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Installation/Operating Manual MK

Original operating manual

All rights reserved. The contents 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 manufacturer's express written consent.

Subject to technical modification without prior notice.

© KSB SE & Co. KGaA, Frankenthal 11/10/2018

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Summary of Contents for MK

Page 1: ...Waste Water Condensate and Heat Transfer Fluid Pump MK Installation Operating Manual ...

Page 2: ...s 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 manufacturer s express written consent Subject to technical modification without prior notice KSB SE Co KGaA Frankenthal 11 10 2018 ...

Page 3: ... 11 3 Transport Temporary Storage Disposal 12 3 1 Checking the condition upon delivery 12 3 2 Transport 12 3 3 Storage preservation 12 3 4 Return to supplier 13 3 5 Disposal 14 4 Description of the Pump Set 15 4 1 General description 15 4 2 Designation 15 4 3 Name plate 15 4 4 Design details 16 4 5 Configuration and function 17 4 6 Noise characteristics 19 4 7 Scope of supply 19 5 Installation at ...

Page 4: ...fety regulations 40 7 4 2 Removing the pump set from the piping 40 7 4 3 Dismantling the pump section 41 7 5 Reassembling the pump set 43 7 5 1 General information Safety regulations 43 7 5 2 Reassembling the pump section 44 7 6 Tightening torques 48 7 7 Spare parts stock 48 7 7 1 Ordering spare parts 48 7 7 2 Recommended spare parts stock for 2 years operation to DIN 24296 48 8 Trouble shooting 5...

Page 5: ...fy that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled Discharge line The pipeline which is connected to the discharge nozzle Pump Machine without drive additional components or accessories Pump set Complete pump set consisting of pump drive additional components and accessories ...

Page 6: ... 2 3 Page 8 1 4 Other applicable 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 of mating and installation dimensions for the pump set weights Hydraulic characteristic curve Characteristic curves showing head NPSHrequired efficiency and power input Genera...

Page 7: ... indicates a hazard which if not avoided could result in damage to the machine and its functions Explosion protection This symbol identifies information about avoiding explosions in potentially 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 serious...

Page 8: ...fied 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 Only use the pump to handle the fluids described in the data sheet or product literature of the pump model or variant Never operate the pump without the fluid to be handled Observe the minimum flow rates indicated in the data shee...

Page 9: ...r 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 cold or moving parts and check that the equipment functions properly Do not remove any protective equipment e g contact guards during operation Provide the personnel with protective equipment and make sure...

Page 10: ... marked with the symbol opposite and the following sections ð Section 2 9 1 Page 10 to ð Section 2 9 4 Page 11 The explosion proof status of the pump set is only assured if the pump set is used in accordance with its intended use Never operate the pump set outside the limits stated in the data sheet and on the name plate Prevent impermissible modes of operation at all times 2 9 1 Marking Pump The ...

Page 11: ...er monitoring equipment is required to ensure that the pump set functions properly Contact KSB for further information on monitoring equipment Bearing temperature monitoring If temperature class T5 is to be complied with the bearing temperature must be monitored For this purpose the pump must be equipped with a temperature sensor at the drive end fixed bearing G 1 8 connection DIN 3852 The tempera...

Page 12: ...er attach the suspension arrangement to the free shaft end or the motor eyebolt Observe the information about weights centre of gravity and fastening points Observe the applicable local accident prevention regulations Use suitable permitted lifting accessories e g self tightening lifting tongs CAUTION Incorrect transport of the pump Damage to the shaft seal For transport lock the pump shaft with a...

Page 13: ...d by our factory duly prepared for storage For storing a pump set which has already been operated observe the instructions in ð Section 6 3 1 Page 31 3 4 Return to supplier 1 Drain the pump as per operating instructions ð Section 7 3 Page 39 2 Flush and clean the pump particularly if it has been used for handling noxious explosive hot or other hazardous fluids 3 If the pump has handled fluids whos...

Page 14: ...d 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 greases and other lubricants during dismantling 2 Separate and sort the pump materials e g by Metals Plastics Electronic waste Greases and other lubricants 3 Dispose of materials in accordance with local regu...

Page 15: ...ound mounting cover plate and flanged discharge pipe with lantern gland packing and motor B Casing material Grey cast iron B Tin bronze C Chrome nickel molybdenum cast steel 2 Pipe connection 2 Rp 2 0 Design status 1 Power code defines the impeller diameter 1 6 100 Installation depth cm 100 190 280 4 3 Name plate No 9971402925 000200 01 Q 10 m3 h H 3 m n 1450 1 min Ident No 00 391 209 AN 886 82 20...

Page 16: ...grated in explosion proof pump sets are supplied in Ex eb IIB Ex db eb IIC type of protection Shaft seal MK MKA Vapour barrier MKY Gland packing Impeller type Three channel impeller Bearings Drive end Radial ball bearing Greased for life Impeller end Bearing bush Product lubricated Optional Internal lubrication by fluid handled Grease lubrication Lubrication by external fluid Explosion protection ...

Page 17: ...lternative external lubrication can be used To protect the drive end radial ball bearing the shaft is enclosed by a vapour barrier below the thrust and radial bearing For pump sets installed with a cover plate MKA the discharge nozzle of the volute casing is connected to the plate via a discharge pipe Function The uniformly rotating impeller of the submerged pump transfers mechanical energy to the...

Page 18: ...to three support column sets and matching incremental lengths of the shaft assembly The pump set is installed in a drive lantern The discharge nozzle of the volute casing is connected to the lantern via a discharge pipe The discharge pipe ends in a flanged bend Function The uniformly rotating impeller of the submerged pump transfers mechanical energy to the fluid passing through The fluid enters t...

Page 19: ... motor MKY Baseplate integrally cast with the lantern Monitoring equipment optional Temperature sensor at the drive end fixed bearing with G 1 8 threaded connection Level control system optional Level control system with rod actuated float switch Level control system with magnetic float switch Level control system with EURO float switch 3 Spatial average as per ISO 3744 valid for pump operation in...

Page 20: ...ischarge When cleaning coated pump surfaces in atmospheres of Explosion group IIC use suitable anti static equipment 5 2 Checks to be carried out prior to installation Check the structural requirements The structural work required must have been prepared in accordance with the dimensions stated in the outline drawing and or general arrangement drawing 5 3 Fitting and setting the float switch contr...

Page 21: ...0 52 81 45 900 51 550 51 570 900 50 920 50 733 51 481 733 52 68 3 550 51 920 51 575 51 902 12 920 12 710 01 920 11 550 11 400 11 Fig 5 Fitting the rod actuated float switch a b c A A B B C C Fig 6 Positioning the rod actuated float switch for installation depth a 1000 mm b 1900 mm c 2800 mm A 1000 mm B 1900 mm C 2800 mm ...

Page 22: ...mp as required 10 Adjust the switching mechanism of float switch 81 45 such that the lever is angled 42 off the horizontal in non actuated position see illustration of float switch a installation position In installed condition the lever position must be as shown in the illustration of the float switch b switching position ð As the float rises the lever is lifted into the position shown and contac...

Page 23: ...otor and optional float switch are located outside the pit or tank ü Motor and optional float switch are ventilated and protected against moisture 1 Remove the transport plugs from the volute casing and the discharge pipe 2 For pump sets with installation depths of 1900 mm and 2800 mm without cover plate MK fit the pipe union 731 which is supplied separately strapped to the pump ð Section 9 1 2 Pa...

Page 24: ...nstalling the pump in the piping remove the flange covers on the suction and discharge nozzles of the pump CAUTION Welding beads scale and other impurities in the piping Damage to the pump Free the piping from any impurities 3 If required fit a suction strainer upstream of the pump nozzle 4 Connect the discharge side pump nozzle with the piping CAUTION Aggressive flushing liquid and pickling agent...

Page 25: ... Observe regulations IEC 60364 and for explosion proof models EN 60079 WARNING Incorrect connection to the mains Damage to the mains network short circuit Observe the technical specifications of the local energy supply companies NOTE A motor protection device is recommended 1 Check the available mains voltage against the data on the motor name plate 2 Select an appropriate starting method 5 8 Chec...

Page 26: ... direction of rotation If required check the electrical connection and correct the direction of rotation The correct direction of rotation of the motor and pump is clockwise seen from the drive end 1 Start the motor and stop it again immediately to determine the motor s direction of rotation 2 Check the direction of rotation The motor s direction of rotation must match the arrow indicating the dir...

Page 27: ...ion 6 2 3 2 Page 30 For grease lubrication optional fill the lubricators with grease For lubrication by external fluid open the flushing liquid connection ð Section 7 2 2 2 Page 36 6 1 3 Start up DANGER Non compliance with the permissible pressure and temperature limits due to a clogged intake or if the pump is operated with the discharge line closed Explosion hazard Leakage of hot fluids Never op...

Page 28: ...e pump has reached full rotational speed slowly open the shut off element in the discharge line and adjust it to comply with the duty point 6 1 4 Shutdown 1 Close the shut off element in the discharge line 2 Switch off the motor and make sure the pump set runs down smoothly to a standstill NOTE If the discharge line is equipped with a non return or check valve the shut off element may remain open ...

Page 29: ... specified limits for permissible ambient temperatures Observe the following parameters and values during operation Table 7 Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 C Minimum 20 C 6 2 2 Frequency of starts DANGER Excessive surface temperature of the motor Explosion hazard Damage to the motor In case of explosion proof motors observe the frequency of starts ...

Page 30: ... the pump surface If necessary the minimum flow must be increased Table 8 Key Symbol Description Unit c Specific heat capacity J kg K g Gravitational constant m s H Pump discharge head m Tf Fluid temperature C TO Temperature at the casing surface C Pump efficiency at duty point Temperature difference K 6 2 3 2 Minimum level of fluid handled DANGER Pump set running dry Explosion hazard Never allow ...

Page 31: ... to the pump set Never pump fluids with excessive gas content Allow sufficient time for gases to leave the fluid handled 6 2 3 6 Abrasive fluids Do not exceed the maximum permissible solids content specified in the data sheet When the pump handles fluids containing abrasive substances increased wear of the hydraulic system and shaft seal are to be expected In this case reduce the commonly recommen...

Page 32: ...nst corrosion Observe the additional instructions on preservation If the pump set is to be stored temporarily only preserve the wetted components made of low alloy materials Commercially available preservatives can be used for this purpose Observe the manufacturer s instructions for application removal 6 4 Returning to service WARNING Failure to re install or re activate protective devices Risk of...

Page 33: ...set regularly Prepare a maintenance schedule with special emphasis on lubricants shaft seal and coupling The operator ensures that maintenance inspection and installation is performed by authorised qualified specialist personnel who are thoroughly familiar with the manual WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents Ensure that the pump set ...

Page 34: ...rvision of operation DANGER Impermissibly high temperatures Explosion hazard Damage to the pump Prolonged operation against a closed shut off element is not permitted heating up of the fluid Observe the temperature limits in the data sheet and in the section on operating limits ð Section 6 2 Page 29 DANGER Excessive temperatures as a result of bearings running hot or defective bearing seals Explos...

Page 35: ...rovided in thrust and radial bearing 303 1 max width across corners of fastener used 18 mm CAUTION Operation outside the permissible bearing temperature Damage to the pump The bearing temperature of the pump set must never exceed 90 C measured on the outside of the bearing bracket NOTE After commissioning increased temperatures may occur at grease lubricated rolling element bearings due to the run...

Page 36: ...of 15 K will reduce grease life by half However bearing life may be reduced by vibrations aggressive gases humidity etc 7 2 2 2 Lubrication of bearing bushes DANGER Excessive temperatures as a result of bearing bushes running hot Explosion hazard Fire hazard Damage to the pump set Make sure the bearing bushes are properly lubricated Regularly check the bearing bushes for correct lubrication The be...

Page 37: ...down regularly Provide each bearing bush in the support column with a separate lubricating device including a lubricator Grease quality Optimum grease properties Table 11 Grease quality to DIN 51825 Soap basis NLGI grade Worked penetration at 25 C in mm 10 Drop point Lithium 2 to 3 220 295 175 C Free of resin and acid Not liable to crumble Rust preventive characteristics a b Fig 9 a Grease lubrica...

Page 38: ... auxiliary piping Risk of burns Explosion hazard Make sure that the barrier fluid or quench liquid are compatible with the fluid handled For lubrication by external fluid provide a flushing water connection which meets the following conditions Maximum flushing water temperature 40 C Minimum pressure required 2 5 bar Fit connection line with shut off valve and non return valve Control by a solenoid...

Page 39: ...ly dispose of flushing 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 Always flush the pump if it has been used for handling noxious explosive hot or other hazardous fluids 2 Always flush and clean the pump before transporting it to the workshop Provide a certificate of decontamina...

Page 40: ...ing and reassembly observe the exploded views and the general assembly drawing 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 visit www ksb com contact on the Internet DANGER Insufficient preparation of work on the pump set Risk of personal injury Properly s...

Page 41: ...03 02 and 303 03 if any with bearing bush 545 5 Undo nuts 920 12 6 Remove support column 712 01 CAUTION Damage to the shaft assembly Warping of the shaft Support the shaft assembly if the shaft is long 7 For installation depths 1900 mm 2800 mm Undo hexagon head bolts 901 03 and nuts 920 03 and carefully take support column 712 02 03 and radial bearings 303 02 and 303 03 if any with the respective ...

Page 42: ...follower 452 62 and unscrew pipe 710 01 from volute casing 102 4 Remove gland follower 452 62 gland packing 461 62 and neck ring 457 5 Undo nuts 920 02 6 Remove volute casing 102 with casing wear ring 502 7 Remove grooved pin 561 02 and take impeller 230 off the shaft 8 Remove radial bearing 303 03 with bush 545 9 Undo nuts 920 01 10 Remove support column 712 01 CAUTION Damage to the shaft assembl...

Page 43: ...new gaskets making sure that they have the same thickness as the old ones Always fit gaskets of asbestos free materials or graphite without using lubricants e g copper grease graphite paste O rings Never use O rings that have been made by cutting an O ring cord to size and gluing the ends together Packing rings Always use pre compressed packing rings CAUTION Contact of O ring with graphite or simi...

Page 44: ... shaft 7 Slide the motor shaft into sleeve 520 8 Bolt the motor to thrust and radial bearing 303 01 with hexagon head bolts 901 01 9 Apply a thin coat of grease to the bearing positions on shaft 210 10 Press ring 550 01 into the first support column 712 01 following thrust and radial bearing 303 01 11 Swiftly press bearing bushes 545 into the corresponding radial bearings 303 02 and 303 03 if any ...

Page 45: ... Washers 6 Nilos ring 7 5 2 2 Re assembling the pump set MKA NOTE If the shaft is worn at the bearing positions it may be turned upside down and installed again for continued use At first re installation in reversed position the running faces on the shaft are as new The bearing bushes have to be replaced at the same time 1 Press sleeve 520 into radial ball bearing 321 in cold condition 2 Pull shaf...

Page 46: ...ate 68 3 and sightly tighten nuts 920 12 18 Fit volute casing 102 with casing wear ring 502 19 Tighten nuts 920 02 20 Run pipe 710 01 through cover plate 68 3 with nut 920 40 disc 550 30 and gasket 400 06 and screw it into the nozzle of casing 102 21 Secure cover plate 68 3 by tightening nuts 920 12 22 Secure the pipe above the plate with another nut 920 11 with disc 550 11 and gasket 400 11 N B M...

Page 47: ...tate the rotor after the final assembly 5 Fit studs 902 01 in drive lantern 341 6 Mount the prepared shaft assembly including motor on the drive lantern 7 Tighten nuts 920 61 8 Apply a thin coat of grease to the bearing positions on the shaft 9 Swiftly press bearing bushes 545 into the corresponding radial bearings 303 02 and 303 03 if any 10 Carefully slide first support column 712 01 on the shaf...

Page 48: ...construction Refer to the name plate for all data Also specify the following data Part number and description ð Section 9 1 Page 52 Quantity of spare parts Shipping address Mode of dispatch freight mail express freight air freight 7 7 2 Recommended spare parts stock for 2 years operation to DIN 24296 Table 13 Quantity of spare parts for recommended spare parts stock Part No Description Number of p...

Page 49: ... 2 3 4 50 550 01 PTFE ring 1 1 2 2 3 4 50 457 Neck ring 1 1 2 2 3 4 50 461 60 61 Gland packing support column10 4 6 8 8 9 12 150 461 62 Gland packing discharge pipe10 2 3 4 4 6 6 100 502 Casing wear ring 2 2 2 3 3 4 50 545 Bearing bush for installation depth 1000 mm for installation depth 1900 mm for installation depth 2800 mm 1 2 3 1 2 3 1 2 3 2 4 6 2 4 6 3 6 9 30 60 90 10 For MKY only ...

Page 50: ...chase order Re adjust to duty point by means of the shut off valve in the discharge line Check whether the impeller could be turned down Density or viscosity of fluid handled higher than stated in purchase order Contact the manufacturer Gland follower over tightened or cocked Tighten gland follower correctly Motor is running on two phases only Check the electrical cable connections Replace the def...

Page 51: ...lift check valve Drain and clean the pit Rotor is out of balance shaft is warped Clean the impeller Re balance the impeller Fit a new shaft Current exceeds the value set in the motor protection switch Set the motor protection switch to the nominal value given on the name plate of the motor Excessive temperature of the fluid handled Lower the fluid temperature Aggressive fluid Use other bearing mat...

Page 52: ...MK MKA installation depth 1000 mm Table 15 List of components Part No Description Part No Description 102 Volute casing 545 Bearing bush 210 Shaft 550 01 11 Disc 230 Impeller 561 01 02 Grooved pin 303 01 Thrust and radial bearing 68 3 Cover plate 303 02 Thrust and radial bearing without vertical hole 710 01 Pipe 321 Radial ball bearing 712 01 Support column without hole 400 11 12 Gasket 801 Flange...

Page 53: ...olute casing 635 Grease cup 210 Shaft 68 3 Cover plate 230 Impeller 710 01 Pipe 303 01 Thrust and radial bearing 710 30 Pipe 303 02 Thrust and radial bearing without vertical hole 712 0113 Support column without hole 321 Radial ball bearing 731 30 31 32 Pipe union 400 11 12 Gasket 801 Flanged motor 411 11 Joint ring 81 39 Clamp 500 01 Ring 81 45 Float switch 502 Casing wear ring 901 01 Hexagon hea...

Page 54: ...escription 102 Volute casing 561 01 02 Grooved pin 230 Impeller 68 3 Cover plate 303 01 Thrust and radial bearing 710 01 21 Pipe 303 02 Thrust and radial bearing without vertical hole 712 01 0214 Support column without hole 303 03 Thrust and radial bearing with vertical hole 731 21 Pipe union 321 Radial ball bearing 801 Flanged motor 400 11 12 Gasket 900 46 Screw 411 01 11 Joint ring 901 01 03 Hex...

Page 55: ...ation depth 2800 mm lubricated by an external fluid Table 18 List of components Part No Description Part No Description 102 Volute casing 550 01 11 Disc 210 Shaft 561 01 02 Grooved pin 230 Impeller 68 3 Cover plate 303 01 Thrust and radial bearing 710 01 40 41 Pipe 303 02 Thrust and radial bearing without vertical hole 712 01 02 0315 Support column without hole 321 Radial ball bearing 731 40 41 42...

Page 56: ...9 Related Documents 56 of 64 MK Part No Description Part No Description 502 Casing wear ring 903 11 Screw plug 520 Sleeve 920 01 02 03 11 12 Nut 545 Bearing bush ...

Page 57: ...on 102 Volute casing 520 Sleeve 210 Shaft 545 Bearing bush 230 Impeller 550 60 Disc 303 01 Thrust and radial bearing 561 01 02 Grooved pin 303 02 Thrust and radial bearing without vertical hole 710 01 Pipe 303 03 Thrust and radial bearing with vertical hole 712 01 Support column with hole 321 Radial ball bearing 712 02 03 Support column without hole 341 Drive lantern 801 Flanged motor 400 60 Gaske...

Page 58: ...9 Related Documents 58 of 64 MK Part No Description Part No Description 500 01 Ring 920 01 02 60 61 62 Nut 502 Casing wear ring ...

Page 59: ... 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 EN 809 Person authorised to compile the technical file Name Function Address company Address Street No Address post or ZIP code city country The EU Declaration of Conformity was issued in on Place date 16 Name Function C...

Page 60: ...lain 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 have also been cleaned For canned motor pumps the rotor and plain bearing have been removed from the pump for cleaning In cases of leakage at the stator can the stator space has been examined for fluid leak...

Page 61: ...6 Installation 20 Installation at site 20 Intended use 8 K Key to safety symbols markings 7 M Maintenance 34 Monitoring equipment 11 N Noise characteristics 19 O Order number 6 Other applicable documents 6 P Partly completed machinery 6 Permissible forces at the pump nozzles 24 Preservation 13 32 Product description 15 R Reassembly 40 Return to supplier 13 Returning to service 32 Running noises 34...

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Page 64: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2324 81 19 EN 01317346 ...

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