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KSB Sewatec User Manual

KSB Sewatec
96 pages
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Dry-installed Volute Casing Pump
Sewatec
50 / 60 Hz
DIN / IEC motors
Bearing brackets S05, S06, S07, S08, S09, S10
Installation/Operating Manual
Mat. No.: 01104332

Table of Contents

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KSB Sewatec Specifications

General IconGeneral
TypeSubmersible Pump
ApplicationWastewater, Sewage
Hydraulic systemSingle-channel impeller
InstallationSubmersible
Frequency50 Hz
Max Liquid TemperatureUp to 40 °C, short term up to 60 °C
Housing MaterialGrey cast iron
Impeller MaterialCast iron, stainless steel
Connection SizeDN 50 to DN 100
WeightVaries depending on model
Voltage230 V or 400 V (depending on model)

Summary

Glossary

1 General

Manual Scope and Purpose

Describes the scope and purpose of the manual.

Partly Completed Machinery Installation

Refers to relevant sections for installing partly completed machinery.

Intended Audience

Identifies the target group of trained and qualified personnel.

Referenced Documents

Lists other applicable documents and their content.

Manual Symbols and Markings

Explains the symbols used throughout the manual.

2 Safety

Safety Symbol Definitions

Defines the meaning of safety symbols and signal words.

General Safety Instructions

Provides general safety instructions for operation and maintenance.

Intended Use and Restrictions

Personnel Qualification Requirements

Risks of Non-Compliance

General Safety Regulations

Operator Safety Guidelines

Maintenance & Installation Safety

Prohibited Operation Modes

Explosion Protection Measures

3 Transport/Temporary Storage/Disposal

Delivery Inspection

Instructions for checking goods for damage upon receipt.

Safe Transport Procedures

Guidelines and warnings for safely transporting the pump set.

Pump Storage and Preservation

Pump Return Procedures

Pump Disposal Guidelines

4 Description of the Pump (Set)

Pump Overview

Provides an overview of the pump's function and types.

Pump Designation System

Name Plate Information

Pump Construction Details

Pump Design and Operation

Noise Level Data

Standard Scope of Supply

Dimensions and Weights Reference

5 Installation at Site

Pre-Installation Checks

Lists essential checks to be performed before pump installation.

Horizontal Pump Installation

Step-by-step guide for installing the pump set horizontally.

Vertical Pump Installation

Piping Installation Notes

Connecting Piping Safely

Nozzle Force and Moment Limits

Vacuum Balance Line Installation

Auxiliary Connections Overview

Coupling Alignment Check

Belt Drive Checks and Tensioning

Universal-Joint Shaft Installation

Pump and Motor Alignment

Aligning Motors with Adjusting Screw

Procedure for aligning motors with adjusting screws.

Aligning Motors Without Adjusting Screw

Lubricant Level Check

Barrier Fluid Connection Setup

Electrical Connection Safety

Direction of Rotation Check

Pump Priming and Venting

Protective Device Re-installation

Vibration Sensor Connection

Temperature Sensor Connection

Sensor Warning and Cut-out Values

Leakage Monitor Connection

6 Commissioning/Start-up/Shutdown

Commissioning and Start-up Procedures

Covers prerequisites and steps for commissioning and start-up.

Pre-Commissioning Checks

Lists essential conditions to be met before commissioning.

Pump Start-up Procedure

Critical warnings and steps for starting the pump.

Operating Limits Overview

Maximum Operating Pressure Limits

Start-up Frequency Limits

Fluid Handling Considerations

Shutdown, Storage, and Preservation

Pump Shutdown Procedures

Returning Pump to Service

7 Servicing/Maintenance

Servicing and Maintenance Safety

General safety precautions for all servicing and maintenance tasks.

Servicing and Inspection

Operational Supervision

Monitoring the pump during operation for normal conditions.

Inspection Hole Visual Check

Lubrication and Lubricant Change

Grease Changing Procedure

Instructions for re-lubricating rolling element bearings.

Leakage Chamber Check

Lubricant Changing Procedure

Pump Drainage and Cleaning

Pump Set Dismantling

Dismantling Safety Precautions

Safety rules and general information for dismantling the pump.

Dismantling Preparations

Separating Pump from Piping

Removing the Belt Drive (Type 3HZ)

Taper Clamping Bush Pulley Removal

DIN 2211 Pulley Removal

Removing Belt Drive (Type 3HM)

Taper Clamping Bush Pulley Removal (Type 3HM)

Instructions for removing pulleys using taper clamping bushes.

DIN 2211 Pulley Removal (Type 3HM)

Instructions for removing pulleys using DIN 2211 method.

Back Pull-out Unit Removal

Impeller Removal Procedures

K & E Impeller Removal (M20)

Steps for removing K and E impellers with M20 screw.

D Impeller Removal

Steps for removing D impellers.

K & E Impeller Removal (Large Screws)

Specific Impeller Removal (E/K Models)

Using Special Impeller Removal Tool

Mechanical Seal Dismantling

Pump-End Mechanical Seal Dismantle

Steps to dismantle the pump-end mechanical seal.

Motor-End Mechanical Seal Dismantle

Steps to dismantle the motor-end mechanical seal.

Gland Packing Dismantling

Shaft and Bearing Removal

Wear Plate Removal (D Impellers)

Pump Set Reassembly

Reassembly Safety and General Info

Safety rules and general information for pump set reassembly.

Shaft and Bearing Installation

Bearing Bracket Prep and Reassembly

Mechanical Seal Installation

Gland Packing Fitting

Impeller Fitting Procedures

K & E Impeller Fitting (M20)

Fitting K and E impellers with M20 screw.

K & E Impeller Fitting (Large Screws)

Fitting K and E impellers with larger screws.

Specific Impeller Fitting (E/K Models)

Taper Fit Impeller Fitting

Back Pull-out Unit Installation

Leak Testing Procedures

Mechanical Seal Leak Test

Steps to check mechanical seal for leakage.

Gland Packing Check and Adjustment

How to check and adjust gland packing.

Motor Mounting Procedures

Belt Drive Fitting

Taper Clamping Bush Pulley Fitting

Fitting pulleys using taper clamping bushes.

DIN 221 Pulley Fitting

Tightening Torque Specifications

Spare Parts Stock Management

Spare Parts Ordering Information

Data required when ordering spare parts.

Recommended Spare Parts Stock

8 Trouble-shooting

Troubleshooting: Low Flow Rate

Addresses issues causing low flow rate.

Troubleshooting: Motor Overload

Troubleshooting steps for an overloaded motor.

Troubleshooting: High Discharge Pressure

Diagnosing and resolving high discharge pressure.

Troubleshooting: Increased Bearing Temp

Investigating causes of increased bearing temperature.

Troubleshooting: Pump Leakage

Identifying and fixing pump leakage.

Troubleshooting: Shaft Seal Leakage

Addressing excessive shaft seal leakage.

Troubleshooting: Pump Vibrations

Troubleshooting pump vibrations.

Troubleshooting: Pump Overheating

Diagnosing pump temperature issues.

Troubleshooting: Fluid Property Issues

Troubleshooting: High Speed Issues

Troubleshooting: Bolt/Seal Issues

Troubleshooting: Worn Shaft Seal

Troubleshooting: Pump Set Misalignment

Troubleshooting: Coupling Distance

Troubleshooting: Low Voltage Issues

9 Related Documents

Pulley-Based Speed Adjustment

How to adjust pump speed using pulleys.

Pulley Mass Moments of Inertia

General Assembly Drawings & Component Lists

Assembly Drawing: Brackets S05-S08

Shows general assembly drawing for specific bearing brackets.

Assembly Drawing: S05-S08, Underfloor, U-Joint

Assembly Drawing: Brackets S09-S10

Detailed Component Views

Impeller Type Details

Provides detailed drawings of different impeller types.

Impeller Fitting Details

Inspection Hole Details (Brackets S05-S10)

Lubricant Details (Brackets S09-S10)

Exploded View: Mechanical Seal Configuration

Exploded View: Gland Packing Configuration

10 EU Declaration of Conformity

EU Declaration of Conformity Details

Details regarding the product's conformity with EU directives.

11 Certificate of Decontamination

Certificate of Decontamination Form

Form for certifying the decontamination of the product.

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