KSB Magnochem-Bloc Installation & Operating Manual Download Page 43

Page: 43 / 96

6 Commissioning/Start-up/Shutdown

43 of 96

Magnochem-Bloc

WARNING

Failure to re-install or re-activate protective devices

Risk of injury from moving parts or escaping fluid!

▷

As soon as the work is completed, re-install and re-activate any safety-relevant
devices and protective devices.

NOTE

If the pump has been out of service for more than one year, replace all elastomer
seals.

Summary of Contents for Magnochem-Bloc

Page 1: ...Mag drive Pump Magnochem Bloc Installation Operating Manual...

Page 2: ...ntents provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the manufa...

Page 3: ...12 2 10 Magnetic coupling 12 3 Transport Temporary Storage Disposal 13 3 1 Checking the condition upon delivery 13 3 2 Transport 13 3 3 Storage preservation 14 3 4 Return to supplier 14 3 5 Disposal...

Page 4: ...egulations 51 7 4 2 Preparing the pump set 52 7 4 3 Removing the back pull out unit including motor 52 7 4 4 Dismantling the back pull out unit 53 7 4 5 Removing the containment shroud 55 7 4 6 Removi...

Page 5: ...d handled Close coupled design Motor directly fitted to the pump via a flange or a drive lantern Discharge line The pipeline which is connected to the discharge nozzle Operating mode Configuration of...

Page 6: ...icable documents Table 1 Overview of other applicable documents Document Contents Data sheet Description of the technical data of the pump set General arrangement drawing outline drawing Description o...

Page 7: ...explosive atmospheres in accordance with EU Directive 2014 34 EU ATEX General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or s...

Page 8: ...nd within the use limits specified in the other applicable documents Only operate pumps pump sets which are in perfect technical condition Do not operate the pump set in partially assembled condition...

Page 9: ...ns for handling hazardous substances Applicable standards directives and laws 2 6 Safety information for the operator user Fit protective equipment e g contact guards supplied by the operator for hot...

Page 10: ...ally adhere to the sections in this manual marked with the symbol opposite and the following sections Section 2 9 1 Page 10 to Section 2 9 4 Page 12 The explosion proof status of the pump set is only...

Page 11: ...p of the filter e g ring filter main flow filter Failure or insufficient heat exchanger performance Failure or insufficient barrier fluid system function An insufficient cooling flow or failure of the...

Page 12: ...ormula in Section 6 2 3 1 Page 40 can be used to check whether additional heat build up may lead to a dangerous temperature increase at the pump surface 2 10 Magnetic coupling DANGER Strong magnetic f...

Page 13: ...set in the specified position Observe the information on weights centre of gravity and fastening points Never suspend the pump set by attaching lifting tackle to the eyebolts on the pump and motor Ob...

Page 14: ...ndoors the pump set is protected for a maximum of 12 months New pumps pump sets are supplied by our factory duly prepared for storage For storing a pump set which has already been operated the shutdow...

Page 15: ...fluid and any fluid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard 1 Dismantle the pump set Collect gre...

Page 16: ...em e g 1 hydraulic system optimised for part load operation C Casing material e g C stainless steel C Impeller material e g C stainless steel H Additional code e g H heatable casing X Special design 1...

Page 17: ...le casing wear rings Heatable Draining facility Impeller type Closed radial impeller with multiply curved vanes Discharge side sealing clearance reduces axial thrust Shaft seal Seal less with magnetic...

Page 18: ...c shaft seal mechanical seal gland packing The fluid handled is sealed to atmosphere exclusively by means of static sealing elements a gasket 3 between the casing 15 and the casing cover 12 and a join...

Page 19: ...g fluids In low boiling fluids operating mode the fluid handled is used to lubricate the plain bearings and to dissipate the heat generated by the magnetic coupling The lubricating and cooling flow is...

Page 20: ...9 45 68 71 72 71 74 80 55 69 72 73 72 74 80 75 71 73 75 73 76 81 90 71 74 76 73 76 82 4 8 Scope of supply Depending on the model the following items are included in the scope of supply Pump Surface co...

Page 21: ...level Observe the weights indicated 1 Check the structural requirements All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing general ar...

Page 22: ...4 Machine mount The installation surface has the required strength and characteristics 1 Position the pump set on the machine mounts 4 and align it with the help of a spirit level on the shaft discha...

Page 23: ...inage or hinder disassembly of the pump Suction lift lines have been laid with a rising slope suction head lines with a downward slope towards the pump A flow stabilisation section having a length equ...

Page 24: ...piping CAUTION Aggressive flushing liquid and pickling agent Damage to the pump Match the cleaning operation mode and duration of flushing and pickling to the casing materials and seal materials used...

Page 25: ...050 032 200 1 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050 032 125 50 1240 1010 878 1824 910 650 748 32 650 555 780 1157 715 490 555 050 032 160 50 1240 1010 878 1824 910 650...

Page 26: ...50 1250 1950 100 2000 1755 2500 3651 1850 900 1400 125 100 400 125 3400 2700 2200 4867 2550 1250 1950 100 2000 1755 2500 3651 1850 900 1400 150 125 200 150 4300 3450 2850 6206 3200 1600 2450 125 2700...

Page 27: ...Risk of burns If bearing bracket is insulated monitor the containment shroud temperature WARNING The volute casing and casing discharge cover take on the same temperature as the fluid handled Risk of...

Page 28: ...tire starting torque is available right from the beginning The pump set will reach the operating speed within a very short period of time Star delta starting For star delta start up the motor is wired...

Page 29: ...rting 1 Check the available mains voltage against the data on the motor name plate CAUTION Incorrect starting method without taking the selected magnetic coupling into account Damage to the pump set O...

Page 30: ...Risk of injuries damage to the pump Always disconnect the pump set from the power supply and secure it against unintentional start up before inserting your hands or other objects into the pump CAUTION...

Page 31: ...uired are connected and operational The lubricants have been checked After prolonged shutdown of the pump set the activities required for returning the equipment to service have been carried out Secti...

Page 32: ...separately from the hydraulic system Fig 12 Connections if the pump set is fitted with a heat exchanger dead end configuration 5 B Venting 7 A Cooling liquid OUT 7 E Cooling liquid IN 10 F External b...

Page 33: ...ed pumps Priming and venting with the external circulation operating mode DANGER Using the pump set in potentially explosive atmospheres Formation of explosive atmospheres Explosion hazard Flush the p...

Page 34: ...the rotor space The fluid handled or the external fluid from the rotor space transfer the heat to the cooling water in the heat exchanger DANGER Insufficient cooling water supply to heat exchanger Exc...

Page 35: ...p set and keeping it warm CAUTION Pump blockage Damage to the pump Prior to pump start up heat up the pump as described in the manual Observe the following when heating up the pump set and keeping it...

Page 36: ...ump set without liquid fill Prime the pump as per operating instructions Always operate the pump within the permissible operating range CAUTION Abnormal noises vibrations temperatures or leakage Damag...

Page 37: ...the data sheet Section 5 6 Page 28 NOTE Pump run up and motor run up must be synchronous Overloading overheating or non compliance with the design data may cause the inner and the outer rotor to drop...

Page 38: ...ous Overloading overheating or non compliance with the design data may cause the inner and the outer rotor to drop out of synchronisation Signs of asynchronous operation Insufficient discharge head No...

Page 39: ...e cooling heating chambers if any or otherwise protect them against freezing 6 2 Operating limits DANGER Non compliance with operating limits for pressure temperature fluid handled and speed Explosion...

Page 40: ...to the pump set Do not re start the pump set before the pump rotor has come to a standstill 6 2 3 Fluid handled 6 2 3 1 Flow rate Unless specified otherwise in the characteristic curves or in the dat...

Page 41: ...tances increased wear of the hydraulic system and the magnetic coupling are to be expected In this case reduce the intervals commonly recommended for servicing and maintenance CAUTION Magnetic particl...

Page 42: ...wn periods start up the pump set regularly between once a month and once every three months for approximately five minutes This will prevent the formation of deposits within the pump and the pump inta...

Page 43: ...or re activate protective devices Risk of injury from moving parts or escaping fluid As soon as the work is completed re install and re activate any safety relevant devices and protective devices NOTE...

Page 44: ...IC use suitable anti static equipment DANGER Strong magnetic field in the area of the magnetic coupling or the individual magnets Danger of death for persons with pacemaker Interference with magnetic...

Page 45: ...and work NOTE All maintenance work service work and installation work can be carried out by KSB Service or authorised workshops For contact details please refer to the enclosed Addresses booklet or vi...

Page 46: ...ction 6 2 Page 39 While the pump is in operation observe and check the following The pump must run quietly and free from vibrations at all times Check the static sealing elements for leakage Check for...

Page 47: ...ualisation Explosion hazard Make sure that the connection between pump and baseplate is electrically conductive 7 2 2 1 Checking the clearances Clearances between impeller and casing The back pull out...

Page 48: ...led insufficiently Lack of lubrication of product lubricated plain bearings Dry running of the plain bearings Monitor the pump set fill with a fill level monitoring device During operation the hydrody...

Page 49: ...ble vessel to contain any leakage Wear protective clothing if required NOTE Before testing the shaft seal function switch off the pump set as stipulated and close the shut off elements in the suction...

Page 50: ...gh the pump to ensure drying Use connection 6B to drain the fluid handled see drawing of auxiliary connections The pump is drained via drain plugs 903 01 on the casing and 903 80 on the casing cover i...

Page 51: ...ormed by specially trained qualified personnel WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage to property Use suitable transport devices lifting equipment...

Page 52: ...rt the back pull out unit to prevent it from tilting CAUTION Improper transport of complete back pull out unit with or without impeller Damage to the plain bearings Use a suitable transport lock to pr...

Page 53: ...iece 132 03 from bearing bracket lantern 344 3 Pull motor 800 with outer rotor 818 02 and intermediate piece 132 03 out of bearing bracket lantern 344 4 Place the outer rotor with the motor in a clean...

Page 54: ...bracket lantern 344 from casing cover 161 Use forcing screws 901 30 if required 4 For models with leakage barrier only remove O ring 412 98 5 Remove guard 7 4 4 2 2 Removing the bearing bracket lanter...

Page 55: ...ut The motor with the intermediate piece has been placed in a clean and level assembly area The outer rotor has been removed and is kept in a clean and level non magnetic workplace 1 Undo hexagon sock...

Page 56: ...dismantling secure the inner rotor assembly impeller casing cover bearing ring carrier plain bearings inner rotor against tilting or tipping over 9 Place inner rotor assembly impeller casing cover be...

Page 57: ...rom damage and above all from contamination metal particles Use a non magnetic guard made of wood or plastic for this purpose see table manufacturing dimensions of guard 7 4 6 Removing the impeller Th...

Page 58: ...1 and bearing sleeve 529 21 may become loose or may come off For this reason check whether taper lock ring 515 21 and bearing sleeve 529 12 can be undone and removed before setting down casing cover 1...

Page 59: ...permissible temperature limits at the motor flange and motor shaft must be higher than the temperatures generated by the pump Contact KSB for temperatures DANGER Leaks and or corrosion damage on moni...

Page 60: ...sed on silicone or PTFE Assembly adhesives For gaskets avoid the use of assembly adhesives if possible Should assembly adhesives be required after all use a commercially available contact adhesive e g...

Page 61: ...cover or bearing ring carrier as per the specifications CAUTION Improperly pressed in bearing bushes 545 21 545 22 Damage to the pump Damage to plain bearings or magnetic coupling When pressing the b...

Page 62: ...the running surfaces of thrust bearing 314 with liquid 8 Place thrust bearing 314 onto bearing bush 545 21 NOTE If the bearing ring carrier 391 cannot be fitted check the alignment of thrust bearing 3...

Page 63: ...lock ring 515 22 NOTE Bearing sleeves 529 21 and 529 22 are identical 16 Slide bearing sleeve 529 22 onto the shaft CAUTION Dry bearing surfaces during assembly Dry running of the bearings at pump sta...

Page 64: ...tightening the nuts Make sure the casing cover is easy to rotate Stop the tightening procedure if jamming occurs Loosen the nut and repeat the tightening procedure If jamming occurs repeatedly dismant...

Page 65: ...y 2 Insert joint ring 411 08 into casing cover 161 3 Place intermediate piece 132 01 onto casing cover 161 4 Tighten hexagon socket head cap screws 914 03 to the torques given in this manual Section 7...

Page 66: ...d secured against tilting CAUTION Improper tightening of the bolts on the containment shroud Damage to the containment shroud Evenly tighten the bolts crosswise 1 Check the inner rotor for contaminati...

Page 67: ...61 NOTE On the fully assembled pump the marking in the casing cover and the eyebolt must point in the same direction upwards 4 Fit bearing bracket lantern 344 on casing cover 161 5 Tighten hexagon nut...

Page 68: ...carried out The individual parts have been placed in a clean and level assembly area All dismantled parts have been cleaned and checked for wear Any damaged or worn parts have been replaced by origin...

Page 69: ...5 Outer rotor 11 Mark the position of the keyway on the hub face of the outer rotor using a felt tip pen 12 Slide the outer rotor onto the motor shaft as far as possible The marking must be aligned wi...

Page 70: ...ailable for holding the outer rotor if necessary 1 Apply a thread locking agent to threaded connecting element 905 to lock the threaded connection 2 Screw threaded connecting element 905 into the moto...

Page 71: ...on of the shaft seal ring s mounting holes using a felt tip pen 15 Slide the outer rotor onto the motor shaft as far as possible The marking must be aligned with the key on the motor shaft 16 Slide di...

Page 72: ...the drive assembly including outer rotor 818 02 into bearing bracket lantern 344 NOTE Make sure that the motor is positioned correctly in relation to the bearing bracket lantern with the eyebolt on th...

Page 73: ...ced by original spare parts The sealing surfaces have been cleaned WARNING Back pull out unit tilting Risk of squashing hands and feet Suspend or support the back pull out unit to prevent it from tilt...

Page 74: ...1 4571 16 M12 1 4571 27 M16 1 4571 68 M20 1 4571 139 914 01 Hexagon socket head cap screw M5 A4 70 5 M6 A4 70 8 5 914 03 Hexagon socket head cap screw M8 A4 70 15 1 7709 17 1 7225 20 M10 A4 70 29 1 77...

Page 75: ...ordering replacement or spare parts Order number Order item number Type series Size Material variant Year of construction Refer to the name plate for all data Also specify the following data Part num...

Page 76: ...more 411 08 09 Joint ring U ring 4 6 8 8 9 12 150 502 01 02 Casing wear ring 2 2 2 3 3 4 20 503 01 02 Impeller wear ring 2 2 2 3 3 4 20 Set of sealing elements for pump casing 4 6 8 8 9 12 150 For le...

Page 77: ...of air pockets in the piping Alter piping layout Fit a vent valve NPSHavailable positive suction head is too low Check alter fluid level Fully open the shut off element in the suction line Change suc...

Page 78: ...the pipelines using anti vibration material Insufficient or excessive quantity of lubricant or unsuitable lubricant Top up reduce or change lubricant Motor is running on two phases only Replace the d...

Page 79: ...chem Bloc 9 Related Documents 9 1 General assembly drawings A B Fig 26 General assembly drawing of model with bolted cover with intermediate piece A Internal circulation external circulation B Low boi...

Page 80: ...9 Related Documents 80 of 96 Magnochem Bloc Fig 27 Fastening of discharge cover on the pump casing on models with bolted cover...

Page 81: ...ocuments 81 of 96 Magnochem Bloc A B Fig 28 General assembly drawing of model with clamped cover without intermediate piece A Internal circulation external circulation B Low boiling fluids dead end co...

Page 82: ...of discharge cover on the pump casing on models with clamped cover Fig 30 Fitting the support foot for motors 160 and 180 A UG1452899_D02 Fig 31 Model with volute casing and ring filter heating chamb...

Page 83: ...Stud 903 0113 0213 0313 0413 Screw plug 920 01 Hexagon nut 132 03 132 03 Intermediate piece 161 161 Casing cover 502 0213 502 0213 Casing wear ring 183 18313 Support foot 210 03 210 03 Shaft 550 87 D...

Page 84: ...4 Containment shroud flange 914 03 Hexagon socket head cap screw 914 28 Hexagon socket head cap screw 900 26 900 26 Eyebolt 901 04 901 0413 Hexagon head bolt 901 17 901 17 Hexagon head bolt 901 30 901...

Page 85: ...e 2 515 11 515 12 two piece Table 24 Overview of plain bearings arrangement Size Bearing bracket Nominal diameter of magnetic coupling mm 85 123 172 1 215 315 040 25 160 CS40 A31 A31 040 25 200 CS40 A...

Page 86: ...1 100 65 250 CS50 B21 B21 A21 100 65 315 CS60 B21 B21 A21 125 80 160 CS50 B21 B21 A21 125 80 200 CS50 B21 B21 A21 125 80 200 1 CS50 B21 B21 A21 125 80 250 CS50 B21 B21 A21 125 80 315 CS60 B21 B21 A21...

Page 87: ...gs arrangement Description Illustration Case A21 Bearing brackets CS50 and CS60 Magnetic coupling 172 UG1452899_D01 Case B21 Bearing brackets CS50 and CS60 Magnetic couplings 85 and 123 UG1452899_D01...

Page 88: ...lements and bearing bushes Fig 33 Positioning of locking elements and bearing bushes on pumps with bearing brackets CS40 CS50 CS60 A Marking on casing cover facing upwards B Opening of locking element...

Page 89: ...owing Directives as amended from time to time Pump set Machinery Directive 2006 42 EC The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 E...

Page 90: ...ier plain bearing inner rotor has been removed from the pump and cleaned In cases of containment shroud leakage the outer rotor bearing bracket lantern leakage barrier and bearing bracket or adapter h...

Page 91: ...luid handled Density 41 Frequency of starts 40 H Heating 35 Heating speed 35 Heating up 35 I Installation without foundation 22 Installation at site 21 Insulation 27 Intended use 8 Internal circulatio...

Page 92: ...Scope of supply 20 Servicing Maintenance 45 Shutdown 38 42 Spare part Ordering spare parts 75 Spare parts stock 75 Special accessories 20 Start up 37 38 Storage 14 42 T Temperature difference 35 Temp...

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Page 96: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2747 81 07 EN 01554607...

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