Instructions Manual

MIF-2100/14-I [01-2021] AU
Self-Priming Pumps

AU AU MONOBLOC

Original manual

This manual contains important instructions and warnings.

You must read them before mounting, making the electrical
connections and starting up. You must also comply with the
instructions for the components related to this pump.

Please remember that this Manual must be kept close to the

motor pump group.
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Contents 7.4.2 Tubular coupling guards .............................. 13
7.4.3 Coupling ...................................................... 13
1 GENERAL ITEMS ...................................................... 3 7.4.4 Mechanical seal .......................................... 14
7.4.5 Pump ........................................................... 14
2 SAFETY ...................................................................... 3 7.5 ASSEMBLY ............................................................. 14
7.5.1 Tubular coupling guards .............................. 14
2.1 MARKING OF WARNINGS IN THIS MANUAL ..................... 3 7.5.2 Coupling ...................................................... 15
2.2 PERSONNEL QUALIFICATIONS AND INSTRUCTION .......... 3 7.5.3 Mechanical seal .......................................... 15
2.3 RISKS OF FAILING TO COMPLY WITH THE SAFETY 7.5.4 Pump ........................................................... 15
INSTRUCTIONS ................................................................. 3 7.5.5 Tightening torque of the screws/nuts .......... 15
2.4 CONSCIENTIOUS SAFETY AT WORK ............................. 3 7.5.6 Tightening torque of the impeller nuts ......... 15
2.5 SAFETY INSTRUCTIONS FOR USERS AND SERVICE 7.6 RECOMMENDED SPARE PARTS ................................. 16
PERSONNEL ..................................................................... 3 7.7 PREVENTATIVE MAINTENANCE .................................. 16
2.6 SAFETY INSTRUCTIONS FOR MAINTENANCE, INSPECTION
AND ASSEMBLY WORK ....................................................... 4
8 TROUBLE-SHOOTING............................................. 17
2.7 MODIFICATIONS AND ARBITRARY MANUFACTURE OF
SPARE PARTS .................................................................. 4 9 ANNEXES ................................................................. 18
2.8 UNAUTHORISED OPERATION MODES ........................... 4 9.1 CROSS DRAWING .................................................... 18
2.9 W ARNINGS FOR EQUIPMENT WITH MARKING ....... 4 9.2 TROLLEY-MOUNTED PUMPS ..................................... 31
9.2.1 Warnings ..................................................... 31
3 TRANSPORT AND STORAGE .................................. 5 9.2.2 Start-up ....................................................... 31
9.2.3 Maintenance................................................ 31
3.1 TRANSPORT AND HANDLING ....................................... 5 9.2.4 Safety .......................................................... 31
3.2 PROVISIONAL STORAGE/CONSERVATION..................... 5 EC DECLARATION OF CONFORMITY 36
4 GROUP DESCRIPTION ............................................. 5 (Directive 2006/42/EC ANNEX IIA) ....... 36
4.1 GENERAL DESCRIPTION ............................................ 5 PUMP SERIES: AU ...................................... 36
4.2 DENOMINATION ........................................................ 5
4.3 FORM OF CONSTRUCTION .......................................... 6
4.4 FORCES AND MOMENTS PERMITTED IN THE NOZZLES .... 6
5 INSTALLATION ......................................................... 7
5.1 CHECK BEFORE ASSEMBLY ........................................ 7
5.2 GROUP POSITIONING ................................................ 7
5.2.1 Groups with horizontal base frame ............... 7
5.2.2 Pump-motor alignment ................................. 8
5.2.3 Monobloc groups .......................................... 8
5.3 PIPE JOINT .............................................................. 8
5.3.1 Auxiliary connections .................................... 9
5.4 ELECTRICAL CONNECTION: ........................................ 9
5.4.1 Motor connection .......................................... 9
5.4.2 Time relay adjustment .................................. 9
5.4.3 Rotation direction. Check ............................ 10
5.5 NON ELECTRIC MOTORS .......................................... 10
6 START-UP ................................................................ 10
6.1 FIRST START-UP ..................................................... 10
6.1.1 Lubricant ..................................................... 10
6.1.2 Filling (priming) of the pump ....................... 10
6.1.3 Final control ................................................ 11
6.1.4 Start-up ....................................................... 11
6.1.5 Shutdown .................................................... 11
6.2 SERVICE LIMITS ...................................................... 11
6.2.1 Switching frequency .................................... 11
6.2.2 Temperature of the liquid to be pumped ..... 11
6.2.3 Density of the liquid to be pumped .............. 11
6.2.4 Viscosity of the liquid to be pumped ........... 11
6.2.5 Maximum pump speed ............................... 12
6.3 STARTING UP AFTER STORAGE ................................. 12
7 MAINTENANCE/CONSERVATION.......................... 12
7.1 GENERAL INSTRUCTIONS......................................... 12
7.2 MAINTENANCE/INSPECTION ..................................... 12
7.2.1 Checking instructions .................................. 12
7.2.2 Lubrication .................................................. 12
7.3 EMPTYING/DRAINAGE ............................................. 13
7.4 DISMOUNTING ........................................................ 13
7.4.1 Fundamental instructions/observations ...... 13

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1 General items These must be complied with, and conserved in a manner
which ensures they are legible.
Note This KSB ITUR equipment has been
developed in line with state-of-the-art 2.2 Personnel qualifications and instruction
technology, manufactured with great care and put through
All Service, Maintenance, Inspection and Assembly personnel
continuous Quality Control. The present Instructions Manual
must be duly qualified. The terms regarding responsibility,
will provide you with knowledge of the equipment and the
competence and supervision of personnel must be regulated
ways it can be applied.
by the user in an exact manner.
It contains important instructions to operate the equipment
Any personnel lacking appropriate know-how must be duly
appropriately and profitably. It is important to comply with the
instructed. This preparation can be obtained upon request by
manual in order to guarantee reliability and a long useful life
the machine user to the manufacturer or supplier of the
for the pump, whilst avoiding any possible risks.
machine.
This manual does not include any local regulations or any
Finally, the user must ensure that all personnel have fully
instructions with regards to assembly personnel, which the
understood the content of the instructions manual.
user shall be responsible for.
This group cannot be used in conditions in excess of
2.3 Risks of failing to comply with the safety
those established in the technical documentation with instructions
regards to the liquid to be pumped, flow, speed (rpm), Failure to comply with the safety instructions may lead to risks
density, pressure and temperature, and with regards to the both for people, the environment and the machine, and may
motor power or anything else set out in the instructions lead to the loss of any entitlement to claims.
manual and contractual documentation. Check with the
manufacturer as appropriate. In particular, failure to comply may cause the following
hazards:
The factory plate shows the model/size, the main service data
and the manufacture number of the equipment. Please include - Failure of important machine/facility functions.
these data in any queries, subsequent orders or requests for - Failure of the prescribed maintenance and conservation
spare parts. methods.
If you require any additional information or have problems with - Personal hazard resulting from electrical, mechanical or
regards to failures, please contact the nearest KSB ITUR
chemical effects.
service.
- Danger to the environment due to escaping noxious
2 Safety products.

This instructions manual contains fundamental indications 2.4 Conscientious safety at work
which must be complied with in assembly, service and
The safety instructions contained in this Manual must be
maintenance. It must be read by assembly personnel,
observed, as must international prescriptions on Health and
competent technical personnel and users before installing and
Safety at Work and any possible Safety Regulations at the
starting up, and it must be available at all times at the place of
workplace of the user.
location of the machine.
Proceed not only in line with this main safety chapter, but also 2.5 Safety instructions for users and service
observing the instructions described in other similarly personnel
important safety points. The operator is responsible for keeping the
2.1 Marking of warnings in this manual temperature of the fluid within the pump classification
temperature limits.
All instructions in this manual which may involve personal
hazard if not complied with are indicated with a general hazard - The installer must ensure that the parts of the machine
sign. which may create danger due to heat or cold are
protected against accidental contact. The operator shall
Safety instructions which may involve a hazard to check as well that the coupling guard is in place and
people and facilities if not complied with in accordance firmly secured.
with ISO 7000-0434.
- The contact protections of moving parts (e.g. couplings)
Safety instructions to prevent electrical hazards in must not be removed whilst the machine is in service.
accordance with IEC 417-5036.
- Provide the personnel with protective equipment and
Safety instructions which may affect the make sure it is used.
Note
equipment and its operation if not complied
with. - Any possible leaks (e.g. through the shaft sealing) of
hazardous products must be channelled in such a
Safety instructions to prevent the risk of explosion. manner as they do not present any risk to people or the
Only applicable to groups with ATEX plate, specially environment, in line with corresponding legislation.
designed to satisfy Directive 94/9/EC on the prevention of the
risk of explosion. - Follow safety instructions due to use of power. In this
respect refer to the applicable national safety regulations
The details shown directly on the machine, such as: and/or regulations issued by the energy supply company.
- Rotation direction arrow
- Fluid connections identifications

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2.6 Safety instructions for maintenance, For rotating parts:
inspection and assembly work - The pump should never work without its coupling guard
The user must ensure that all maintenance, inspection and in place and firmly secured.
assembly tasks are carried out by authorised, qualified, - Do not wear loose or baggy clothing or wear long hair
specialised personnel who have been sufficiently informed loose near rotation areas to avoid clothes or hair getting
through careful study of the instructions manual. caught and causing serious accidents.
It is a fundamental principle that any work on the machine - Do not force jammed rotating parts manually when the
must be carried out whilst it is shutdown. It is essential to pump is in operation.
respect the pump shutdown procedure described in the
instructions manual. When the pump is joined to considerably long piping,
waterhammer may occur when it is stopped. Should this arise,
When the pump is stopped it is liable to remain under appropriate anti-waterhammer elements must be put in place.
pressure. The pump frame must have returned to
environmental temperature. Before dismantling it, is must be All the safety regulations indicated by the pump drive
depressurised by making drain openings (or air vents) leading manufacturer must be observed and complied with.
to a safe area.
Inappropriate installation may lead to the unit breaking and
All pumps or motor pumps which pump hazardous materials consequent risks to persons and/or the environment. It is
must be decontaminated. therefore necessary to:
Connect an earth conductor to the metal casing of the pump - Vent the pumps appropriately before operation, checking
or baseplate if the fluid handled is electrostatically charged. that the pump is full of liquid.
Never connect the earth of the electric welding equipment to - Check that the pump discharge and suction valves are
pump or baseplate. fully open and that there is no dirt or foreign bodies in the
piping.
As soon as the work is complete, all safety and protection
devices must be installed and put into operation. Regarding overload conditions:
Before starting up again, all that described in the First Start-Up - Do not exceed the maximum permitted values
section must be fulfilled. (temperature, suction pressure, discharge pressure,
rpm.) indicated in this instructions manual, offer and
Due to the fact that the unit contains small parts such as technical catalogue.
nuts, screws, etc., whose accidental contact may lead to
small cuts on the hands, operators are recommended to - Do not exceed the maximum loads permitted on the
suction and discharge connections.
use gloves when handling.
- The pumps must only be used in the conditions and with
The following additional risk-prevention instructions the liquid indicated in the offer and/or order.
shall be fulfilled:
An unforeseen failure in the drive power may lead to danger
The pumped liquid may cause injuries, burns, poisoning, etc. It due to spontaneous start-up of the unit; it is up to the
is therefore necessary: customer to take the necessary steps to avoid this.
- To check the temperature and amount of leaks occurring When the CONTROL SYSTEM is not supplied by KSB ITUR,
at the mechanical seal or packing area. Conduct such the customer is responsible for the entire machine complying
leaks to a safe area through a controlled drainage with the machine safety directive, including these controls
system, specially indicated for the case of break of
mechanical seal. 2.7 Modifications and arbitrary manufacture of
spare parts
- To take appropriate measures to avoid direct contact with
the pumped liquid when it is necessary to prime or fill the The machine must not be modified or changed without prior
pump or unit. agreement from the manufacturer. Only original spare parts
and accessories approved by the manufacturer can guarantee
- Before dismantling the pump, if the liquid is toxic or
safety. The use of other parts invalidates any liability of KSB
dangerous, it must be decontaminated. For this purpose
ITUR for consequential damage.
the unit must be cleaned inside by introducing a cleaning
liquid into the pump and emptying it subsequently 2.8 Unauthorised operation modes
through the drainage connection. The cleaning liquid
must not create hazardous situations and must be The safe service of the supplied pump can only be guaranteed
compatible with the pump components (CONSULT) through correct use, in line with section 4 of the Instructions
Manual. The operation limits established in the Datasheet
- To take appropriate measures to avoid contact with the must not be exceeded under any circumstance.
pump if liquids are pumped at temperatures over 40ºC.
If flammable fluid, it must be ensured at all times that the
- In the event of a liquid with high steam pressure being pump is full of liquid, so that there is never an explosive zone
used, beware of the danger of explosion due to pressure 0 inside it. In addition, the parts subjected to pressure must be
confinement with the pump stopped. This confinement of ductile material
must be avoided by opening inlet or discharge valves, or
by providing a properly conducted air-vent connection in
the pump discharge for liquid evacuation. 2.9 Warnings for equipment with marking
KSB ITUR pumps marked with the ATEX plate are
valid for group II category 2 and 3, zones 1, 21, 2 and

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22 temperature class as shown on the plate and Conformity similar items to wrap pump, columns and other components.
Certificate. We also discourage the use of hooks.
Reliability may be lost through incorrect use, poor 3.2 Provisional storage/Conservation
connections or any modifications, however small.
The equipment and its components must be stored indoors, in
If the liquid is fuel, the pump frame pieces are a clean, dry place, away from vibrations and where relative
constructed from ductile material and the impact test humidity is as constant as possible.
described in EN 13463-1 has been passed.
Note All caps or covers of piping connections must
It is necessary to take into account the rules on the be installed to prevent dirt and other materials
connection and use of electrical devices in hazardous get into the equipment. Do not remove them until it is required
areas, in particular national regulations on installation. Only during the installation of equipment!
qualified personnel who are familiar with these rules should
handle this type of machine. The electric motor must be disconnected, the
connection cables removed and the terminal box
Any repair made by the end user, unless explicitly closed with its cover on. Switchboards must be in
approved by KSB ITUR, shall release the manufacturer vertical position and disconnected.
from any liability relating to Directive 2014/34/EU.
If commissioning does not take place immediately after
Individual pieces supplied as spare parts must be originals, delivery, it is advisable to store equipment and its components
supplied and checked by KSB ITUR taking following measures:
Short term storage (less than 6 months)
3 Transport and storage
 Inspect the protective coating or painted surfaces. If
3.1 Transport and handling any deficiency is to be seen, proceed to repair it. If
repainting needed consult KSB ITUR for the
Note Improper handling of equipment and / or its
characteristics of the paint.
individual elements can severely damage the
paint or protective coating of them, and can lead to premature  It is necessary to protect with preservation products
oxidation of the surfaces and shorten the operating life of the low alloy parts (e.g. grey casting, nodular casting,
equipment. etc…) in contact with liquid. Preservation products
available on the sector market can be used, in line
The transport and handling of the equipment must with the manufacturer’s instructions on application
be carried out using suitable means in line with the and disposal.
weight to be supported. The weight is generally
shown on the delivery note or in the drawing; if it is not, and  The shiny (mechanised) parts and surfaces of the
the equipment cannot be handled safely, please contact KSB equipment and elements must be protected from
ITUR. corrosion using silicone-free grease or oil.
Danger to life from falling parts! The pump (or parts)  Turn shaft by hand (at least once a month)
could slip out of the suspension arrangement. Stay Long term storage (exceeding 6 months)
at safety distance from the parts during transport.
Consult KSB ITUR.
Note Do not remove the equipment from their
transport pallets until final installation is to 4 Group description
take place. Once disassembled, the equipment should be kept
in horizontal position for transport, and never supported or 4.1 General description
hold by its ends.
Horizontal centrifugal self-priming pump for the pumping of
When pumps are dismounted from their transport neutral or aggressive liquids, clean liquids or liquids with solids
pallet, suitable means must be used to ensure the in suspension.
stability of the equpment, until it is finally secured at
is definitive location. 4.2 Denomination
Remember that the equipment must never be lifted AU – (M) 50 / 20 / (4)
using only the eyebolts or lifting lugs of each
element (e.g. by means of eyebolts of motor and Series
pump) because they are designed for the individual
transport of the element. Never lift or transport the pump or Monobloc construction
the equipment by the free end of the shaft. It is also important DN suction nozzle [mm – “]
not to use the pump and pipe flanges either joining elements
(e.g. couplings) Number: Impeller outlet width [mm]
Use proper lifting straps or slings. These (out of Letter: Impeller hydraulics
scope of supply) must not bear against sharp edges
and corners. If he equipment is to be lifted using Characteristics of the monobloc motor:
straps or slings, these must always be run Number: kW electric motor
underneath the motor and pump support. G: Gasoline engine
D: Diesel engine
Note In line with previous recommendations, do not
use transport elements or means that can
damage paint or protective coating of the equipment and
components. That it is not advised the use of chains and

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4.3 Form of construction Bearings: The monobloc (M) construction does not have
friction bearings. The non-monobloc construction has oil or
Pump casing with axial suction and radial discharge. Semi- grease lubricated bearings, depending on the size of the
open single-stage impeller. pump.
The monobloc (M) construction has a rigid coupling. Shaft sealing: Mechanical seal.
The non-monobloc construction has a flexible coupling.

4.4 Forces and moments permitted in the nozzles

CAST IRON OR BRONZE CASING (1)

SUCTION DISCHARGE
FORCES MOMENTS FORCES MOMENTS
[N] [N.m] [N] [N.m]
SIZE Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz
PUMP
AU-1,5
AU-2 THREADED CONNECTIONS, DO NOT ADMIT STRESSES
AU-3
AU-50 330 300 270 280 200 230 300 270 330 280 200 230
AU-65 420 370 340 300 220 240 370 340 420 300 220 240
AU-80 500 450 410 320 230 260 450 410 500 320 230 260
AU-100 670 600 540 350 250 290 600 540 670 350 250 290
AU-150 1000 900 810 500 350 410 900 810 1000 500 350 410
AU-200 1340 1200 1080 650 460 530 1200 1080 1340 650 460 530
(1) FOR NODULAR CAST, CARBON STEEL OR STAINLESS STEEL CASING, MULTIPLY THESE VALUES BY 2.0

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5 Installation base frame. Once the mortar cement has set, tighten the
anchor pins in a balanced manner.
Note The design of the pipe systems, anchorings
and other installation areas corresponds to Connect the suction and discharge nozzles to the installation
other parties. KSB ITUR only offers details and comments as and proceed with an initial alignment of the equipment.
a help, but does not assume any responsibility with regards to Proceed to fill the lower part, or the cavities between the base
the design, assembly and operation of any installation. We frame profiles, with concrete.
recommend that customers should check with a specialist in
the design of castings, pipes, wells, etc, to supplement and When using folded steel base frames, make a small mould in
interpret the information provided by KSB ITUR and to ensure the front and rear part.
proper operation.
5.1 Check before assembly
Before positioning, check that the assembly base is in line with
the dimensional plan of the equipment.
The slab upon which the equipment is to be positioned must
have completely set.
The concrete used must be of sufficient resistance (minimum
X0) to allow functional assembly in line with DIN-1045.
The concrete must be of minimum contraction, normal
The upper surface of the base must be horizontal and flat. granulometry, with a water/cement ratio (W/C Ratio) of≤ 0.5. It
is necessary to use additives which improve fluidity for correct
If the anchor pins are to be placed in existing holes, place the
filling.
anchor pins in their orifices suspended from the pump.
We recommend treating the concrete in line with DIN-1045.
Do not connect the suction and discharge nozzles until the
equipment is completely installed on its base and the cement In order to carry out the final alignment, wait until the
has completely set. installation is ready and at operation temperature.
5.2 Group positioning
5.2.1 Groups with horizontal base frame
5.2.1.1 Base frame with bent sheet
Levelling

5.2.1.2 Base frame with u profile

Place wedges on both sides of the anchor pins if the base

frame does not include levelling screws.
When the distance between anchor pins is over 800 mm, use
levelling wedges in the middle, both on the sides and at the
Fitting the shims
front.
L Bolt-to-bolt distance 1 Shim
Use a spirit level to level the equipment. Use wedges to alter
the height at different points. The maximum deviation 3 Shim if (L) > 800 mm 2 Foundatin bolt
permitted is 0.2 mm/m.
The separation between the two coupling halves must be
maintained. Check that the foundation has the required strength and
characteristics. In addition, it has been prepared in
All equipment supplied on a transport bench (forklift accordance with the dimensions given in the outline
truck, carriage, etc) should be secured using the drawing/general arrangement drawing.
envisaged attachment device or brake. Ask KSB
ITUR for the specific instructions manual for your transport 1. Position the pump set on the foundation and level it with
bench if you do not have one already. (See annex 9.2) the help of a spirit level placed on the shat and
discharge nozzle. Permissible deviation: 0.2 mm/m
Cementing
2. Use sims (1) hor height compensation, if necessary.
Pour an initial layer of mortar cement into the orifices of the
bolts, contacting throughout the periphery with the base of the

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Note Always fit shims, if any, immediaty to the left The equipment must always be aligned after
and right of the founsation bolts (3) between Note mounting and preparing for start up, check
the baseplate/foundation frame and the foundation. For a that the assembly can rotate freely when operated by hand
bolt-to-bolt distance (L)>800 mm fot additional shims (2)
5.2.3 Monobloc groups
halfway between the bolt holes.
Levelling
All shims must lie perfectly flush.
3. Insert the foundation bolts (3) into the holes provided. Use a spirit level to level the equipment. Use wedges to alter
the height at different points. The maximum deviation
4. Use concrete to set the foundation bolts (3) into the permitted is 0.2 mm/m.
foundation.
Pump - motor alignment
5. Wait until the concrete has set firmly, then level the
baseplate. The equipment is aligned at factory, and this alignment must
never be lost. The following instructions must be followed
6. Tighten the foundation bolts (3) evenly and firmly. when dismounting or returning the motor:
For baseplate more than 400 mm wide grouting the baseplate - Check that the flange support surface of the motor
with low-shrinkage concrete is recommended. support and of the motor itself are perfectly clean and
smooth.
5.2.2 Pump-motor alignment
- The motor shaft should easily enter the pump shaft (or
In order to prevent misalignment between the axes, it is bushing). If it is not, do not force assembly as this will
necessary to correctly install, check and maintain the coupling. damage the motor bearings. Check the alignment
See the instructions manual for the coupling. between both shafts and repair or replace them as
The coupling may produce a source of ignition or high necessary.
temperature in the event of incorrect operation. The
5.3 Pipe joint
coupling must be classified as non-electric equipment with at
least the same type of area and temperature as the pump. It is In no case can the pump be used as a fixed point for the
necessary to follow the instructions in the coupling manual pipes.
which is included with the pump.
The pipe system must at no time exercise force in
When the supply includes the complete group (pump – motor), excess of the values shown in the chart in point 4.4
the equipment has been aligned at factory, although, due to (due to connection, thermal variation, etc) in the
transport and to the anchoring to the casting, the equipment pump.
should be realigned before proceeding with start-up.
The short pipes must be of at least the diameter of the pump
The correct alignment of the standard KSB ITUR coupling connections. The diameter of long pipes is, in some cases,
involves correcting any possible errors of parallelism and determined by economic criteria.
concentricity using metal wedges in the motor.
Transition pieces at larger diameters must have an extension
Use appropriate instruments to carry out the following angle of around 8°, in order to prevent pressure drops.
measurements in 4 positions offset 90º between the faces of
the coupling: The convenience of installing foot valves when the pump is
working in suction or retention when loaded, along with seal
a1 a1 valves, will depend on the type of installation.
The thermal expansions of the pipes must be compensated
Ø Ø with suitable measures, in order not to exceed the maximum
D D
stresses permitted on the pump.
The diameters of the pipes, valves and accessories must be
a2 a2
calculated in line with the load losses envisaged in the
installation, meaning the fluid speeds will be:

b b - Speed in the discharge pipe: from 2 to 3 m/s

Ø Ø
D D - Speed in the suction pipe: from 1 to 2 m/s
Exceeding the admitted stresses of the pipes may
S1 S2 lead to leaks in the pump and to the fluid escaping.
Hazard of death with hot liquids!
When designing the suction piping check that the available
|a1-a2| and b maximums [mm] NPSH is higher than required NPSH of the pump in order to
DØ S1 S2
[mm] 0-1500 1500-3000 3000-4000 [mm] [mm] avoid cavitation in whole admissible operation range.
[rpm] [rpm] [rpm] The suction and discharge nozzle covers of the pump must be
removed before connecting the pipes.
58-140 0.20 0.15 0.10 4 5
Before starting up a new installation, it is necessary
160-225 0.30 0.20 0.15 6 to thoroughly clean the tanks, pipes and accessories
250-280 0.35 0.30 --- 8 by brushing and blowing. Welding material, scales
and other impurities are often cast off some time after. We
Note: For other types of coupling, see their instructions recommend using an oversized sieve filter in suction in order
manual.

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to prevent dirt larger than that permitted by the pump from the motor in order to ensure a good conductivity between the
coming in. pump and the earth of the electric motor.
If hoses are fitted, these must be firmly in place before 5.4.1 Motor connection
proceeding with start-up or during operation, in order to Whilst connecting the cables, ensure it is not possible
prevent any possible whiplash as a result of the pressure for voltage to appear.
generated by the pump.
Check that the earth connection is in line with local
High suction pressure may overload the bearings and lead to regulations.
their overheating. This circumstance must be avoided, to
which end the suction pressure must not exceed that shown in The motor may produce a source of ignition or high
the data sheet, either through manual control by the operators temperature in the event of incorrect operation. For
or through devices which shutdown the equipment in the event this reason, the motor must be classified with at least
of excessive pressure. the same type of zone and temperature as the pump. It is
The pump must not work without liquid under any necessary to follow the instructions in the motor manual which
circumstance. If this condition may come about, the is included with the pump.
installation must be fitted with safety devices which prevent Connection in single speed motors
the operation of the pump without liquid inside, or have
Direct start-up:
automatic devices to discharge the minimum flow of the pump.
See the section on minimum flow. In direct start-up the motor can be used in two different
connections:
5.3.1 Auxiliary connections
The voltage and the connection, e.g. 400 VY, 240 VD is
The equipment is normally delivered mounted and ready for stamped on the motor plate. This means that the motor can
immediate operation, with only the hydraulic and exterior connect at 400 volts in star connection (Y) or at 240 volts in
electrical connections being necessary. delta connection (D).
When using clean fluids, the cooling of the mechanical seal is
by way of the recirculation of the pumping fluid (it is not
necessary to inject exterior fluid).

Note Auxiliary pipes are designed exclusively to

support internal stresses due to the pressure
of the circulating fluid, to which end it is forbidden to subject
them to additional exterior stresses (e.g. for support, etc.)
If the pumping liquid is fuel and the leak can lead to
ignition, this contingency should be avoided through
constant control of the seal tightness of the auxiliary pipe
joints by the plant operator.
Star connection Delta connection
5.4 Electrical connection: Star-delta start-up:
The electrical connection must be carried out by a In star-delta start-up, the line voltage must coincide with the
specialist electrician. Applicable regulations must be voltage shown on the motor for delta start up (D). The six
complied with. terminals indicated in the following diagram will be connected:
Check the mains voltage available and the factory plate, and
choose the appropriate connection. Connection to the star-delta contactor

The technical connection conditions and the conditions

of the local energy supply company must be observed
when carrying out the connections.
We strongly recommend the use of a safety circuit
breaker for the motor and a thermistor associated to a
trigger device.
These instructions apply to asynchronous three-phase
standard electric motors with a squirrel cage both in
horizontal and vertical execution, in IP-23, IP-54 and IP-55
protection grades, with frame sizes of between 56L and
355S, both inclusive, with voltages of 200 to 500 V 5.4.2 Time relay adjustment
between phases. In the star-delta start-up of three-phase motors, it is necessary
The electric motor as well as whole electric installation to ensure that the passage from star to delta takes place
shall accomplish with all safety norms that may be quickly. Prolonged time will cause damage to the pump.
applied to it. Time relay adjustment in the star-delta connection:
Earthing Motor power Time adjustment -Y
Before starting up the pump, the earth of the pump, the ≤ 30 kW < 3 sec.
baseplate or the motor must be connected to an effective > 30 kW < 5 sec.
earthed point of the installation.
If the baseplate is not within the scope of supply of KSB ITUR,
do not paint either the support surfaces of the pump feet or of

9
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5.4.3 Rotation direction. Check BEARINGS:
Check the motor rotation direction by Lubricated with grease. PUMP WITHOUT GREASE
Note NIPPLES: The pump bearings are closed on both sides and
starting up and immediately shutting down.
The rotation direction must correspond with that shown by the have lifetime lubrication. Lubricant is not required.
pump arrow located on the pump casing or support. If the Lubricated with grease. PUMP WITH GREASE NIPPLES:
rotation direction is not correct, any two phases L1, L2 or L3 of The pump leaves the factory with the bearings greased for
the power cable must be inverted in the motor terminal box. approximately 1000 hours of operation. See lubricant in
The incorrect rotation of the pump may lead to the incorrect section 7.2.2.
operation of the seal and the heating of its faces. For this Pumps lubricated with oil: The pump
Note
reason, correct rotation direction must be ensured using the leaves the factory without oil in the bearings
arrow shown on the pump, with the pump completely filled support. Once installed, proceed to fill it. See lubricant in
with liquid and properly vented. section 7.2.2.
5.5 Non electric motors See section 7.2.2 to know the type of lubrication of each pump
Shall fulfil all that may be applicable to non electric material FRICTION BEARINGS:
and follow the instructions stated in their specific instructions
manual. Lubricated with pumping fluid If the pumped fluid is clean
(without particles in suspension) and non-aggressive, the
Likewise in the case of internal combustion engine refer to the friction bearings are lubricated with the pumped fluid.
instructions of the engine manual for recommendations for Lubricant is not required.
safe gas exhaust and air supply required in the installation
room. The bearings must be lubricated with oil/grease in a good
state, to which end it is essential to follow the lubrication
6 Start-up instructions indicated in 7.2.2.
Before starting up, both the pump and the mechanical seal If the bearings support suffers impediments which prevent
process pipes, where appropriate, must be completely filled correct air-cooling, the resulting excess temperature may be
with liquid. excessive for the classification temperature class. For this
It is necessary to prevent the formation of explosive reason, the support must be kept free of obstacles, thus
atmosphere within the frame and the seal housing. Although facilitating natural air cooling.
there are interior evacuation conducts which remove the 6.1.2 Filling (priming) of the pump
possibility of the air becoming blocked, it is necessary to fully
vent the pump and its process pipes, when fitted, before The pump must be primed before starting up for the first time
starting up. or following a long period of inactivity. To do this:
Start-up shall be carried out when all the necessary EQUIPMENT IN LOAD:
mechanical, hydraulic, electrical and pneumatic connections
are complete. The coupling guard must as well be in place 1. Disconnect the voltage from the motor or batteries.
and firmly secured. 2. Close the suction valve and the discharge valve.
Motor checks. 3. Remove the venting plug located in the casing or open a
When making the electrical connection, ensure the discharge pipe vent (before the check valve).
type of current and nominal voltage shown on the 4. Partially open the suction valve until the liquid overflows
motor's factory plate concur with the type of current through the vent.
and the mains voltage in the place of installation.
5. Close the vent.
Follow the indications described in the motor manual.
6. Fully open the suction valve.
6.1 First start-up
7. Check the rotation direction of the pump.
The pump cannot operate with a closed discharge valve, as
this may lead to overheating of the pumped liquid. If it is 8. Fully open the discharge valve.
necessary to work with the discharge valve closed, a minimum
EQUIPMENT IN SUCTION
flow relief device is required at the output. This device does
not form part of the pump and will be separate from the 1. Disconnect the voltage from the motor or batteries.
pump's discharge flange.
2. Close the discharge valve.
Other recommended devices include the constant output
orifice plates, constant bypass valves and automatic 3. Remove the venting plug located in the casing or
recirculation valves. If you require further details, please check open a discharge pipe vent (before the check valve).
with KSB ITUR. 4. Pour the liquid to be pumped through the vent until it
The pump cannot work in closed suction valve conditions. If overflows.
this condition may come about, the plant operator must use a 5. Close the vent.
device which detects this condition and forces the pump to
halt when it occurs. 6. Check the rotation direction of the pump.
6.1.1 Lubricant 7. Fully open the discharge valve.
Monobloc pumps do not have friction bearings, meaning they The priming should be checked in subsequent start-ups.
do not require lubricant.

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Shaft sealing Maximum flow permitted by the pump
Packing: The gland nuts must be gently tightened (by hand). Unless indicated in another datasheet, the maximum flow
The gland must form a right angle to the shaft. There should permitted is 1.1x optimum flow of the pump with the supplied
be a larger leak after filling the pump and before starting up. impeller diameter.
Mechanical seal: The mechanical seal does not require 6.1.5 Shutdown
maintenance. Check that there are no leaks. Close the discharge pipe valve.
6.1.3 Final control If there is anti-return in discharge with counterpressure, leave
the discharge valve open.
Make the final check of the group alignment in accordance
- Shutdown the motor. Check that shutdown is normal.
with 5.2. The coupling/shaft must allow easy manual rotation.
- In prolonged periods of non-operation, close the suction
Note Check all the auxiliary connections are pipe valve and the auxiliary connection valves.
correct and functioning.
- In suction pumps using a low vacuum tank, the supply of
According to the rules on the prevention of liquid must also be maintained at the shaft seal whilst the
accidents at work, equipment cannot be started up pump remains shutdown.
without protection for the coupling. If the buyer has
expressly requested that this guard be excluded from supply, - The pump must be protected from freezing whenever this
it must be provided by the user. risk exists, and must be emptied in prolonged periods of
non-operation.
Before and during the operation of the pump, the
coupling guard must be in place and firmly secured. If, whilst the pump is shutdown, it must remain on standby for
Regularly check this state in order to prevent problems service, start up at regular intervals for around 5 minutes (see
resulting from incorrect positioning or deficient attachment. also 7.2):
The coupling guard must be free of any foreign elements. - Fire pumps: 1x/month, at minimum.
6.1.4 Start-up - Drink-safe water pumps: 1x/48 hours, at minimum.
Before starting up the group, check all the sections with - Reserve pumps: 1x/week, at minimum.
regards to chapter 6.
(It is best to change the operating pump every day).
The start-up must be carried out with the suction valve
completely open and the discharge valve partially closed. The seal tightness and function of the auxiliary connections
Once the pump has reached its service speed and the suction must be examined during these start-ups.
air has been eliminated, regulate the operation point using the 6.2 Service limits
discharge valve.
6.2.1 Switching frequency
If the electric motor guard is triggered when starting up, close In order to prevent abnormally high temperatures and
the discharge valve more until the equipment starts up overloading of the motor, pump, coupling, seals, etc, the
normally. switching frequencies indicated below must not be exceeded:
The pump must NEVER work with zero flow or flow
which is less than the operating minimum, as internal MOTOR POWER MAX. SWITCHING/HOUR
recirculation will cause the fluid to heat up quickly, Up to 3 kW 20
leading to hazards (including explosion) as a result of the high From 4 to 11 kW 15
pressures reached within the frame. Check the minimum flow
From 11 to 45 kW 10
in the operation curves.
From 45 kW 5
Minimum flow necessary for the pump
6.2.2 Temperature of the liquid to be pumped
The pumps cannot work below the minimum flow specified in
the datasheets. The permitted operation temperature is indicated in
the order and in the ATEX conformity declaration. If
If this condition may come about, the installation must be fitted the pump is to work at a higher temperature or you do not
with safety devices which prevent the operation of the pump have the data sheet, please ask KSB ITUR.
without liquid inside, or have automatic devices to discharge
the minimum necessary flow of the pump.
For liquids other than water, the minimum flow is determined 6.2.3 Density of the liquid to be pumped
by the following formula: The power absorbed by the pump increases in direct
3.600.000 x Pa proportion to the density of the impelled liquid. In order
Qmin = Pe x Ce to prevent overloading in the motor, pump and coupling, this
density must not exceed that shown in the order and in the
In which: ATEX declaration of conformity.
Qmin: Minimum flow in m3/h 6.2.4 Viscosity of the liquid to be pumped
Pa: Power absorbed by the pump in kW at closed valve. The power absorbed by the pump increases with the
viscosity of the impelled liquid. In order to prevent
Ce: Specific heat of the fluid in J/kg*ºC.
overloading in the motor, pump and coupling, this viscosity
Pe: Specific weight of the fluid in kg/m3 must not exceed that shown in the order and in the ATEX
declaration of conformity.

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6.2.5 Maximum pump speed After a few hours operation:
In order to protect the pump from over speed, the maximum Note Check the bearing temperature at the point in
rotation speed shall be that shown on the name plate the bearing location area. Normal
engraved in the pump- If the speed shall not be indicated in temperature can reach up to 40°C above environmental
the name plate it is necessary to consult with KSB ITUR. temperature, but must never exceed 90°C.
If eventually it would be wished to perform the pump at higher Observe the possible anomalies shown in point 8 of this
speed, it is necessary to consult with KSB ITUR. manual.
6.3 Starting up after storage The reserve pumps should be started up and shutdown once
a week, in order to ensure they are always in service
If the storage and/or shutting down of the pump has been for conditions.
a prolonged period of time (over 6 months), it is necessary to:
The failure of one or both sides of the seal may lead to
- Check the state of the joints. excess heating. This can be corrected by following the
- Check the levelling. instructions of the seal manufacturer, both with regards to its
assembly and the maintenance of the auxiliary seal devices,
- Check all the auxiliary connections. where appropriate. Alternatively, the pump may be fitted with a
- Renew the lubrication of the bearings (where fitted). monitoring device if the purchaser has so specified.
7.2.2 Lubrication
- Change the packing (when fitted).
The type of lubrication of the bearings of the pump depends
- After a short storage period, simply turn the pump shaft on its size and construction:
manually to unlock the rotor equipment.
SIZE Construction LUBRICATION
- Follow the specific post-storage instructions in the motor
manuals and other items. AU-M-1,5 Monobloc Not applicable
- Observe all the steps shown in the "Start-up" section. AU-M-2 Monobloc Not applicable

If the equipment is to be halted for a certain AU-M-3 Monobloc Not applicable

Note
period of time and there is the possibility of AU-M-50 Monobloc Not applicable
freezing temperatures, it is necessary to completely drain the AU-1,5 Bearing bracket Lifelong
pump in order to prevent any deterioration from the freezing of
the contained fluid. AU-2 Bearing bracket Lifelong
AU-3 Bearing bracket Lifelong
7 Maintenance/Conservation AU-50 Bearing bracket Oil
7.1 General instructions AU-65 Support Lifelong
Before dismounting, ensure that: AU-80 Bearing bracket Grease

The motor must not be started up involuntarily, and AU-100 Bearing bracket Oil
so must be disconnected from the grid (e.g. AU-150 Support Grease
removing cut-outs, unplugging, disconnecting the AU-200 Support Oil
automatic circuit breaker, etc.) or the start-up batteries
Before lubricating the pump, ensure that:
(disconnect operating energy).
The pump is shutdown and cannot be started up
The pump is free of pumped fluid, cleaning it
accidentally.
internally with appropriate liquid whenever it is a
hazardous fluid (hot, contaminant…) The bearing support temperature is less than 40ºC,
in order to prevent burns to the hands. To do this,
7.2 Maintenance/inspection measure the temperature with a thermocouple.
7.2.1 Checking instructions The absence of oil/grease in the bearing support may lead to
During the first minutes of operation: a lack of lubrication of the Shaft seal rings, which will come
into dry contact with the shaft. This contact may lead to a high
In cases of mechanical seal shaft temperature which might cause ignition. To prevent this,
- There may be a brief large leak during start up. Should regularly check the oil/grease level in the bearings support.
this leak persist, shutdown the group and determine the BEARINGS:
cause. The causes may be, amongst others, dirt in the
pumped area or dry operation due to incomplete Lubricated with grease. PUMP WITHOUT GREASE
discharge of the pump air. NIPPLES:
The pump has special bearings, with dual closure and grease
In cases of packing seal: in the interior, capable of working without outer grease
- There is no leak; immediately loosen the gland to obtain maintenance. The pump does not, therefore, have grease
small dripping. nipples in the support.
- Excessive fluid leak; leave to settle for 10 minutes; tighten Note Special attention must be paid to the type of
the gland by turning 1/6th and leave for 5 minutes. bearing when this is replaced, which must be
Repeat the process until between 20 and 60 drops per of the same type (2RS).
minute are achieved.

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Lubricated with grease PUMP WITH GREASE NIPPLES: Oil
Pump ≤1500 ≤2000 ≤3000 ≤3600
quantity
1st re-lubrication size rpm rpm rpm rpm
[l]
The pump leaves the factory with the bearings greased for ISO ISO ISO ISO
AU-50 0,42
approximately 1000 hours of operation. After this time (or one VG100 VG100 VG68 VG68
year, whatever may occur first) proceed to first re-lubrication. ISO ISO ISO ISO
Check re-lubrication quantity in each greaser in the attached AU-100 0,65
VG100 VG100 VG68 VG68
chart ISO ISO
AU-200 --- --- 1,0
Subsequent re-lubrications VG100 VG68

The periodicity for subsequent re-lubrications should be 4000 The lubrication oil must always be clean and at its appropriate
hours of operation or once a year (whatever may occur first). level, in order to avoid high temperatures on the bearings
Check re-lubrication quantity in each greaser in the attached support. To this end, it is essential to follow the instructions on
chart oil change and regular checks of the oil level.

Pump size AMOUNT OF GREASE [g] Check with your oil supplier when a temperature outside of the
indicated margins is reached, or when the environmental
AU-80 6 temperature is going to be less than -5°C.
AU-150 25
7.3 Emptying/Drainage
Grease change (re-filling)
The emptying and drainage of pumps used to expel
Change grease after approx. 8000 hours of operation or once liquids which are a health hazard must be carried out
every two years (whatever may occur first). in such a way as there is no risk to people or to the
For complete grease change it is necessary first to dismantle environment, in line with legislation. If necessary, use
the bearings and carefully clean their positions in the support protective clothing and mask.
in order to remove old grease. 7.4 Dismounting
Afterwards proceed to re-filling of grease up to approx. 75% of 7.4.1 Fundamental instructions/observations
the free space in the bearing and approx 40% of the free
Note Before dismounting, ensure the pump cannot
space at bearing cover.
be started up.
Type of grease:
The suction and discharge valves must be closed.
We recommend using lytic-based lubrication grease with
antioxidant additives, of consistency 2, in line with DIN-51502 The pump frame must have returned to environmental
K2K. temperature.

Pumps lubricated with oil The pump frame must be depressurised and emptied.
The pump leaves the factory without oil in the bearings Comply with all safety measures in accordance with 7.1.
support. Once installed, proceed to fill it. When working on the motor, also take into account the rules
and instructions of the manufacturer.
Oil filling
7.4.2 Tubular coupling guards
- Release the support upper cap.
When dismounting, follow the chapters on assembly but in
- Pour oil through this orifice until the level is between the reverse order.
minimum and maximum marks of the control dipstick.
7.4.3 Coupling
- Replace the upper cap. (Rest of pumps)
1.- Remove the coupling guard
Oil change 2.- Uncouple the pump from the motor, as indicated:
Proceed to first oil change after 300 hours of operation. For 2.1.- COUPLING WITHOUT DISTANCER. Release the
subsequent changes oil should be changed every 8000 hours motor attachment bolts and remove the motor along with
of operation (or once every year, whatever may occur first). If the male coupling.
the environment is dusty, humid or aggressive, this change
should be carried out more often. 2.2.- COUPLING WITH DISTANCER. Release the
coupling attachment screws and remove the distancer
- Before changing the oil, start up the pump in order to pipe. Separate the male coupling.
fluidifly it.
3.- If the pump needs to be repaired, release the casing/cover
- Release the upper filling cap and the lower drainage cap. attachment screws, along with those of the rear support foot.
- Empty the support oil and let it drain off. 4.- If you need to release the coupling, use an extractor. Never
- Replace the lower cap and proceed to fill as indicated in bang in order to extract, as this may cause serious damage to
the preceding section. the bearings.

Oil chart
Oil recommended for normal use (bearing temperature up to
+70ºC), in line with the operation revolutions and the size of
the pump (ISO-VG oil grade is shown)

13
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- Release and extract the casing cover.
- Remove the shaft thrower (when fitted) and release the
support covers.
- Extract the shaft with the bearings, by hitting the pump
end with a plastic hammer.
Failure of the bearings may cause ignition through increased
heat on the surface of the bearings. This can be avoided by
using officially approved quality bearings, which are supplied
as original spare parts.
Regularly check the correct state of the thrower, and
replace in the event of deterioration.
7.5 Assembly
7.5.1 Tubular coupling guards

7.4.4 Mechanical seal 1. Install the distancer cylinder and seal using the
clamps (1)
- Dismount in reverse order to assembly. 1
Note For the correct operation of the seal it is
necessary to:
- Take great care when cleaning the different parts of the
mechanical seal, especially the contact faces. Never use
lubricant on the contact faces, use only clean water with
a cloth specifically for cleaning optical devices.
- Not damage the O-rings during assembly.
- Not turn the mechanical seal while dry.
7.4.5 Pump 2. Position the side cover (2) leaving the rims (3) in the
It is necessary to dismount practically the entire pump in order upper section
to extract the bearings, shaft, etc.
3. Join the side cover (2) with the fastening screws (4)
To do this, observe the attached sectional plan. to the lifting plate (5). The screws should not be fully
As a general guide to dismount the equipment, follow these tightened at this moment. If there is no lifting plate,
steps: mount the assembly plate and place the screws
through the threaded orifices.
For monobloc construction:
3
- Dismount the installation pump. 5
- Release the nuts of the pump casing and remove
afterwards the pump casing from the assembly cover-
pedestal with motor.
4 2
- Pay special attention to the pump casing, since it does
not have stability and must be properly supported.
- Once the pump casing is removed, wear plate (if it is
supplied with) is to be seen inside the pump casing.
- Unthread the impeller nut or the impeller itself, and 4. Without tightening the screws (4) completely, turn the
extract it. Mechanical seal is accessible at this moment. equipment around the shaft.
- Extract the mechanical seal (see point 7.4.4) 5. Adjust the length of the covers so the shaft and the
- Release and extract the casing cover. attachment are fully covered.
- Release the rigid coupling (coupling fastener) and 6. Secure the lifting plate (5) to its support (6) using the
remove the pump shaft (except for version with gasoline corresponding screws (7). If there is no lifting plate,
engine, in this case there is one singe shaft, motor’s the locking screws (4) are longer and also fulfil this
one). function.
For construction with flexible coupling:
- Remove the coupling guard and then the coupling as
described in point 7.4.2 and point 7.4.3 (when fitted).
- Extract the support - cover, including the moving parts.
The wear plate is accessible at this moment (when fitted).
- Release the impeller nut and extract it.
- Extract the mechanical seal (see point 7.4.4) 4
6 5
7

14
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7. Finish tightening the locking screws (4). wear plate (or to pump casing if it is not fitted with wear ring,).
This clearance has to be between 0,15 and 0,35 mm..
7.5.2 Coupling
Once the pump mounted and before tightening the
1.- Mount the pump (when it has been dismounted) and
coupling fastener, gently move the pump shaft to non-
tighten the casing - cover attachment nuts.
motor side until the impeller touches the wear plate (if
2.- Couple the pump to the motor, as indicated: fitted) or pump casing (if no wear plate is fitted) . Then
move back slightly pump shaft to the motor side until
2.1.- COUPLING WITHOUT DISTANCER. Position the
motor in place, introducing the male coupling. Position the clearance stated in over paragraph is reached. Finally
pins, but DO NOT tighten them until alignment is complete. tighten the coupling fastener to fix the position.

2.2.- COUPLING WITH DISTANCER. Mount the male A non-existent clearance would cause high
coupling, introducing the teeth in the rubber plugs located friction between the wear plate and the impeller,
in the female coupling. Mount the intermediate pipe and while excessive clearance would increase the
secure it using the screws, both to the plate and to the liquid recirculation, with consequent loss of hydraulic
male coupling. performance of the pump.
3.- Align the coupling (see point 5.2 of this manual) Additional observations:
4.- Mount the coupling guard. - All the joints intervening in the dismounting of the pump
must be renewed.
7.5.3 Mechanical seal
- Use the bearings (320) indicated.
- Mount the fixed part of the mechanical seal.
- Do not forget to correctly position the thrower (507)
through the window of the cover (161).

Note -
Check the correct location of pieces,
especially the seals and impellers, and
tighten the impeller nuts as shown in the chart in point
7.5.6.
- Do not forget to position all the safety and
protection elements, such as coupling guards,
before starting up the equipment.
The pump materials have been selected in accordance with
the process fluid indicated in the datasheets. If this fluid is
modified, check with KSB ITUR that the new fluid is suitable
for the pump.

- Mount the rotating part of the seal on the shaft sleeve, 7.5.5 Tightening torque of the screws/nuts
taking care not to damage the o-ring. Attach it to the shaft
Steel Stainless steel
sleeve (where appropriate) with separation bushing, and
introduce it in the shaft, through to the stopper. ISO Metric Tightening Torque in [N∙m]
thread (for non-lubricated thread)
M4 3.1 2.15
M5 6.1 4.25
M6 10.4 7.3
M8 25.2 17.7
M10 49.5 34.8
M12 85.2 59.9
M16 211 148
M20 412 290
M24 710 500
M27 1050 750
- Mount the impeller until it comes into contact with the M30 1420 1000
shaft sleeve.
7.5.6 Tightening torque of the impeller nuts
- Firmly tighten the impeller nuts.
- Finish mounting the pump. Metric Tightening Torque in [N∙m]
thread (for non-lubricated thread)
7.5.4 Pump M14x1.5 38
Mount the pump in reverse order to when dismounting (see M20x1.5 100
point 7.4.5) M27x1.5 250
M33x1.5 460
For monobloc construction. M52x1.5 2000
Note It is the great importance the correct axial
adjustment of the impeller. This is to say,
proper adjustment of clearance between impeller blades and

15
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7.6 Recommended spare parts
Recommended spare parts (1)
Piece denomination Reference Nº
Start-up 2 years 5 years
Joints (set) 400/411/412 1 2 5
Mechanical seal 433 1 2 3
Wear plate(if fitted) 135 1 2
Antifriction bearing (set) 320/321 1 2
Shaft seal ring (set) 421 1 2
Thrower 507 (*) 1 2
Shaft sleeve 523 (*) 1 2
Coupling bush (set) 860 1 2
Impeller nut 922 1 2
Circlip (set) 932 1 2
Parallel key (set) 940 1 2
Pump shaft(s) (set) 210 1
Impeller 230 1
Coupling 840 1
(1) Amounts recommended for a continuous service pump.
(*) Certain pump sizes won’t carry this piece
7.7 Preventative maintenance

DESCRIPTION OF THE OPERATION TO

Nº PROCEDURE REGULARITY CONSEQUENCE
BE CARRIED OUT
1 Check for mechanical seal leaks Visual inspection Weekly 16
2 Check the support oil level Visual inspection Weekly 13, 14
Check for leaks between the casing and the
3 Visual inspection Monthly 15
cover
4 Check for leaks between flanges Visual inspection Monthly 15
5 Check for grease or oil leaks Visual inspection Monthly 3, 13, 14
6 Check for heating of the bearings With thermocouple Quarterly 2, 5, 12
Check tightness of connecting bolts for
motor/base frame, pump/base frame,
7 Manually Twice a year 17
cover/casing, support/support supplement,
flanges/casing
Checking and
dismounting the 1, 3, 4, 6, 7, 9, 10,
8 COMPLETE PUMP CHECK Yearly
pump. See point 7 of 12, 13, 14
the manual
Dismount casing,
9 Check for wear of the impeller and rings Yearly
visual inspection
Dismount support
10 Check for wear of the shaft and bearings Yearly
visual inspection
See point 7.4.3 and
11 Change the rubber coupling bushes Yearly
7.5.2 of the manual
In accordance Check the
12 Check functional characteristics loss Instrument reading
with use installation, 8
See point 7.2.2 of See point 7.2.2
13 Refill the support oil or grease
the manual of the manual
Oil see point
See point 7.2.2 of
14 Change the oil or grease of the bearings 7.2.2. Grease
the manual
Twice a year
Every time they
15 Change the joints Manually
are removed
See point 7.4.4 and When leaks are
16 Change the mechanical seal
7.5.3 of the manual detected
Twice a year and
See point 5.2 of the
17 Check and align the coupling every time they
manual
are dismounted

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8 Trouble-shooting
The pump does not move the fluid
| The pump does not eliminate the suction air
| | Insufficient pressure or flow
| | | Excessive absorbed power
| | | | Excessive vibrations and noise
| | | | | Excessive bearing housing/bracket temperature
| | | | | | Leakage through the mechanical seal
| | | | | | | Quick deterioration of wear plate
| | | | | | | | Cause Solution
Suction or discharge valves closed or poorly Open the suction valve or search for work point with
x x
regulated the discharge valve
x Incorrect rotation direction Change the motor connections
x x Air comes in through the suction pipe, Check the seal tightness of the pipe
Correctly prime the pipe by positioning vent
x Pump or suction pipe poorly primed
connections in the highest points
Increase the rotation speed. If this is not possible, a
Maximum height generated by the pump lower than
x larger impeller or larger pump needs to be assembled.
that required by the installation
Please ask.
x Formation of air pockets in the piping Fit a vent/purge valve before the check valve
Measure the speed, check the motor drive power
x Rotation speed incorrect
supply voltage
x There is no liquid in the pump Immediately shut down the pump and prime it.
x The suction clapper does not close Check the state of seals and clapper holder
Remove the blockage. Dismount the inspection point
x Internal recirculation connection blocked
or cover in the suction side and clean.
x x Poorly primed Prime the pump again
Dismount the seal system and check it, or check the
x Air comes in through the sealing system
seal tightness.
Dismount the impeller, and inspect, balance or change
x x x Impeller obstructed, deteriorated or imbalanced
it.
x x Wear plate deteriorated or incorrectly assembled Dismount the wear plate and change it
Increase the rotation speed. If this is not possible, a
x Counter pressure too high larger impeller or larger pump needs to be assembled.
Please ask.
x Liquid viscosity or density greater than normal. Reduce the design point or change the motor
x x x x Poor alignment between the pump and motor Align the coupling
x Obstruction inside the pump, impeller or nozzles Dismount the pump and clean
Real height to be generated by the pump is lower
x than that of the design point, meaning the flow and Partially close the discharge valve
power are greater
Ball bearings deteriorated, poorly assembled, Change them, check assembly, lubricate them or
x x x
poorly lubricated or excessively lubricated. drain oil out of the support.
Dismount the pump and check its elements are
x Excessive contact in rotating parts
correctly assembled
x x Misaligned or deformed shaft Dismount it and replace it
x Loose impeller support nuts Dismount the pump and tighten them
x x x Pipe tensions on the pump Reinforce the pipes and level the equipment
Lack of rigidity in the foundations or anchor bolts
x Make new foundations or tighten the bolts
loose
Poorly assembled coupling, without suitable
x Check the coupling
separation between its two parts
Very deteriorated mechanical seal, seal spring
Dismount and replace the seal, or dismount, review
x broken or without elasticity, poorly assembled seal,
damage and change as appropriate.
or joints broken, deformed or without elasticity.
x Pipe obstruction Clean the pipes
x Re-changeable sleeve scratched or deteriorated Dismount and change the sleeve

17
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9 Annexes
9.1 Cross drawing

CROSS DRAWING
AU MONOBLOC
1 2 3 4 5 6 7 8 9 10 11 12
PUMP SIZE
M1,5/10 X X (G)
M2/14 X X (G)
M3/18 X X (G) X (D)
M50/20 X
M50/25 X X (D)
AU PUMP SIZE 1 2 3 4 5 6 7 8 9 10 11 12
1,5/10 X
2/14 X
3/18 X
50/20 X
50/25 X
65/10 X
65/18 X
80/15 X
80/22 X
100/30 X
150/25 X
150/35 X
150/45 X
200/40 X
200/55 X
200/68 X

18
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PUMP SIZE
M1,5/10
M2/14
M3/18

Ref. Denomination Ref. Denomination

102 Volute casing 550 Washer
135 Wear plate 759 Valve plate
162 Suction cover 900 Countersunk head screw
210 Shaft 901 Hexagon head screw
230 Impeller 902 Stud
341 Motor stool 914 Hexagon socket head cap screw
400 Gasket 916 Plug
411 Joint ring 920 Hexagon nut
412 O-ring 922 Impeller nut
433 Mechanical seal 940 Parallel key
515 Taper lock ring 550 Washer

19
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PUMP SIZE
M1,5/10/G
M2/14/G
M3/18/G

Ref. Denomination Ref. Denomination

102 Volute casing 576 Handle
135 Wear plate 759 Valve plate
161 Casing cover 800 Motor
162 Suction cover 900 Countersunk head screw
230 Impeller 901 Hexagon head screw
400 Gasket 902 Stud
411 Joint ring 916 Plug
412 O-ring 920 Hexagon nut
433 Mechanical seal 932 Spring lock washer
523 Shaft sleeve 99-15 Strip
550 Washer

20
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PUMP SIZE
M3/18/D

Ref. Denomination Ref. Denomination

102 Volute casing 721 Taper piece
135 Wear plate 759 Valve plate
162 Suction cover 800 Motor
210 Shaft 900 Countersunk head screw
230 Impeller 901 Hexagon head screw
341 Motor stool 902 Stud
Hexagon socket head cap
400 Gasket 914
screw
411 Joint ring 916 Plug
412 O-ring 920 Hexagon nut
433 Mechanical seal 922 Impeller nut
515 Taper lock ring 940 Parallel key
550 Washer

21
 AU

PUMP SIZE
M50/20 M50/25

Ref. Denomination Ref. Denomination

102 Volute casing 515 Taper lock ring
135 Wear plate 550 Washer
161 Casing cover 759 Valve plate
162 Suction cover 900 Countersunk head screw
210 Shaft 901 Hexagon head screw
230 Impeller 902 Stud
Hexagon socket head cap
341 Motor stool 914
screw
400 Gasket 916 Plug
411 Joint ring 920 Hexagon nut
412 O-ring 940 Parallel key
433 Mechanical seal

22
 AU

PUMP SIZE
M50/25/D

Ref. Denomination Ref. Denomination

102 Volute casing 550 Washer
135 Wear plate 721 Taper piece
161 Casing cover 759 Valve plate
162 Suction cover 800 Motor
210 Shaft 900 Countersunk head screw
230 Impeller 901 Hexagon head screw
341 Motor stool 902 Stud
Hexagon socket head cap
400 Gasket 914
screw
411 Joint ring 916 Plug
412 O-ring 920 Hexagon nut
433 Mechanical seal 940 Parallel key
515 Taper lock ring

23
 AU

PUMP SIZE
1,5/10
2/14
3/18

Ref. Denomination Ref. Denomination

102 Volute casing 433 Mechanical seal
135 Wear plate 550 Washer
162 Suction cover 759 Valve plate
210 Shaft 900 Countersunk head screw
230 Impeller 901 Hexagon head screw
321 Deep groove ball bearing 902 Stud
350 Bearing housing 916 Plug
400 Gasket 920 Hexagon nut
411 Joint ring 922 Impeller nut
412 O-ring 932 Circlip

24
 AU

PUMP SIZE
50/20 50/25

Ref. Denomination Ref. Denomination

102 Volute casing 433 Mechanical seal
135 Wear plate 507 Thrower
161 Casing cover 550 Washer
162 Suction cover 637 Oil filler plug
210 Shaft 643 Oil dipstick
230 Impeller 759 Valve plate
320 Angular contact ball bearing 900 Countersunk head screw
321 Deep groove ball bearing 901 Hexagon head screw
331 Bearing pedestal 902 Stud
360 Bearing cover 916 Plug
400 Gasket 920 Hexagon nut
411 Joint ring 922 Impeller nut
411 Gasket 940 Parallel key
412 O-ring

25
 AU

PUMP SIZE
65/10 65/18

Ref. Denomination Ref. Denomination

102 Volute casing 507 Thrower
135 Wear plate 550 Washer
161 Casing cover 759 Valve plate
162 Suction cover 900 Countersunk head screw
183 Support foot 901 Hexagon head screw
210 Shaft 901 Hexagon head bolt
230 Impeller 902 Stud
Hexagon socket head cap
321 Deep groove ball bearing 914
screw
350 Bearing housing 916 Plug
360 Bearing cover 920 Hexagon nut
400 Gasket 922 Impeller nut
411 Joint ring 932 Spring lock washer
433 Mechanical seal

26
 AU

PUMP SIZE
80/15 80/22

Ref. Denomination Ref. Denomination

102 Volute casing 433 Mechanical seal
135 Wear plate 550 Washer
161 Casing cover 636 Grease nipple
162 Suction cover 759 Valve plate
210 Shaft 900 Countersunk head screw
230 Impeller 901 Hexagon head screw
320 Angular contact ball bearing 902 Stud
321 Deep groove ball bearing 916 Plug
331 Bearing pedestal 920 Hexagon nut
400 Gasket 922 Impeller nut
411 Joint ring 923 Bearing nut
412 O-ring 932 Circlip
421 Radial lip seal 940 Parallel key

27
 AU

PUMP SIZE
100/30

Ref. Denomination Ref. Denomination

102 Volute casing 433 Mechanical seal
135 Wear plate 507 Thrower
161 Casing cover 550 Washer
162 Suction cover 637 Oil filler plug
210 Shaft 643 Oil dipstick
230 Impeller 759 Valve plate
320 Angular contact ball bearing 900 Countersunk head screw
321 Deep groove ball bearing 901 Hexagon head screw
331 Bearing pedestal 902 Stud
360 Bearing cover 914 Hexagon socket head cap screw
400 Gasket 916 Plug
411 Joint ring 920 Hexagon nut
412 O-ring 922 Impeller nut
421 Rotary shaft lip type seal 940 Parallel key

28
 AU

PUMP SIZE
150/25 150/35 150/45

Ref. Denomination Ref. Denomination

102 Volute casing 507 Thrower
135 Wear plate 523 Shaft sleeve
161 Casing cover 550 Washer
162 Suction cover 636 Grease nipple
164 Inspection cover 759 Valve plate
183 Support foot 900 Countersunk head screw
210 Shaft 901 Hexagon head screw
230 Impeller 901 Hexagon head bolt
320 Angular contact ball bearing 902 Stud
321 Deep groove ball bearing 914 Hexagon socket head cap screw
350 Bearing housing 916 Plug
360 Bearing cover 920 Hexagon nut
400 Gasket 922 Impeller nut
411 Joint ring 940 Parallel key
412 O-ring
421 Rotary shaft lip type seal
433 Mechanical seal
500 Nilos ring

29
 AU

PUMP SIZE
200/40A 200/40B
200/55A 200/55B
200/68A 200/68B

Ref. Denomination Ref. Denomination Ref. Denomination

102 Volute casing 400 Gasket 901 Hexagon head screw
135 Wear plate 411 Joint ring 901 Hexagon head bolt
161 Casing cover 412 O-ring 902 Stud
162 Suction cover 421 Rotary shaft lip type seal 914 Hexagon socket head cap screw
164 Inspection cover 433 Mechanical seal 916 Plug
183 Support foot 507 Thrower 920 Hexagon nut
210 Shaft 523 Shaft sleeve 922 Impeller nut
230 Impeller 550 Washer 940 Parallel key
320 Angular contact ball bearing 560 Pin
321 Deep groove ball bearing 637 Oil filler plug
350 Bearing housing 643 Oil dipstick
360 Bearing cover 759 Valve plate

30
 AU
9.2 Trolley-mounted pumps

9.2.1 Warnings 9.2.4 Safety

The instructions in this annex must be used along with the All the instructions in the pump instructions manual
corresponding pump instructions. on safe operation and handling of the equipment
must be followed.
All the instructions in this manual should be followed,
especially those regarding operation safety and handling of In particular, in order to prevent the equipment from moving
the equipment. and creating a hazard, it should ALWAYS be positioned on a
flat, non-sloping surface, with locking wedges preventing any
We reserve the right to make technological innovation movement.
modifications.
9.2.2 Start-up
Before starting up the equipment, check that it is completely
stable and that the wheels are locked in place using locking
wedges. These locking wedges are not supplied by KSB ITUR
and should therefore be provided by the customer.
The surface upon which the wheels are placed must be flat,
non-sloping and clean in order to prevent any displacement.
If operation is by way of an electric motor with a pluggable
connection, check that the circuit breaker or operation selector
is in shutdown position before connecting to the grid.
The start-up instructions in the pump and motor manuals must
be followed.
9.2.3 Maintenance
Apart from the particular instructions on maintenance of the
pump and motor, it is only necessary to regularly check the
lubrication, and the state and correct attachment of the wheels
to the shaft.

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 Decontamination certificate AU

Type ….…………………………………………………………..

Order number/ Order item number *) ……………………………………………………………..

Delivery date .………………………………………………………………………….

Field of application … ……………………………………………………………………….

Fluid handled*) ……………………………………………………………..

Please tick where applicable*)

Reason for return*) ……………………………………………………………..

Comments ……………………………………………………………..

……………………………………………………………..

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

 No special safety precautions are required for further handling.

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

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

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

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

............................................................ ………………………………… ………………………………

Place, date and signature Address Company stamp

*) Required fields
 WARRANTY
KSB ITUR undertakes:

To repair or replace at any of its ASSOCIATED TECHNICAL SERVICE CENTRES or at its factory in Zarautz, free of charge and for a period of
12 months as of the date of dispatch from our warehouses, any product which shows manufacture defects. This warranty will be reduced to 6
months for continuous or permanent operation pumps. This warranty does not include any pieces which are liable to experience deterioration
through the envisaged use of the product. The instructions set out in the maintenance and operation manual for the equipment must be fulfilled
in order to prevent excessive wear and tear.

Whenever the equipment or pumps supplied by KSB ITUR are to be used prior to installation, in such a manner as they require handling,
assembly and adjustment either before or after installation by parties other than KSB ITUR, KSB ITUR shall not be liable for any defects in the
equipment following installation unless the purchaser is able to legally prove that these defects existed prior to installation and assembly.

KSB ITUR shall in no case be liable for any direct or indirect damage which the Product may suffer as a result of defective installation, incorrect
storage, lack of maintenance, negligent handling, handling by unauthorised personnel, overloading or deficient functions, or for any damages
resulting from external influences such as chemical, electrochemical and electrical agents. The responsibility of KSB ITUR is limited in all cases
to the replacement, as speedily as possible, of the defective part, without it being in any way liable for other responsibilities or compensation.

EC DECLARATION OF CONFORMITY
(Directive 2006/42/EC ANNEX IIA)

KSB ITUR Spain, S.A., with address in footer

PUMP SERIES: AU
S/N: 997242000000 000000 – 998000000000 000000

KSB ITUR hereby declares, under its responsibility, that its aforementioned
machine, to which this Declaration refers, is in conformity with the
applicable provisions of the following Directives:

Machinery: 2006/42/EC

Applied harmonised standards: ISO 12100, EN 809

The collection of relevant technical documentation will be made in the

address in the footer

Zarautz, 28.11.2019
Post Head of Product Management
and Product Development
Name Yolanda Isusquiza
1260.8/06-EN

KSB ITUR Spain, S.A.

20800 ZARAUTZ (Gipuzkoa) Spain
Tel.: +34 943 899 899 – Fax +34 943 130 710
www.ksb.es