Information
Anlagendaten / site information: Ansprechpartner / contact partner:
Name / Name: Name / Name:
Adresse / Address: Tel.-Nr. / Tel.-No.:
Fax.-Nr. / Fax.-No.:
Land / Country:
Email:
Ventildaten / Valve information

Schroedahl Ventiltype / valve type:
Schroedahl Kommissionsnummer / serial number:
Datum der Inbetriebnahme / date of commissioning:
Betriebsstunden / operation hours:
Aktuelle Betriebsdaten der Pumpe / Current pump operating data

Zulaufdruck / suction pressure:
Gegendruck Bypass / back pressure bypass:
Enddruck / discharge pressure:
Fördermenge / flow rate:
Mindest kontinuierliche Prozessmenge / Miniumum continuous process flow:
Temperatur Fördermedium / medium temperature:
Beschreibung der Betriebsstörung / Description of failure
Datum der Störung / date of failure:
Kurzbeschreibung der Störung / brief failure description:

9.6 Valves and equipment
Data Sheet
Operating Manual
HGM 405 of 492

Strainers
Main pump
Type Y-type strainer

Standard ZN 1652
Manufacturer nach Wahl KSB / acc. to KSB
Type YFB1-80-PN16
Quantity 2
Installation Horizontal or vertical
Weight kg 35
DN DN: 80
PN PN: 16
Type Fine wire mesh 0.5 mm
Material CrNiSt
Length mm 318
Head loss m 0.69 (with clean strainer)
The strainer in the inlet pipe serves as an additional pump protection and is destined to hold back welding beads,
scale and other impurities (>500µm) from the pump. It is not intended to as a filtration system, since the gaps
within the pumps are smaller than 500µm. A strainer with smaller mesh width can be quoted as an additional
option. In any case, a filtration system must be installed by customer, independent from the mesh size of the
strainer.
Rev./ Rev.
Spec./Spec. Date/Date
Installation & Maintenance MM-FYC/MM-FYC 0 20.05.07
Manual Sheet:/Fiche: 1 of/sur 3
ENGINEERING Spa
Manuel d'installation et de
maintenance
READ CAREFULLY BEFORE USING THE PRODUCT
Before reading the instructions please consider the drawings are an integral part of this manual
and that all information & limitations contained in these drawings are applicable.
The supplied strainers are designed and manufactured to retain impurities according to the
required filtration grade. They shall be used only for the medium and within the
pressure/temperature limits indicated on the drawings as well as the name plates fixed on the
strainers. Exceeding such pressure /temperature limits is not allowed and may be very dangerous.
The strainers are supplied without safety devices. It is the user responsibility to adopt safety
procedures and regulations in order to prevent the improper use of the strainers.
The life expectancy of the filters is 10 years.
LIRE ATTENTIVEMENT AVANT D'UTILISER LE PRODUIT
Avant de lire ces instructions, veuillez consulter les schémas qui sont partie intégrante de ce
manuel et tenir compte de toutes les informations et restrictions contenues dans ces schémas.
Les filtres à tamis que nous fournissons sont conçus et fabriqués pour retenir les impuretés
conformément aux degrés de filtration requis. Ils doivent être utilisés uniquement à cette fin et en
respectant les limites de pression et de température indiquées sur les schémas ainsi que les
plaques d'identification fixées sur les filtres à tamis. Il est interdit de dépasser ces limites de
pression et de température sous peine de danger.
Les filtres à tamis sont fournis sans dispositif de sécurité. Il est de la responsabilité de l'utilisateur
d'adopter les procédures et règles de sécurité permettant d'éviter toute utilisation impropre des
filtres à tamis.
La durée de vie des filtres est de 10 ans.
INSTALLATION INSTRUCTION
For a proper installation ensure that the following recommendations are followed:
1. Before installation carefully inspect the strainer for possible damage during transportation
or handling.
2. Check the inside of the strainer for foreign objects that may have fallen inside.
3. When installing the strainer in the pipeline the arrow on the body must point to the direction
of the flow.
4. When installing the strainer make sure that a space for the withdrawal of the screen (2) is
allowed.
INSTRUCTIONS RELATIVES À L'INSTALLATION
Pour une installation correcte, veuillez respecter les recommandations suivantes:
1
1. Avant de procéder à l'installation, contrôler soigneusement si le filtre à tamis n'a pas été
endommagé lors du transport ou de la manipulation.
2. Vérifier l'intérieur du filtre et repérer la présence d'objets étrangers ayant pu tomber
dedans.
3. Lors de la mise en place du filtre à tamis dans la conduite, la flèche inscrite sur le corps
doit être dirigée dans le sens du flux.
4. Lors de la mise en place du filtre à tamis, s'assurer de laisser un espace suffisant pour le
retrait de l'écran (2).
MAINTENANCE ISTRUCTIONS
Maintenance on the strainer as per instruction here below is recommended after start up during
any plant shutdown and anytime pressure drop is too high.
A quick clean up system is to blow off small impurities through the drain valve/plug (6/7).
For a complete maintenance follow the points here below:
1. Make sure the line is shut off before starting any operation.
2. Open the drain plug (7) and valve (6) to release the pressure and let all liquid out of the body.
3. Unscrew and remove nuts (4).
4. Remove cover (3).
5. Before remove the filtering element unscrew the bolts that keep it in place (if any).
6. Withdraw the filtering element and carefully inspect it for damages. If any hole in the screen is
found obstructed, clean it with compressed air and/or any suitable tool. If the screen is broken
in any part replace it with a new one. Never reinstall a damaged screen.
7. Carefully clean the inside of the strainer body.
8. Install the new the screen (2) or the cleaned one.
9. Install a new gasket (5).
10. Reinstall the cover (3) and tighten nuts (4).
11. Close the drain valve (6), install and tighten drain plug (7).
12. Slowly give pressure to the line checking for leakage from cover (3) or drain plug (7).
13. Write the latest date of this operation on a metal tag firmly attached to the strainer body.
INSTRUCTIONS RELATIVES À LA MAINTENANCE
Conformément aux instructions ci-après, il est recommandé d'effectuer la maintenance pendant

l'arrêt de l'installation et à chaque chute de pression trop importante.
Pour un nettoyage rapide du système, il suffit d'évacuer les petites impuretés à l'aide de la vanne/
du bouchon de décharge (6/7).
Pour une maintenance complète, suivre les indications ci-après:
1. S'assurer que la ligne est à l'arrêt avant de démarrer toute opération.

2. Ouvrir le bouchon de décharge (7) et la vanne (6) afin de libérer la pression et évacuer le
2
liquide du corps.
3. Dévisser et retirer les écrous (4).
4. Retirer le couvercle (3).
5. Avant de retirer l'élément de filtration, dévisser les vis qui le maintiennent en place (si
présentes).
6. Retirer l'élément de filtration et contrôler soigneusement tout signe d'endommagement. En cas
d'obstruction d'un trou de l'écran, le nettoyer à l'air comprimé et/ou tout autre outil adapté. En
cas de rupture de l'écran, le remplacer par un nouveau. Ne jamais réinstaller un écran
endommagé.
7. Nettoyer soigneusement l'intérieur du corps du filtre.
8. Installer le nouvel écran (2) ou celui qui a été nettoyé.
9. Mettre un nouveau joint (5).
10. Remettre le couvercle (3) et serrer les vis (4).
11. Fermer la vanne (6), installer et serrer le bouchon de décharge (7).
12. Remettre doucement la ligne en pression tout en contrôlant l'apparition de fuite au niveau du
couvercle (3) ou du bouchon de décharge (7).
13. Noter la date de cette dernière opération sur une étiquette métallique solidement attachée au
corps du filtre.
NUTS DRIVING TORQUE TABLE/ ECROUS TABLE DE COUPLE
Material/ Materiel : ASTM A193 B7 / A194 2H
Size
Driving Torque
FYC/Dimension Dia x thr
Class/Classe /Couple
FYC (inch)
(Nm)
Size/DN
2”/50 150 ½”UNC 73
2.½”/65 150 ½”UNC 73
3”/80 150 ½”UNC 73
4”/100 150/PN.16 ½”UNC 73
5”/125 150/PN.16 ½”UNC 73
6”/150 150/PN.16 ⅝”UNC 142
8”/150 150/PN.16 ¾”UNC 251
10”/150 150/PN.16 ¾”UNC 251
12”/150 150/PN.16 ⅞”UNC 396
Size Driving Torque

Dia x thr
FYC/Dimension Class/Classe /Couple
(inch)
Size/DN (Nm)
2”/50 300/PN.16-25-40 ½”UNC 73
2.½”/65 300/PN.16-25-40 ½”UNC 73
3”/80 300/PN.16-25-40 ½”UNC 73
4”/100 300/PN.25-40 ¾”UNC 251
5”/125 300/PN.25-40 ¾”UNC 251
6”/150 300/PN.25-40 ¾”UNC 251
8”/150 300/PN.25-40 ⅞”UNC 396
10”/150 300/PN.25-40 ⅞”UNC 396
12”/150 300/PN.25-40 1”-8UN 607
3
4
9.7 Instruments
See Chapter 9.1 for List of Measuring Points
HGM 411 of 492

Instruments
KKS N° DOCU N° DÉSIGNATION FOURNISSEUR

DOCU KSB TYPE
PI 101 SM000601-01 PRESSURE GAUGE WIKA

M000606-01 MANOMÈTRE PGT23.100
PI 102 SM000601-01 PRESSURE GAUGE WIKA

M000613-01 MANOMÈTRE PGT23.100
PDIA 101 KM005000-21 DIFFERENTIAL PRESSURE SENSOR KSB

K005000-21 PUMPMETER PM 10/10
YE 103 KM013000-20 MEASURING NIPPLE KOCH-NEUBURG

K013000-20 Nipple de Mesure SPM
YE 104 KM013000-20 MEASURING NIPPLE KOCH-NEUBURG

K013000-20 Nipple de Mesure SPM
997469628 - 100 Montsignery - French Guiana

KSB designation PRESSURE GAUGE
KSB designation PRESSURE GAUGE
Doc. No. SM000601-01

Doc. No
Supplier WIKA
Supplier
Standard ZN 16065
Standard
Model
KKS No. Designation
KKS. No. Designation
Type Nominal size Sensor length Measuring range Connection Inlet Outlet
PI 101 065AG100-D MIT DRUCKTRANSMITTER

M000606-01 PGT23.100 100 . 0 - 6 BAR 1 G 1/2 B .
PI 102 135AG100-D MIT DRUCKTRANSMITTER

M000613-01 PGT23.100 100 . 0 - 160 BAR 1 G 1/2 B .
Connection type legend:

1 2 3 4
Screwed Welded Flanged Clamped
9974696285 - 100 Montsignery - French Guiana 1 / 1

KSB Dokumentenname: SM000601-01_EN
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KSB designation PUMPMETER
KSB designation DIFFERENTIAL PRESSURE SENSOR
Doc. No. KM005000-21

Doc. No
Supplier KSB
Supplier
Standard .
Standard
Model
KKS No. Designation
PDIA 101 . .
K005000-21 PM 10/10 . . -1,0 - 0 BAR 5 G 1/2 .

1 2 3 4

Instrument type Differential pressure sensor and display with
analog output
Manufacturer KSB
Type See cover sheet
Measurement Local sensors with display unit
Differential pressure
Nominal size 90 x 68 x 27 mm
Accuracy class +/- 1%
Pressure data Relative pressures / differential pressure
Scale range See cover sheet
Damping 1000 ms
Permissible temperature Ambient: TMIN – 30 °C, TMAX + 60 °C
Medium: TMIN – 30 °C, TMAX + 140 °C
Temperature error T = -10°C ... 100°C +/- 1%
T = -30°C...-10°C u. 100°C...140°C +/- 2,5%
Pressure connection Cable with M8-Connection

Degree of protection IP65
Design KSB PM
Pressure elements Sensing element SUS630 (1.4542)
Pressure port SUS304 (1.4301)
Overload pressure: 40 bar
Burst pressure: 60 bar
Working pressure Static load: Full scale value
Dynamic load: 0.9 x full scale value
Rise Time: 1 ms
Display unit GRILAMID TR 55 und Ultramid A3UG5
Shows absolute pressure and differential
pressure with small intervals.
Weight Approx. 0.3 kg
DATA SHEET
ALTERATION
STELLE/DEPARTMENT NR. / NO.

ECS1S525 BLATT-NR.
NORM/STANDARD SHEET-NO
GEPR/APPROVED SCHUTZVERMERK DIN 34-1-D COPYRIGHT DIN 34-1-E 1

BEARB/PREPARED ERS. FÜR / REPLACES ENTST. AUS / ORIGINAL FROM von / of
21.06.2017 WALTHER
DATUM/DATE NAME 2
08.04.2021 KSB DocNo: KM005000-21_EN 1 / 26

Pressure transmitter
Pressure connection M 8 with Adapter to G1/2”
Wiring M16 Connector Plug
Wiring protection IP65
EMV (electro-magnetic Guideline 2004/108/EG
immunity)
Power supply UB DC V +24 V DC +/- 15%, min. 150 mA
Permissible residual ripple  0.1
Output signal 4...20 mA 2-wire system
Output signal adjustment  0.1% of span
Zero point/Span electr.
Response time 1 ms
Linearity  0.1 % (limit point calibration) of span
Wiring connections
Variant 1 Signal output as differential pressure Variant 1

Colour Function
Cable 1 Brown Power supply (-)
1 2 3 4 5
Cable 2 White Anolog output (+)
Cable 3 Blue Power supply (+)
Brown
White
Black
Gray
Blue
Cable 4 Black Anolog output (-) -
Cable 5 Gray No function OUTPUT
- + 4 ... 20 mA
+
24 VDC
Variant 2 Signal output as suction pressure Variant 2

Cable connections Var 2 Colour Function
Cable 1 Brown Power supply (+)
1 2 3 4 5
Cable 2 White Anolog output (+)
Cable 3 Blue Power supply (-)
Brown
White
Black
Gray
Blue
Cable 4 Black Anolog output (-) -
Cable 5 Gray No function OUTPUT
+ - 4 ... 20 mA
+
24 VDC
Variant 3 Will be wired with other pump instruments.

Refer to order related wiring diagram.
DATA SHEET
ALTERATION
STELLE/DEPARTMENT NR. / NO.

ECS1S525 BLATT-NR.
NORM/STANDARD SHEET-NO
GEPR/APPROVED SCHUTZVERMERK DIN 34-1-D COPYRIGHT DIN 34-1-E 2

BEARB/PREPARED ERS. FÜR / REPLACES ENTST. AUS / ORIGINAL FROM von / of
21.06.2017 WALTHER
DATUM/DATE NAME 2
08.04.2021 KSB DocNo: KM005000-21_EN 2 / 26

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08.04.2021 KSB DocNo: KM005000-21_EN 14 / 26

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08.04.2021 KSB DocNo: KM005000-21_EN 26 / 26

KSB designation MEASURING NIPPLE
KSB designation MEASURING NIPPLE
Doc. No. KM013000-20

Doc. No
Supplier KOCH-NEUBURG
Supplier
Standard ZN 407
Standard
Model
KKS No. Designation
YE 103 M8X24 .
K013000-20 SPM . . . 1 M8 .
YE 104 M8X24 .
K013000-20 SPM . . . 1 M8 .

1 2 3 4

'()*+,-./012011.//034*'56786669:6;<=
01234567879

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9.8 Gear unit
Not Included in KSB Scope of Supply
HGM 487 of 492

9.9 Protective equipment
Not Included in KSB Scope of Supply
488 of 492 HGM

Index
Index
A O
Applications 8 Operating limits 72
Order number 6
B Other applicable documents 6
Bearings 24
P
C Partly completed machinery 6
Centreline displacement 44 Preservation 17
Clearances
Clearances 137
Thrust bearing clearance 138
R
Total theoretical axial clearances 138 Removing the sound insulating hood 85
Commissioning 61 Return to supplier 19
Connecting the piping Returning to service 77
Flange connection 54
Minimum flow line and balancing liquid line 55
Welded joint 55
S
Safety 8
Connections 24
Safety awareness 9
Coupling alignment 43
Servicing 80
D Servicing work 81
Shaft seal 24
Design 24
Shutdown 74
Designation 21
Spare part
Dismantling the coupling guard 33 Ordering spare parts 97
Disposal 20 Recommended spare parts stock 98
Drive 24 Spare parts stock for commissioning 98
Spare parts stock for two years' operation 98
E Storage 17
Event of damage 6
Ordering spare parts 97 T
Explosion protection 10 Tightening torques 139
Transport 11
F
Faults W
Causes and remedies 100 Warnings 7
Warranty claims 6
I
Impeller type 24
Installation at site 30
Intended use 8
K
Key to safety symbols/markings 7
L
Labelling 22
Name plate 23
M
Mechanical seal 67
Mounting the sound insulating hood 71
HGM 489 of 492

All Maintenance, service and installation work can be carried out by KSB-Service.
Service-addresses
Service-address Germany
KSB Service GmbH

Nachtweideweg 1-7
67227 Frankenthal
0
Tel. +49 6233 86-3100
0
Fax +49 6233 86-3933
Round-the-clock phone number in case of necessity:
Tel. +49 6233 86-0
Internet:
http://www.ksb.com/contact
KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com

100 en

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Montsinéry - French Guiana

Order number: 9974696285 HGM 2/12

Original operating manual

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

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

5.8.4 Permissible displacement................................................................................................................... 46

7 Servicing/Maintenance ........................................................................................................................ 78

9 Relevant Documentation................................................................................................................... 104

Index ................................................................................................................................................... 489

1.2 Installation of partly completed machinery

1.3 Target group

1.4 Other applicable documents

1.6 Key to safety symbols/markings

2.2 Intended use

2.2.1 Prevention of foreseeable misuse

2.3 Personnel qualification and training

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

2.5 Safety awareness

2.6 Safety instructions for the operator/user

2.7 Safety information for maintenance, inspection and installation

2.8 Unauthorised modes of operation

2.9 Explosion protection

3.1 Checking the condition upon delivery

3.2.1 Transporting packaged pump set components

Fig. 1: Transporting the transport box

3.2.2 Transporting partly packaged and unpackaged pump set components

3.2.2.1 Transporting the pump (set)

Transport with baseplate

Transport without baseplate

Fig. 4: Transporting the pump without baseplate (example)

3.2.2.2 Transporting the pump rotor

Fig. 5: Transporting the pump rotor

3.2.2.3 Transporting the accessories

3.3 Storage / preservation

Table 4: Ambient conditions for storage

Storage ≤ 12 months Standard preservation is suitable for up to 12 months of storage.

Table 5: Preservation for storage ≤ 12 months

Storage > 12 months

Table 6: Preservation for storage > 12 months

1 Made by Fuchs Europe Schmiermittel GmbH, Mannheim

Preserving the internal parts with water/glycol mixture:

3.4 Return to supplier

1. Drain the pump as per operating instructions.

1. Dismantle the pump (set).

4.1 General description

4.2 Product information as per Regulation No. 1907/2006 (REACH)

Example: HGM 3/7

Table 7: Designation key

4.4 Pump signage

KSB SE & Co. KGaA

Fig. 7: Pump signage

Fig. 8: Baseplate signage

4.4.1 Name plate

KSB SE & Co. KGaA

Fig. 9: Name plate (example)

4.5 Design details

3 Version with 90° elbow available.

4.6 Configuration and function

Fig. 10: Illustration of the high-pressure pump

4.7 Dimensions and weights

5.1 Checklist for assembly / installation

Table 8: Checklist for assembly / installation

5.1.1 Alignment certificate

□ Suction line □ Balancing line □ _ □ _

□ Discharge line □ _________ □ _ □ _________