INSTALLATION, OPERATION & MAINTENANCE

MANUAL
VERTICAL IN-LINE PUMP
 Vertical In-Line Pump
SPECIFICATION
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1. Introduction

2. Safety
2.1 Danger in the event of non-observance of the safety instructions
2.2 Safety instructions for installation and maintenance work
2.3 Unauthoriesed modification and manufacture of spare parts

3. Transport and interim storage

3.1 Shipping
3.2 Transport for installation/dismantling purposes

4. Intended use
4.1 Purpose
4.2 Fields of application
4.3 Contraindications

5. Description and function

5.1 Description of the product

6. Installation and electrical connection

6.1 Installation
6.2 Electrical connection

7. Commissioning
7.1 Checking the direction of rotation

8. Maintenance
8.1 Motor
8.1.1 Changing the motor
8.2 Mechanical seal
8.1.1 Changing the mechanical seal

9. Faults, causes and remedies

10. Disposal

11. Diagram
11.1 Pump flow diagram
11.2 Pump exploded diagram
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SPECIFICATION
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1. Introduction
This manual gives detailed information for installing, operating, and maintaining your
Pump. The assembly drawing provided with this manual shows the confi-
guration of the pump and all of its principal parts, as the name of each part is given
in the text and assembly darwing.
Proper installation and maintenance of this pump still contribute to maximum efficiency
and long trouble-free. Read the following instructions carefully, with frequent reference
to the pump. Then reread them step-by-step as the installation is made. Keep this
manual handy for service and maintenance. It will simplify your job.

2. Safety
Those operating instructions contain basic information which must be adhered to during
installation, operation and maintenance. For this reason, these operating instructions
must without fail be read by the service technician and the responsible specialist/operator
before installation and commissioning.

2.1 Danger in the event of non-observance of the safety instructions

Non-observance of the safety instructions can result in risk of injury to persons and
damage to the environment and the product/unit. Non-observance of the safety
instructions results in the loss of any claims to damages.

In detail, non-observance can, for example, result in the following risks.

- Danger to persons from electrical, mechanical and bacteriological influences
- Pollution of the encironment due to leakage of hazardous materials
- Damage to property
- Failure of important product/unit functions
- Failure of required maintenance and repair procedures

2.2 Safety instructions for installation and maintenance work

Work on the product/unit should only be carried out when it has been brought to a standstell.
It's mandatory that the procedure described in the installation and operating instructions for
shutting down the product/unit are complied with.

2.3 Unauthorised modification and manufacture of spare parts

Modifications to the product are only permissible after consultation with the manufacturer.
Original spare parts and accessories authorised by the manufacture ensure safety.
The use of other parts will absolve us of liability for consequential events.
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SPECIFICATION
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3. Transport and interim storage

Improper transport/incorrect storage can lead to personal injury.
Make sure the pump is securely positioned and is stable during storage and transport as
well as prior to all installation and other assembly work.

3.1 Shipping, Transport inspection, Storage

- The pump is enclosed in a box or lashed to a pllet ex works and is protected against
dirt and moisture.
- On arrival, inspect the pump immediately for any transport damage. If damage is
detected, the necessary steps involving the forwarding agent must be taken within
the specified period.

3.2 Transport for installation/dismantling purposes

- To lift with a crane, the pump must be supported by suitable belts. Place loops around
the pump which tighten from the pump's own weight.
- The pump itself and pump parts can be extremely heavy. Falling parts pose risk of cuts,
crush injuries, bruises or impacts, which may laed to death
- Always use suitable lifting equipment and secure parts against falling.
- Never stand underneath a suspended load.
- Ware protective clothing for all work (Safety shoes, helmet .. etc)

4. Intended use
4.1 Purpose
- The glanded pumps of the following series 'KIL' are used as circulation pumps in the
following fields of application.

4.2 Fields of application

- They may be used for : Hot-water heating system, Cooling and cold water circulation
system, Industrial circulation system, Heat carrier circuits.

4.3 Contraindications
- Unpermitted substances in the fluid can destroy the pump. Abrasive solids (e.g. sand)
increase pump wear. Pumps without an Ex rating are not suitable for use in potentially
explosive areas.
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SPECIFICATION
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5. Description and function

5.1 Description of the product
- The pump housing has an in-line construction, i.e. the flanges on the suction and press-
sure sides lie along a centre line. The shaft is sealed with a mechanical seal on the
outside. The pump is mounted directly to a sufficiently affixed pipeline as an in-line pump
(Fig.1).

Fig. 1 (Pipe installation)

6. Installation and electrical connection

* Incorrect installation and improper electrical connections can be life threatening.

- Have the electrical connections established by approved electricians only, in compliance
with the applicable regulations.
- Adhere to regulations for accident prevention.
* Failure to install safety devices on the motor, terminal box or on the coupling can cause
electrical shock or contact with rotating parts, potentially resulting in life threatening injuries.
- Keep a safe distance during commissioning.
- Always wear protective clothing, gloves and goggles when working.
* Danger of damage due to incorrect handling.
- Have the pump installed by qualified personnel only.
* The pump must not be allowed to operate dry for more than 1 minute. Dry running causes
a build-up of energy in the pump, which can damage the shaft, impeller, and mech. Seal.
- A min. flow of approximately 10% of the maximum flow rate must be ensured at all times.
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SPECIFICATION
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6.1 Installation

* Danger of damage due to incorrect handling.

- Never set up the pump unit on unfortified surfaces or surfaces which connot bear lods.
- The pump should only be installed after completion of all welding and soldering work
and, if necessary, flushing of the pipe system. Dirt can cause the pump to fail.
- Standard pumps must be protected from the weather and installed in a frost/dust-free,
well-ventilated environment which is not potentially explosive.
- Install the pump in a place that is easy to access so that subsequent inspections,
maintenance (e.g. machnical seal) or replacement is easily possible.

* Positioning/alignment
- A hook or eyelet with the corresponding bearing capacity is to be installed vertically
above the pump, to which hoisting gear similar aids can be attached when conducting
maintenance or repair work on the pump
- The motor terminal box must not face downward. If necessary, the motoro or motor
Imepller unit can be rotated once the hexagon head bolts have been loosened. While
rotating the motor or motor impeller unit, ensure that the housing O-ring seal does not
become damage.
- When pumping out of a tank, ensure that the liquid level is always high enough above the
suction port of the pump so that the pump never runs dry. The minimum intake pressure
must be observed.

6.2 Electrical connection

* An improper electrical connection can result in a fatal electrical shock.

- Have the electrical connection establisched by an electrician approved by the local
electricity supplier only and in accordance with local regulations.
- Observe the installation and operating instructions for the accessories.

* An inadequate mains design can lead to system failures and even to cable fire due to mains
overload.
- When designing the mains, with regard to the used cable cross-sections and fuses, pay
special attention to the fact that, in multi-pump operation, it is possible that all pumps
operate at the same time for short periods.
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SPECIFICATION
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* Earth the pump/installation in accordance with the regulations.

- The connection diagram for the electrical connection can be found in the terminal box
cover (see also Fig. 2~4)
- For connection voltage see motor rating plant.

Fig.
Fig 2 (Mains connection 3) Fig.
Fig 3 (Mains connection 1)

Fig. 3 (Mains connection 1)

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SPECIFICATION
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* We recommend space heater for motors which, due to climatic conditions, are at risk of
condensation. Corresponding motor variations which are equipped with space heater at the
factory, can be ordered as a special version.
(Space heater is used to protect the motor windings against condensation water insied the motor)

7. Commissioning
Failure to install safety devices on the motor, terminal box or on the coupling can cause
electrical shock or contact with rotating parts, porentially resuling in life threatening injuries.
The tools used during maintenance work must be removed completely before the pump is
started up. Keep a safe distance during commissioning. Always wear protective clothing,
gloves and goggles when working.

* Running dry will destroy the mechanical seal.

- Make sure that the pump does not run dry.
- To avoid cavitation noises and damage, a minimum intake pressure must be guaranteed
at the suction port of the pump. This minimum intake pressure depends on the operation
situation and the duty point of the pump, and must be defined accordingly. The main
parameters for edfining the minimum intake pressure are the NPSH of the pump at its
duty point and the vapour pressure of the fluid.

* If the pump/system is installed improperly, liquid may be ejected during commissioning.

Individual components may also become loose.
- Keep a safe distance from the pump during commissioning.

7.1 Checking the direction of rotation

* Switch on briefly and check whether the direction of rotation corresponds to the arrow on
the motor (fan cover or flange). If the direction of rotation is incorrect, proceed as fllow:
- Swap 2 phases on the motor terminal board

8. Maintenance
There is risk of fatal injury from electrical shock when working on electrical equipment.
- Work on electrical equipment may only be done by electricians approved by the local
electricity supplier.
- Before working on electrical equipment, switch it off and secure it against being switched
on again.
- Follow the installation and operating instructions for the pump, level control device and
other accessories.
(In the 'KIL' model pump is equipped with coupling protection, which can be removed with a tool)
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SPECIFICATION
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8.1 Motor
Increased bearing noises and unusual vibrations indicate bearing wear. The bearing or motor
must then be replaced.

8.1.1 Changing the motor

# Dismantling
- Disconnect the system from the power and secure it against being switched on.
- Close the shut-off valves in front of and behind the pump.
- Depressurize the pump by opening the bleed valve.

* Danger due to extremely hot or extremely cold pressurised fluid.

Depending on the temperature of the fluid and the system pressure, when the venting
screw is opened completely, extremely hot or extremely cold fluid in liquid or vapour
from may escape or shoot out at high pressure.
- Always exercise caution when opeing the venting screw.

- Disconnect the motor if the cable for dismantling the motor is too short.
- Loosen the coupling bolts.
- Remove the motor.

# Installation
- Push the coupling enroot ring between the shaft and motor coupling.
The coupling enroot ring must sit there without any play.
- Connect the motor and tighten the coupling bolts.
- Open the valves in front of and behind the pump.
- Reset the fuse.
* Comply with the commissioning measures, see chapter 7 "Commissioning" on page 8.

8.2 Mechanical Seal

There may be a slight amount of drip leakage during the running-in period. However, a weekly
visual inspection is required. If there is clearly detectable leakage, the seal is to be changed.
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SPECIFICATION
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8.2.1 Changing the mechanical seal

# Dismantling
- Disconnect the system from the power and secure it against being switched on.
- Close the shut-off valves in front of and behind the pump.
- Depressurize the pump by opening the bleed valve.

* Danger due to extremely hot or extremely cold pressurised fluid.

Depending on the temperature of the fluid and the system pressure, when the venting
screw is opened completely, extremely hot or extremely cold fluid in liquid or vapour
from may escape or shoot out at high pressure.
- Always exercise caution when opeing the venting screw.

- Loosen the coupling bolts.

- Loosen the motor bolts and disconnection the motor.
- Loosen the casing nuts and disconnection the adapter.
- Remove the pump shaft, casing cover, mechanical seal and impeller.
- Loosen the impeller nut and disconnection the impeller.
- Remove the mechanical seal from the pump shaft.
- Clean the seating surfaces of the mechanical seal.
- Clean the seating surfaces of the pump shaft carefully.
If the shaft is damaged, it must be replaced.

# Installation
- Push the new mechanical seal onto the shaft.
- Push the impeller onto the shaft.
- Insert a new O-ring.
- Push the pump shaft, casing cover, mechanical seal and impeller onto the casing.
- Connect the adapter and tighten the casing nut.
- Push the coupling enroot ring between the shaft and motor coupling.
The coupling enroot ring must sit there without any play.
- Connect the motor and tighten the coupling and motor bolts.

9. Faults, causes and remedies

Observe the safety instructions in chapter 8 "Maintenance" on page 8.
* If the malfunction cannot be rectified, please contact Keumduk pump Office.
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SPECIFICATION
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10. Disposal
- Proper disposal and recycling of this product prevents damage to the environment and risks
to personal health. Disposal in accordance with the regulations requires the product to be
- Disposal in accordance with the regulations requires the product to be drained and cleaned.
- Lubricants must be collected.
- The pump components are to be separated according to material.

11. Diagram
11.1 Pump flow diagram
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SPECIFICATION
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11.2 Pump exploded diagram