Grundfos KPV Installation And Operating Instructions Manual

GRUNDFOS INSTRUCTIONS

KP, KPV, KPVS

Split-case centrifugal pumps

Installation and operating instructions

Table of contents

2

KP, KPV, KPVS

English (US)

Installation and operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Français (CA)

Notice d'installation et de fonctionnement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Español (MX)

Instrucciones de instalación y operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Annexe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Anexo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3

English (US)

English (US) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe Grundfos

KP, KPV, KPVS pumps.

Sections 1-6 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 7-11 give important information about the product, as

well as information on service, fault finding and disposal of the

product.

CONTENTS

Page

1. Limited warranty

4

2. General information

4

2.1 Symbols used in this document

4

2.2 Other important notes

5

3. Receiving the product

5

3.1 Unpacking the product

5

3.2 Inspecting the product

6

3.3 Temporary storage after delivery

6

4. Installing the product

7

4.1 Location

7

4.2 Pump foundation

7

4.3 Securing the baseplate

7

4.4 Mechanical installation

8

4.5 Electrical connection

9

4.6 Outlet pipe

10

4.7 Shaft seals

10

4.8 Coupling alignment (KP)

11

5. Starting up the product

12

5.1 Priming

12

5.2 Pre-start checklist

12

5.3 Motor direction of rotation

12

5.4 Starting the pump

13

6. Handling and storing the product

13

7. Product introduction

13

7.1 Applications

13

7.2 Pumped liquids

13

7.3 Pump identification

14

8. Servicing the product

16

8.1 Maintaining the product

16

8.2 Disassembling the pump

18

8.3 Reassembling the pump (KP, KPV, KPVS)

20

8.4 Recommended spare parts

22

8.5 KP, Horizontal, cross-section and parts list

23

8.6 KPV, Vertical, cross-section and parts list

24

8.7 KPVS, Vertical Split Coupling Split Case, cross-section

and parts list

25

8.8 Taking the product out of operation

26

9. Fault finding the product

27

10. Technical data

29

10.1 Operating conditions

29

11. Disposing of the product

29

WARNING

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

WARNING

The use of this product requires experience with and

knowledge of the product. Persons with reduced

physical, sensory or mental capabilities must not use

this product, unless they are under supervision or

have been instructed in the use of the product by a

person responsible for their safety. Children must not

use or play with this product.

CAUTION

Successful operation depends on careful attention to

the procedures described in this manual. Keep this

manual for future use.

English (US)

4

1. Limited warranty

New equipment manufactured by seller or service supplied by

seller is warranted to be free from defects in material and

workmanship under normal use and service for a minimum of

twelve (12) months from date of installation, eighteen (18) months

from date of shipment, unless otherwise stated in product

warranty guide (available upon request). In the case of spare or

replacement parts manufactured by seller, the warranty period

shall be for a period of twelve months from shipment. Seller's

obligation under this warranty is limited to repairing or replacing,

at its option, any part found to its satisfaction to be so defective,

provided that such part is, upon request, returned to seller's

factory from which it was shipped, transportation prepaid. Parts

replaced under warranty shall be warranted for twelve months

from the date of the repair, not to exceed the original warranty

period. This warranty does not cover parts damaged by

decomposition from chemical action or wear caused by abrasive

materials, nor does it cover damage resulting from misuse,

accident, neglect, or from improper operation, maintenance,

installation, modification or adjustment. This warranty does not

cover parts repaired outside seller's factory without prior written

approval. Seller makes no warranty as to starting equipment,

electrical apparatus or other material not of its manufacture. If

purchaser or others repair, replace, or adjust equipment or parts

without seller's prior written approval, seller is relieved of any

further obligation to purchaser under this paragraph with respect

to such equipment or parts, unless such repair, replacement, or

adjustment was made after seller failed to satisfy within a

reasonable time seller's obligations under this paragraph. Seller's

liability for breach of these warranties (or for breach of any other

warranties found by a court of competent jurisdiction to have

been given by seller) shall be limited to: (a) accepting return of

such equipment exw plant of manufacture, and (b) refunding any

amount paid thereon by purchaser (less depreciation at the rate

of 15 % per year if purchaser has used equipment for more than

thirty [30] days), and canceling any balance still owing on the

equipment, or (c) in the case of service, at seller's option, redoing

the service, or refunding the purchase order amount of the

service or portion thereof upon which such liability is based.

These warranties are expressly in lieu of any other warranties,

express or implied, and seller specifically disclaims any implied

warranty of merchantability or fitness for a particular purpose, and

in lieu of any other obligation or liability on the part of the seller

whether a claim is based upon negligence, breach of warranty, or

any other theory or cause of action. In no event shall seller be

liable for any consequential, incidental, indirect, special or

punitive damages of any kind. For purposes of this paragraph, the

equipment warranted shall not include equipment, parts, and

work not manufactured or performed by seller. With respect to

such equipment, parts, or work, seller's only obligation shall be to

assign to purchaser the warranties provided to seller by the

manufacturer or supplier providing such equipment, parts or

work. No equipment furnished by seller shall be deemed to be

defective by reason of normal wear and tear, failure to resist

erosive or corrosive action of any fluid or gas, purchaser's failure

to properly store, install, operate, or maintain the equipment in

accordance with good industry practices or specific

recommendations of seller, including, but not limited to seller's

installation and operation manuals, or purchaser's failure to

provide complete and accurate information to seller concerning

the operational application of the equipment.

2. General information

2.1 Symbols used in this document

The text accompanying the three hazard symbols DANGER,

WARNING and CAUTION will be structured in the following way:

Example

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious personal injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate personal injury.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

5

English (US)

2.2 Other important notes

3. Receiving the product

3.1 Unpacking the product

3.1.1 Lifting and handling

Lifting KP (horizontal) pump without motor

1. Before unloading the product, move the shipping container to

an open area equipped with overhead lifting equipment.

2. Install a lifting strap on each side of the bearing housing. See

fig. 1.

Fig. 1 KP bare shaft pumps, correct lifting points

KP (horizontal) pumps, complete with motor

1. Before unloading the product, move the shipping container to

an open area equipped with overhead lifting equipment.

2. Lift complete horizontal KP pump units by fork truck from

beneath the pump's steel base.

Fig. 2 Horizontal KP complete pumps, correct lifting points

A blue or grey circle with a white graphical symbol

indicates that an action must be taken to avoid a

hazard.

A red or grey circle with a diagonal bar, possibly with

a black graphical symbol, indicates that an action

must not be taken or must be stopped.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

Notes or instructions that make the work easier and

ensure safe operation.

WARNING

Damage to personnel or product

Death or serious personal injury

- Allow only qualified personnel to handle the

product during receiving, inspecting, and

unpacking.

WARNING

Overhead load

Death or serious personal injury

- Do not lift the product by the lifting lugs or eye

bolts on the motor.

Unload and handle the product with a sling.

- All complete horizontal KP pump units must be

lifted by fork truck from beneath the pump's steel

base.

WARNING

Crushing hazard

Death or serious personal injury

- Always lift the pump with lifting equipment.

- Use the correct lifting points.

Do not use lifting lugs on the pump or eye bolts on

the motor to lift the entire pump assembly.

Lifting equipment is the responsibility of the

customer. The following instructions are suggestions

only.

Before proceeding, read the warnings and

instructions in sections 2. General information

through 8.1 Maintaining the product.

TM04 0380 0608

TM06 8436 0517

English (US)

6

Lifting KPV, KPVS (vertical) pumps

Before unloading the product, move the shipping container to an

open area equipped with an overhead lifting mechanism.

1. Install a lifting strap on each of the pallet's 4 x 4 in. floor

boards. Attach the straps securely at the corners of the pallet

near the top of the pump motor. See fig. 3.

2. Attach the other end of the straps to a lifting hook.

3. Rotate the pump assembly to the vertical position.

4. Remove excess packaging for easier access to the pump

assembly.

5. Position two lifting straps around the motor, below the junction

box and 180 degrees apart. See fig. 4.

6. Tighten the straps securely.

7. Attach the free ends of the lifting straps to a lifting hook.

8. Tie a strap around the upper portion of the motor to hold the

lifting strips tight against the motor. Ensure the straps stay

tight against the motor while moving the pump assembly.

9. Utilize appropriately rated lifting equipment to move the pump

assembly to the installation location.

Fig. 3 KPV, KPVS pumps, correct lifting points for pallet

Fig. 4 KPV, KPVS pumps, correct lifting points

3.2 Inspecting the product

• Check that the product received is in accordance with the

order.

• Check that the voltage and frequency of the product match the

voltage and frequency of the installation site. See section

7.3 Pump identification.

• Check the product for defects and damage immediately upon

arrival. Any accessories ordered will be packed in a separate

container and shipped with the product.

• If any equipment is damaged in transit, promptly report this to

the carrier's agent. Make complete notations on the freight bill.

3.3 Temporary storage after delivery

If the product is not to be installed and operated immediately after

receiving it, store it in a clean, dry place at a moderate ambient

temperature. Protect the pump from moisture, dust, dirt and

foreign bodies. Prior to and during storage, we recommend these

precautions:

1. Ensure that the bearings are filled with the recommended

grease to prevent moisture from entering around the shaft.

See section 8.1.2 Lubricating the pump bearings.

2. Ensure that the inlet and outlet ports of the pump and all other

openings are covered with cardboard, wood or masking tape

to prevent foreign objects from entering the pump.

3. Cover the product with a tarpaulin or other suitable covering if

it is to be stored where there is no protective covering.

4. Rotate the shaft 2 turns every 2 weeks to coat the bearings,

stuffing box (packing), and shaft seal faces with lubricant to

impede oxidation and corrosion.

5. This equipment contains vegetable fiber gaskets that can dry

out during long storage periods. To avoid leaks, fill the pump

with water and let stand for 24 hours prior to startup or

pressure testing. Typically, this will allow the dry gaskets to

wick moisture back into themselves, sealing the pump.

6. Split case pumps must be pressurized only with the medium

they are intended to pump. Do not perform any pressurized

"air" test.

TM06 8345 0117 - TM06 8347 0117TM06 8348 0117

Attach lifting

straps to the

pallet

Use lifting

straps to

rotate the

pallet with the

pump

assembly to

vertical

position

Strap

7

English (US)

4. Installing the product

All installations must be performed by personnel experienced with

the placement, connection, and alignment of pumping equipment.

The following instructions are general in nature, and may not deal

with the specifics of your installation. Read these instructions

thoroughly before installing and operating your KP, KPV, or KPVS

pump.

4.1 Location

• Locate the pump as close as possible to the liquid supply. Use

the shortest and most direct inlet pipe practical. Refer to

section 4.4.2 Inlet pipe.

• Locate the pump below system level wherever possible. This

will facilitate priming, assure a steady liquid flow, and provide

a positive inlet pressure.

• The Net Positive Suction Head (NPSH) available must always

be equal to or exceed the required NPSH specified on the

pump performance curve. Make sure that sufficient NPSH is

provided at the inlet.

• Always allow sufficient accessibility space for maintenance

and inspection. Provide a clearance of 24 in. (610 mm) with

ample head room for use of overhead lifting equipment strong

enough to lift the product.

• Do not expose the product to sub-zero temperatures to

prevent the pumped liquid from freezing. If there is frost during

shutdown periods, see the shutdown information included in

section 8.8 Taking the product out of operation.

4.2 Pump foundation

Install the pump permanently on a firm, raised concrete

foundation of sufficient size to dampen any vibration and prevent

any deflection or shaft misalignment. The foundation may float on

springs or be a raised part of the floor.

Proceed like this:

1. Pour the foundation without interruption to 0.75 - 1.5 in. (20-

35 mm) below the final pump level.

2. Scour and groove the top surface of the foundation before the

concrete sets to provide a suitable bonding surface for the

grout.

3. Place anchor bolts in pipe sleeves for positioning allowance.

See fig. 5 and fig. 6.

4. Allow enough bolt length for grout, base, flange, nuts, and

washers.

5. Allow the foundation to cure several days before proceeding

to install the pump.

Fig. 5 KP anchor bolt installation

Fig. 6 KPV, KPVS anchor bolt installation

4.3 Securing the baseplate

When the raised concrete foundation has been poured and

allowed to set, proceed as follows:

1. Lower the base plate over the anchor bolts and rest it on loose

adjustment wedges or shims placed near each anchor bolt

and at intervals not exceeding 24 in. (610 mm) along each

side.

2. Place the shims or wedges so that they raise the bottom of the

base plate 0.75 in. - 1.25 in. (20-32 mm) above the pad,

allowing clearance for grout.

3. Level the pump shaft, flanges, and base plate using a spirit

level, adjusting the wedges or shims, as required.

4. Make sure that the pipes can be aligned to the pump flanges

without placing any strain on either flange.

5. After pump alignment has been established, put nuts on

anchor bolts and tighten them just enough to keep the base

plate from moving.

6. Construct a formwork around the concrete foundation and

pour grout inside and around the base plate. See fig. 5 for KP

and fig. 6 for KPV, KPVS. The grout will compensate for

uneven foundation, distribute the weight of the pump, and

prevent shifting.

7. Allow at least 24 hours for the grout to set before proceeding

with the pipe connections.

8. After the grout has thoroughly hardened, check the anchor

bolts and tighten them if necessary. Recheck the pump

alignment after tightening the anchor bolts.

TM05 4775 2512

Grout

Base plate

Finished grouting

0.75 to 1.25 in.

(20 to 32 mm)

allowance for

grout

Formwork

Pipe sleeve

Washer

Lug

Top of foundation

Wedges or shims

left in place

0.25

TM06 6124 0816

Place a spirit level on top of the pump to check that it

is level.

Use an approved, non-shrinking grout.

KPV, KPVS

stand

Anchor bolts for

supporting the base

Wedges or shims

(as required)

Grouted pad for

anchoring/

housekeeping

English (US)

8

4.4 Mechanical installation

4.4.1 Piping

• Make sure that both the inlet and outlet pipes are

independently supported and properly aligned so that no strain

is transmitted to the pump when the flange bolts are tightened.

Use of expansion joints or vibration pads does not preclude

the need to properly support the pipes. Make sure that the

pipes are as straight as possible, so as to avoid unnecessary

bends and fittings.

• KP, KPV, KPVS pumps have 250 lb flanges which are drilled

according to the pump's service. Non-standard hardware may

be required.

• Do not apply force to pipes when making connections.

4.4.2 Inlet pipe

Select and install the inlet pipe in a manner that minimizes

pressure loss and permits sufficient liquid flow into the pump

during starting and operation. Many NPSH issues can be traced

to improper selection and installation of the inlet pipe.

Observe the following precautions when installing the inlet pipe:

• Run the inlet pipe as straight as possible to avoid unnecessary

bends and fittings. Ideally, make sure that the length is at least

ten times the pipe diameter. A short inlet pipe can be the same

diameter as the inlet port. A long pipe must be one or two

sizes larger than the inlet port, depending on the length, and

with a reducer between the pipe and the inlet port.

• Use an eccentric reducer, with the tapered side down. See fig.

7.

• If possible, run a horizontal inlet line along an even gradient.

We recommend a gradual upward slope to the pump under

suction lift conditions, and a gradual downward slope under

positive inlet pressure conditions.

• Avoid any high points, such as pipe loops (see fig. 8), as this

may create air pockets and throttle the system or cause erratic

pumping.

• Install a gate valve in the inlet line to be able to isolate the

pump during shutdown and maintenance, and to facilitate

pump removal. Where two or more pumps are connected to

the same inlet line, install two gate valves to be able to isolate

each pump from the line.

• Always install gate valves or butterfly valves in positions that

prevent air pockets.

• During pumping operation, the valves on the inlet line must

always be fully open.

• Install properly sized pressure gauges to enable the operator

to monitor the pump performance and determine whether the

pump conforms to the parameter of the performance curve. If

cavitation, vapor binding, or other unstable operating

situations occur, the pressure gauges will indicate wide

fluctuation in the inlet and outlet pressures.

Fig. 7 Inlet pipe

Fig. 8 Air pocket prevention

Do not let the pump support the pipes. Use pipe

hangers or other supports at proper intervals to

provide pipe support near the pump.

At no point must the diameter of the inlet pipe be

smaller than that of the pump inlet port.

Do not use globe valves, particularly when NPSH is

critical.

TM05 4773 2512TM 05 4774 2512

Correct

Eccentric

reducer

Taper is down

Air pocket

Wrong

Concentric

reducer

Correct

Air pocket

Wrong

9

English (US)

4.5 Electrical connection

4.5.1 Motors

The motor control circuit must include the following components

in order to comply with the National Electrical Code:

Motor disconnecting device

• Install a motor disconnecting device that is capable of

disconnecting both the controller (motor-protective circuit

breaker) and the motor from their source of power.

• Locate the disconnecting device in such a way that the

controller (motor-protective circuit breaker) can be seen from

the disconnecting device. In all cases, the distance from the

disconnecting device to the controller must be less than 50 ft

(15.24 m).

In most installations, the disconnecting device will be a circuit

breaker or fusible disconnect switch.

Motor short circuit and ground fault circuit interrupter

A short circuit and ground fault circuit interrupter is usually a

circuit breaker or fusible disconnect switch.

• Select the circuit breaker or fuse in accordance with section

430-52 and table 430-152 of the National Electrical Code.

Motor controller with overcurrent protection (magnetic

starter)

• Install these components in accordance with applicable local

and state electrical codes in addition to the National Electrical

Code.

• The operating voltage and frequency are marked on the motor

nameplate.

• Check that the voltage, phase and frequency of the incoming

power source correspond to the voltage, phase and frequency

of the motor(s).

• Electrical characteristics must match those specified on the

motor nameplate.

• The electrical connections must be carried out as shown on

the motor nameplate or in the wiring diagram on the back of

the terminal box cover. If further information is needed, contact

the motor supplier.

• Mount the control panel or the motor-protective circuit

breaker(s) close to the pump to provide convenient control and

easy installation.

• Make sure that the starters and overload control devices are

suitable for operating the pump motors on the voltage, phase

and frequency available. Always follow the control

manufacturer's instructions for proper installation and

connection.

• Grease-lubricated motors are fully lubricated at the time of

manufacture and do not require further lubrication if prompt

installation follows. If the motor has been in storage for six

months or longer, refer to section 8.1.1 Lubricating the motor

and lubricate it before starting.

DANGER

Electric shock

Death or serious personal injury

- The electrical installation must be carried out by a

qualified electrician in accordance with local

regulations and the manuals provided with the

electrical accessories.

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

DANGER

Explosive environment

Death or serious personal injury

- Observe the rules and regulations generally or

specifically imposed by the relevant responsible

authorities or trade organizations in relation to

running powered equipment in an explosive

environment.

English (US)

10

4.5.2 Variable frequency drive operation

• In principle, all three-phase motors can be connected to a

variable frequency drive.

• However, variable frequency drive operation will often expose

the motor insulation system to a heavier load and cause the

motor to be more noisy than usual due to eddy currents

caused by voltage peaks.

• In addition, large motors driven via a variable frequency drive

will be loaded by bearing currents.

• When the pump is operated via a variable frequency drive,

check the following operating conditions:

4.6 Outlet pipe

• A short outlet pipe can be the same diameter as the pump

outlet port. A long pipe must be one or two sizes larger than

the outlet port, depending on the length.

• It is best to use long horizontal outlet pipes.

• Install a gate valve near the outlet port to be able to isolate the

pump during shutdown and maintenance, and to facilitate

pump removal.

• Any high points in the outlet pipe may entrap air or gas and

thus impede pump operation.

• If water hammer occurs, that is if check valves are used, close

the outlet gate valve before pump shutdown.

4.7 Shaft seals

The KP pumps are available with stuffing boxes with packing

rings or mechanical shaft seals.

4.7.1 Stuffing boxes (KP)

The stuffing boxes are normally packed before shipment.

If the pump is installed within 60 days, the packing material will be

in good condition for operation with a sufficient supply of

lubricating liquid.

If the pump is stored for more than 60 days, it may be necessary

to repack the stuffing boxes.

The stuffing box must be supplied at all times with a source of

clean, clear liquid to flush and lubricate the packing rings.

4.7.2 Packing gland adjustment (KP)

Make sure that the flushing fluid lines are connected and their

valves are open.

With the pump running, adjust the packing gland to permit 40 or

60 drops per minute for shaft lubrication.

Tighten the packing gland evenly to provide uniform compression

on the packing material.

Do not operate packing dry, and do not over-tighten the packing

gland to eliminate leaking as this will cause the shaft sleeve to be

damaged.

After initial startup, additional packing and adjustment may be

required.

4.7.3 Mechanical seals

Mechanical shaft seals require no maintenance or adjustment.

KP, KPV, KPVS pumps equipped with mechanical shaft seals are

matched to the operating conditions for which the pump was sold.

Observe the following precautions to avoid shaft seal damage

and to obtain maximum shaft seal life:

Purge all air from the seal chambers and recirculation lines prior

to operating the pump.

• Clean and purge the inlet pipe in new installations before

installing and operating the pump. Pipe scale, welding slag

and other abrasives can cause rapid shaft seal failure.

• A mechanical shaft seal does not leak at all during normal

operation, therefore if any appreciable leakage occurs, the

seal must be removed, inspected and if necessary replaced.

We recommend keeping a stock of spare parts to reduce

equipment down time.

If in doubt whether the motor supplied can handle

variable frequency drive operation, contact the motor

supplier.

Operating

conditions

Action

2-, 4- and 6-pole

motors of 45 hp

and up

Check to make sure that one of the motor

bearings is electrically isolated. If not,

contact Grundfos.

Noise-critical

applications

Fit a dU/dt filter between the motor and the

variable frequency drive, it reduces the

voltage peaks and thus the noise.

Particularly noise-

critical applications

Fit a sinusoidal filter.

Cable length Fit a cable that meets the specifications

laid down by the variable frequency drive

supplier. The length of the cable between

motor and variable frequency drive affects

the motor load.

Supply voltage up

to 500 V

Check that the motor is suitable for

variable frequency drive operation.

Supply voltage

between 500 V and

690 V

• Fit a dU/dt filter, it reduces the voltage

peaks and thus the noise,

or

• check that the motor has reinforced

insulation.

Supply voltage of

690 V and upwards

• Fit a dU/dt filter, it reduces the voltage

peaks and thus the noise,

and

• check that the motor has reinforced

insulation.

Do not run the pump dry or against a closed valve.

Dry operation will cause shaft seal failure within

minutes.

Do not exceed temperature or pressure limitations

for the mechanical seal used.

11

English (US)

4.8 Coupling alignment (KP)

1. If the pump and motor were shipped mounted on a common

base frame as an assembly, remove the coupling guard.

2. Checking parallel and angular alignment

Place a straight edge and feeler gauges or a dial indicator

across both coupling hubs to check for horizontal, vertical,

and angular misalignment of the coupling hubs. See fig. 9.

Coupling alignment is correct when the measurements show

that all points of the coupling faces are within 0.005 in. (0.127

mm) of each other, or when the straight edge contacts both

hubs evenly in both horizontal and vertical positions. If

misalignment is detected, loosen the motor and shift or shim

as necessary to re-align. Then re-tighten the anchor bolts.

Always align the motor to the pump as pipe strain will occur if

the pump is shifted. Never reposition the pump on the base

frame.

3. Check shaft alignment once again after final piping

connections to the pump have been made, motor wiring

checked, correct direction of rotation has been established,

and pipes have been filled with liquid. See figs 10 and 11.

Fig. 9 KP, checking angular or parallel alignment

Fig. 10 KP, plan view clockwise (CW) rotation

Fig. 11 KP, plan view counterclockwise (CCW) rotation

• Leave the coupling guards off until the pump priming

procedure has been completed.

• Install the coupling guards after installation has been

completed to protect personnel from rotating machinery.

TM 05 4767 2512TM 05 4768 2512

TM05 9288 3173TM05 9289 3173

WARNING

Moving machine parts or blades

Death or serious personal injury

- Ensure an approved coupling guard is in place

before operating the product. Failure to observe

this warning could result in injury to operating

personnel.

Outlet

Inlet

Clockwise (CW) rotation

Outlet

Inlet

Counterclockwise (CCW)

rotation

English (US)

12

5. Starting up the product

5.1 Priming

KP, KPV, KPVS pumps are non-self-priming and must be

completely primed, that is filled with liquid, before starting.

• If the pump will be operating with a positive inlet pressure,

prime it by opening the inlet valve and allowing liquid to enter

the pump housing. Open the vents at the top of the upper

pump housing and the top of each inlet dome, and make sure

that all air is forced out of the pump by the liquid before closing

the vents.

• IMPORTANT: Rotate the shaft by hand while priming and

venting to free entrapped air from the impeller passageways.

• If the pump will be operating with a suction lift, priming must

be accomplished by other methods. Use foot valves, ejectors

or vacuum pumps, or fill the pump housing and inlet line

manually with liquid.

5.2 Pre-start checklist

Make the following inspections before starting your KP, KPV,

KPVS pump.

1. Make sure that the inlet and outlet pipes have been cleaned

and flushed to remove dirt and debris.

2. Make sure that all wiring connections to the motor and starting

device are in accordance with the wiring diagram and produce

proper rotation.

3. If the motor has been in storage for a long time, either before

or after installation, refer to the motor instructions before

starting.

4. Check the voltage, phase, and frequency with the motor

nameplate.

5. Turn the impeller by hand to make sure that it rotates freely.

6. Tighten the plugs in the gauge and drain the holes. If the

pump is fitted with pressure gauges, keep the gauge cocks

closed when they are not in use.

7. Recheck the motor-to-pump alignment per section

4.8 Coupling alignment (KP).

8. Check inlet and outlet pipes for leaks, and make sure that all

flange bolts are securely tightened.

9. If the pump will run on a variable frequency drive, do not ramp

up the pump from reduced speeds. Go directly on-line at full

speed, especially at commissioning so adequate pressure is

generated to flush wear rings and create a hydrostatic bearing

effect.

5.3 Motor direction of rotation

After the unit has been wired and checked to ensure that all

components in the system, such as disconnect devices, magnetic

starters, pilot devices and motors, are properly connected, check

the motor direction of rotation as follows:

• Make sure that the coupling is disconnected, then momentarily

energize the motors to ensure that the direction of rotation is

correct as indicated by the arrow cast into the pump housing.

If the direction of rotation is incorrect, interchange the two

wires at the motor-protective circuit breaker terminals T1 and

T2.

• For Wye-Delta motors the direction of rotation has to be

verified for both wye and delta connections.

• For proper direction of rotation, reference rotation drawing in

section 4.8 Coupling alignment (KP).

Never run the pump dry in the hope that it will prime

itself. The result will be serious damage to the shaft

seals, pump wear rings and shaft sleeves.

Do not operate the product above the range of the

nameplate conditions. This may damage the product.

Never check the motor direction of rotation unless

pump and motor couplings have been disconnected

and physically separated. Failure to follow this

instruction can result in serious damage to the pump

and the motor if the direction of rotation is wrong.

The pumps must not be operated while dry. Use

extreme caution that motors are energized only

momentarily to determine proper direction of rotation.

13

English (US)

5.4 Starting the pump

1. Install a coupling guard.

2. Fully open the gate valve (if any) in the inlet line, and close

the gate valve in the outlet line.

3. If applicable, turn on any external source of cooling or

lubricating fluid to the shaft seals.

4. Fill the inlet line with liquid and completely prime the pump.

5. Start the pump.

6. Immediately make a visual check of the pump and inlet pipe

for pressure leaks.

7. Immediately after the pump has reached full operating speed,

slowly open the outlet gate valve, and open the bleed valves

at system high points. Do not open the outlet gate valve

completely until the system is full of liquid, purged of air and

checked for leaks.

8. After entirely filling the system, fully open the outlet gate valve

and close the system bleed valves.

9. If the pump is fitted with pressure gauges, open the gauge

cocks and record pressure readings for future reference.

Verify that the pump is performing in accordance with the

parameters specified in the performance curves.

10. Check and record voltage, amperage per phase, and

kilowatts, if a wattmeter is available.

6. Handling and storing the product

See section 8.8 Taking the product out of operation.

7. Product introduction

7.1 Applications

We recommend KP, KPV, KPVS pumps for these applications:

• circulation in heating and air conditioning systems, water

condensing and boiler feed systems

• liquid transfer and pressure boosting in various industrial

systems

• water distribution and water treatment in public water systems.

7.2 Pumped liquids

Use clean, thin, non-aggressive liquids, not containing solid

particles or fibers. Do not pump liquids that will attack the pump

materials chemically.

When pumping liquids with a density and/or viscosity higher than

that of water, pressure and flow will be reduced. Alternatively, use

motors with correspondingly higher outputs.

The stuffing box packing rings or the mechanical shaft seal O-

rings chosen must be suitable for the liquid to be pumped.

Special stuffing box packing rings or shaft seal O-rings may be

required if the pump is used for pumping treated water:

• at temperatures above 176 °F (80 °C)

• containing additives to prevent system corrosion, calcareous

deposits, etc. (this may be the case in heating and ventilating

systems).

When pumping liquids other than water, select an appropriate

stuffing box or shaft seal. For further information, please contact

Grundfos.

WARNING

Moving machine parts

Death or serious personal injury

- Mount an approved coupling guard before

operating the product.

For KPVS pumps, ensure the jacking screw (114) is

firmly seated and sealed by turning it

counterclockwise. This will prevent media leakage

during operation.

The absolute maximum operating temperature for the

pump is 275 °F (135 °C).

English (US)

14

7.3 Pump identification

All PACO pumps are identified by catalog and serial numbers.

These are stamped on the pump nameplate, as shown in fig. 12,

affixed to the pump housing. Refer to these numbers in all

correspondence with Grundfos.

7.3.1 Nameplate

Fig. 12 KP, KPV, KPVS nameplate

7.3.2 KP KPV model number and construction code

7.3.3 Type key

* 2" outlet on pumps with impellers ≤ 13"

TM05 7638 1313

Example 29 60123 140001 1852

Product code

Model code

Materials of construction

Motor code

Production code 29

29: Split case (KP, KPV)

31: Split coupled split case (KPVS)

Model code 60 12 3

Pump outlet

20 = 2"*

30 = 3"

40 = 4"

50 = 5"

60 = 6"

80 = 8

10 = 10"

12 = 12"

14 = 14"

16 = 16"

20 = 20"

24 = 24"

Nominal maximum impeller diameter

95 = 9.5"

12 = 12"

13 = 13"

14 = 14"

15 = 15"

19 = 19"

20 = 20"

24 = 24"

25 = 25"

27 = 27"

28 = 28"

Impeller design

Clockwise rotation:

1, 3, 5, 7, 9

Counterclockwise rotation:

0, 2, 4, 6, 8

Materials of construction 1 4 00 0 1

Packing or seal

3 = Standard packing

1 = Type 21, single seal, ceramic seat, Buna

2 = Type 21, single seal, Tungsten carbide seat,

Viton

6 = Type 21, single seal, Ni-Resist seat, Viton

7 = Type 21, single seal, Ni-Resist seat, Buna

8 = Type 1B, single seal, Ni-Resist seat, Buna

9 = Type 21, single seal, Ni Resist seat, Viton

A = Type 1, single seal, ceramic seat, Buna

B = Type 1, single seal, Ni-Resist seat, Viton

C = Type 1, single seal, Tungsten Carbide seat,

Viton

D = Type 1, single seal, Ni Resist seat, Buna

E = Type 1, single seal, ceramic seat, Buna

F = Type 1, single seal, Si Cbrd seat, EPDM

G = Type 8-1, single seal, Si C brd seat, Viton

H = Type 8-1, single seal, ceramic seat, Buna

ID of packing or seal

2 = 1"

3 = 1 - 1/4"

E = 1 - 1/2"

4 = 1 - 3/4"

5 = 2 - 1/4"

6 = 2 - 3/4"

7 = 3"

K = 3 - 1/2"

V = 4"

H = 4.1"

B = 4.7"

N = 5.5"

15

English (US)

** For packed pumps only (packed pumps standard with

distribution ring, recirculation lines, and hardened stainless

steel sleeves).

Materials of construction 1 4 00 0 1

General configuration (Horizontal)

Code no. Item

00 Standard

01 Double wear rings

02 Oil lube bearings

03 (01) + (02)

04 (01) + (05)

05 Recirculation lines

20 Double ext shaft

21 Double wear rings

22 Recirculation lines

24 (21) + (22)

30 Double ext shaft

31 Double wear rings

32 Recirculation lines

34 (31) + (32)

70 250 lb flange

71 Double wear rings

72 (71) + (73)

73 Recirculation lines

90 250 lb flange

91 Double wear rings

General configuration (Vertical)

Code no. Item

50 Standard (Vesconite for KPVS)

51 Double wear rings

52 Sleeve bearing

53 (51) + (52)

80 250 lb flange for 300 psi CWP

81 Double wear rings

82 Sleeve bearing

83 (81) + (82)

92 250 lb flange for 400 psi CWP

93 Double wear rings

94 Sleeve bearing

95 (93) + (94)

Shaft/sleeve metallurgy

0 = Steel/bronze

1 = Steel/stainless steel

3 = Stainless steell/bronze**

6 = Stainless steel/stainless steel or stainless steel/no sleeves

(KPVS)

7 = SS/hardened stainless steel

A = 316 SS/Ni Al Bronze

X = Special

Pump metallurgy

0 = Standard fitted

1 = Bronze fitted

2 = Standard all bronze

5 = All iron

8 = Ductile iron/bronze fitted

E = Ductile iron/stainless steel fitted

X = Special

Motor code 1782

Enclosure

1 = ODP

2 = TEFC

3 = Explosion Proof

Voltage

Hp

1-phase 3-phase

115/230 V 200 V 230/460 V

1/3

1/2

3/4

1

1-1/2

21

29

35

41

47

23

31

37

43

49

24

32

38

44

50

2

3

5

7-1/2

10

53

59

65

71

76

55

61

67

73

77

56

62

68

74

78

15

20

25

30

40

--

81

84

01

02

03

82

85

87

88

89

50

60

75

100

125

--

04

05

06

07

--

90

91

92

93

94

150

200

250

300

--

95

96

97

98

RPM

1 = 3500

2 = 1750

3 = 1150

Materials of construction 1 4 00 0 1

English (US)

16

8. Servicing the product

8.1 Maintaining the product

8.1.1 Lubricating the motor

Always follow the motor manufacturer's lubricating instructions, if

they are available, and periodically check grease fittings and

drain plugs for leaks. If the lubricating instructions are not

available, refer to the table below for recommended lubricating

intervals.

• The motor can be lubricated both when it is running or when it

is at rest.

Remove the grease drain plug (if any) and filler plug on the

grease fitting. Grease with clean lubricant until grease

appears at the drain hole or along the motor shaft.

The table below lists the recommended types of grease for motor

lubrication. These types have all been thoroughly tested and

must be used whenever possible.

8.1.2 Lubricating the pump bearings

Regreasable bearings are packed with grease at our factory prior

to shipping. This initial filling of grease is good for one year or

2000 hours of normal operation, whichever occurs first. After one

year or 2000 hours of normal operation, a regular grease

maintenance schedule must be implemented.

8.1.3 Grease replacement (KP, KPV)

1. Remove the four (4) cap screws and remove the bearing

covers (113C and 113D) to allow access to the bearing.

2. Use a clean rag to remove as much old grease as possible

from the bearing.

3. Re-pack the bearing with sufficient grease to completely fill

and cover the balls inside the bearing.

4. Turn the pump shaft to ensure even and complete lubrication.

5. For drive end bearing maintenance, slide the bearing cover

back as far as possible and visually inspect bearing for

grease.

6. Proceed as stated above removing old grease with a clean

rag. If the bearing covers cannot be moved sufficiently to

allow access to bearing, remove the coupling hub.

7. Reinstall the bearing covers when the task is complete.

Bearing manufacturers recommend that you fill the bottom third of

the bearing with grease. After filling the bottom third with grease,

rotate the shaft to cover the balls inside the bearing.

DANGER

Moving machine parts

Death or serious personal injury

- Before any inspection, maintenance, service or

repair of the product, make sure that the motor

controls are in the "OFF" position, locked and

tagged.

Recommended lubricating intervals

Motor rpm Motor hp Operating conditions

1750 and

below

10-40 Standard Severe Extreme

50-150 1-3 years

6 months -

1 year

6 months -

1 year

200 and up 1 year 3 months 6 months

above

1750

All hp

1 year 3 months 6 months

1 year 3 months 3 months

Standard conditions:

Operating 8 hours per day, normal or light load, clean air, 100 °F

(37 °C), maximum ambient temperature.

Severe conditions:

Operating continuously 24-hours, shock loads or vibrations,

poor ventilation, 100-150 °F (37-65 °C), ambient temperature.

Extreme conditions:

Operating continuously, heavy shocks or vibrations, dirt or dust

in the air, extremely high ambient temperature.

Recommended bearing grease for motors

Manufacturer Bearing lubricant

Chevron SRI grease NLGI No. 2

Texaco Polystar RB2 NLGI No. 2

WARNING

Catastrophic failure

Death or serious personal injury

- Maintain proper lubrication schedule

- Do not operate the unit without proper lubrication

as this can result in overheating of the bearings,

bearing failures, pump seizures and actual

breakup of the equipment, exposing operating

personnel to personal injury.

Recommended bearing grease for pumps

Manufacturer Lubricant

Shell Dolium

®

Exxon Polyrex

®

Chevron

SRI Grease NLGI 22

Black Pearl NLGI 2

Phillips Polytrac™

Texaco Polystar RB

Do not over-grease. Too much grease can cause

overheating and premature bearing failure.

17

English (US)

8.1.4 Oil lubrication (KP, KPV)

Follow a regular oil maintenance program. KP, KPV pumps with

oil lubricated bearings are fitted with a transparent reservoir, a

constant-level oiler, that maintains the oil level about the center

line of the lower bearing. See 85 in fig. 13. When necessary,

renew the oil supply in the reservoir of the constant-level oiler. To

refill it, remove the reservoir and fill it with oil. After filling the

reservoir with oil, replace it into operating position.

Fig. 13 Oil lubricated bearing construction

Change the oil after the first 200 hours of operation. To change

the oil, remove the drain plug (16K) at the bottom of the bearing

cover and the filler plug (16B), at the top of the bearing frame.

After draining the oil, replace the fittings and refill the reservoir

with an oil selected from the table List of acceptable oil lubricants

below. After the first oil change, the oil must be changed again at

2000 hours and then at intervals of 8000 hours or once a year

thereafter.

8.1.5 Stuffing box (packing) or shaft seal water lubrication

(KP)

The stuffing (packing) box must be supplied at all times with a

source of clean, clear liquid to flush and lubricate the packing.

Only a sufficient volume of sealing liquid to create a definite

direction of flow from the stuffing box inward to the pump casing

is required. Pipe from the pump outlet dome to the packing box is

supplied when requested.

8.1.6 Maintaining packing (KP)

Pack the stuffing box with fresh packing before initial startup,

after repairs to the pump, and in case of excessive leaks. Any

time the packing is replaced, inspect the shaft sleeves for wear,

roughness or scouring and replace with new ones if necessary.

For instructions on filling the stuffing box see section Replacing

packing, each side. For seal gland adjustment see section

8.2.2 Bearing, seal and packing replacement.

8.1.7 Flexible coupling maintenance (KP, KPV)

The coupling is pre-greased at the factory. After disassembly it

must be greased again. For annual greasing refer to the coupling

manufacturer's instructions.

TM05 8898 2713

List of acceptable oil lubricants

Lubricant

manufacturer

Bearing oil brand name

Aral Refining Co. Aral Oil CMU Aral Oil Tu 518

British Petroleum Co. BP Energol TH 100-HB

Calypsol Oil Co. Calypsol Bison Oil SR 25 or SR 36

Standard Oil Co. Chevron Hydraulic Oil Circulating Oil 45

Esso Corporation Esso-Mar 52 Teresso 47 Esstic 50

Fina Oil Company Fina Hydran 43 Fina Cirkan 32

Gulf Refining Co. Gulf Harmony 47 Gulf Paramount 45

Socony Mobil Oil Co. Vac HLP 25 Mobilux D.T.E. 25

Shell Oil Company Shell Tellus Oil 29

Sundco Oil Company Sunvis 821

Texas Company Texaco Ursa oil P 20

Wisura Rining Co. Wisura Norma/Tempo 25 (36)

English (US)

18

8.2 Disassembling the pump

8.2.1 Preparations before disassembling the pump

KP, KPV, KPVS pumps are designed for ease of maintenance

and, as such, the seals, sleeves, wear rings, clearances and

bearings can be inspected without having to remove the complete

rotating element or having to disconnect the inlet or outlet pipes,

or disturbing the alignment of the pump set.

Work on this equipment is to be performed only by qualified

personnel. Read the following instructions completely before

performing any work on the pump.

Before beginning disassembly of the pump, proceed as follows:

1. Close the inlet and outlet isolation valves.

2. Turn off any external source of cooling or lubricating fluid to

the shaft seals.

3. Drain the pump case by opening the drain plug and vent

plugs.

4. Disconnect and lock off the motor power source.

8.2.2 Bearing, seal and packing replacement

All normally required parts for KP pumps are available in kit form.

Refer to figs. 14 and 15.

Bearing replacement

1. Remove the motor.

2. Remove the coupling half from the pump shaft (51) using a

wheel puller and remove the coupling key (11A).

3. Remove the bearing covers (113C) and (113D).

4. Loosen the set screws in the eccentric locking rings of the

bearings (53 and 54) and turn the rings in the opposite

direction of the direction of rotation to loosen from the shaft, or

remove the retaining snap ring, whichever is applicable.

5. Remove the cap screws from each bearing housing (124) and

slide, with bearing, off its end of the shaft.

6. Remove the bearings (53, 54) from the bearing housings.

7. Install the new seals and seal seats.

8. Reinstall the bearing housings less the bearings, noting that

the slinger (79) is in the correct position. Take care not to

break the seal seats of the seal type pumps by striking them

against the shaft.

9. Clean out the bearing housings and slide the new bearings

over the shaft and into the bearing housings. Press only on

inner race of the bearing. Use a bearing warmer, if available.

10. Turn the eccentric locking rings in the direction of pump

rotation to tighten on the shaft and tighten the set screws, or

replace the spacer and the retaining snap ring, whichever is

applicable.

11. Pack the ball bearings and bearing cover cavities with clean

ball bearing grease. See section 8.1.2 Lubricating the pump

bearings.

12. Replace the bearing covers (113C, 113D).

13. If applicable replace the packing glands after following

packing instructions in section Replacing packing, each side.

14. Gently tap the coupling half on the shaft (51) over the key

(11A). Do not tap it if it can be pushed on. Using too much

force to drive on the coupling half can damage the ball

bearings and/or fracture the seal faces. If there is difficulty

pushing the coupling onto the shaft, heat up the coupling half

to a temperature of not more than 300 °F (148 °C) and then

use protective gloves to slide the coupling half onto the shaft.

15. Replace motor and realign.

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

CAUTION

Toxic material

Minor to moderate personal injury.

- Wash down the pump before doing any work on it.

WARNING

Hot, caustic, flammable or toxic materials,

including vapors

Death or serious personal injury

- Be extremely cautious when venting and/or

draining hazardous liquids.

Wear protective clothing when there are caustic,

corrosive, volatile, flammable, or hot liquids.

Do not breathe toxic vapors.

Do not allow sparks, open fire, or hot surfaces

near the equipment.

WARNING

Moving machine parts

Death or serious personal injury.

- Do not insert a screwdriver between the impeller

vanes to prevent rotation.

A clearance of 24 in. (610 mm) on each side of the

pump will allow for maximum access while servicing.

A minimum of 24 in. (610 mm) clearance is required

to remove the upper pump housing when accessing

the rotating element.

Take care to ensure the seal seats in the bearing

housings of seal type pumps are not broken during

housing removal.

On vertically mounted pumps, remove the rotating

assembly in order to replace the lower bearing and

seal assembly.

19

English (US)

Mechanical seal replacement

1. Follow the above steps to remove the bearing housings (124).

2. Remove the old seal head and the seal seat from the shaft

sleeve and bearing housing or seal cap.

3. Inspect the shaft sleeves (116) for scoring or pitting.

4. Replace if the surface is rough to your fingernail.

Proper seal seat installation

1. Clean the seal cap or bearing housing (124).

2. Lightly lubricate the new seat's rubber cap with liquid soap.

3. Press in the seal seat into the seal housing, making sure the

seat is seated squarely and all the way into seal cap or

bearing housing. Do not touch the seal seat or the head faces.

Proper seal head installation

1. Clean and lightly lubricate the shaft sleeves (116) or the shaft

(51). Make sure that there are no sharp edges or corners to

cut the seal's rubber parts.

2. Lightly lubricate the seal face elastomers with liquid soap.

3. Slide the assembly onto the sleeve or shaft until the spring

touches the shoulder. Do not compress the spring. Make sure

that the notches on the carbon ring match the retainer's lugs

and the spring is in position on the seal head.

4. Reinstall the bearing housings (124) with bearings, noting that

slingers (79) are in correct places. Take care not to strike seal

seats against shaft.

5. Follow remaining bearing replacement steps to complete

assembly.

Replacing packing, each side

1. Remove the packing gland.

2. Remove the old packing distribution ring, if any, and use a

packing hook to remove the packing behind the distribution

ring.

3. If the packing retainer comes out, replace it against the

retaining ring.

4. Insert two new packing rings one at a time, staggering the

joints 180 ° and pushing them firmly back against the packing

retaining washer.

5. Insert the distribution ring, if any.

6. Insert three more packing rings (applies to most sizes)

staggering joints 180 °. If no distribution ring is used, one

extra packing ring is required.

7. Replace the packing gland.

8. Adjust the packing gland to permit a leakage of 40 to 60 drops

per minute for shaft lubrication.

9. Never overtighten the packing gland. For suction lift

applications, should it become necessary to overtighten the

packing while starting the pump, make sure to loosen the

packing immediately after the pump is started, allowing a

leakage of a 40 to 60 drops per minute. After initial startup,

additional packing and adjustment may be required.

8.2.3 Bearing and seal replacement for KPVS

1. Remove the coupling guard and the coupling. See section

8.2.2 Bearing, seal and packing replacement.

2. Remove the seal housing cap screws and the seal housing

(124a).

3. Remove the seal head assembly (105) from the shaft (51).

Water-soluble lubricant may be applied to the shaft to ease

the removal of the seal head. Pull the seal head assembly

from the shaft, using a slight twisting motion (as necessary) to

loosen the bellows from the shaft.

4. Discard the seal, the spring and the retainer.

5. Remove and discard the seal seat and gasket from the seal

housing (124a) and thoroughly clean the inside cavity of the

seal housing and flange.

6. The interior surface of the bellows on the new shaft seal is

coated with a bonding agent that adheres to the pump shaft.

When the old shaft seal is removed, the bellows may crack or

split during removal. We recommend that you install a new

mechanical shaft seal if it becomes necessary to remove the

existing shaft seal from the shaft.

7. Clean and lubricate the pump shaft (51) with a water-soluble

lubricant and make sure that no sharp edges exist to cut or

scratch bellows of the new seal.

8. Install the new gasket onto the seal housing.

8.2.4 Disassembling Horizontal pumps (KP)

1. Remove the nuts and bolts that hold the pump housing halves

together (6A, 6B), and remove cap screws holding bearing

housing (124) to pump housing.

2. Remove roll pin (26B) then lift off upper pump housing (6A).

3. Place the gaskets in water to keep them from drying out and

shrinking.

4. Remove shaft assembly from the case.

5. To disassemble rotating assembly, refer to section Bearing

replacement.

6. Unscrew and remove shaft sleeves (116) or impeller locknuts

by turning them in direction of pump rotation. One has RH

(right-hand) threads. The other has LH (left-hand) threads.

Use a strap wrench. Do not place the wrench on the part of

sleeve that comes in contact with the seal or packing.

7. Remove the wear ring retaining parts as necessary, locking

pin (24) and/or rings (65).

8. Slide the wear ring (45) off the impeller.

9. Make an orientation mark for later reference on the impeller

(49) on the coupling side before removing it from the shaft, to

help ensure it will be reassembled identically.

10. Press the impeller (49) from the shaft (51) and the key (11).

It is not necessary to remove the bearings from the

bearing housings. However, we recommend that you

replace the bearings.

English (US)

20

8.2.5 Disassembling Vertical pumps (KPV)

1. Remove the coupling guard and remove the coupling grid.

2. Remove all the cap screws on the bearing housings (124)

except for the two on the lower pump housing (6B) to hold the

rotating assembly in place while removing the upper pump

housing (6A).

3. Remove the roll pin (26B) then lift off the upper pump housing

(6A).

4. Place the gaskets in water to keep them from drying out and

shrinking.

5. Remove the shaft assembly from the pump housing.

6. To disassemble the rotating assembly, refer to section Bearing

replacement.

8.2.6 Inspecting the components

1. While the pump is disassembled, inspect all components for

wear, damage, deterioration or erosion.

2. Inspect the shaft sleeves and replace them if they are worn or

deeply scored.

3. Check the impeller wear ring (if used) and the pump housing

wear ring (45) for erosion or wear and replace them if badly

deteriorated, to renew original pump performance. The design

clearance is 0.018 in. to 0.022 in. (0.457 mm to 0.558 mm)

diametrically. Clearances greater than 0.040 in. (1.016 mm)

will affect pump performance and new wear rings must be

installed.

4. Examine the lapped faces of the mechanical seals for scoring,

heat checking or cracking. Examine mechanical seal

elastomers (rubber components) for deterioration or

hardening. Replace mechanical seals if any damage exists.

5. Check any external source of cooling or lubricating fluid lines,

and/or recirculation lines and ports for clogs, kinks or other

restrictions.

6. Clean machined mating surfaces of all components to remove

grit, grime and/or old sealing material before reassembling

pump.

8.3 Reassembling the pump (KP, KPV, KPVS)

1. Reinstall the impeller (49) and the key (11) on the shaft (51),

centering the impeller on the shaft with respect to the sleeve

or the lock nut threads. Be sure the impeller is installed on the

shaft the same way it came off, with the vane curvature and

per the orientation mark made during disassembly. For proper

rotation, see figs. 10 and 11. Note that:

– The pump will deliver little or no water if the impeller is

installed backwards.

– Be sure a good O-ring gasket is in place on each sleeve, if

the shaft has sleeves. Replace as necessary.

2. Replace the shaft sleeves (116) or nuts, turning them in the

opposite direction of pump rotation. Do not place a wrench on

the part of the sleeve that comes in contact with the seal or

the packing. Tighten evenly so the impeller position will not

shift.

3. Replace the wear ring retaining ring (65) over the wear ring

(45).

4. Slide the wear ring (45) over each impeller hub.

5. Replace the wear rings (45) on the impeller (49). Replace with

new seals or packing. Replace the bearing housing (124) on

the shaft (51) carefully so as not to damage the seal (11B).

Replace the bearing (54) into the outboard housing and

washer and snap ring. Replace the coupling key (11A) with

the coupling half.

6. For packing type pumps, follow the steps in section

8.2.2 Bearing, seal and packing replacement then the steps in

section Replacing packing, each side.

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Grundfos KPV Installation And Operating Instructions Manual

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