Operating instructions

1384.81/2--10 Omega V
Volute casing pump
with radial impeller

Pump set
Vertical installation DB
DK
DJ

These operating instructions contain fundamental information and precautionary notes.

Please read the manual thoroughly prior to installation of unit, electrical connection and
commissioning. It is imperative to comply with all other operating instructions referring to
components of individual units.

Any work on the unit must only be carried out with the electrical connections (incl. control cable)
disconnected (or unplugged). Make sure that the pump set cannot be switched on accidentally.

Ident--No.: 01 059 621

 Omega V

For usage in hazardous locations

refer to supplementary operating
instructions 1387.81.

2
 Omega V

Contents Page
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Marking of Instructions in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Personnel Qualification and Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Non--Compliance with Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Safety Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety Instructions for the Operator / User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety Instructions for Maintenance, Inspection and Installation Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.7 Unauthorized Modification and Manufacture of Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.8 Unauthorized Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Transport and Interim Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Intermediate Storage / Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Description of the Product and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4.1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Design Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Types of Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Accessories (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.6 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Installation at Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Checks to Be Carried out Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.3 Installing the Pump / Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.4 Connecting the Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.5 Final Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Commissioning, Start--up / Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.2 Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.3 Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.5 Shutdown / Storage / Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.6 Returning to Service after Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7 Maintenance / Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.2 Maintenance / Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7.3 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.5 Instructions for Replacing Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.6 Monitoring schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Special Instructions for Subassemblies (Shaft Seal Variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8.1 Gland packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2 Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations) . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 Forces and Moments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11 Trouble--Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11.2 Trouble--shooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12 Routine Maintenance and Inspection Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
13 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3

1 General
This KSB pump has been developed in accordance with
state--of--the--art technology; it is manufactured with
utmost care and subject to continuous quality control.
These operating instructions are intended to facilitate
familiarization with the pump and its designated use.
The manual contains important information for reliable, proper
and efficient operation. Compliance with the operating
instructions is of vital importance to ensure reliability and a long
service life of the pump and to avoid any risks.
These operating instructions do not take into account local
regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for
installation.
This pump / unit must not be operated beyond the limit values
specified in the technical documentation for the medium
handled, capacity, speed, density, pressure, temperature and
motor rating. Make sure that operation is in accordance with the
instructions laid down in this manual or in the contract
documentation.
The name plate indicates the type series / size, main operating
data and works / series number; please quote this information
in all queries, repeat orders and particularly when ordering
spare parts.
If you need any additional information or instructions exceeding
the scope of this manual or in case of damage please contact
KSBs nearest customer service centre.
2 Safety
These operating instructions contain fundamental information
which must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read
and understood both by the installing personnel and the
responsible trained personnel / operators prior to installation
and commissioning, and it must always be kept close to the
location of operation of the machine / unit for easy access.
Not only must the general safety instructions laid down in this
chapter on Safety be complied with, but also the safety
instructions outlined under specific headings.
2.1 Marking of Instructions in the Manual
The safety instructions contained in this manual whose
non--observance might cause hazards to persons are specially
marked with the general hazard sign, namely
safety sign in accordance with DIN 4844 -- W9.
The electrical danger warning sign is
safety sign in accordance with DIN 4844 -- W8.
4
Omega V
The word
Caution
is used to introduce safety instructions whose non--observance
may lead to damage to the machine and its functions.
Instructions attached directly to the machine, e.g.
-- arrow indicating the direction of rotation
-- markings for fluid connections
must always be complied with and be kept in perfectly legible
condition at all times.
2.2 Personnel Qualification and Training
All personnel involved in the operation, maintenance,
inspection and installation of the machine must be fully qualified
to carry out the work involved.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question
is not already in possession of the requisite know--how,
appropriate training and instruction must be provided. If
required, the operator may commission the manufacturer /
supplier to take care of such training. In addition, the operator
is responsible for ensuring that the contents of the operating
instructions are fully understood by the responsible personnel.
2.3 Non--Compliance with Safety Instructions
Non--compliance with safety instructions can jeopardize the
safety of personnel, the environment and the machine itself.
Non--compliance with these safety instructions will also lead to
forfeiture of any and all rights to claims for damages.
In particular, non--compliance can, for example, result in:
-- failure of important machine / unit functions
-- failure of prescribed maintenance and servicing practices
-- hazard to persons by electrical, mechanical and chemical
effects
-- hazard to the environment due to leakage of hazardous
substances
2.4 Safety Awareness
It is imperative to comply with the safety instructions contained
in this manual, the relevant national health and safety
regulations and the operators own internal work, operation and
safety regulations.
 Omega V

2.5 Safety Instructions for the Operator / User
-- Any hot or cold components that could pose a hazard must
be equipped with a guard by the operator.
-- Guards which are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed whilst the
machine is operating.
-- Leakages (e.g. at the shaft seal) of hazardous media
handled (e.g. explosive, toxic, hot) must be contained so as
to avoid any danger to persons and the environment.
Pertinent legal provisions must be adhered to.
-- Electrical hazards must be eliminated. (In this respect refer
to the relevant safety regulations applicable to different
countries and/or the local energy supply companies.)
3 Transport and Interim Storage
3.1 Transport
Transport of the unit requires proper preparation and handling.
Always make sure that the pump or the unit remains in stable
position during transport and cannot slip out of the transport
suspension arrangement. Do not use lifting slings on the free
shaft end of the pump or on the motor eyebolt.
Also make sure that the coupling guard is not damaged by the
sling arrangement.
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and
damage to property.

2.6 Safety Instructions for Maintenance, Transport in horizontal position is recommended in all cases,
Inspection and Installation Work since this ensures stable positioning of the unit without any risk
of accident, whatever the method of transport, e.g. road, rail or
The operator is responsible for ensuring that all maintenance, ship, etc.
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with For transport purposes the unit shall be secured on suitable
the manual. pallets or sleds. All loose and movable parts must be secured.
Work on the machine must be carried out only during standstill.
The shutdown procedure described in the manual for taking the
machine out of service must be adhered to without fail.
Pumps or pump units handling media injurious to health must
be decontaminated.
Immediately following completion of the work, all
safety--relevant and protective devices must be re--installed
and/or re--activated.
Please observe all instructions set out in the chapter on
Commissioning before returning the machine to service.

2.7 Unauthorized Modification and Manufacture Fig. 1: Transport of pump (Fig.0) and installation type DJ
of Spare Parts
Modifications or alterations of the machine are only permitted
after consultation with the manufacturer. Original spare parts
and accessories authorized by the manufacturer ensure safety.
The use of other parts can invalidate any liability of the
manufacturer for consequential damage.

2.8 Unauthorized Modes of Operation

The warranty relating to the operating reliability and safety of
the pump / unit supplied is only valid if the machine is used in
accordance with its designated use as described in section 1
of these operating instructions. The limits stated in the data Fig. 2: Transport of motor
sheet must not be exceeded under any circumstances.
The motor eyebolts must only be used for lifting the
motor alone, never for lifting the complete unit.

5
 Omega V

4 Description of the Product and

Accessories
4.1 Technical Specification

Design
The KSB pump of the Omega V series is a vertically installed,
single--stage, axially split volute casing pump with
double--entry radial impeller. Connection flanges are
manufactured according to EN, DIN, ISO, BS or ASME, as
preferred.

Fig. 3: Never transport the unit as shown above!
Fields of application
In waterworks, irrigation and drainage pumping stations, power
stations, for industrial water supply, dock installations, fire
extinguishing systems, refineries, pipelines and tank farms,
also for handling crude oil and refinery intermediates.

4.2 Designation
Omega V XXX XXX X

Type series
Discharge nozzle DN mm
Nominal impeller dia.
Impeller type (A,B,C)

4.3 Design Details

Fig. 4: Transport of the unit with motor stool,
vertical installation type DB and DK 4.3.1 Pump Casing
Axially split volute casing with replaceable casing wear rings.
Observe angles of pull when lifting. Suction and discharge nozzles in lower half of casing are at the
Angle of pull > 90 not permitted. same level (inline version).
Use two separate sets of lifting slings!
4.3.2 Impeller
The double--entry radial impeller is manufactured for the
operating data provided in each case. Also with impeller wear
rings, if requested.
In double--entry radial impellers the axial thrust is largely
balanced.

4.3.3 Pump Shaft

Fig. 5: Pull directions (opening angle of slings)
3.2 Intermediate Storage / Preservation
When the unit is temporarily put into storage, only the wetted
low alloy components, e.g. JL1040 (GG--25) must be
preserved. Commercially available preservatives can be used
for this purpose. Please observe the manufacturers
instructions for application / removal.
The shaft is fully sealed against the liquid being pumped.
Shaft--protecting sleeves are fitted in the seal area.
4.3.4 Shaft Seal
The shaft seals at the drive end and non--drive end are gland
packings or mechanical seals, as requested.
Due to the product--lubricated lower RESIDOR bearing, one
bottom shaft seal is omitted.
4.3.5 Bearings and Lubrication
The pump is fitted on drive side with covered deep--groove ball
bearings which are grease--lubricated for life.
This bearing is the fixed bearing. On the non--driven end
(bottom), there is the product--lubricated RESIDOR --bearing.

6
 Omega V

4.4 Types of Installation 5.3 Installing the Pump / Unit

The pump is installed vertically, direct--coupled, configuration Caution Before setting up the pump, check the
DJ, DB and DK, (see appendix). operating data. Ensure that the data on the
name plate matches the data in the order and the system
4.5 Accessories (optional) data, e.g. operating voltage, frequency, pumped liquid
The following accessories are available: temperature etc.
The attachment shows the installation types DJ, DB, and DK.
g
Configuration
Accessories DJ DB DK The designation of parts can be taken from these drawings
Motor Y x 1) (part No.)
Foot / rail x ----
Foot and motor stool ---- x ---- While the installation type DJ can be independent of the size of
Foot ---- ---- x the pump or the motor, the installation types DB and DK depend
(incl. support foot and motor stool) on the size of the pump and the motor according to the
Coupling and coupling guard ---- x 1) attachment General Arrangement Drawing (see
Sealing and flushing water piping x x correlation).
Set of pressure gauges x x
Cyclone separator with pipework x x The site management must inform the installation personnel
about the local safety regulations prior to beginning the
Vent valve (manual or automatic) x x installation.
Temperature sensor for rolling x x
element bearings (PT 100)
For all work subsequently described, the pump must be set up
Signal transmitter for PT 100 x x so it cannot fall over, and must be secured accordingly.
Drain line x x The foot is to be bolted to the pump using the connecting
1) included in standard scope of supply elements supplied (see General Assembly Drawing and List of
Y special design Components -- Annex).

4.6 Dimensions and Weights Furthermore, the motor stool and possibly the supports must be
For dimensions and weights please refer to the tables in the assembled. The motor stool must also be fixed with pins
appendix. besides being bolted.

5 Installation at Site
5.1 Safety Regulations
Electrical equipment operated in zone 1
hazardous locations must comply with the
explosion protection regulations. This is indicated on the
motor rating plate.
If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and the
regulations of the test certificate supplied with the equipment
and issued by the responsible approval authorities must be
observed and complied with.
The test certificate must be kept close to the location of
operation for easy access (e.g. foremans office).
5.2 Checks to Be Carried out Prior to
Installation
All structural work required must have been prepared in
accordance with the dimensions and loads stated in the
dimension table / installation plan.
The concrete foundations shall have sufficient strength
(min. BN 25) to ensure safe and functional installation in
accordance with DIN 1045 or equivalent standards.
Make sure that the concrete foundation has set firmly before
placing the unit on it. Its surface shall be truly horizontal and
even.
The foot must be bolted to the foundation blocks Using
adjusting screws, the pump must be aligned so that the
machined motor connecting flange of the motor stool is
horizontally level in all directions, i.e. the pump stands exactly
in vertical position. Subsequently, the recesses arranged in the
foundation for the foundation blocks are grouted carefully with
a concrete mixture. It must be assured that the base structure
is resistant to torsion and twisting. After the concrete mixture
has set, the pump is to be connected to the piping without
transmitting stresses or strains, and the motor installed. The
shafts must be carefully aligned with respect to each other and
the alignment of the coupling must be checked once again.
Observe operating instructions of the coupling!
Faulty alignment can lead to destruction of torque--transmitting
coupling elements and to bearing damage at the pump and
motor.
According to the regulations concerning technical working
equipment, machines may only be operated with appropriate
contact protection. For this reason a coupling guard to DIN
31001 must be installed prior to commissioning. Furthermore,
the direction of rotation of the unit must be checked whether it
corresponds to the rotational direction arrow on the pump
casing.
Additional loads on discharge and suction nozzle, e.g. caused
by:
1. Weight of water--filled pipes
2. Changes in length of piping due to temperature fluctuations
3. Reaction forces due to unbraced expansion joints, may not
exceed the specified values * .
(See section 10 -- Forces and Moments).

7

5.3.1 Unlocking Pump Rotor
Prior to commissioning or prior to the alignment of the pump and
the motor, the pump rotor must be unlocked.
Loosen and unscrew hex. head bolt (901.17) from the
non--drive end bearing cover (160).
Remove plug (916 -- acc. to parts list) in the nipple joint (731)
on the top casing half (105.02).
Mount flushing line (719.02) according to the drawing as well as
the operating instructions Barrier water/flushing line.
Secure pipe unions with LOCTITE, type 221.
Fig. 6: Locking and unlocking the pump rotor
5.3.2 Aligning the Pump / Drive
Improper alignment of the unit can cause damage to
both the coupling and the unit itself!
A pump set in vertical installation types DB and DK is correctly
aligned, if a straight--edge placed axially on both coupling
halves is the same distance from each shaft at all points around
the circumference. In addition, the distance between the two
coupling halves must remain the same all around the
circumference. Use a feeler gauge, a wedge gauge or a dial
micrometer to verify (see fig. 7).
straight edge
straight edge gauge
Fig. 7: Coupling alignment, using gauge and straight edge
Special instructions see appendix.
8
Omega V
5.4 Connecting the Piping
Never use the pump itself as an anchorage
Caution
point for the piping.
Suction lift lines shall be laid with a rising slope towards the
pump and suction head lines with a downward slope towards
the pump. The pipelines shall be anchored in close proximity to
the pump and connected without transmitting any stresses or
strains. Their weight must not exert any load on the pump. With
short pipelines, the nominal diameters shall be at least equal to
the nominal diameters of the pump nozzles. For long pipelines
the most economical nominal diameter has to be determined
from case to case.
Any additional loads on the discharge and suction
nozzles, e.g. caused by:
Weight of the water--filled pipes, changes in the length of pipes
owing to temperature fluctuations, reaction forces due to
unbraced expansion joints must not exceed the values stated
in the installation plan.
An excessive, impermissible increase in the pipeline
forces may cause leaks on the pump where the medium
handled can escape into the atmosphere.
Danger of life when hot media are handled!
The flange covers on the pump suction and discharge nozzles
must be removed prior to installation in the piping.
5.4.1 Auxiliary Connections
The locations of the auxiliary connections (sealing liquid,
flushing liquid, etc.) are indicated on the installation plan or
piping layout (see appendix).
Please refer to the appendix for detailed assembly instructions.
Caution These connections are required for proper
functioning of the pump and are therefore of
vital importance!
5.4.2 Coupling Guard
In compliance with the accident prevention regulations
the pump must not be operated without a coupling
guard. If the customer specifically requests not to include a
coupling guard in our delivery, then the operator must supply
one.
5.5 Final Check
Re--check the alignment as described in section 5.3.2.
It must be easy to rotate the shaft by hand at the coupling.
Caution Check the integrity and proper functioning
of all connections.
 Omega V

6 Commissioning, 6.4.2 Start--up

Start--up / Shut down Caution Dry--running will result in increased wear and
must be avoided.
Caution Compliance with the following requirements is
of paramount importance. Damage resulting If a non--return valve is not fitted at the discharge--side, close
from non--compliance shall not be covered by the scope of the discharge--side gate valve.
warranty. If a shut--off valve is fitted in the suction line, open it fully.
All additional connections for flushing or sealing liquid etc., if
6.1 Commissioning fitted, must be opened fully and the flow must be checked.
Before starting up the pump make sure that the following Switch on the motor.
requirements have been checked and fulfilled: As soon as the pump starts to deliver -- this can be recognised
by the rising gauge pressure -- slowly open the discharge--side
-- Has the pump been firmly bolted to the foundation? gate valve fully.
-- Have the coupling and pump unit been aligned as The pump may operate against the closed gate
Caution
specified? valve only during start--up and shutdown, as
-- Can the unit be easily rotated by hand at the coupling? otherwise inadmissible temperature rise occurs resulting in
(Carry out at least one full rotation) damage.
-- Are the pipes properly fitted?
6.4.3 Pump Operating Range
-- Has the coupling guard been fitted?
The flow rate Q adjusts itself automatically to the delivery
-- Have staff been informed about sources of danger and head according to the H--Q characteristic. The pumps
measures been taken to comply with the accident permitted operating range is subject to limits, which have
prevention regulations? separate causes.
-- Correct start--up procedure for suction lift operation.
-- Is the unit protected against overload (appropriate safety 1. Part load operating limit for low flow rate
valve)? This limit is indicated in the H--Q characteristic by Qmin or by the
-- Have the seals been fitted as described in the appendix? discontinuation of the characteristic curve.
-- Have any additional devices been prepared and fitted as
specified in the appendix? Caution It is not permissible to operate the pump in the
-- Has the pump been vented as specified in section 6.3.? range from Q=0 to Qmin Prolonged operation in
this range causes greatly increased mechanical loads which
6.2 Shaft Seal the components cannot withstand. Brief passage through the
critical range is permissible, e.g. during start--up.
For commissioning the shaft seal please refer to section 8.1 /
8.2. If the pump has been out of service for a prolonged period, 2. NPSH--related limits in the part load and overload ranges
the measures specified in section 6.6 must be carried out. These two limits are determined by the ratio of NPSHrequired to
NPSHavailable. They are determined as follows:
6.3 Venting
Before start--up, the pump and the pipes must be vented and
filled with the liquid to be pumped. This is done at the vent plug
on the casing (903). For suction lift operation, the pump must
also be evacuated, i.e. a vacuum must be produced.

6.4 Commissioning
6.4.1 Checking the Direction of Rotation
Caution For trouble--free operation of the pump, the
correct direction of rotation of the impeller is of
paramount importance. If running in the wrong direction of
rotation, the pump cannot reach its duty point; vibrations and
overheating will be the consequence. The unit or the shaft seal
might be damaged.

Correct direction of rotation:

The direction of rotation must correspond to the direction
indicated by the arrow on the pump. This can be verified by
switching the pump on and then off again immediately.
Before checking the direction of rotation make sure that
there is no foreign matter in the pump casing.
Never put your hands or any other objects into the pump!

9

The intersections of NPSHrequired and NPSHavailable are
projected onto the H--Q characteristic, where they indicate the
operating limits (refer to the diagram below). Checking of the
NPSH--related operating limit is not necessary for operating the
pump under design conditions. If system--related changes
occur, an NPSH check must be carried out. If necessary,
consult the nearest after--sales service centre.
Qmin
NPSHrequired
NPSHavailable
6.4.4 Shut down
Close the shut--off element in the discharge line. If the
discharge line is equipped with a check valve, the shut--off
element may remain open, provided there is back pressure in
the line.
The shut--off element in the suction line must not be
closed when switching off the pump. Switch off the
motor, making sure that the unit runs smoothly down to
a standstill.
Depending on the system the pump shall have an adequate
after--run period -- with the heat source switched off -- to allow
the medium handled to cool down sufficiently to avoid any heat
build--up within the pump.
In the case of prolonged shutdown, the shut--off element in the
suction line has to be closed.
Close the auxiliary connections.
In the event of frost and / or prolonged shutdowns, the pump
must be drained or otherwise protected against freezing.
10
Omega V
6.5 Shutdown / Storage / Preservation
Each KSB pump leaves the factory carefully assembled. If
commissioning is to take place some time after delivery, we
recommend that the following measures be taken for pump
storage.
6.5.1 Storage of New Pumps
-- New pumps are supplied by our factory duly prepared for
storage.
Maximum protection for up to 12 months, if the pump is
properly stored indoors.
-- Store the pump in a dry location.
6.5.2 Measures to be Taken for Prolonged Shutdown
1. The pump remains installed; periodic check of
operation
In order to make sure that the pump is always ready for instant
start--up and to prevent the formation of deposits within the
pump and the pump intake area, start up the pump set regularly
once a month or once every 3 month for a short time (approx.
5 minutes) during prolonged shutdown periods. Prior to an
operation check run ensure that there is sufficient liquid
available for operating the pump.
2. The pump is removed from the pipe and stored
Before putting the pump into storage carry out all checks
specified in sections 7.1 to 7.4. Then apply appropriate
preservatives:
-- Spray--coat the inside wall of the pump casing, and in
particular the impeller clearance areas, with a preservative.
Spray the preservative through the suction and discharge
nozzles. It is advisable to close the nozzles (for ex. with
plastic caps or similar).
3. Locking the pump rotor
The shaft assembly of the vertically installed OMEGA runs in
a RESIDUR plain bearing. To transport the pump, the pump
rotor must be secured against shocks which would otherwise
damage the plain bearing.
6.6 Returning to Service after Storage
Before returning the pump to service carry out all checks and
maintenance work specified in sections 5.1 and 5.2.
In addition, the instructions laid down in section 6.1
Commissioning and section 6.4.3 Operating
limits must be observed.
Upon completion of the work, all safety--related and
protective equipment must be properly refitted and
/ or reactivated before starting the pump set.
 Omega V

7 Maintenance / Repair
7.1 General Instructions
The operator is responsible for ensuring that all maintenance,
inspection and installation work is carried out by authorized,
duly qualified staff who are thouroughly familiar with these
operating instructions.
A regular maintenance schedule will help avoid expensive
repairs and contribute to trouble--free, reliable operation of the
pump with a minimum of maintenance expenditure and work.
Work on the pump and the motor must only be
carried out with the electrical connections
disconnected. Make sure that the pump set cannot be
switched on accidentally (danger of life!).
Pumps handling liquids posing health hazards must be
decontaminated. When draining the medium see to it
that there is no risk to persons or the environment. All relevant
laws must be adhered to (danger of life!).
7.2 Maintenance / Inspection
7.2.1 Supervision of Operation
The pump shall run quietly and free from
Caution
vibrations at all times. The pump must never be
allowed to run dry.
Prolonged operation against a closed shut--off element
is not permitted in order to prevent the medium handled
from heating up.
At room temperatures of up to 30 C (86 F) the bearing
temperature shall be below 90 C (194 F). At higher room
temperatures, the bearing temperature shall be below 100 C
(212 F).
During pump operation the shut--off element in the inlet
line must not be closed.
Any stand--by pumps installed shall be switched on and then
immediately off again once a week to keep them operational.
Attention shall be paid to the correct functioning of the auxiliary
connections.
Caution If the flexible coupling elements begin to show
signs of wear, they must be replaced in due
time. See section Coupling.
If an external supply of sealing, flushing or lubricating liquid is
used, make sure supply pressure is 1.0 to 2.0 bar higher than
pressure at the suction nozzle.
The pump rotor must be locked whenever the pump
is transported.
-- The pump rotor must be locked to prevent damage to the
RESIDUR -- bearing.
-- To lock the pump rotor, the flushing line attached to the
non--drive end (719.02) including the elbow (731.05) must
be dismantled.
-- The flushing line must be fastened with a cable tie (81--73
acc. to parts list) to a rib on the top casing half (105.02).
-- The free end of the nipple joint (731.04) on the top casing
half must be closed to prevent contamination.
-- Secure the hex. head bolt (901.17) provided for locking the
pump rotor using LOCTITE, type 221, and screw it into the
threaded hole of the cover (160) so that the screw engages
the centering hole of the pump shaft (211). (see Fig. 6).
-- Lock the rotor axially and radially by tightening the bolt
(901.17) according to the tightening torques specified. (See
Fig. 6 Locking and Unlocking of the Pump Rotor, point
5.3.1).

Rotor Lock -- Tightening Torques

On pump with gland packing, the packing must drip slightly
during operation. The gland cover may therefore only be
tightened slightly (see Section 8 Special Instructions for
Subassemblies -- Shaft Seal Variants).

g g
Tightening-- -- l e s s t h a n / e q u a l t o --
torque in Nm
10 16 23 30 38 48

Pumpsize 80 - 210 125 - 230 150 - 460 200 - 520 250 - 480 300 - 560
80 - 270 125 - 290 150 - 605 200 - 670 250 - 600 300 - 700
80 - 370 125 - 365 200 - 320 250 - 370 300 - 435 350 - 430
100 - 250 125 - 500 200 - 420 300 - 300 350 - 360 350 - 510
100 - 310 150 - 290
100 - 375 150 - 360

11
 Omega V

7.2.2 Shaft Seal Maintenance -- Secure the rotor prior to removing it. When using KSB lifting
For required maintenance work on gland packings please refer equipment the Operating Instructions Lifting device
to section 8.1. Shaft seal. Mechanical seals are must be followed for the removal of the rotor.
maintenance--free. -- Remove the screw connection (901.04) and the nuts
(920.05) which secure the bearing cover (360) so that the
7.2.3 Bearing Maintenance bearing housing can be lifted out of its recess.
The bearings are maintenance--free. The top deep--groove ball -- Lift the rotor and store safely in a horizontal position for
bearing has been supplied at the factory with permanent dismantling purposes.
grease lubrication. Relubrication is not required. The bottom
-- Remove the nuts (920.02) and lift off the bearing cover
RESIDUR bearing is maintenance--free (plain bearing;
(160). The grooved nut (920.01), the spring (950) and the
lubricated by medium pumped).
disc (550.03) can then be removed.
7.3 Dismantling -- Lift off the bearing housing (350.02), the shaft sleeve
(524.02) the bearing bush (545) and the spacer sleeve
Before dismantling, secure the pump so as to make sure
(525).
it cannot be switched on accidentally. The shut--off
elements in the suction and discharge lines must be closed. -- The impeller (234) is located with sliding fit on the shaft and
can normally be removed easily. In case of difficulty, it can
The pump must have cooled down to ambient temperature, be loosened by gently tapping with a plastic hammer.
pump pressure must be released and the pump must be
drained. -- Remove the shaft seal housing (441) with shaft seal and
shaft sleeve (524.01).
Dismantling and reassembly must always be carried out in
accordance with the relevant sectional drawing. -- Remove coupling half.
-- Remove the nuts (920.5), bearing housing (350.01 with
7.3.1 Fundamental Instructions and spacer ring (550.02) and circlip (932) together with spacer
Recommendations ring (550.01)
Repair and maintenance work to the pump must only be carried -- Remove bearing cover (360) and deep groove ball bearing
out by specially trained personnel, using original spare parts. (321).
Observe the safety regulations laid down. Any work on the
motor shall be governed by the specifications and regulations
of the respective motor supplier.
Dismantling and reassembly must always be carried out in
accordance with the relevant general drawing. The general
drawing and other relevant documents are found in the annex.
The dismantling sequence can be derived from the general
drawing.
In case of damage you can always contact our nearest
customer service centre.

7.3.2 Preparations for Dismantling

The pump is designed so that the complete rotor can be
removed in the sequence described below without removing
the suction or discharge pipe or disturbing the alignment of the
pump unit:
-- Close the suction and discharge--side gate valves and drain
the pump by opening the drain plug (903.01 bottom) and
vent plug (903.01 top).
-- Remove any pipes between additional equipment and the
pump.
-- Remove the coupling guard.
Decouple pump--side coupling half as described in the
appendix.
-- Loosen and push back the seal cover (471), if a mechanical
seal is fitted.
-- Suspend top casing half (105.02) from lifting tackle and
secure it. (When using a KSB lifting equipment, the
operating instructions Lifting Equipment must be
observed (see appendix).
-- Undo the flange screws (901.01 / 901.02) and separate the
upper casing half (105.02) from the lower casing half
(105.01) with the aid of the forcing screws. Remove with
lifting gear. The interior of the pump (impeller with casing
wear rings, shaft seal) is now accessible for inspection.

12
 Omega V

7.4 Reassembly
Reassembly is effected in reverse order to dismantling. For all
work on the pump unit refer to the general drawing, in
conjunction with the list of components, for orientation.
The rules of sound engineering practice and also the
instructions for removal and installation of shaft seal, bearings,
impeller wear rings and casing wear rings (sections 7.5.1 and
7.5.2) must be observed.
The tightening torques indicated for nuts and bolts shall be
observed. The table below indicates the tightening torques for
threads depending on the materials used.
Property class (Material) 8.8 10.9 A.-50 A.-70 1.4462
0,2% yield stress 640 900 210 450
Rp 02 in N/mm2 1) 250 450
Metric ISO threads Tightening torque
coarse--pitch fine--pitch MA in Nm
M4 3,1 4,4 1,0 2,15
M5 6,1 8,7 2,00 4,25
M6 10,4 14,9 3,40 7,30
M8 25,2 36,1 8,30 17,7
M8x1 27,2 39,0 8,90 19,1
M10 49,5 71,0 16,2 34,8
M10x1,25 52,5 75,4 17,3 36,9
M12 85,2 122,2 28,0 59,9
M12x1,5 89,5 128,5 29,4 62,9
M12x1,25 93,9 134,7 30,8 66,0
M16 211 302,7 69,2 148
M16x1,5 226 324,7 74,3 159
M20 412 591,9 135 290
M20x1,5 461 661,0 151 324
M24 710 1019,6 233 276 500
M24x2 780 1118,6 256 305 548
M27 1050 1501,3 343 409 736
M27x2 1130 1627,1 372 443 797
M30 1420 2036,4 466 554 1000
M30x2 1580 2269,9 519 618 1110
M33 1940 2779,4 636 ---- 1360
M33x2 2130 3062,6 700 ---- 1500
M36 2480 3552,3 812 ---- 1740
M36x3 2630 3775,4 863 ---- 1850
1) Nominal values to DIN ISO 898 Part 1, DIN 267 Part 11 and DIN 267 Part 18

It is imperative to lock and seal the screwed connections

specially marked in the general drawings.
Symbols for screwed connections to be locked and sealed:
ALTEMP Q NB 50 grease

ALTEMP Q NB 50 grease

Glued in with Loctite 2701

Special adhesive 2503/L 28

Desmodur

13
 Omega V

O--rings and V--rings must be replaced and their seats on the Caution This measure is essential to compensate for
shaft must be cleaned. In addition, all the sealing elements differences in thermal expansion between the
must be fitted into the respective components before pump shaft (211) and the components fitted on it.
installation.
Rotor assembly is now complete.
For assembling the rotor, position the pump shaft (211)
Insert the rotor into the pump casing.
securely. All fits, threads and sliding fits of the shaft must be
cleaned and coated with assembly paste. Apply Loctite 574 to the casing wear ring surfaces and the
sealing surfaces of the casing.
Insert the keys required for assembly into the pump shaft (211).
Install the rotor, making sure that the direction of rotation is
Mount the impeller (234), which has a sliding fit. When fitting the
correct.
impeller, observe the direction of rotation (see diagram below).
Align the rotor and ensure that the fixing pins are correctly
seated in the casing.
The pins (561.01) must be positioned as shown in the diagram
below.
The bearing housings (350.01) must be fastened to the bearing
brackets by means of the screwed connections (901.04), with
the sealing cap (580) inserted at the non--drive end. The seating
positions are determined by the recesses.
Fit the bearing covers.
To assemble the casing cover, apply Loctite 574 to the casing
joint surface of the lower casing half.
For assembling the casing wear rings (502), observe section
Tighten the flange bolts diagonally from the inside towards the
7.5.2 Replacing the casing wear rings.
outside.
Put the casing wear rings onto the running surfaces of the
Insert the key for fitting the coupling into the pump shaft (211).
impeller. Ensure that the bezels of the rings are on the outside
(towards the bearing). Insert the pins required for fixing the When fitting the coupling and accessories, refer to the relevant
casing wear rings. section of the operating instructions.
The remaining components are fitted first on the movable
bearing side (i.e. the drive side) of the pump shaft.
Push the shaft protecting sleeve (524.01) onto the pump shaft
(211). Ensure that the groove provided engages in the key of
the impeller.
Push the shaft seal housing (441) onto the shaft and install the
shaft seal as described in section 8.1, Gland packing. Slip on
(502)
V--ring (411.01).
Insert the radial shaft seal ring (421.02) into the bearing cover Casing wear rings
(360) and push the bearing cover over the shaft.
Heat the deep--grooved ball bearing (321) and fit it onto the
pump shaft (211). It is essential to avoid one--sided pressure or 561.01
hammer blows on the outer races. The bearing is secured by
the disc (550.01) and the circlip (932).
To fit the shaft protecting sleeve (524.01), shaft seal housing
(441), V--ring (411.01) and bearing cover (360) at the non--drive
end, proceed as described above for the drive side.
Heat the deep--groove ball bearing (321) and fit it onto the
sleeve (520).
Push the sleeve (520) with deep--groove ball bearing (321) onto
the pump shaft (211) with key (940.01) inserted.
Tension the rotor parts elastically with keywayed nut (920) and
cup spring (950). For this purpose tension the cup spring (950)
to blocking point and then undo the keywayed nut (920) again
by half a turn (180).

14
 Omega V

7.5 Instructions for Replacing Subassemblies
7.5.1 Replacing the Shaft Seal
Proceed as described in section 8.1 and 8.2.
7.5.2 Replacing Casing Wear Rings and / or Impeller
Wear Rings
The impeller clearance 1) clearance between impeller 234 and
casing wear ring 502 is given in the table below.
For impeller removal proceed as described in section 7.3,
Dismantling.
After dismantling as described in section 7.3.2, the casing wear
rings (502) can be removed. When fitting the rings, ensure that
their bezels are on the outside (towards the bearing). The pins
(561.01) must be positioned as shown in the diagram below.
If the impeller has not been fitted with a wear ring at the factory,
and changing the casing wear ring alone does not achieve
anything close to the required impeller clearance (the impeller
neck is badly worn by clearance flows), the impeller neck must
be turned off on a lathe (contact KSB before doing so) and an
impeller wear ring fitted in addition (available as spare part).
Alternatively, a new impeller can be supplied at short notice.

Impeller clearances and trim dimensions for impeller wear rings

Clearance (as--new) Dimensions of impeller wear ring

No. Pump Shaft Nominal clea- Min. Max.
size unit rance clearance clearance
(max. perm.)
S min S max
D2 - D1
DW 2 D5 b
[mm] [mm] [mm] [mm] [mm]
1 80-210 0,3 0,15 0,2 134 r6 18
2 80-270 0,3 0,15 0,2 134 r6 18
3 80-370 0,3 0,15 0,2 134 r6 18
40
4 100-250 0,35 0,17 0,2 163 r6 22
5 100-310 0,35 0,17 0,2 163 r6 22
6 100-375 0,35 0,17 0,2 163 r6 22
7 125-230 0,35 0,18 0,23 178 r6 22
8 125-290 0,35 0,18 0,23 178 r6 22
9 125-365 0,35 0,18 0,23 178 r6 22
50
10 125-500 0,35 0,18 0,23 178 r6 22
11 150-290 0,45 0,22 0,26 210 r6 30
12 150-360 0,45 0,22 0,26 210 r6 30
13 150-460 0,45 0,22 0,26 210 r6 30
14 150-605 0,45 0,22 0,26 210 r6 30
60
15 200-320 0,5 0,24 0,28 243 r6 30
16 200-420 0,5 0,24 0,28 243 r6 30
17 200-520 0,5 0,24 0,28 243 r6 30
18 200-670 70 0,5 0,24 0,28 243 r6 30
19 250-370 0,5 0,24 0,28 276 r6 30
20 250-480 0,5 0,24 0,28 276 r6 30
80
21 250-600 0,5 0,24 0,28 276 r6 30
22 300-300 70 0,5 0,24 0,28 259 r6 30
23 300-435 80 0,6 0,29 0,35 313 r6 35
24 300-560 0,6 0,29 0,35 313 r6 35
90
25 300-700 0,6 0,29 0,35 313 r6 35
26 350-360 80 0,5 0,24 0,28 294 r6 35
27 350-430 0,6 0,32 0,37 333 r6 35
90
28 350-510 0,6 0,32 0,37 353 r6 35

S (min max)

15
 Omega V

7.6 Monitoring schedule

For a detailed description of the pump version, components
and accessories supplied by KSB please refer to section 13 of
this operating manual.

Component monitored Action Value required

Mechanical seal
Check for leakage (daily) see section 8.2 and *
(if applicable)
Gland packing
Check for leakage (daily) 10 to 120 drops / min.
(if applicable)
Suction side measuring instrument, ps
Check pressure (daily) *
(if applicable)
Discharge side measuring instrument, pd
Check pressure (daily) *
(if applicable)
Thermometer
(suction / discharge nozzle) Check temperature (weekly) *
(if applicable)
Flushing line sight glass Check flushing water flow
Water flows
(if applicable) (weekly)
Vibration measurement
Check weekly *
(if applicable)
Bearing temperature
(if applicable) Check weekly Section 7.2
(drive--end rolling element bearing)
Annex from p. 49, detailed manufacturer
Coupling Check weekly
information
Drive
See manufacturers documentation Ensure contact--free installation
(if applicable)
Coupling guard Check monthly No contact permitted
Earthing connection Check monthly Connection must be fitted and marked.

* see list of measuring points (if applicable) in section 13,

Annex.

In the event of deviations proceed as described in the table

given in section 11.2 (Trouble--shooting).

16

8 Special Instructions for
Subassemblies (Shaft Seal Variants)
The shaft seal variant supplied is shown in the purchase order
and order--processing documents.
8.1 Gland packing
The gland packings used by KSB are asbestos--free and
suitable for drinking water applications.
Installation and commissioning
Before installation, ensure that the gland space is clean (no
packing remnants or corrosion). The shaft protecting sleeve
must be bright and have no scoring. Otherwise a new shaft
protecting sleeve must be used.
Cutting the packing rings to size
If moulded packing rings are not available, the rings can best
be cut to size using a special cutting gauge. If no cutting gauge
is available, take a tube with the same diameter as the shaft,
wind the packing around the tube in a spiral and cut the rings
from the spiral. We recommend a straight cut.
Installing the packing rings
Push the packing rings with the stuffing box insert into the gland
space one by one. The joints of the packing rings must be offset
by 90. The number of rings and the arrangement of the lantern
ring are shown in the general drawing (see appendix). After
fitting all the packing rings, put on the stuffing box insert and
gland cover and tighten them so that the packing rings adapt to
the gland space. Then loosen the gland cover again to relieve
the load on the packing. This procedure is not necessary if
moulded packing rings are used.
Omega V
Commissioning
When the pump is started up, the gland must only be gently
tightened (by hand). A high leakage rate (approx. 50 to 200
drops per minute), depending on the liquid being pumped, must
be accepted until the packing material has settled and has
adapted to the temperature conditions (approx. 10 to 15
minutes).
Then the gland cover must be carefully and evenly tightened to
reduce the leakage to a minimum. If there is no leakage, there
is a risk that the packing will run hot.
Also note the following:
Leakage and temperature rise: If necessary, shut down the
pump. After a short cooling period (approx. 10 to 15 minutes)
the pump can be restarted. The necessary minimum leakage
depends on the liquid being pumped, the pressure, sliding
velocity and temperature. It is approx. 10 to 120 drops per
minute (20 drops of water correspond to approx. 1 ml).
Dismantling
A packing puller must be used for pulling out the packing rings.
Maintenance
Gland packings must be repacked in accordance with the
section Installation and commissioning after prolonged
standstill, repair work or heavy leakage. Therefore, the leakage
rate must be observed during operation, also to avoid possible
overheating.
17
 Omega V

8.2 Mechanical Seal Variants (Mech. Seal Size / Pump Size Combinations)

Mechanical seal variants

No Pump size Shaft unit Nom. mech. Non--balanced Balanced
seal size
dw D for operating for operating pressures
pressures up to 16 > 16 bar
bar

1 80 - 210
2 80 - 270
3 80 - 370
40 50 M 7 N 4 / 50 HJ 92 N / 50
4 100 - 250
5 100 - 310
6 100 - 375
7 125 - 230
8 125 - 290
9 125 - 365
50 60 M 7 N 4/ 60 HJ 92 N / 60
10 125 - 500
11 150 - 290
12 150 - 360
13 150 - 460
14 150 - 605
60 70 M 7 N 4/ 70 HJ 92 N / 70
15 200 - 320
16 200 - 420
17 200 - 520
18 200 - 670 70 80 M 7 N 4/ 80 HJ 92 N / 80
19 250 - 370
20 250 - 480
80 90 M 7 N 4/ 90 HJ 92 N / 90
21 250 - 600
22 300 - 300 70 80 M 7 N 4/ 80 HJ 92 N / 80
23 300 - 435 80 90 M 7 N 4/ 90 HJ 92 N / 90
24 300 - 560
90 11 M 74 N / 110 H 75 N / 110
25 300 - 700
26 350 - 360 80 90 M 7 N 4/ 90 HJ 92 N / 90
27 350 - 430
90 110 M 74 N / 110 H 75 N / 110
28 350 - 510

18
 Omega V

8.2.1 Mechanical Seal Type H7N4

(Shaft unit dw 40 to 80 mm)

The mechanical seal type H7N4 used is a single--acting,

bi--rotational, non--balanced seal which does not require
circulation pipework in cold water applications, due to the pump
design.

Caution Dry--running of the seal must be avoided at

all costs!

Installation
For the installation of the total seal assembly (mechanical seal,
seal housing) see operating instructions for the pump.
The shaft protection sleeves and also the surfaces of the casing
are subjected to accurate finishing processes with regard to the
O--ring seats, in order to achieve a complete and reliable seal.
Care must be taken during installation to keep these parts
absolutely clean, to avoid the surfaces from being damaged
and prevent entry of foreign particles.
The seat ring (8) together with the relevant O--ring (9), is fitted Item Description Material No. of
into the seal cover (see general drawing). The O--ring can be items
lubricated for easy sliding movement. Special attention must be 1 Housing Cr-Ni-Mo-steel 1
given to ensure that pressure is applied evenly. The contact 2 O-Ring Viton 1
surfaces are generally fitted dry. 3 Spring Cr-Ni-Mo-steel 1
In mechanical seals of the M7N4 design, the rotating assembly 4 Thrust plate Cr-Ni-Mo-steel 1
is supplied as one unit, consisting of a housing and pin ( 1 + 5), 5 Pin Cr-Ni-Mo-steel 2
fitted spring loaded ring (6), O--ring (2), spring (3), thrust plate
(4) and grub screws (7). The grub screws (7) must be loosened 6 Spring--loaded ring Si-SiC 1
so far as to prevent them from protruding from the housing (1) 7 Grub screw Cr-Ni-Mo-steel 2
at the inner diameter. The O--ring (2) can be slightly lubricated 8 Seat ring Si-SiC 1
to facilitate assembly. 9 O-Ring Viton 1
The complete rotating assembly is pushed onto the shaft
Special instructions for mechanical seal assembly
protection sleeve in compliance with the installation
dimensions which are given in the mech. seal drawing, or until -- The contact faces must only be cleaned with propyl alcohol
it reaches the stop on the shaft protection sleeve. Finally the and paper tissue.
grub screws are tightened and secured with LOCTITE. -- Never use cleaning rags or cloth.
-- Clean carefully to remove any smears.
-- Do not touch the contact faces with bare fingers.
-- Never use force during mechanical seal assembly.
-- Never put the spring--loaded ring and the seat ring face
down on the contact faces without the protective wrapping.
-- Cover the contact face with a cardboard washer and press
the seat ring into its position slowly and evenly, lubricating
it with a generous amount of water or alcohol. Use a spacer
sleeve, if necessary. Verify that the seat ring position is
normal to the shaft axis.
-- In the mechanical seal area, the shaft shall be slightly
lubricated with water, alcohol or silicone grease. Sealing
elements made of EP rubber must never come into
contact with mineral oil base lubricants (swelling,
possibly decomposition).

19

Commissioning
Flood the pump and the seal chamber with the medium to be
handled and vent carefully. The seal is operational now.
On single--acting mechanical seals, the pressure in the seal
chamber of the pump (stuffing box) must always exceed
ambient pressure, to prevent any air intake at the seal faces,
which would result in dry running and thus failure of the
mechanical seal.
In all operating conditions, the product to be sealed off must
be available in liquid state at the mechanical seal, particularly
during pump start--up and shutdown. This must be ensured by
appropriate facilities on the pump (e.g. heating).
Should the mechanical seal fail, the liquid to be sealed off may
spurt out. Take suitable precautions to prevent hazards to
persons and the environment, e.g. install splash guards, wear
safety goggles, etc. Proper disposal of leakage shall be
arranged for and supervised by the operator.
Maintenance
Mechanical seals operated in compliance with the manual
are maintenance--free in their entire service life.
The mechanical seal should be inspected in accordance with
the plant inspection schedule.
During planned plant outage periods the spring--loaded rings
and the seat rings should be checked for visible damage in
installed condition.
If the mechanical seal is inspected during plant outage, the
contact faces should be re--worked.
Faults
Determine and document the nature of the fault.
In the event of a fault as evidenced by excessive leakage,
observe the tendency of the leakage amount. Changes in
operating conditions must be documented. If an excessive
temperature rise is detected, the mechanical seal must be shut
down for safety reasons.
During the warranty period the mechanical seal shall only be
removed and dismantled with the manufacturers approval or
under instructions of the mechanical seal manufacturers
service engineers.
If the fault cannot be remedied by the operator or if the cause
is unclear, please contact the KSB service center.
20
Omega V
Dismantling
For dismantling of the mechanical seal assembly please refer
to section 7.3 Dismantling. Grub screws (7) and joint rings
(2+9) shall be replaced whenever the mechanical seal has
been dismantled!
Repair
If the seal needs to be repaired, always return the complete
seal to the manufacturer. The manufacturer will know best
which parts can be re--worked and which parts have to be
replaced to ensure an optimum sealing effect.
If repair on the spot is necessary, it should be carried out in
a clean workshop preferrably by fitters or skilled operator
staff. Spring--loaded rings, seat rings, all elastomer
materials and springs should be replaced in any case.
Make sure to comply with the instructions for handling
hazardous substances and the applicable accident
prevention regulations when repairing, dismantling and
cleaning used mechanical seals. If you have any queries in this
context please inform yourself before commencing any
repair work.
Spare parts
Only original spare parts shall be used. Non--compliance
with this requirement entails the risk of seal malfunctions
which may jeopardize the safety of personnel and the
environment.
It will also lead to forfeiture of all warranty claims.
 Omega V

8.2.2 Mechanical Seal -- Type M74N The seat ring (8) together with the relevant O--ring (9), is fitted
(Shaft unit dw = 90 mm) into the seal cover (see general drawing). The O--ring can be
lubricated for easy sliding movement. Special attention must
This mechanical seal type is a single--acting, bi--rotational, be given to ensure that pressure is applied evenly. The contact
non--balanced mechanical seal with multiple spring surfaces are generally fitted dry.
arrangement. In mechanical seals of the M74N design, the rotating assembly
It is imperative to avoid dry running of the is supplied as one unit, consisting of a housing and pin ( 1 + 5),
Caution fitted spring loaded ring (6), O--ring (2), spring (3), thrust plate
mechanical seal!
(4) and grub screws (7). The grub screws (7) must be loosened
so far as to prevent them from protruding from the housing (1)
Special instructions for mechanical seal installation at the inner diameter. The O--ring (2) can be slightly lubricated
to facilitate assembly.
-- Application limits The complete rotating assembly is pushed onto the shaft
Pressure to be sealed off p max.: 25 bar protection sleeve in compliance with the installation
dimensions which are given in the mech. seal drawing, or until
Product temperature t: --40...220 C it reaches the stop on the shaft protection sleeve. Finally the
Sliding velocity vg: 20 m/s grub screws are tightened and secured with LOCTITE.

-- Safety Degrease the grub

screws and insert
Any work on the mechanical seal shall only be performed with a thread sealant
after the pump has stopped and pump pressure has been (e.g. Loctite). Use
released. new grub screws
In addition to the safety instructions contained in this manual, whenever the me-
the general health and accident prevention regulations chanical seal has
shall be observed. been dismantled!

Preparations for installation

Check pump components for: Item Description Material No. of
-- chamfered edges (sliding cones 2 mm/ 30 or to DIN items
24960). 1 Housing Cr-Ni-Mo-steel 1
-- radiused transitions 2 O--ring Compat. elastomers 1
-- locating surfaces, surfaces for O--rings: fine finished Rz 3 Spring Cr-Ni-Mo-steel 1
10 (DIN 4768)
4 Thrust plate Cr-Ni-Mo-steel 1
-- Shaft surface in the area of the dynamically loaded joint
5 Pin Cr-Ni-Mo-steel 2
ring: roughness depth Rmax 5 mm.
6 Rotating ring Buka, Buke, Bume 1
The shaft must be provided with the requisite recesses for the
7 Grub screw Cr-Ni-Mo-steel 2
housing screws of the mechanical seal.
8 Seat ring Buke, Buko, Buka 1
Check pump for:
9 O--ring Compat. elastomers 1
-- damage at the mating surfaces with the mechanical seal
-- connecting dimensions, rectangularity and concentricity to -- Apply a thin coat of grease to the shaft in the mechanical
the shaft axis seal area.
-- Sealing elements made of EP rubber must never come
Installation into contact with mineral oil base lubricants (swelling,
possibly decomposition).
For the installation of the total seal assembly (mechanical seal,
seal housing) see operating instructions for the pump. -- Unwrap the mechanical seal and inspect for damage to the
spring--loaded ring and the seat ring, the O--rings and the
The shaft protection sleeves and also the surfaces of the casing
mating surfaces.
are subjected to accurate finishing processes with regard to the
O--ring seats, in order to achieve a complete and reliable seal. -- Never put the spring--loaded ring and the seat ring face
Care must be taken during installation to keep these parts down on the contact faces without the protective wrapping.
absolutely clean, to avoid the surfaces from being damaged -- Thoroughly clean all components with alcohol and cellulose
and prevent entry of foreign particles. tissue.

21

Installation
Never use force during mechanical seal installation.
-- Slip the degreased O--ring onto the seat ring.
-- Cover the contact face with a cardboard washer.
-- Push the seat ring slowly and evenly into its seat. Use a
spacer sleeve, if necessary. Lubricate with a generous
amount of water or alcohol.
-- Verify that the seat ring position is normal to the shaft axis.
-- Push the rotating assembly with the degreased joint rings
onto the shaft. Thread in the degreased grub screws with
1 drop of thread sealant each (e.g. Loctite No. 243) and
position the mechanical seal by tightening the grub screws.
The installation dimensions given in the drawing must be
adhered to.
-- The contact faces must only be cleaned with propyl alcohol
and paper tissue (no cleaning rags or cloth). Clean carefully
to remove any smears. Do not touch the contact faces with
bare fingers afterwards.
The contact faces must not be lubricated; they must be clean
and dry.
-- Assemble the seal cover with the installed seat ring.
Commissioning
Flood the pump and the seal chamber with the medium to be
handled and vent carefully. The seal is operational now.
Reliable seal operation
On single--acting mechanical seals, the pressure in the seal
chamber of the pump (stuffing box) must always exceed
ambient pressure, to prevent any air intake at the seal faces,
which would result in dry running and thus failure of the
mechanical seal.
In all operating conditions, the product to be sealed off must
be available in liquid state at the mechanical seal, particularly
during pump start--up and shutdown. This must be ensured by
appropriate facilities on the pump (e.g. heating).
If the operating conditions indicated are observed and the
instructions given in this operating manual are complied with,
the mechanical seal can be expected to give trouble--free
operation.
Should the mechanical seal fail, the liquid to be sealed
off may spurt out. Take suitable precautions to
prevent hazards to persons and the environment, e.g. install
splash guards, wear safety goggles, etc. Proper disposal of
leakage shall be arranged for and supervised by the operator.
22
Omega V
Faults
Determine and document the nature of the fault.
In the event of a fault as evidenced by excessive leakage,
observe the tendency of the leakage amount. Changes in
operating conditions must be documented. If an excessive
temperature rise is detected, the mechanical seal must be shut
down for safety reasons.
A continuous flow of leakage indicates a fault.
During the warranty period the mechanical seal shall only be
removed and dismantled with the manufacturers approval or
under instructions of the mechanical seal manufacturers
service engineers.
If the fault cannot be remedied by the operator or if the cause
is unclear, please contact the KSB service centre.
Maintenance
Mechanical seals operated in compliance with the manual are
maintenance--free; however, wear parts will have to be
replaced as required.
The mechanical seal should be inspected in accordance with
the plant inspection schedule. We recommend to have the
mechanical seal inspected by KSB service centre.
If the mechanical seal is inspected during plant outage, the
contact faces should be re--worked and all elastomer seals and
springs should be replaced.
Reparatur
If the seal needs to be repaired, always return the complete
seal to the manufacturer. The manufacturer will know best
which parts can be re--worked and which parts have to be
replaced to ensure an optimum sealing effect.
If repair on the spot is absolutely necessary (e.g. no spare
seal available, long transport distances, problems with customs
procedures), skilled operator staff may carry out the repair
work in a clean workshop to the directions of KSB service
centres.
 Omega V

Mechanical seal removal 8.2.3 Mechanical Seal Type HJ92N

Shut down the pump in accordance
with the operating manual, allow to cool down and
release pump pressure.
There must be no pumped product at the
mechanical seal The pump must be drained.
Secure the pump to prevent inadvertent start--up.
(Shaft unit dw = 40 to 80 mm)
Note:
Refer to sections 8.2.1 and 8.2.2 for general recommendations
and instructions for handling this seal type.
For detailed information please refer to the operating manual
for seal type HJ92N.

Follow the safety instructions

(safety data sheets)!

Make sure to comply with the applicable accident

prevention regulations when removing a mechanical seal.
Also observe the instructions for handling hazardous
substances if the mechanical seal has already been in
operation. If you have any queries about the applicable
regulations please inform yourself before commencing any
repair work.
Any work on the mechanical seal is only permitted with the
pump shut down and pump pressure released.
Removal of the mechanical seal shall be performed
analogously with mechanical seal installation, but in reverse
order.

Removing the subassembly

See section 7.3.
-- Replace the grub screw (7) and the joint rings (2+9)
whenever the mechanical seal has been dismantled.

Spare parts
Only genuine spare parts shall be used. Non--compliance
with this requirement entails the risk of seal malfunctions
which may jeopardize the safety of personnel and the
environment.
It will also lead to forfeiture of all warranty claims.To keep a
complete spare seal on stock.

23
OPERATING MANUAL
MECHANICAL SEAL (MS)
HJ92N
PLEASE READ this manual carefully and OBSERVE the information contained as to:
H Safety H Storage H Installation H Start up H Maintenance H Repair

J SAFETY J OPERATING LIMITS

Shaft diameter dw: 18 to 100 mm
Any person in the operators plant who is involved in the installa-
Press. to be sealed off p max.: 25 bar *)
tion, removal, operation, commissioning and maintenance of
the mechanical seal must have read and thoroughly under- Fluid temperature t: --40 to 220 C
stood these operating instructions, particularly the safety in- Sliding velocity vg: 20 m/s
structions contained therein. It is advisable for the operator to *) depending on the seal face materials
have this confirmed. The mechanical seal shall not be operated at several applica-
tion limits at the same time.
The mechanical seal is a precision product (ISO 9001) and safe Higher loads (pressure, temperature, speed) may lead to in-
to operate. However, it may constitute a hazard if it is not used creased wear and damage the contact faces or the elastomer
in accordance with its designated use, or if operated improperly elements.
by unskilled personnel. Such operating conditions would shorten the useful life of the
seal but also entail the risk of sudden seal failure with hazards
The operator has to determine the consequences of any me- to personnel and the environment.
chanical seal failure and decide whether safety precautions
need to be taken to protect personnel or the environment. J OPERATING DATA
The operating data for the application in question, such as fluid
The pump shall be installed in such a way that any fluid spurting to be sealed off, operating pressure, operating temperature, ro-
out cannot cause personal injury and that leakage can be pro- tational speed, etc., are indicated on the respective pump data
perly disposed of. sheets.
Any operating mode liable to impair the safe and reliable func- J DESIGNATED USE
tion of the mechanical seal is not permitted.
Mechanical seals shall only be installed, operated, removed or Any operation outside the operating conditions stated in the
Operating Limits section is deemed to be non--conforming
repaired by authorized, qualified and appropriately instructed
personnel. with the designated use.
To ensure safe operation of the mechanical seal, check with the
Any work on the mechanical seal shall only be performed with seal manufacturer before using the seal for other operating
the pump shut down and the pump pressure released. conditions or in a different location of operation.
Staff responsibilities for the work involved must be clearly defi-
ned and complied with, to prevent unclear competencies with
J MATERIALS
regard to safety aspects. Materials as per drawing and/or order.

In addition to the instructions contained in this manual, the ge- J DRAWINGS

neral occupational health and safety regulations must be adhe-
red to.
Unauthorized modifications and alterations liable to jeopardize
the safe operation of the mechanical seal are not permitted.
General assembly drawing of pump.
The applicable design is shown on the general pump drawing
in the original scale and latest revision, see section 9 of the
pumps operating manual, which shall be used in conjunction
with this document.

J SPECIFICATION
J DECLARATION H Single mechanical seal
H Balanced
within the meaning of EC Directive Machinery 98/37/EC. H Bi--rotational
H Connecting dimensions to DIN 24960 KB
A mechanical seal does not function independently. It is inten- H Installation dimensions l1K
ded to be incorporated into or assembled with machinery.

24 Operating maual mechanical seal

Rev. 0, 13.02.2004
Due to their protected spring (1.5), mechanical seals of this type
are particularly suitable for fluids containing solids and/or highly
viscous fluids, for ex. in sugar, paper or waste water applica-
tions. The seal design is rugged and reliable. The spring neither
clogs nor sticks. Max. axial end play between shaft and hou-
sing: 0.5 mm in any direction.
For operation at negative pressures (down to --0.2 bar), no seat
lock is required for the seat ring (2).
Torque transmission between the shaft and the seal is normally
effected by grub screws(1.6); or by special drive elements (1.2)
on individual models.
J LIQUID SUPPLY TO MECHANICAL
SEAL
To ensure trouble--free operation of the mechanical seal, a sui-
table circulation process has been selected on the pump, see
section 9 of the pumps operating manual. This process avoids
product deposits in the seal chamber.
J EMISSIONS
Mechanical seals are dynamic seals which for physical and
technical reasons cannot be completely leak--free. The amount
of leakage largely depends on the seal selection, production to-
lerances, operating conditions, smooth running of the machine,
etc. Compared with other dynamic sealing systems, however,
mechanical seals have little leakage.
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent ha-
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-
ronment.
Leakage may be liquid or gaseous, its aggressiveness corres-
ponding to that of the fluid to be sealed off.
Any mechanical seal leakage must be drained off in a controlled
way and safely disposed of.
. Components which may come into contact with the seal lea-
kage shall either be corrosion resistant or must be adequately
protected.
J STORAGE
Unless otherwise agreed in the contract, mechanical seals are
delivered in standard packaging suitable for dry transport by
truck, train or plane. The symbols or handling instructions given
on the packaging must be adhered to.
For incoming goods inspection:
D Check packaging for external damage.
D Carefully open packaging, making sure not to damage or
lose any components packed separately.
D Check consignment for completeness (delivery note). The
supplier shall be notified immediately of any damaged
goods or missing parts.
The instructions given below shall apply both to mechanical
seals delivered and stored in their undamaged, original packa-
ging, and to mechanical seals already installed in a pump,
which have not been in operation yet.
Operating maual mechanical seal
Rev. 0, 13.02.2004
The mechanical seals need not be preserved.
D Do not apply anti--corrosives.
' Risk of deposits and possible chemical attacks on ela-
stomer secondary seals.
When applying preservatives to entire systems where mecha-
nical seals are installed please check the following:
D Verify the compatibility of the preservatives chosen with the
materials of construction and the elastomer components of
the mechanical seal.
D Verify that mechanical seal movement is not restricted by re-
sin deposits or sticking.
During storage, seal face materials and elastomers will un-
dergo material specific time dependent changes (distortion,
ageing), which can impair the perfect function of the mechanical
seal. The specified storage period must therefore be complied
with.
The manufacturer cannot be held responsible for damage re-
sulting from improper storage.
The room where mechanical seals are kept must be dust--free
and moderately ventilated, with an even temperature. We re-
commend: relative humidity below 65%, temperature between
15 C and 25 C.
The mechanical seal shall be protected from:
D direct heat from sun, heating
D ozone and ultraviolet light from halogen lamps, fluorescent
lamps, sunlight, arc welding
' danger of embrittlement of elastomer materials
The seals shall be stored in their original packaging on a level
surface.
The mechanical seal needs to be checked:
D after a storage period of approx. 2--3 years
D if the packaging has been damaged
D after a shock load (e.g. if the mechanical seal package has
been dropped)
' at the manufacturers workshop or nearest service centre.
J BEFORE INSTALLATION
Checks to be carried out on the pump components:
Shaft surface in the area of the dynamically loaded seal ring:
roughness depth Rmax 5 mm.
Checks to be carried out on the pump:
D Check contact surfaces between the pump and the mecha-
nical seal for damage.
D Connecting dimensions, squareness and concentricity to
shaft.
D Shaft run--out as per DIN ISO 5199: between 50 mm and
100 mm, depending on the diameter.
D Apply a thin coat of suitable grease to the shaft in the
mech.seal area.
' Never use mineral oil base lubricants on sealing elements
made of ethylene propylene rubber (swelling, possibly de-
composition).
' Grease recommended for elastomer sealing elements
(O--rings, etc.): type TURMOPOLGREASE SH2, produ-
cer: Lubricant Consult (LUBCON).
25
' Double PTFE encapsulated O--rings must be fitted so that
the joint of the outer sheath points in opposite direction to
the mounting direction, so that the friction force generated
when sliding on the O--ring closes the joint. Kinks in the foil
will result in leakage.
J INSTALLATION TOOLS / EQUIPMENT
D Propyl alcohol + paper tissue (no cleaning rags)
D Lubricating grease for elastomer seals: type TURMOPOLGREASE
SH2, producer: Lubricant Consult (LUBCON)
D Thread--locking compound, e.g. type LoctiteR Nr. 243,
producer: Loctite Corporation
D O--ring extractor
D Set of hex. keys (WAF 2 mm -- 6 mm)
D Cardboard washers to protect the contact faces during in-
stallation
D Manual screw press (compulsory from DN 80 mm).
J INSTALLATION
Refer to the general pump assembly drawing when installing
the mechanical seal.
Mechanical seals are precision--machined machinery compo-
nents which have been inspected several times. They must be
installed with due care and in compliance with certain procedu-
res, particularly regarding the contact faces and elastomer
seals.
Utmost cleanliness must be ensured in the immediate vicinity
of the location where a mechanical seal is to be installed.
Never use force when installing a mechanical seal.
D Unpack the seal and inspect the spring--loaded ring, seat
ring, O--rings and contact faces for damage.
' Never place the spring--loaded ring and the seat ring on
the table facing down without protecting the contact fa-
ces.
D Thoroughly clean all parts with alcohol and paper tissue.
The sequence of operations required to install the mechanical
seal in the machine depends on the design of the machine in
question, which is described in the pumps operating manual.
Unless otherwise stated, apply a very thin coat of grease to
O--rings which will slide into or onto other components during
mechanical seal installation.
26
Possible installation sequence:
D Slide the degreased O--ring onto the seat ring.
D Cover the contact face of the seat ring with a cardboard
washer. Generously lubricate the seat ring with water or al-
cohol and press it slowly and evenly into its seat. Use a spa-
cer, if necessary. Check squareness of seat ring to the shaft
axis.
D Apply a thin coat of grease to the shaft protecting sleeve in
the mechanical seal area.
' Never use mineral oil base lubricants on sealing ele-
ments made of ethylene propylene rubber (swelling,
possibly decomposition).
D Slide the rotating seal assembly with greased O--rings onto
the shaft protecting sleeve.
D Fit the degreased grub screws, having applied one drop of
thread--locking compound (e.g. Loctite R No. 243) to each
screw.
D Tighten the grub screws to lock the torque--transmitting
sleeve into place.
D Clean the contact faces with propyl alcohol and paper tissue
(no cloth, no cleaning rags!) to remove any smears. Do
not touch the contact faces with bare fingers after that.
' Do not apply lubricants to the contact faces. The contact
faces must be installed in clean and dry condition.
D Fit the seal cover with pre--assembled seat ring.
J COMMISSIONING
Prime the pump and the seal chamber with the fluid handled
and vent thoroughly. The seal is now ready for operation.
J SAFE OPERATION
For single mechanical seals, the pressure in the seal chamber
of the pump must always exceed ambient pressure, to prevent
any air intake at the seal faces, which would result in dry running
and thus failure of the mechanical seal.
In all operating conditions, the product to be sealed off must be
available in liquid state at the mechanical seal, particularly du-
ring pump start--up and shutdown.
If the operating conditions indicated are observed and the in-
structions given in this operating manual are complied with, the
mechanical seal can be expected to give trouble--free opera-
tion.
J HEALTH AND SAFETY
Mechanical seals are often used for sealing off hazardous sub-
stances (chemicals, pharmaceuticals, etc.). The applicable in-
structions and regulations for handling hazardous materials
must absolutely be adhered to.
Operating maual mechanical seal
Rev. 0, 13.02.2004
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent ha-
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-
ronment..
J FAULTS/MALFUNCTIONS
Determine and document the nature of the fault/malfunction.
In the event of a fault as evidenced by excessive leakage, ob-
serve the tendency of the leakage amount. Changes in opera-
ting conditions must be documented. If an excessive tempera-
ture rise is detected, the mechanical seal must be shut down for
safety reasons.
A continuous flow of leakage indicates a fault/malfunction at the
mechanical seal.
During the warranty period the mechanical seal shall only be re-
moved and dismantled with the manufacturers approval or in
the presence of his representative.
If the fault/malfunction cannot be remedied by the operator or
if the cause is unclear, please contact your responsible KSB
service centre.
J SERVICING / MAINTENANCE
Mechanical seals operated in compliance with manual are
maintenance--free. Wear parts, however, must be replaced as
required.
The mechanical seal shall be inspected in accordance with the
plant inspection schedule. We recommend to have the mecha-
nical seal inspected by competent KSB service staff.
If the mechanical seal is removed during plant inspection, the
contact faces shall be re--worked and all elastomer seals and
springs shall be replaced.
J REPAIR
If the seal needs to be repaired, always return the complete seal
to the manufacturer. The manufacturers service personnel will
know best which parts can be re--worked and which parts have
to be replaced to ensure an optimum sealing effect.
If repair on the spot is absolutely necessary (e.g. no spare seal
available, long transport distances, problems with customs pro-
cedures), skilled operator staff may carry out the repair work in
a clean workshop to the directions of the seal manufacturers fit-
ters.
J SPARE PARTS
Use only genuine spare parts, to prevent
D the risk of mechanical seal malfunction, involving hazards
to persons and the environment.
D forfeiture of any and all warranty claims.
To ensure quick mechanical seal replacement, we recommend
to stock a complete spare seal.
Operating maual mechanical seal
Rev. 0, 13.02.2004
J REMOVING THE SEAL FROM
THE PUMP
D Shut down the pump, allow to cool down and release pres-
sure as per operating instructions
D No product should contact the mechanical seal Drain the
pump, if necessary!
D Secure the pump against inadvertent start--up!
D Follow the safety instructions (safety data sheets)!
When removing the mechanical seal make sure to observe the
applicable health and safety regulations, as well as the regula-
tions for handling hazardous substances, if the mechanical seal
has already been in operation. If in doubt, the necessary infor-
mation has to be obtained before starting repair work.
Any work on the mechanical seal shall only be performed with
the pump shut down and the pump pressure released.
The sequence of operations required to remove the mechanical
seal from the pump depends on the design of the pump in ques-
tion, which is described in the pumps operating manual.
Removal of the mechanical seal shall be effected in analogy
with, but in reverse order to, installation.
J CUSTOMER SERVICE
Services provided by the seal manufacturer range from plan-
ning advice to product support after commissioning.
For this purpose, the manufacturer has established a worldwide
network of subsidiaries abroad, partner companies, sales offi-
ces and service centres, to handle any problems.
J PURCHASE ORDERS
For enquiries and purchase orders, the following details are re-
quired:
D KSB order No.
D No. of general pump assembly drawing
D Part item No., description, material, quantity as per drawing.
J DISPOSAL
Usually, mechanical seals can easily be disposed of after a tho-
rough cleaning.
D Metal parts (steel, stainless steel, non--ferrous metals),
shall be sorted and disposed of in the appropriate waste me-
tal collection facility.
D Plastics (elastomers, PTFE) are special waste. After sor-
ting, some of them can be recycled.
' CAUTION! Material containing fluorine must not be inci-
nerated.
D Ceramic contact face materials (carbon, ceramics, carbide)
can be separated from their carrier materials and -- being
physiologically harmless -- disposed of as residual waste.
We reserve the right to technical modifications designed to
improve the product, even if they are not mentioned in this ma-
nual yet.
27
 Omega V

8.2.4 Mechanical Seal -- Type H75N

(Shaft unit dw = 90 mm)

General instructions concerning assembly/installation, com-

missioning, maintenance, faults and repair have already been
given in sections 8.2.1 and 8.2.2.
(For detailed information please refer to operating manual for
seal type H75N).

28
OPERATING MANUAL
BURGMANN MECHANICAL (M.S.)
H75N
PLEASE READ this manual carefully and OBSERVE the information contained as to:
H Safety H Storage H Installation H Start up H Maintenance H Repair

J SAFETY J OPERATING LIMITS

Shaft diameter dw: 28 to 100 mm
Any person in the operators plant who is involved in the installa-
Press. to be sealed off p max.: 40 bar *)
tion, removal, operation, commissioning and maintenance of
Fluid temperature t: --40 to 220 C
the mechanical seal must have read and thoroughly under-
Sliding velocity vg: 20 m/s
stood these operating instructions, particularly the safety in-
*) depending on the seal face materials
structions contained therein. It is advisable for the operator to
have this confirmed. The mechanical seal shall not be operated at several applica-
tion limits at the same time.
The mechanical seal is a precision product (ISO 9001) and safe Higher loads (pressure, temperature, speed) may lead to in-
to operate. However, they may constitute a hazard if they are creased wear and damage the contact faces or the elastomer
not used in accordance with their designated use, or if operated elements.
improperly by unskilled personnel.
Such operating conditions would shorten the useful life of the
The operator has to determine the consequences of any me- seal but also entail the risk of sudden seal failure with hazards
chanical seal failure and decide whether safety precautions to personnel and the environment.
need to be taken to protect personnel or the environment.
J SPECIFICATION
The pump shall be installed in such a way that any fluid spurting The operating data for the application in question, such as fluid
out cannot cause personal injury and that leakage can be pro- to be sealed off, operating pressure, operating temperature, ro-
perly disposed of. tational speed, etc., are indicated on the respective pump data
sheets.
Any operating mode liable to impair the safe and reliable func-
tion of the mechanical seal is not permitted.
J DESIGNATED USE
Mechanical seals shall only be installed, operated, removed or Any operation outside the operating conditions stated in the
repaired by authorized, qualified and appropriately instructed Operating Limits section is deemed to be non--conforming
personnel. with the designated use.
To ensure safe operation of the mechanical seal, check with the
Any work on the mechanical seal shall only be performed with
seal manufacturer before using the seal for other operating
the pump shut down and the pump pressure released.
conditions or in a different location of operation.
Staff responsibilities for the work involved must be clearly defi-
ned and complied with, to prevent unclear competencies with J MATERIALS
regard to safety aspects.. Materials as per drawing and/or order.

In addition to the instructions contained in this manual, the ge- J DRAWINGS

neral occupational health and safety regulations must be adhe-
red to.
Unauthorized modifications and alterations liable to jeopardize
the safe operation of the mechanical seal are not permitted.
General assembly drawing of pump.
The applicable design is shown on the general pump drawing
in the original scale and latest revision, see section 9 of the
pumps operating manual, which shall be used in conjunction
with this document.

J SPECIFICATION
J DECLARATION
H Single mechanical seal
within the meaning of EC Directive Machinery 98/37/EC. H Balanced
H Bi--rotational
A mechanical seal does not function independently. It is inten- H Rotating spring--loaded ring
ded to be incorporated into or assembled with machinery. H Stationary seat ring

Operating maual mechanical seal 29

Rev. 0, 13.02.2004
H Multiple springs in guide sleeves
H axial mobility/play up to dw 55 = 2 mm, and 3 mm
H Torque transmission by grub screws
H Connecting dimensions to DIN 24960 KB
H Installation dimensions l1K
J LIQUID SUPPLY TO MECHANICAL
SEAL
To ensure trouble--free operation of the mechanical seal, a sui-
table circulation process has been selected on the pump, see
section 9 of the pumps operating manual. This process avoids
product deposits in the seal chamber.
J EMISSIONS
Mechanical seals are dynamic seals which for physical and
technical reasons cannot be completely leak--free. The amount
of leakage largely depends on the seal selection, production to-
lerances, operating conditions, smooth running of the machine,
etc. Compared with other dynamic sealing systems, however,
mechanical seals have little leakage.
Leakage may be liquid or gaseous, its aggressiveness corres-
ponding to that of the fluid to be sealed off.
Any mechanical seal leakage must be drained off in a controlled
way and safely disposed of.
. Components which may come into contact with the seal lea-
kage shall either be corrosion resistant or must be adequately
protected.
J STORAGE
Unless otherwise agreed in the contract, mechanical seals are
delivered in standard packaging suitable for dry transport by
truck, train or plane. The symbols or handling instructions given
on the packaging must be adhered to.
For incoming goods inspection:
D Check packaging for external damage.
D Carefully open packaging, making sure not to damage or
lose any components packed separately.
D Check consignment for completeness (delivery note). The
supplier shall be notified immediately of any damaged
goods or missing parts.
The instructions given below shall apply both to mechanical
seals delivered and stored in their undamaged, original packa-
ging, and to mechanical seals already installed in a pump,
which have not been in operation yet.
The mechanical seals need not be preserved.
D Do not apply anti--corrosives.
' Risk of deposits and possibly chemical attack of the ela-
stomer secondary sealing elements.
When applying preservatives to entire systems where mecha-
nical seals are installed please check the following:
D Verify the compatibility of the preservatives chosen with the
materials of construction and the elastomer components of
the mechanical seal.
D Verify that mechanical seal movement is not restricted by re-
sin deposits or sticking.
30
During storage, seal face materials and elastomers will un-
dergo material specific time dependent changes (distortion,
ageing), which can impair the perfect function of the mechanical
seal. The specified storage period must therefore be complied
with.
The manufacturer cannot be held responsible for damage re-
sulting from improper storage.
The room where mechanical seals are kept must be dust--free
and moderately ventilated, with an even temperature. We re-
commend: relative humidity below 65%, temperature between
15 C and 25 C.
The mechanical seal shall be protected from:
D direct heat from sun, heating
D ozone and ultraviolet light from halogen lamps, fluorescent
lamps, sunlight, arc welding
' danger of embrittlement of elastomer materials.
The seals shall be stored in their original packaging on a level
surface.
The mechanical seal needs to be checked:
D after a storage period of approx. 2--3 years
D if the packaging has been damaged
D after a shock load (e.g. if the mechanical seal package has
been dropped)
' at the manufacturers workshop or nearest service centre.
J BEFORE INSTALLATION
Checks to be carried out on the pump components:
Shaft surface in the area of the dynamically loaded seal ring:
roughness depth Rmax 5 mm.
Checks to be carried out on the pump:
D Check contact surfaces between the pump and the mecha-
nical seal for damage.
D Connecting dimensions, squareness and concentricity to
shaft
D Shaft run--out as per DIN ISO 5199: between 50 mm and
100 mm, depending on the diameter.
D Apply a thin coat of a suitable grease to the shaft in the
mech. seal area.
' Never use mineral oil base lubricants on sealing elements
made of ethylene propylene rubber (swelling, possibly de-
composition).
' Grease recommended for elastomer sealing elements
(O--rings, etc.): type TURMOPOLGREASE SH2, produ-
cer: Lubricant Consult (LUBCON).
' Double PTFE encapsulated O--rings must be fitted so that
the joint of the outer sheath points in opposite direction to
the mounting direction, so that the friction force generated
when sliding on the O--ring closes the joint. Kinks in the foil
will result in leakage.
J INSTALLATION TOOLS / EQUIPMENT
D Propyl alcohol + paper tissue (no cleaning rags)
D lubricant for elastomer--sealing rings: Type TURMOPOL-
GREASE SH2, make Lubricant Consult (LUBCON)
Operating maual mechanical seal
Rev. 0, 13.02.2004
D Thread--locking compound, e.g. type LoctiteR Nr. 243, Primary seal components
producer: Loctite Corporation 1.1 Spring--loaded ring
D O--ring extractor 2 Seat ring
D Set of hex. keys (WAF 2 mm -- 6 mm) Secondary seal elements
D Cardboard washers to protect the contact faces during in- 1.4 O--ring (dynamic)
stallation 3 O--ring (static)
D Manual screw press (compulsory from DN 80 mm)
Spring components
1.5 Guide sleeve
J INSTALLATION 1.6 Spring
Refer to the general pump assembly drawing when installing Torque transmission and housing components
the mechanical seal. 1.2 Torque--transmitting sleeve
1.3 Thrust ring
Mechanical seals are precision--machined machinery compo- 1.7 Grub screw
nents which have been inspected several times. They must be
Possible installation sequence:
installed with due care and in compliance with certain procedu-
res, particularly regarding the contact faces and elastomer D Slide the degreased O--ring onto the seat ring.
seals. D Cover the contact face of the seat ring with a cardboard
Utmost cleanliness must be ensured in the immediate vicinity washer. Generously lubricate the seat ring with water or al-
of the location where a mechanical seal is to be installed. cohol and press it slowly and evenly into its seat. Use a spa-
Never use force when installing a mechanical seal. cer, if necessary. Check squareness of seat ring to the shaft
Unpack the seal and inspect the spring--loaded ring, seat ring, axis.
O--rings and contact faces for damage. D Apply a thin coat of grease to the shaft protecting sleeve in
D Never place the spring--loaded ring and the seat ring on the the mechanical seal area.
table facing down without protecting the contact faces. ' Never use mineral oil base lubricants on sealing ele-
D Thoroughly clean all parts with alcohol and paper tissue. ments made of ethylene propylene rubber (swelling,
possibly decomposition).
The sequence of operations required to install the mechanical D Slide the rotating seal assembly with greased O--rings onto
seal in the machine depends on the design of the machine in the shaft protecting sleeve.
question, which is described in the pumps operating manual. D Fit the degreased grub screws, having applied one drop of
Unless otherwise stated, apply a very thin coat of grease to thread--locking compound (e.g. Loctite R No. 243) to each
O--rings which will slide into or onto other components during screw.
mechanical seal installation. D Tighten the grub screws to lock the torque--transmitting
sleeve in place.
D Clean the contact faces with propyl alcohol and paper tissue
(no cloth, no cleaning rags!) to remove any smears. Do
not touch the contact faces with bare fingers after that.
' Do not apply lubricants to the contact faces. The contact
faces must be installed in clean and dry condition.
D Fit the seal cover with pre--assembled seat ring.

J COMMISSIONING
Prime the pump and the seal chamber with the fluid handled
and vent thoroughly. The seal is now ready for operation.

J SAFE OPERATION
For single mechanical seals, the pressure in the seal chamber
of the pump must always exceed ambient pressure, to prevent
any air intake at the seal faces, which would result in dry running
and thus failure of the mechanical seal.
In all operating conditions, the product to be sealed off must be
available in liquid state at the mechanical seal, particularly du-
ring pump start--up and shutdown.
If the operating conditions indicated are observed and the in-
structions given in this operating manual are complied with, the
mechanical seal can be expected to give trouble--free opera-
tion.

J HEALTH AND SAFETY

Mechanical seals are often used for sealing off hazardous sub-
stances (chemicals, pharmaceuticals, etc.). The applicable in-
structions and regulations for handling hazardous materials
Fig. 1: General mech. seal design must absolutely be adhered to.

Operating maual mechanical seal 31

Rev. 0, 13.02.2004
Should the mechanical seal fail, the hot liquid or steam to be
sealed off may spurt out. Splash guards fitted on the machine,
safety goggles worn by the operating staff, etc. may prevent ha-
zards to persons. The operator/owner is responsible for the pro-
per disposal of leakage, in order to prevent hazards to the envi-
ronment.
J FAULTS/MALFUNCTIONS
Determine and document the nature of the fault/malfunction.
In the event of a fault as evidenced by excessive leakage, ob-
serve the tendency of the leakage amount. Changes in opera-
ting conditions must be documented. If an excessive tempera-
ture rise is detected, the mechanical seal must be shut down for
safety reasons.
A continuous flow of leakage indicates a fault/malfunction at the
mechanical seal.
During the warranty period the mechanical seal shall only be re-
moved and dismantled with the manufacturers approval or in
the presence of his representative.
If the fault/malfunction cannot be remedied by the operator or
if the cause is unclear, please contact your responsible KSB
service centre.
J SERVICING / MAINTENANCE
Mechanical seals operated in compliance with manual are
maintenance--free. Wear parts, however, must be replaced as
required.
The mechanical seal shall be inspected in accordance with the
plant inspection schedule. We recommend to have the mecha-
nical seal inspected by competent KSB service staff.
If the mechanical seal is removed during plant inspection, the
contact faces shall be re--worked and all elastomer seals and
springs shall be replaced.
J REPAIR
If the seal needs to be repaired, always return the complete seal
to the manufacturer. The manufacturers service personnel will
know best which parts can be re--worked and which parts have
to be replaced to ensure an optimum sealing effect.
If repair on the spot is absolutely necessary (e.g. no spare seal
available, long transport distances, problems with customs pro-
cedures), skilled operator staff may carry out the repair work in
a clean workshop to the directions of the seal manufacturers fit-
ters.
J SPARE PARTS
Use only genuine spare parts, to prevent
D the risk of mechanical seal malfunction, involving hazards
to persons and the environment.
D forfeiture of any and all warranty claims.
To ensure quick mechanical seal replacement, we recommend
to stock a complete spare seal.
32
J REMOVING THE SEAL FROM
THE PUMP
D Shut down the pump, allow to cool down and release pres-
sure as per operating instructions.
D No product should contact the mechanical seal Drain the
pump, if necessary!
D Secure the pump against inadvertent start--up!
D Follow the safety instructions (safety data sheets)!
When removing the mechanical seal make sure to observe the
applicable health and safety regulations, as well as the regula-
tions for handling hazardous substances, if the mechanical seal
have already been in operation. If in doubt, the necessary infor-
mation has to be obtained before starting repair work.
Any work on the mechanical seal shall only be performed with
the pump shut down and the pump pressure released.
The sequence of operations required to remove the mechanical
seal from the pump depends on the design of the pump in ques-
tion, which is described in the pumps operating manual.
Removal of the mechanical seal shall be effected in analogy
with, but in reverse order to, installation.
J CUSTOMER SERVICE
Services provided by the seal manufacturer range from plan-
ning advice to product support after commissioning.
For this purpose, the manufacturer has established a worldwide
network of subsidiaries abroad, partner companies, sales offi-
ces and service stations, to handle any problems.
J PURCHASE ORDERS
For enquiries and purchase orders, the following details are re-
quired:
D KSB order No.
D No. of general pump assembly drawing
D Part item No., description, material, quantity as per drawing
J DISPOSAL
Usually, mechanical seals can easily be disposed of after a tho-
rough cleaning.
D Metal parts (steel, stainless steel, non--ferrous metals),
shall be sorted and disposed of in the appropriate waste me-
tal collection facility.
D Plastics (elastomers, PTFE) are special waste. After sor-
ting, some of them can be recycled.
' CAUTION! Material containing fluorine must not be inci-
nerated.
D Ceramic contact face materials (carbon, ceramics, carbide)
can be separated from their carrier materials and -- being
physiologically harmless -- disposed of as residual waste.
We reserve the right to technical modifications designed to
improve the product, even if they are not mentioned in this ma-
nual yet.
Operating maual mechanical seal
Rev. 0, 13.02.2004
 Omega V

9 Spare Parts
Recommended Spare Parts
Recommended spare parts stock for 2 years operation to VDMA 24296 (also for continuous operation)

Part no. Description Number of pumps (incl. stand--by pumps)

2 3 4 5 6 8 10
and more
Number of spare parts *
234 Impeller 1 1 1 2 2 3 30 %
502 Casing wear ring 4 4 4 6 6 8 50 %
503 Impeller wear ring 4 4 4 6 6 8 50 %
211,940 Shaft with keys and shaft nuts 1 1 2 2 2 3 30 %
920,932
321 Rolling element bearing 2 2 4 4 6 8 100 %
524 Shaft protecting sleeve 4 4 4 6 6 8 50 %
461 Packing ring 32 32 48 48 48 64 40 %
411,412 Set of sealing elements 4 6 8 8 9 12 150 %
421
433 Mechanical seal Spring--loaded 4 6 8 8 8 12 90 %
ring
Seat ring 4 6 8 8 8 12 90 %
O--rings 4 6 12 16 16 20 150 %
Seals on 4 6 12 16 16 20 150 %
Seat ring
Set of springs 1 2 2 2 2 4 20 %
* These figures already allow for components required twice for replacement

33
 Omega V

Interchangeability of rotor components

Pump sizes Pump shaft diameter

40 50 60 70 80 90

80 - 210 *
80 - 270 *
80 - 370 *
100 - 250 *
100 - 310 *
100 - 375 *
125 - 230 *
125 - 290 *
125 - 365 *
125 - 500 *
150 - 290 *
150 - 360 *
150 - 460 *
150 - 605 *
200 - 320 *
200 - 420 *

200 - 520 *
200 - 670 *
250 - 370 *
250 - 480 *
250 - 600 *
300 - 300 *
300 - 435 *
300 - 560 *
300 - 700 *
350 - 360 *
350 - 430 *
350 - 450 *

34
 Omega V

10 Forces and Moments

The given forces and moments are mean values for The values given in the table do not apply to the reaction
simultaneous loading in the three planes. If the forces and forces of braceless expansion joints.
moments in one particular direction are larger than given in the
table, consult KSB.

Dimensions in mm

Pump Impeller dimensions in mm Permissible nozzle Mass moments of Permissi- Permissi-

sizes inertia J ble opera- ble test
ting pressure
pressure
free passage max. diameter Clearances forces moments (without coupling) in bar in bar
10 % in N in Nm in kgm2
A B C A B C A B C Fx, Fy, Fz Mx, My, Mz without with 1) 2) 1) 2)
1); 3) 1); 3) water water
80-210 15 11 -- 215 215 -- 0.30 0.30 -- 800 500 0.023 0.028 16 25 28 37.5
80-270 13 9 -- 275 275 -- 0.30 0.30 -- 800 500 0.037 0.044 16 25 28 37.5
80-370 11 8 -- 345 345 -- 0.30 0.30 -- 800 500 0.027 0.032 16 25 28 37.5
100-250 19 14 -- 254 254 -- 0.35 0.35 -- 1000 700 0.048 0.058 16 25 28 37.5
100-310 15 11 -- 325 325 -- 0.35 0.35 -- 1000 700 0.092 0.110 16 25 28 37.5
100-375 13 10 -- 408 408 -- 0.35 0,35 -- 1000 700 0.229 0.275 16 25 28 37.5
125-230 23 17 -- 245 245 -- 0.35 0.35 -- 1500 1000 0.161 0.193 16 25 28 37.5
125-290 19 12 -- 301 301 -- 0.35 0.35 -- 1500 1000 0.125 0.150 16 25 28 37.5
125-365 14 10 -- 392 392 -- 0.35 0.35 -- 2000 1500 0.261 0.313 16 25 28 37.5
125-500 14 10 -- 482 482 -- 0.35 0.35 -- 2000 1500 0.688 0.825 16 25 28 37.5
150-290 27 20 14 289 289 289 0.45 0.45 0,45 2500 1500 0.169 0.288 16 25 28 37.5
150-360 22 15 -- 355 355 -- 0.45 0.45 -- 2500 2000 0.199 0.338 16 25 28 37.5
150-460 17 12 -- 462 462 -- 0.45 0.45 -- 2500 2000 0.456 0.775 16 25 28 37.5
150-605 16 11 -- 569 569 -- 0.45 0.45 -- 3000 2000 1.074 1.825 24 25 28 37.5
200-320 30 22 17 338 338 338 0.50 0.50 0,50 4000 2750 0.442 0.575 16 25 24 37.5
200-420 26 18 -- 415 415 -- 0.50 0.50 -- 4000 2750 0.588 0.725 16 25 24 37.5
200-520 20 14 -- 540 540 -- 0.50 0.50 -- 4000 2750 1.288 1.675 16 25 24 37.5
200-670 18 12 -- 665 665 -- 0.50 0.50 --4000 2750 3.654 4.750 24 25 28 37.5
1) see next page
2) see next page
3) see next page

35
 Omega V

Dimensions in mm

Pump Impeller dimensions in mm Permissible nozzle Mass moments of Permissi- Permissi-

sizes inertia J ble opera- ble test
ting pressure
pressure

free passage max. diameter Clearances forces moments (without coupling) in bar in bar
10 % in N in Nm in kgm2
A B C A B C A B C Fx, Fy, Fz Mx, My, Mz without with wa- 1) 2) 1) 2)
1); 3) 1); 3) water ter
250-370 39 27 20 390 390 390 0.5 0.5 0,5 4000 2750 0.721 1.225 10 25 15 37.5
250-480 30 20 -- 478 478 -- 0.5 0.5 -- 4000 2750 0.956 1.625 16 25 24 37.5
250-600 23 16 -- 622 622 -- 0.5 0.5 -- 4000 2750 2.206 3.750 24 25 28 37.5
300-300 39 27 -- 323 323 -- 0.5 0.5 -- 4000 3000 0.571 0.800 10 25 15 37.5
300-435 45 32 30 450 450 450 0.6 0.6 0,6 4000 3000 1.785 2.500 10 25 15 37.5
300-560 35 23 -- 553 553 -- 0.6 0.6 -- 5000 3000 2.411 3.375 16 25 24 37.5
300-700 26 18 -- 719 719 -- 0.6 0.6 -- 5000 3000 6.346 8.250 24 25 28 37.5
350-360 39 27 -- 382 382 -- 0.5 0.5 -- 5000 3000 1.116 1.563 10 25 15 37.5
350-430 57 40 -- 430 430 -- 0.6 0.6 -- 5000 3000 2.232 3.125 10 25 15 37.5
350-510 52 36 35 518 518 518 0.6 0,6 0,6 5000 3000 3.393 4.750 10 25 15 37.5
1) Casing material JL 1040 and GGG-NiCrNb 20 2
2) Casing material JS 1030 and 1.4517
3) Casing material JS 1030; 1,4-times the given value
4) Casing material 1.4517; 1,9-times the given value

11 Trouble--Shooting
11.1 General Power
The diagram opposite is to facilitate understanding of the Head
causes of faults and their remedies as indicated in the Efficiency
trouble--shooting table.
The cause of many operating faults on pumps is often
hydraulic. The hydraulic behavior of a pump is illustrated by its
characteristic curves H, P, Eta and NPSH in combination with
the plant characteristic curves HA and NPSHA.The operating Operating Limit
point B is where the system curve HA and the characteristic
curve H intersect. Consult the manufacturer if the cause of a
fault is unclear.

Capacity

36
 Omega V

11.2 Trouble--shooting Table

Pump fails to pump liquid after being switched on

Pump does not run smoothly (noise, vibrations)

Inadmissible temperature increase at pump /

Exessive leakage at shaft seal

Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid

Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

Cause Remedy 1)
F F F F F F F F F Operating point B does not Re--adjust operating point
lie at the calculated inter-
sections of Q and H
F Pump or piping incomple- Vent.
tely vented or not primed
F F F F F F Suction pipe or impeller Clean impeller
blocked Check plant for impurities
Remove deposits in pump and / or piping
Check strainer / suction opening
F F F Formation of air pockets in Correct suction conditions
the piping Alter piping
F F F F F Suction head too high Check mode of operation
(NPSHavailable too low) / Correct suction conditions
water level too low Increase positive suction head
Increase back pressure by throttling
Install pump at a lower level
Alter intake pipe if resistances are too high
F F F F Air is drawn in at shaft seal Clean sealing liquid line, possibly introduce
sealing liquid from an external source or
increase pressure
Check level of liquid in feed tank
Replace shaft seal
Replace shaft protecting sleeve
F F F F F Wrong direction of rotation Interchange two phases of the power cable
Check electrical connections
Check impeller position, correct if
necessary
F F F Speed too low Increase speed 1)
Check switchgear
Fit larger impeller 1)
F F F F Internals worn Check duty point / pump selection
Increase back pressure by throttling
Check medium handled for contamination
by chemicals and solids content
Replace worn components
F F Pump pressure is lower Re--adjust operating point
than specified in the order Increase back pressure by throttling.
1) Consult KSB

37
 Omega V

Trouble--shooting Table

Pump fails to pump liquid after being switched on

Pump does not run smoothly (noise, vibrations)

Inadmissible temperature increase at pump /

Exessive leakage at shaft seal

Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid

Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

Cause Remedy 1)
F F Higher density or viscosity Reduce speed
of medium handled than In the case of persistent overloading, turn
specified in the order down impeller, if necessary 1)
F F F F F Speed too high Reduce speed
In the case of persistent overloading, turn
down impeller, if necessary 1)
F Tie bolts / seals Check
Tighten tie bolts
Replace gaskets
Check pipe connections and pump moun-
ting, if necessary, improve mounting of pi-
ping.
F Worn shaft seal Check flushing / sealing liquid pressure
clean sealing liquid line, possibly introduce
sealing liquid from an external source or
increase pressure
Replace shaft seal
Replace worn components
Replace shaft protecting sleeve.
F F F F Unfavourable flow to Alter piping
suction nozzle of pump If necessary, alter intake pipe if resistances
are too high
Check whether pipe routing results in twi-
sted or irregular flow (e.g. downstream of
an elbow) and correct, if necessary.
1) Consult KSB

38
 Omega V

Trouble--shooting Table

Pump fails to pump liquid after being switched on

Pump does not run smoothly (noise, vibrations)

Inadmissible temperature increase at pump /

Exessive leakage at shaft seal

Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid

Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

Cause Remedy 1)
F F Gland cover, seal cover Alter
tightened incorrectly, Replace
wrong packing material Correct
Replace gland packing
Replace worn components
F F Lack of cooling liquid or Check flushing / sealing liquid pressure
cooling liquid chamber con- Clean sealing liquid line, possibly introduce
taminated sealing liquid from an external source or
increase its pressure
Increase cooling liquid flow
Clean cooling liquid line.
F F Pump mis--aligned or reso- Re--align pump / drive
nance vibrations in the pi- Check piping connections and pump
ping mounting, if necessary, improve mounting
of piping
Apply vibration--damping measures
F Excessive axial thrust Check duty point / pump selection
Check mode of operation
Check suction -- side flow.
F Too little, too much or un- Clean bearing
suitable lubricant Replace lubricant
Top up, reduce or change lubricant
F F F F Motor is running on two Replace defective fuses
phases only Check electrical connections
Check switchgear.
F F F Rotor is out of balance Clean rotor
Check run--out, straighten if necessary
Re--balance rotor.
F F F Bearings damaged Replace / change
F F Flow rate too low Re--adjust operating point
Fully open shut--off valve in the intake pipe
Fully open shut--off valve in the discharge
pipe
Recalculate or measure the hydraulic los-
ses HV.
1) Consult KSB

39
 Omega V

Trouble--shooting Table

Pump fails to pump liquid after being switched on

Pump does not run smoothly (noise, vibrations)

Inadmissible temperature increase at pump /

Exessive leakage at shaft seal

Bearing temperature too high
Power consumption too high

Pump ceases to pump liquid

Pump pressure too high
Pump pressure too low

Flow rate too high

Leakage at pump
Drive overloaded
Flow rate too low

seal casing

Cause Remedy 1)
F F In star / delta operation Check electrical connections
motor hangs at star Check switchgear.
stage
F F F Inadmissible air or gas Vent
content in liquid Check integrity of suction pipe, seal if
necessary
F F F F F Air drawn in at pump Correct suction conditions
inlet Reduce flow velocity at suction pipe
entry
Increase suction head
Check integrity of suction pipe and seal,
if necessary
Replace defective pipes.
F Cavitation (rattling noise) Correct suction conditions
Check mode of operation
Increase suction head
Install pump at a lower level
F F Foundation not rigid Check
enough Alter
F F F F F Inadmissible parallel Re--adjust operating point
operation Alter pump characteristic H1).
F F Shaft is out of true Renew / Replace

F F F F Impeller rubs against ca- Check rotor

sing components Check impeller position
Check that the piping is connected
without transmitting any stresses or
strains.

1) Consult KSB

40
 Omega V

12 Routine Maintenance and Inspection Intervals

Interval Number of per- Time Maintenance job

sonnel required [h]

Check leakage on mechanical seal or lea-

kage of packed gland
Daily 1 1/10 (see section 8.1 Gland packing).

Check pump operation (positive suction pres-

Weekly 1 1/4 sure, total head, bearing temperature, noises
and vibrations)
Check torsional play of coupling
1 1/4 (see section Coupling),
Monthly If available, switch to stand--by pump or carry
out a test run (for 5 min.)
1 1/4
Replace deep--groove ball bearings (see
every 20.000 2 3 section 7.3 Dismantling and
operating hours 7.4 Reassembly).

General inspection and overhaul of pump in

accordance with the operating instructions.

every 4 years or if total Check and renew, if required:

head of pump drops
2 6 -- wear parts such as: bearings, casing wear
ring (impeller wear ring, if any), shaft
protecting sleeve
-- impeller and shaft
-- Replace sealing elements

41
 Omega V

13 Appendix
Types of installation and directions of rotation / flow directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
-- Foundation (installation DJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
-- Foundation (installation DB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
-- Foundation (installation DK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Sealing / flushing water piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

-- Arrangement of sealing water and flush pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Flushing line for bottom RESIDUR bearing (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

-- Flushing line for Residur bearing (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Flushing line for Gland packing (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

-- Flushing line for Residur bearing (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
-- Flushing line for Residur bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Coupling (N--EUPEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

General drawing of pump with parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

-- Shaft seal: Gland packing DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
-- Shaft seal: Mechanical seal DB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Mechanical seals, standard design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Mechanical seals, standard design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Shaft seal, mechanical seals Typ Crane 58U and 58B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Dimensions and weights (modul) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

-- Omega V 80 - 210 up to 150 - 605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
-- Omega V 200 - 320 up to 350 - 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

General arrangement drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

-- Omega V 80 - 210 up to 80 - 370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
-- Omega V 100 - 250 up to 100 - 375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
-- Omega V 125 - 230 up to 125 - 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
-- Omega V 150 - 290 up to 150 - 605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
-- Omega V 200 - 320 up to 200 670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
-- Omega V 250 - 370 up to 250 - 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
-- Omega V 300 - 300 up to 300 - 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
-- Omega V 350 - 360 up to 350 - 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Lifting device disassembly of upper casing half and pump rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

42
 Omega V

Types of installation
Horizontal

Type of installation 3E

Pump set with close--coupled motor (type IM B3) 1)

Baseplate, baseframe, coupling guard and motor height adjustment
Vertical

Type of installation DB 2) Type of installation DK 2) Type of installation DJ 2)

2) Depending of motor size Version with intermediate bearing

Direction of rotation / flow direction

Horizontal Vertical
Direction of rotation Direction of rotation Direction of rotation Direction of rotation
anticlockwise, clockwise, viewed from the anticlockwise, clockwise, viewed from the
viewed from the drive end drive end viewed from the drive end drive end

1) General arrangement drawing Pump set 3 E -- Baseplate/baseframe with motor height adjustment shows the main variants available

43
 Omega V

Foundation (installation DJ)

Foundation (Foot and Rail)

Part no. Description

89-4 Shim
182 Foot
550 Shim
898 Foundation block
901 Hex. head bolt
593 Rail
904 Grub screw
920 Nut

Foundation (installation DB)

Foundation (Foot and Motor stool)

Part no. Description

89-4 Shim
182 Foot
341 Motor stool
550 Shim
531 Locking sleeve
898 Foundation block
901 Hex. head bolt
904 Grub screw
920 Nut

44
 Omega V

Foundation (installation DK)

Foundation (Foot, Motor stool and Support foot)

Part no. Description

89-4 Shim
182 Foot
183 Support foot
550 Shim
898 Foundation block
901 Hex. head bolt
904 Grub screw
920 Nut

45
 Omega V

Sealing / flushing water piping

The pump is equipped with sealing / flushing water piping.
These pipes are sheathed PTFE hoses which are flexible,
temperature and highly pressure resistant.
Another favourable property of PTFE (polytetrafluorethylene)
is the extremely low friction coefficient which prevents pipe
clogging.
Normally we supply this assembly ready mounted to the pump.
If this is not the case, mount the hoses and fittings as per the
attached drawings (see appendix).

Arrangement of sealing water and flush pipes

46
 Omega V

Flushing line for bottom RESIDUR bearing (1)

Flushing line for Residur bearing (2)

(2)
(1)

Part no. Description

719.01/02 Hose
731.02 Double nipple
731.04 Double nipple
731.05 Bend
731.10 T--joint
(731.12) Socket

Flushing line for Gland packing (1)

Flushing line for Residur bearing (2)

(2) (1)

Part no. Description

719.01/02 Hose
731.02 Double nipple
731.04 Double nipple
731.05 Bend
731.10 T--joint

47
 Omega V

Flushing line for Residur bearing

Part no. Description

719.02 Hose
731.04 Double nipple
731.05 Long bend
731.09 Short Bend

48

Coupling (N--EUPEX)
(Flexible couplings N--EUPEX and N--EUPEX--DS, types A
and ADS)
-- N--EUPEX couplings provide radial, angular, axial and
torsional flexibility. They are positive--locking.
-- Torque is transmitted by flexible coupling elements
(flexibles).
-- The non--linear spring characteristic and the favourable
damping properties of the N--EUPEX coupling effectively
counteract any dangerous increase in vibrations.
General instructions and safety notes
When fitting and removing N--EUPEX couplings please note
the following requirements:
D The coupling shall only be operated,
serviced or repaired by authorized,
skilled and duly qualified staff.
D The coupling shall only be used and
operated within the conditions
stipulated in the technical specification
and supply contract.
D Unauthorized modification and removal
of protective equipment is not permitted.
D Any work on the coupling shall only be
performed with the machine shut down.
The driver must be secured against
inadvertent start--up (e.g. by locking the
key--operated switch or removing the
power supply fuses). At the switch--on
point a notice shall be affixed to the
effect that work is being performed on
the coupling.
D Immediately switch off the driver when
changes in coupling behaviour occur,
such as changed running noises.
D The coupling must be suitably protected
against accidental contact.
Omega V
Installation
-- Design of types A / ADS
The N--EUPEX coupling types A / ADS consist of a coupling
part 1 which houses the flexible coupling blocks (12), the finger
part 3 and the coupling part 2, which bolts onto part 3.
The bolted connection between part 2 and part 3 makes it
possible to separate the coupled machines without axial
displacement (if clearance P is observed).
Part 1 Part 12 Part 13 Part 2
S1
-- Mounting the coupling components
Before fitting the coupling components, carefully clean the shaft
ends and the coupling parts. Make sure to remove the flexible
coupling blocks before cleaning the coupling parts with a
solvent.
Heed the manufacturers instructions for the use of
solvents.
Caution Use appropriate tools when pulling on the
coupling parts, to prevent damage to the shaft
bearings due to the axial joining force.
Make sure to use suitable lifting tackle.
The shaft ends must not protrude from the hub faces. The
coupling is locked in axial direction by means of the set screw
or end plate, as applicable / set screw and end plate,
respectively.
Caution The set screws shall only be tightened by
means of a hexagon socket head wrench to
DIN 911, without extension.
Non--compliance with these instructions may cause
the coupling to burst. Danger of life by flying
fragments!
49
 Omega V

Heating up the coupling parts (to max. +150 C) may facilitate Using a dial micrometer will make for increased measuring
pulling on the coupling parts. If temperatures exceed +80 C, accuracy.
the flexible coupling blocks must be removed from the coupling To allow one shaft end to rotate freely, the driving section can
parts before the heating process. be separated on types A and ADS by loosening the screwed
Protect against burns from contact with hot connection between parts 2 and 3 and pulling part 3 out of the
components! recesses in part 1.
If the coupling blocks have been removed, they shall be Caution After the connection has been re--established,
re--installed after the coupling parts have been pulled on. Make check the tightening torque of the bolts.
sure the heated coupling parts have cooled down to under 80
C before doing so. All coupling blocks used must be of identical
size and marking.
Push the machines to be coupled together.
Take appropriate precautions to prevent injury by
crushing.

Make sure to observe dimension S1. On types A and ADS, the

connection between parts 2 and 3 shall be re--established
before aligning the coupling, and the tightening torque of the
screwed connection between parts 2 and 3 shall be checked
(for tightening torques and clearance S1 please refer to point
6.6).
Aligning the coupling
(Also refer to section 5.3.2).
The couplings will only tolerate misalignment of the shaft ends
to be coupled to a certain extent.
When aligning the coupling, the radial and angular
misalignment of the shaft ends should therefore be minimized.
With identical operating conditions, the useful life of the flexible
coupling blocks will be increased as a result.
Coupling alignment shall be effected in two planes which are
normal to each other. Use a straight--edge (radial
misalignment) and feeler gauge (angular misalignment) as
shown below to verify.

Straight edge

Feeler gauge

50
 Omega V

Correlation between tightening torques, dimension P and clearance S1

N-EUPEX N-EUPEX-DS Tightening

g g torque
q TA and width across flats SW for bolts
coupling coupling to DIN 912 Part 2/3

Size Size TA SW P S1
Nm [mm] [mm] [mm]
110 118 14 6 33 2-4
125 135 17,5 6 38 2-4
140 152 29 8 43 2-4
160 172 35 8 47 2-5
180 194 44 8 50 2-6
200 218 67,5 10 53 2-6
225 245 89 10 61 2-6
250 272 145 14 69 3-8
280 305 185 14 73 3-8
315 340 200 14 78 3-8
350 350 260 17 83 3-8
400 430 340 17 88 3-8
440 472 420 17 99 5-10
480 514 550 19 104 5-10
520 556 670 19 115 5-10
560 ---- 710 19 125 6-12
610 ---- 1450 22 135 6-12
660 ---- 1450 22 145 6-12
710 ---- 1450 22 155 6-12
Commissioning the coupling Operation
Measures to be taken prior to commissioning General operating data
Before commissioning the coupling check the proper During coupling operation, watch out for
installation of the flexible coupling elements, i.e. make sure the -- changed running noises,
flexibles are flush with the hub face, and check whether the set -- sudden vibrations.
screws are properly tightened. Also verify coupling alignment
and clearance S1 and correct, if necessary. Check whether all Caution If any irregularities occur during operation,
screwed connections have been tightening with the tightening switch off the driver immediately and refer to
torques specified. Finally, fit the coupling guard against the trouble--shooting table to determine the cause.
accidental contact The trouble--shooting table lists possible faults, causes and
suggested remedies.

51
 Omega V

Trouble--shooting Before commencing any maintenance, repair or

General other work on the coupling, the operator must shut
down the entire driving mechanism. The drivers, in
The faults listed below shall serve as orientation only when particular, must be secured against inadvertent start--up
determining failure causes.
In a complex plant system, all other components will have to be Also, the accident prevention regulations in force at the
included in the search for possible failure causes. installation site shall be complied with.
The coupling shall give low--noise and vibration--free operation
in all phases of operation. Any other operating behaviour shall
be considered a fault which must be remedied immediately.

Trouble--shooting list

Fault Possible Causes Remedy

Sudden changeg in noise level and/or
/ Misalignment Shut down the unit.
sudden vibrations

Eliminate cause for misalignment,

g , if any.
y
(E.g. re--tighten the foundation bolts).
Inspect for wear,
wear proceed as described
in section Coupling
Coupling -- Maintenance and Repair
Repair

Flexibles are worn Shut down the unit.

Torque transmission by Dismantle the coupling and remove what is left of the
metal to metal contact
metal--to--metal flexible coupling blocks.
blocks

Inspect the coupling parts and replace

any damaged components.

Coupling
C li blblocks
k shall
h ll always
l be
b replaced
l d by
b complete
l
sets of new coupling blocks; only use.
coupling blocks with identical markings.

Verify
y alignment
g and correct,, if necessary.
y

Check the tightening torques of the screwed connec-

tion between parts 2 and 3.

Maintenance and repair To determine the chord dimension DSV, rotate one coupling part
General by hand up to the stop and mark the coupling parts (see
illustration). Hand--rotate one coupling part into the opposite
The torsional play between the two coupling parts shall be
direction up to the stop. The two marks will diverge. The
checked in acc. with the maintenance schedule of the plant, but
distance between the marks is the chord dimension DSV. If DSV
at least once a year.
exceeds the value given in the table, the flexible coupling
If torsional play must not be limited for extremely smooth blocks have to be replaced.
coupling operation, the plastic flexibles can be allowed to wear
Caution Coupling blocks shall always be replaced
down to approx. of their original thickness before they have
by complete sets of new coupling blocks;
to be replaced. To assess the wear condition of the coupling
only use coupling blocks with identical
blocks, the table below indicates the permissible torsional play
identification numbers.
as indicated by the chord dimension DSV on the outside
coupling diameter.

52
 Omega V

Table: Wear mark on N-EUPEX-coupling

Size 58 68 80 95 110 125 140 160 180 200 225 250 280 315 350 400 440 480 520 560 610 660 710
Wear-
mark 5.5 5.5 5.0 6.0 7.0 8.0 8.0 8.0 8.0 8.5 9.0 10.0 11.5 10.5 11.5 13.0 14.0 15.5 17.5 17.5 19.5 21.0 22.5
DSV

Table: Wear mark on N-EUPEX-DS-coupling

Size 66 76 88 103 118 135 152 172 194 218 245 272 305 340 380 430 472 514 556
Wear-
mark 6.0 7.0 5.0 7.0 9.0 10.5 11.5 9.0 8.0 7.0 6.5 7.0 8.0 6.5 7.0 10.0 12.0 14.0 16.0
DSV

Replacing wear parts
Use only genuine N--EUPEX flexible blocks as spare parts, to
ensure correct torque transmission and trouble--free operation.
Please note:
On types A and ADS, the flexibles can be replaced without axial
displacement of the coupled machines
After the screwed connection between parts 2 and 3 has been
undone, part 3 can be shifted in axial direction. By rotating part
3, the flexible coupling blocks are freely accessible. To facilitate
axial displacement, sizes 225--430 are provided with forcing
threads in part 1. From size 440, the forcing threads are located
in part 3 (see illustrations).

For reassembly carefully follow the instructions in the sections

on Installation and Commissioning.

53
 Omega V

General drawing of pump with parts list Shaft seal: Gland packing / DB

Shaft Axial overhang of shaft protecting

Special adhesive 2503/L28 Desmodur diameter sleeve
dW A 0.5
40 4
50 2.5
60 2
Sealed with Loctite 574 70 2
80 3
90 2

ALTEMP Q NB 50 grease

54
 Omega V

Part no. Description Part no. Description Part no. Description

102 Volute casing 421 Radial shaft seal ring 550 Washer
105.01 Lower casing half 441 Housing for shaft seal 561 Grooved pin
105.02 Upper casing half 452 Gland cover 719 Hose
160 Cover 455 Gland packing 901 Hex. head bolt
182 Foot 457 Stuffing box insert 902 Stud
211 Pump shaft 458 Neck ring 903 Screwed plug
234 Impeller 461 Lantern ring 904 Grub screw
321 Deep groove ball 502 Casing wear ring 914 Socket head cap screw
bearing
341 Motor stool 503 Impeller wear ring 920 Nut
350 Bearing housing 524 Shaft protecting sleeve 930 Safety device
360 Bearing cover 525 Spacer sleeve 932 Circlip
411 V-ring 531 Locking sleeve 940 Key
412 O-ring 545 Bearing bush 950 Cup spring

55
 Omega V

General drawing of pump with parts list Shaft seal: Mechanical seal / DB

Shaft Axial overhang of shaft protecting

Glued in with Loctite 2701 diameter sleeve
dW A 0.5
40 4
50 2.5
Special adhesive 2503/L28 Desmodur 60 2
70 2
80 3
90 2
A Sealed with Loctite 574

ALTEMP Q NB 50 grease

56
 Omega V

Part no. Description Part no. Description Part no. Description

102 Volute casing 421 Radial shaft seal ring 719 Hose
105.01 Lower casing half 433 Mechanical seal 901 Hex. head bolt
105.02 Upper casing half 441 Housing for shaft seal 902 Stud
160 Cover 457 Neck ring 903 Screwed plug
182 Foot 458 Lantern ring 904 Grub screw
211 Pump shaft 502 Casing wear ring 914 Socket head cap screw
234 Impeller 503 Impeller wear ring 920 Nut
321 Deep groove ball 524 Shaft protecting sleeve 930 Safety device
bearing
341 Motor stool 525 Spacer sleeve 932 Circlip
350 Bearing housing 531 Locking sleeve 940 Key
360 Bearing cover 545 Bearing bush 950 Cup spring
411 V-ring 550 Washer
412 O-ring 561 Grooved pin

57
 Omega V

Mechanical seals, standard design

Standardized mechanical seal to DIN 24960 -- short design, non--balanced
Sizes for shaft diameter dw = 40 to 80 mm (with single spring)

211 524.01 457.02 525.02 411 433 471 901.16

Flushing line
connection

dw

Standardized mechanical seal to DIN 24960 -- short design, non--balanced

Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)

211 524.01 457.02 525.02 411 433 Flushing line 471 901.16
connection
dw = 90

110

Part no. Description Part no. Description

211 Pump shaft 471 Seal cover
433 Mechanical seal 524.01 Shaft protecting sleeve
441 Housing for shaft seal 525.02 Spacer sleeve
457.02 Neck ring 901.16 Hex. head bolt

58
 Omega V

Mechanical seals, standard design

Balanced mechanical seal (for operating pressures > 16 bar) to DIN 24960
Sizes for shaft diameter dw = 40 to 80 mm (with covered spring
457.02 411 433 471 901.16
Flushing line connection

525.02

524.01

211
dw

Balanced mechanical seal (for operating pressures p > 16 bar) to DIN 24960
Sizes for shaft diameter dw = 90 mm (with multiple spring arrangement)
211 524.01 457.02 525.02 411 433 Flushing line 471 901.16
connection
110
dw = 90

Part no. Description Part no. Description

211 Pump shaft 471 Seal cover
433 Mechanical seal 524.01 Shaft protecting sleeve
441 Housing for shaft seal 525.02 Spacer sleeve
457.02 Neck ring 901.16 Hex. head bolt

59
 Omega V

Shaft seal -- mechanical seals -- Type Crane 58U and 58B

Description Preparation for installation
The mechanical seals, 58U and 58B, are precision--made and 1. The installation dimensions and tolerances must comply
must be treated accordingly. The contact faces are lapped to with those outlined in the relevant literature.
a high degree of accuracy and prior to despatch they are 2. The cover which will accept the seat ring must be checked
covered in a protective sleeve to prevent damage. If the with regard to depth and installation dimensions.
protective sleeve is removed for installation purposes, then
great care must be taken to avoid any damage to the finely
finished, lapped surfaces.
Whenever replacing worn out or damaged mechanical seals,
the section of the shaft or sleeve which will accept the new seal
must be cleaned and oiled.

780 Retainer 578 Balanced face

305 Grub screw 096 Snap ring
582 (092) Spring 500 Seat type BP
583 Thrust ring 501 Seat ring
123 O-ring 902 Seat type BO
574 Rotating face 123 (R) O-ring
564 Support ring

Installation and operation
1. Clean and lightly lubricate the shaft / sleeve with a suitable
lubricant.
Attention:
Sealing elements manufactured in EP--Elastomer materials
must not come in contact with mineral oil and grease.
2. Push on the rotating unit applying light manual pressure.
3. Push the seat ring together with the joint ring into the cover
applying even manual pressure. The joint ring shall also be
lubricated using a suitable lubricant.
4. The contact faces must be cleaned prior to installation into
the machine. Tighten the cover bolts evenly. Overtightening
can affect the true running of the rubbing faces and
therefore have an adverse effect on the functioning of the
mechanical seal.
5. Manually turn the shaft. Fill the machine whilst
simultaneously monitoring the venting equipment within the
seal area. Check the circulation pipe.

60
 Omega V

Dismantling and assembly of the rotating unit

The first step is to remove the snap ring (096) from the retainer
(780). The springs are compressed to achieve this. This can
be done by using a simple tool, as illustrated.
Caution Lapped surfaces of the rotating face must be
protected.

Wing nut

Grub screw

Thrust plate with glued--on

protective support

Locking nut

Baseplate
1. The rotating face (574 / 578) is pushed down and the snap
ring (096) is removed from the groove using a pointed tool.
Assembly is carried out in reverse sequence.
The following must be noted during assembly:
The drive cams in the retainer (780) must engage into the
grooves of the thrust ring (583) or the rotating face (574 / 578).
Fit the snap ring (096) into the groove of the retainer (780),
leaving one end of the snap ring protruding by approx 6 -- 12 mm
to the side of the drilled hole

At the outer circumference of the retainer (780) there are 2

2. Now remove in the following sequence: the rotating face
(574 / 578), the O--ring (123), the thrust ring (583) and the
springs (582 / 092).
marker grooves. The lower one runs precisely through the
centre of the drilled hole for the internal socket head screws,
which indicates that the thread of the screws is metric.
The upper groove assists during installation. If the initial
tension of the mechanical seal is set correctly to the installation
length, then the thrust ring shall be in alignment (be flush) with
this groove.

61
 Omega V

Table of dimensions Omega V 80 -- 210 up to 150 - 605

N.B.: If the pumps direction of rotation
is ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is reversed
(mirror image).
Flanges: d1
- Flat surface flanges
- Flange thickness to ANSI 5D
- Connect pipes without stress

ll
h5
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
A B
- 8B Leakage liquid drain G 3/4

h4
6B
Keyway and key to 6B
DIN 6885 sheet 1
Shaft diameter:
Tolerance h6 to DIN 7155

Section A - B
a1 a2
only for Omega V 150-605 s1 s2

1M 1M

DN 2
DN1
m4

m6

z2 x--holes
d2
h2
m3
m5

h3
z

Direction of rotation:
n6
CLOCKWISE

n5

Major external pump dimensions all dimensions in mm

Pump Flange dimensions Pump dimensions
size DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) z2 d2
80-210 168 340
300 300
80-270 125 80 35 29 140 190 300 715 380
80-370 330 330 225 450
100-250 195 390
330 330
100-310 150 100 37 32 170 225 300 715 450
100-375 370 370 260 520
125-230 210 420 4 18
125-290 370 370 230 460
200 125 41 35 200 355 870
125-365 260 520
125-500 450 450 305 610
150-290 245 490
400 400 355 870
150-360 200 265 530
200 150 41 37
150-460 450 450 305 610
400 990
150-605 600 500 300 370 740 6 18
1) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

62
 Omega V

Major external pump dimensions and weights all dimensions in mm

Pump Foot dimensions Shaft Weights [kg]
size m3 m4 m5 m6 n5 n6 d1 l1 Pump Water
content
80-210 185 10
80-270 640 275 100 380 450 340 35 80 195 15
80-370 205 20
100-250 210 20
100-310 695 315 115 420 500 400 35 80 225 25
100-375 245 30
125-230 250 35
125-290 600 450 275 40
855 360 210 475 45 100
125-365 300 45
125-500 700 560 335 55
150-290 350 50
600 450 45 100
150-360 855 360 210 475 360 60
150-460 700 560 440 75
55 125
150-605 1060 460 315 575 900 700 650 90

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
80-210
80-270 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
80-370
100-250
100-310 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
100-375
125-230 d2
125-290
PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250 number
125-365
of holes n
125-500
150-290
150-360 PN 16 Table 16/11
Class 250 PN 25 Table 25/11 Class 250
150-460
150-605 PN 25 Table 25/11
1) Other flange designs are available on request k

Flange dimensions -- Drilling diagram all dimensions in mm

Standard DN 80 DN 100 DN 125 DN 150 DN 200
d2 k n d2 k n d2 k n d2 k n d2 k n
ISO 7005/2
DIN 2501 PN 16 19 160 8 19 180 8 19 210 8 23 240 8 23 295 12

ISO 7005/2
DIN 2501 PN 25 19 160 8 23 190 8 28 220 8 28 250 8 28 310 12

BS 4504 Table 16/11 19 160 8 19 180 8 19 210 8 23 240 8 23 295 12

BS 4504 Table 25/11 19 160 8 23 190 8 28 220 8 28 250 8 28 310 12
ANSI B 16.1 Class 250 23 168 8 23 200 8 23 235 8 23 270 12 28 330 12

63
 Omega V

Table of dimensions Omega V 200 -- 320 up to 350 - 510

N.B.: If the pumps direction of rotation
is ANTI--CLOCKWISE, the position of
the suction and discharge nozzle is reversed
(mirror image).
Flanges: d1
- Flat surface flanges
- Flange thickness to ANSI 5D
- Connect pipes without stress

ll
h5
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
A B
- 8B Leakage liquid drain G 3/4

h4
6B
Keyway and key to 6B
DIN 6885 sheet 1
Shaft diameter:
Tolerance h6 to DIN 7155

Section A - B
a1 a2
only for Omega V 150-605 s1 s2

1M 1M

DN 2
DN1
m4

m6

z2 x--holes
d2
h2
m3
m5

h3
z

Direction of rotation:
n6
CLOCKWISE

n5

Major external pump dimensions all dimensions in mm

Pump Flange dimensions Pump dimensions
size DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) z2 d2
200-320 450 450 285 570
240 400 990
200-420 500 310 620 6 18
250 200 48 41 500
200-520 600 300 370 740
440 1095
200-670 650 550 350 430 860
250-370 33 (51) 1) 32 (48) 1) 500 500 320 440 1095 640
300
250-480 300 250 550 355 710
51 48 550 500 1230
250-600 650 350 415 830
300-300 350 36 (54) 1) 33 550 500 300 360 440 1095 720 6 22
300-435 38 (57) 1) (51) 1) 650 550 350 365 500 1230 730
300
300-560 400 700 350 430 860
57 51 650 570 1380
300-700 750 400 480 960
350-360 400 38 (57) 1) 650 550 350 410 500 1230 820
350-430 450 350 41 (60) 1) 36 (54) 1) 750 465 930
650 400 570 1380
350-510 400 38 (57) 1) 700 420 840
1) For casing material GGG-NiCrNb 202, JS 1030, 1.4517
2) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

64
 Omega V

Major external pump dimensions and weights all dimensions in mm

Pump Foot dimensions Shaft Weights [kg]
size m3 m4 m5 m6 n5 n6 d1 l1 Pump Water
content
200-320 450 80
1060 460 575 700 560 55 125
200-420 520 95
315
200-520 1120 520 635 840 115
900 700 65 140
200-670 1180 560 685 990 140
250-370 65 140 665 125
1180 560 685
250-480 315 900 700 830 145
75 160
250-600 1210 590 715 1215 180
300-300 1210 590 715 65 160 630 100
315 900 700
300-435 1250 630 755 75 160 905 190
300-560 1375 670 795 1425 225
400 1200 950 85 180
300-700 1415 710 835 1690 275
350-360 1250 630 315 755 900 700 75 160 865 160
350-430 1285 240
1415 710 400 835 1200 950 85 180
350-510 1395 290

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
200-320 Table 16/11
200-420 PN 16
Class 250 PN 25 Table 25/11 Class 250
200-520
200-670 PN 25 Table 25/11
250-370 PN 10 Table 10/11 Class 125
250-480 PN 16 Table 16/11 PN 25 Table 25/11 Class 250
Class 250
250-600 PN 25 Table 25/11 d2
300-300
PN 10 Table 10/11 Class 125 number
300-435
PN 25 Table 25/11 Class 250 of holes n
300-560 PN 16 Table 16/11
Class 250
300-700 PN 25 Table 25/11
350-360
350-430 PN 10 Table 10/11 Class 125 PN 25 Table 25/11 Class 250
350-510
1) Other flange designs are available on request k

Flange dimensions -- Drilling diagram all dimensions in mm

Standard DN 200 DN 250 DN 300 DN 350 DN 400 DN 450
d2 k n d2 k n d2 k n d2 k n d2 k n d2 k n
ISO 7005/2
DIN 2501 PN 10 23 295 8 23 350 12 23 400 12 23 460 16 28 515 16 28 565 20

ISO 7005/2
DIN 2501 PN 16 23 295 12 28 355 12 28 410 12 28 470 16 31 525 16 31 585 20

ISO 7005/2
DIN 2501 PN 25 28 310 12 31 370 12 31 430 16 34 490 16 37 550 16

BS 4504 Table 10/11 23 295 8 23 350 12 23 400 12 23 460 16 28 515 16 28 565 20

BS 4504 Table 16/11 23 295 12 28 355 12 28 410 12 28 470 16 31 525 16 31 585 20
BS 4504 Table 25/11 28 310 12 31 370 12 31 430 16 34 490 16 37 550 16
ANSI B 16.1 Class 125 23 299 8 28 362 12 28 432 12 28 476 12 28 540 16 31 578 16
ANSI B 16.1 Class 250 28 330 12 28 387 16 31 451 16 31 514 20 34 572 20 34 629 24

65
 Omega V

General arrangement drawing Omega V 80 -- 210 up to 80 -- 370

Type of arrangement DB Type of arrangement DK

h7

A 5
B
5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270
a1 a2 n6

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Section A - B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights [kg]
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Water
content
80-210 168 340 185 10
300 300
80-270 125 80 34 29 140 190 300 715 380 195 15
80-370 330 330 225 450 205 20
1) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

66
 Omega V

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
80-210
80-270 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
80-370
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange d2
DN 125 DN 80
number
d2 k n d2 k n of holes n
ISO 7005/2 PN 16
DIN 2501 19 210

ISO 7005/2 PN 25
DIN 2501 28 220 19 160
8 8
BS 4504 Table 16/11 19 210
BS 4504 Table 25/11 28 220 k
ANSI B 16.1 Class 250 23 235 23 168

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 100 L 250 780 315 15
----
max. 200 L 400 665
640
450 250
80 210
80-210 830
min. 225 M 450 695 330
---- max. 250 M 550 860 790
720
710 435
min. 100 L 250 780 315 25
----
max. 200 L 400 665
640 275 100 380
450
340
250
80-270 830
min. 225 M 450 695 330
---- max. 315 S 660 860 970
720
710 830
min. 132 S 300 800 375 45
80-370 ----
max. 200 L 400 830 665
640
450 250
2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

67
 Omega V

General arrangement drawing Omega V 100 -- 250 up to 100 - 375

Type of arrangement DB Type of arrangement DK

h7

A 5
B
5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270
a1 a2 n6

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Section A - B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights ( [kg]
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Water
content
100-250 195 390 210 20
330 330
100-310 150 100 37 32 170 225 300 715 450 225 25
100-375 370 370 260 520 245 30
1) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

68
 Omega V

Standard flange design 1):

Pump JL 1040/ GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
100-250
100-310 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
100-375
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flang Discharge flange d2
DN 150 DN 100
number
d2 k n d2 k n of holes n
ISO 7005/2
DIN 2501 PN 16 23 240 19 180

ISO 7005/2
DIN 2501 PN 25 28 250 8 23 190 8
BS 4504 Table 16/11 23 240 19 180
BS 4504 Table 25/11 28 250 190 k
23
ANSI B 16.1 Class 250 23 270 12 200

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 100 L 250 780 315 25
----
max. 225 M 450 830 695
695 500
330
100 250
100-250
min. 250 M 550 790 435
---- max. 315 M 660
860
970
760 810
850
min. 132 M 300 800 375 55
----
max. 225 M 450 830 695
695 500
330
100-310
min. 250 M 550 790 315 115 420 400 435
---- max. 315 800
860
1230
760 810
1500
min. 160 M 350 481 75
----
max. 225 M 450
830
695
695 500
330
100-375
min. 250 M 790 435
---- max. 280 S
550 860
865
760 810
610
2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

69
 Omega V

General arrangement drawing Omega V 125 - 230 up to 125 -- 500

Type of arrangement DB Type of arrangement DK

h7

A 5
B
5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270
a1 a2 n6

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Section A-B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights [kg]
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Water
content
125-230 210 420 250 35
125-290 370 370 230 460 275 40
200 125 41 35 200 355 870
125-365 260 520 300 45
125-500 450 450 305 610 335 55
1) z = The dimensions to be maintained around the casing cover for dismantling of the rotor

70
 Omega V

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
125-230
125-290
125-365 PN 16 Table 16/11 Class 250 PN 25 Table 25/11 Class 250
125-500
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange d2
DN 200 DN 125
d2 k n d2 k n number
of holes n
ISO 7005/2
DIN 2501 PN 16 23 295 19 210
ISO 7005/2
DIN 2501 PN 25 28 310 28 220
12 8
BS 4504 Table 16/11 23 295 19 210
BS 4504 Table 25/11 28 310 28 220
ANSI B 16.1 Class 250 28 330 23 235 k

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 132 S 300 955 415 45
----
max. 280 M 550 865
855 600
660
125 230
125-230
min. 315 S 1015 830
---- max. 315 M
660 970 820 860
850
min. 132 M 300 955 415 55
----
max. 280 M 550 865
855 600 450
660
125-290
min. 315 S 660 1015 970 360 210 475 830
---- max. 315 800 1230
905 920
1500
min. 160 L 350 985 525 90
125-365 ----
max. 280 M 550 1015 865
600
660
855
min. 200 L 400 985 610 170
125-500 ----
max. 315 M 660 1045 970
700 560
910
2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

71
 Omega V

General arrangement drawing Omega V 150 -- 290 up to 150 -- 605

Type of arrangement DB Type of arrangement DK

h7

A B
5

5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270
a2 only for
a1 n6
pump size 150-605

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Section A - B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights [kg]
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Water
content
150-290 245 490 350 50
400 400 355 870
150-360 200 265 530 360 60
200 150 41 37
150-460 450 450 305 610 440 75
400 990
150-605 600 500 300 370 740 650 90
1) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

72
 Omega V

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
150-290
150-360 PN 16 Table 16/11
Class 250 PN 25 Table 25/11 Class 250
150-460
150-605 PN 25 Table 25/11
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange d2
DN 200 DN 150 number
d2 k n d2 k n of holes n
ISO 7005/2
DIN 2501 PN 16 23 295 23 240

ISO 7005/2
DIN 2501 PN 25 28 310 28 250 8
12
BS 4504 Table 16/11 23 295 23 240
BS 4504 Table 25/11 28 310 28 250 k
ANSI B 16.1 Class 250 28 330 23 270 12

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 160 L 350 985 485 93
150 290
150-290 ----
max. 225 M 450 1015 695 330
600 450
min. 160 L 350 985 485 90
150-360 ----
max. 280 M 550 1015 695
855 360 210 475
660
min. 200 L 400 1105 665 240
150-460 ----
max. 315 L 660 1165 1110
700 560
1200
min. 280 S 550 1135 865 610
150-605 ----
max. 355 900 1165 1455
1060 460 315 575 900 700
2200
2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

73
 Omega V

General arrangement drawing Omega V 200 -- 320 up to 200 -- 670

Type of arrangement DB Type of arrangement DK

h7

A 5
B
5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270

a1 a2 n6

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Section A - B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights (kg)
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 1) Pump Water
content
200-320 450 450 285 570 450 80
240 400 990
200-420 500 310 620 520 95
250 200 48 41 500
200-520 600 300 370 740 840 115
440 1095
200-670 650 550 350 430 860 990 180
1) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

74
 Omega V

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
200-320
200-420 PN 16 Table 16/11
Class 250 PN 25 Table 25/11 Class 250
200-520
200-670 PN 25 Table 25/11
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange d2
DN 250 DN 200
number
d2 k n d2 k n of holes n
ISO 7005/2
DIN 2501 PN 16 28 355 23 295

ISO 7005/2
DIN 2501 PN 25 31 370 12 28 310
12
BS 4504 Table 16/11 28 355 23 295
BS 4504 Table 25/11 31 370 310 k
ANSI B 16.1 Class 250 28 387 16 28 330

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 180 L 350 1105 995 180
200 320
200-320 ----
max. 280 M 550 1135 865 660
1060 460 575 700 560
min. 200 L 400 1105 665 240
200-420 ----
max. 315 L 660 1135 1110 1200
min. 250 M 550 1200 790 435
200-520 ----
max. 355 900 1455
1120 520 315 635
2200
900
min. 315 S 660 1270 1110 830
----
max. 355 900 1455
1180 560 700
2200
200-670 685
min.
----
max.
400 1000 1310 1615 1220 560 1160 3200
2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

75
 Omega V

General arrangement drawing Omega V 250 -- 370 up to 250 -- 600

Type of arrangement DB Type of arrangement DK

h7

A 5
B
5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270

a1 a2 n6

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Section A - B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights [kg]
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) Pump Water
content
250-370 33 (51) 1) 32 (48) 1) 500 500 320 440 1095 640 665 125
300
250-480 300 250 550 355 710 830 145
51 48 550 500 1230
250-600 650 350 415 830 1215 180
1) For casing material GGG-NiCrNb 202, JS 1030 1.4517
2) z = The dimensions to be maintained around the casing cover for dismantling of the rotor

76
 Omega V

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
250-370 PN 10 Table 10/11 Class 125
250-480 PN 16 Table 16/11 PN 25 Table 25/11 Class 250
Class 250
250-600 PN 25 Table 25/11
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange d2
DN 300 DN 250
number
d2 k n d2 k n of holes n
ISO 7005/2
DIN 2501 PN 10 23 400 23 350

ISO 7005/2
DIN 2501 PN 16 28 410 12 28 355

ISO 7005/2
DIN 2501 PN 25 31 430 16 31 370
12 k
BS 4504 Table 10/11 23 400 23 350
12
BS 4504 Table 16/11 28 410 28 355
BS 4504 Table 25/11 31 430 16 31 370
ANSI B 16.1 Class 125 28 432 12 362
28
ANSI B 16.1 Class 250 31 451 16 387 16

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 250 M 550 1240 790 435
250 370
250-370 ----
max. 315 L 660 1270 1110 1200
1180 560 685
min. 250 M 550 1375 790 435
250-480 ----
max. 355 900 1455
900
2200
315 700
min. 315 M 660 1405 970 910
----
max. 355 900 1455
1210
2200
250-600 590 715
min.
---- max.
400 1000 1445 1615 1350 1260 3200

2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

77
 Omega V

General arrangement drawing Omega V 300 -- 300 up to 300 -- 700

Type of arrangement DB Type of arrangement DK

h7

A 5
B
5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270

a1 a2 n6

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Selection A - B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights [kg]
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) Pump Water
content
300-300 350 36 (54) 1) 550 500 300 360 440 1095 720 630 100
33 (51) 1)
300-435 38 (57) 1) 650 550 365 500 1230 730 905 190
300 350
300-560 400 700 430 860 1425 225
57 51 650 570 1380
300-700 750 400 480 960 1690 275
1) For casing material GGG-NiCrNb 202, JS 1030 1.4517
2) z = the dimensions to be maintained around the casing cover for dismantling of the rotor

78
 Omega V

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
300-300
PN 10 Table 10/11 Class 125
300-435
PN 25 Table 25/11 Class 250
300-560 PN 16 Table 16/11
Class 250
300-700 PN 25 Table 25/11
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange d2
DN 350 DN 400 DN 300 number
d2 k n d2 k n d2 k n of holes n
ISO 7005/2
DIN 2501 PN 10 23 460 28 515 23 400
12
ISO 7005/2
DIN 2501 PN 16 28 470 31 525 28 410

ISO 7005/2 16
DIN 2501 PN 25 34 490 37 550 31 430 16
16 k
BS 4504 Table 10/11 23 460 28 515 23 400
12
BS 4504 Table 16/11 28 470 31 525 28 410
BS 4504 Table 25/11 34 490 37 550 31 430 16
ANSI B 16.1 Class 125 28 476 12 28 540 28 432 12
ANSI B 16.1 Class 250 31 514 20 34 572 20 31 451 16

Motor Dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 200 L 400 1210 665 170
300 300
300-300 ----
max. 315 S 660 1270 970
1210 590 715
830
315 900 700
min. 280 M 550 1375 865 660
300-435 ---
max. 315 800 1405 1230
1250 630 755
1500
min. 315 M 660 1555 970 910
300-560 ---
max. 400 1000 1595 1730
1375 670 795
3200
400 1200 950
min. 315 800 1555 1230 1500
300-700 ----
max. 400 1000 1615 1615
1415 710 835
3200
2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

79
 Omega V

General arrangement drawing Omega V 350 -- 360 up to 350 -- 510

Type of arrangement DB Type of arrangement DK

h7

A 5
B
5D
s1 s2
h6
h5
h4

X 6B
6B
250

Grouting

170 270

a1 a2 n6

1M 1M
m6
DN2
DN1

m4
h2

m3

m5
h3 Z

n5 Direction of rotation:
CLOCKWISE View X
Selection A - B
Connections:
- 1M Pressure gauge G 1/2
- 5D Vent G 1/2
- 6B Drainage G 1/2
- 8B Leakage liquid drain G 3/4

Flanges:
- Flat surface flanges
- Flange thickness to ANSI Position of the terminal box to be in accordance
- Connect pipes without stress with motor dimension sheet

Major external pump dimensions and weights all dimensions in mm

Pump size Flange dimensions Pump dimensions Weights [kg]
DN1 DN2 s1 s2 a1 a2 h2 h3 h4 h5 z 2) Pump Water
content
350-360 400 38 (57) 1) 650 550 350 410 500 1230 820 865 160
350-430 450 350 41 (60) 1) 36 (54) 1) 750 465 930 1285 240
570 1380
350-510 400 38 (57) 1) 700 650 400 420 840 1395 290
1) For casing material GGG-NiCrNb 202, JS 1030 1.4517
2) z = The dimensions to be maintained around the casing cover for dismantling of the rotor

80
 Omega V

Standard flange design 1):

Pump JL 1040 / GGG-NiCrNb 202 JS 1030 / 1.4517
size Nominal pressure acc. to: Nominal pressure acc. to:
DIN 2501 BS 4504 ANSI B 16.1 DIN 2501 BS 4504 ANSI B 16.1
ISO 7005/2 ISO 7005/2
350-360 PN 25
350-430 PN 10 Table 10/11 Class 125 PN 16 Table 25/11 Class 250
350-510 PN 25
1) Other flange designs are available on request

Flange dimensions -- Drilling diagram all dimensions in mm

Standard Suction flange Discharge flange d2
DN 400 DN 450 DN 350 number
d2 k n d2 k n d2 k n of holes n
ISO 7005/2
DIN 2501 PN 10 28 515 28 565 23 460

ISO 7005/2
DIN 2501 PN 16 31 525 31 585 20 28 470 16
16
BS 4504 Table 10/11 28 515 28 565 23 460
BS 4504 Table 16/11 31 525 585 470 k
31 28
ANSI B 16.1 Class 125 28 540 578 16 476 12

Motor dimensions and weights IEC-Motors, IP 55 2) all dimensions in mm

Pump size Type of Motor size c1 h6 h7 m3 m4 m5 m6 n5 n6 Weight
arrangement of motor
DB DK [kg]
min. 250 M 550 1375 790 435
350-360
----
max. 315 800 1405 1230
1250 630 315 755 900 700
1500
min. 315 M 660 1555 940 910
350-430
----
max. 355 900 1555 1455 2200
1415 710 400 835 1200 950
min. 315 L 660 1555 1110 1200
350-510
---
max. 400 1000 1595 1615 3200
2) Dimension and weight deviations subject to selected motor manufacturer are to be considered

81
 Omega V

Lifting device disassembly of upper Reassembly

casing half and pump rotor -- Reassembly to be made in the reverse order of
disassembly.
Disassembly of upper casing half (105.02) and pump rotor.
The lifting device is provided to ensure safe disassembly and Figure 1 Figure 2
reassembly of casing cover and rotor. For safe and expert
handling, see opposite figures.
The lifting device (figure 1) consists of two elements: the
bracket and the fork.

Safety instructions for transport of suspended

loads have to be absolutely observed!
-- To secure the upper casing half (105.02), losen companion
bolts of the lower part of the casing and only slightly losen
the companion bolts of the upper part of the casing.

Do not remove the bolts.

-- Suspend the boom in a lifting device and bolt it to the top

casing half using forcing screws (Fig. 2).
-- To support the upper casing half, screw in hexagon bolts as
illustrated in figure 2, detail X.
-- Losen cover from the casing with the two upper lifting
screws and remove the remaining companion bolts.
-- Upper casing half and deposit in a safe place.
-- For disassembly of the rotor, screw bracket and fork
together.
-- Pull apart the coupling halves at the pump side. Figure 3
-- Mount lifting device provided to remove the rotor as
illustrated in figure 3, detail Y, the fork being placed
underneath bearing cover (360).
-- Remove screw (901.04). Next undo nut (920.05) until
bearing casing can be lifted out of the recess.
-- Pull out rotor and deposit it in a safe place until it is further
disassembled.

82
 Omega V

Table of Connections and Measuring Points

5D
26M1 4M1

1M1 1M2

6B
6B

View X

1M1 1M2
DN 2
DN1

4M1
26M1

Item No. Description Connections Value required

5D Venting G 1/2

9D (if applicable) Venting of barrier liquid G 1/2

6B Casing drain G 1/2

8B Leakage drain G 3/4 Enter order--specific data !

1 M.1 (if applicable) Pressure gauge connection, G 1/2 Enter order--specific data !
suction side

1 M.2 Pressure gauge connection, G 1/2 Enter order--specific data !

discharge side

4 M.1 (if applicable) Temperature measuring point, bearing G 3/8 See section 7.2
Drive end

26 M.1 (if applicable) Thread for SPM measurement, M8 Enter order--specific data !
drive end

83
 Omega V

. . . and should something have to be replaced,

KSBs competent Spare Parts Service is at your disposal for the products

D Amarex/KRT D Amamix/Amaprop
D Sewatec D Amajet
D Amacan D Getec
D Omega

To: KSB Aktiengesellschaft Postfach 200743 Date:

Turmstr. 92 D-06008 Halle/Saale
D-06110 Halle/Saale
Ersatzteilabteilung

Fax: (+49) 345/48 26 4691 Tel: (+49) 345/48 26--0

From:

In order to ensure the smooth processing of your spare parts inquiry, we request that you let us have the following data:

1. Works No. / Item No. enter here

D The works No. is given on the name plate

of your pump
e.g. 2--M01--753328
or KRT-F 100-250/7 4 UG-249
2--M01--753328
9970428626 000100 2

in addition:

Pump type
e.g. KRT-F 100-250/7 4 UG-249

Sample
2. Required part with part No.
enter
here

D The description of the parts is given

in the operating instructions
e.g. Impeller, Part no. 230

in addition:

for multi--vane impeller:

impeller diameter in mm

for terminal gland:

cable length in mm
Omega V
Omega V
Omega V
 Omega V

Subject to modification without notice

12/2004
1384.81--10

KSB Aktiengesellschaft
P.O. Box 200743 06008 Halle (Saale) Turmstrae 92 06110 Halle (Germany)
Tel. +49 (345) 48 26 0 Fax +49 (345) 48 26 46 99 www.ksb.com