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KSB Multitec A SX, Installation & Operating Manual

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Glossary

5 of 68

Multitec A SX

Glossary

Certificate of decontamination

A certificate of decontamination certifies that the
pump (set) has been properly drained to eliminate
any environmental and health hazards arising
from components in contact with the fluid
handled.

Discharge line

The line which is connected to the discharge
nozzle

Drive

Electric/hydraulic drive, diesel engine or turbine up
to max. 4000 rpm

Hydraulic system

The part of the pump in which the kinetic energy
is converted into pressure energy

Pool of pumps

Pumps which are purchased and stored
independently of their later use

Pump

Machine without drive, additional components or
accessories

Pump set

Complete pump set consisting of pump, drive,
additional components and accessories

Rotor

Fully assembled unit of all rotating parts, without
mechanical seal, rolling element bearings or plain
bearings

Suction lift line/suction head line

The line which is connected to the suction nozzle

Summary of Contents for Multitec A SX

Page 1: ...Sprinkler Pump Multitec A SX 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 manufacturer s express written consent Subject to technical modification without prior notice KSB SE Co KGaA Frankenthal 29 01 2018 ...

Page 3: ...rary Storage Disposal 13 3 1 Transport 13 3 2 Storage preservation 13 3 3 Return to supplier 14 3 4 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 18 4 7 Scope of supply 18 4 8 Dimensions and weights 19 5 Installation at Site 20 5 1 Safety regulations 20 5...

Page 4: ...k 40 7 2 3 Lubrication and lubricant change of rolling element bearings 42 7 3 Drainage disposal 44 7 4 Dismantling the pump set 44 7 4 1 General information Safety regulations 44 7 4 2 Preparing the pump set 45 7 4 3 Dismantling the bearings 45 7 4 4 Removing the shaft seal 49 7 4 5 Dismantling the hydraulic system 50 7 5 Reassembling the pump set 51 7 5 1 General information Safety regulations 5...

Page 5: ...gine or turbine up to max 4000 rpm Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Pool of pumps Pumps which are purchased and stored independently of their later use Pump Machine without drive additional components or accessories Pump set Complete pump set consisting of pump drive additional components and accessories Rotor Fully assembled unit ...

Page 6: ...d qualified specialist technical personnel ð Section 2 4 Page 9 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 Drawing of auxiliary connections Description of auxiliary connection...

Page 7: ...1 General 7 of 68 Multitec A SX Symbol Description 1 2 Step by step instructions Note Recommendations and important information on how to handle the product ...

Page 8: ... one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions 2 2 General This manual contains general installation operating and maintenance instructions that must be observed to en...

Page 9: ...ation damage Never exceed the permissible operating limits specified in the data sheet or product literature regarding pressure temperature etc Observe all safety information and instructions in this manual 2 4 Personnel qualification and training All personnel involved must be fully qualified to install operate maintain and inspect the machinery this manual refers to The responsibilities competen...

Page 10: ...consent Use only original spare parts or parts authorised by the manufacturer The use of other parts can invalidate any liability of the manufacturer for resulting damage The operator ensures that all maintenance inspection and installation work is performed by authorised qualified specialist personnel who are thoroughly familiar with the manual Only carry out work on the pump set during standstil...

Page 11: ... the pump is heated the operator of the system is responsible for observing the specified temperature classes and fluid temperature operating temperature The table below lists the temperature classes and the resulting theoretical temperature limits of the fluid handled A possible temperature rise in the shaft seal area has already been taken into account The temperature class specifies the maximum...

Page 12: ...ting limits The minimum flows indicated in ð Section 6 2 3 Page 35 refer to water and water like fluids Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures at the pump surface However if the physical properties of the fluids handled differ from those of water it is essential to check whether an additional heat build u...

Page 13: ...ifting tackle as shown Fig 1 Transporting the pump Fig 2 Transporting the complete pump set 3 2 Storage preservation If commissioning is to take place some time after delivery we recommend that the following measures be taken for pump set storage CAUTION Damage during storage due to humidity dirt or vermin Corrosion contamination of the pump set For outdoor storage cover the packed or unpacked pum...

Page 14: ...so be neutralised and anhydrous inert gas must be blown through the pump for drying purposes 4 Always complete and enclose a certificate of decontamination when returning the pump set ð Section 11 Page 65 Always indicate any safety and decontamination measures taken NOTE If required a blank certificate of decontamination can be downloaded from the KSB web site at www ksb com certificate_of_deconta...

Page 15: ...n Code Description Multitec Type series A Type of installation SX Variant SX sprinkler pump 100 Nominal discharge nozzle diameter mm 3 No of stages impeller combination 8 1 Hydraulic system 25 Material code 65 Seal code 4 3 Name plate Sprinklerpumpe Typ Fabrikations Nr VdS Anerkennungs Nr Q zul nn Laufraddurchmesser max Anlaufstrom l min 1 min Jahr H Pm kW m mm A Ident No 00 107 606 ZN 3814 D 31 M...

Page 16: ...dial discharge nozzle can be turned by 90 Horizontal vertical installation Pump casing Radially split volute casing Casing in ring section design Impeller type Closed radial impeller with multiply curved vanes Bearings Radial bearings are silicon carbide plain bearings Self aligning Plain bearing lubricated by fluid handled Fixed bearings are rolling element bearings Grease or oil lubrication Shaf...

Page 17: ...mpeller 11 via the diffuser 9 This process is repeated in all stages until the fluid has passed the last impeller 11 It then passes through the discharge casing 3 to the discharge nozzle 2 from where it leaves the pump The clearance gap 1 prevents any fluid from flowing back from the stage casing 10 into the suction range of the previous impeller If required a balance drum 12 is fitted behind the ...

Page 18: ...llowing items are included in the scope of supply Pump Drive Electric hydraulic drives Diesel engines or turbines up to max 4000 rpm Shaft coupling Flexible coupling with or without spacer Contact guard Coupling guard to EN 294 DANGER Risk of ignition by frictional sparks Risk of explosion Choose a coupling guard material that is non sparking in the event of mechanical contact see DIN EN 13463 1 I...

Page 19: ...4 Description of the Pump Set 19 of 68 Multitec A SX 4 8 Dimensions and weights For dimensions and weights refer to the general arrangement drawing outline drawing of the pump set ...

Page 20: ...lation Place of installation WARNING Installation on foundations which are unsecured and cannot support the load Personal injury and damage to property Make sure the foundation concrete is of sufficient strength min C12 15 to DIN 1045 Only place the pump set on a foundation whose concrete has set firmly Only place the duckfoot bend on horizontal and level surfaces Refer to the weight given in the ...

Page 21: ...lways insert them to the left and right of the foundation bolts 4 and in close proximity to these bolts For a bolt to bolt clearance 800 mm fit additional shims 3 halfway between the adjoining holes All shims must lie perfectly flush 3 Insert the foundation bolts 4 into the holes provided 4 Use concrete to set the foundation bolts 4 into the foundation 5 Wait until the concrete has set firmly then...

Page 22: ...he type of plant and pump However such elements must not obstruct proper drainage or hinder disassembly of the pump ü The suction lift line suction head line has been laid with a rising downward slope towards the pump ü The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump nozzles ü To prevent excessive pressure losses adapters to larger diameters have a di...

Page 23: ...ts Damage to the pump Match the cleaning operation mode and duration for flushing and pickling service to the casing and seal materials used 5 4 2 Permissible forces and moments at the pump nozzles Fx Fz Fy My Mz Mx D N Fig 7 Forces and moments at the pump nozzles Direction of forces FX horizontal parallel to the pump axis FY vertical to the pump axis FZ horizontal at a right angle to the pump axi...

Page 24: ...peratures at the coupling or bearings caused by misalignment of the coupling Explosion hazard Make sure that the coupling is correctly aligned at all times CAUTION Misalignment of pump and motor shafts Damage to pump motor and coupling Always check the coupling after the pump has been installed and connected to the piping Also check the coupling of pump sets supplied with pump and motor mounted on...

Page 25: ... After having installed the pump set and connected the piping check the coupling alignment and if required re align the pump set at the motor 5 6 1 Motor with levelling screw 1 3 2 Fig 9 Motor with levelling screw 1 Hexagon head bolt 2 Levelling screw 3 Lock nut ü The coupling guard and step guard if any have been removed 1 Check the coupling alignment 2 Unscrew the hexagon head bolts 1 at the mot...

Page 26: ...d bolts at the motor 3 Insert shims underneath the motor feet until the difference in shaft centreline height has been compensated 4 Re tighten the hexagon head bolts 5 Check that the coupling and shaft can easily be rotated by hand WARNING Unprotected rotating coupling Risk of injury by rotating shafts Always operate the pump set with a coupling guard If the customer specifically requests not to ...

Page 27: ...G Incorrect connection to the mains Damage to the mains network short circuit Observe the technical specifications of the local energy supply companies NOTE It is recommended to fit a motor protection device However this device must not trip the pump set it must serve as an indicator only 5 7 1 Setting the time relay CAUTION Switchover between star and delta on three phase motors with star delta s...

Page 28: ...t your hands or any other objects into the pump Check that the inside of the pump is free from any foreign objects CAUTION Incorrect direction of rotation with non reversible mechanical seal Damage to the mechanical seal and leakage Separate the pump from the motor to check the direction of rotation CAUTION Motor and pump running in the wrong direction of rotation Damage to the pump Refer to the a...

Page 29: ...th the regulations The pump set has been installed and aligned in accordance with the tolerances specified The pipelines have been connected without warping the pump nozzles 6 1 2 Filling in lubricants Grease lubricated bearings Grease lubricated bearings have been packed with grease at the factory Oil lubricated bearings Fill the bearing bracket with lubricating oil Oil quality see ð Section 7 2 ...

Page 30: ...hes the connection elbow of the constant level oiler 4 4 Completely fill the reservoir of the constant level oiler 1 5 Snap the constant level oiler 1 back into its operating position 6 Fit the vent plug 2 again 7 After approximately 5 minutes check the oil level in the glass reservoir of constant level oiler 1 The oil reservoir must be properly filled at all times to provide an optimum oil level ...

Page 31: ...e coupling guard and footboard if any 5 Check the distance between the coupling and coupling guard The coupling and coupling guard must not come into contact 6 1 5 Start up DANGER The permissible pressure and temperature limits will be exceeded if the pump is operated with the suction and discharge lines closed Explosion hazard Leakage of hot or toxic fluids Never operate the pump with the shut of...

Page 32: ...ve installed must open steadily when the operating speed has been reached without abnormal noise vibrations or increased power consumption of the pump set 5 After the duty point has been reached check motor input power and bearing temperature 6 After the operating temperature has been reached and or in the event of leakage switch off the pump set and re tighten the bolts between lantern and casing...

Page 33: ... shaft seal Depending on the type of installation the pump set requires sufficient after run time with the heat source switched off until the fluid handled has cooled down ü The shut off element in the suction line is and remains open 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...

Page 34: ...bserve the specified limits for permissible ambient temperatures 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 specified in the manufacturer s product literature CAUTION Re starting while motor is still running down Damage to the pump set Do not re start the pump set...

Page 35: ...ature 35 of Qopt 4 See hydraulic characteristic curves A temporary minimum flow rate of 25 of QOpt 4 has been defined This temporary flow rate shall be limited to one hour s uninterrupted operation and approx 200 hours year The calculation formula below can be used to check if an additional heat build up could lead to a dangerous temperature increase at the pump surface Table 11 Key Symbol Descrip...

Page 36: ...ained completely through the drain plugs provided on the stage casings optional If this is not possible we recommend to proceed as described in the following section The pump set is removed from the pipe and stored ü The pump has been properly drained and the safety instructions for dismantling the pump have been observed 1 Fill the pump with a water repellent preservative e g RUSTELO DEWATERING 9...

Page 37: ... service ð Section 7 Page 38 WARNING Failure to re install or re activate protective devices Risk of personal injury from moving parts or escaping fluid As soon as the work is complete re install and or re activate any safety relevant and protective devices NOTE If the pump has been out of service for more than one year replace all elastomer seals ...

Page 38: ...ntentionally Always make sure the electrical connections are disconnected before carrying out work on the pump set WARNING Fluids posing a health hazard and or hot fluids Risk of personal injury Observe all relevant laws When draining the fluid take appropriate measures to protect persons and the environment Decontaminate pumps which handle fluids posing a health hazard A regular maintenance sched...

Page 39: ...hazard Fire hazard Damage to the pump set Regularly check the lubricant level Regularly check the rolling element bearings for running noises CAUTION Increased wear due to dry running Damage to the pump set Never operate the pump set without liquid fill Never close the shut off element in the suction line and or supply line during pump operation CAUTION Impermissibly high temperature of fluid hand...

Page 40: ... rolling element bearings due to the running in process The final bearing temperature is only reached after a certain period of operation up to 48 hours depending on the conditions Please note the following when checking the bearing temperature Manual temperature checks are not sufficient If the bearing temperature exceeds 100 C during start up switch off the pump and check the following Check the...

Page 41: ...e drum 59 4 0 8 NOTE If the clearances given are exceeded by more than 1 mm referring to the diameter replace the affected components or restore the original clearance by means of a casing wear ring Contact KSB 7 2 2 3 Cleaning filters CAUTION Insufficient inlet pressure due to clogged filter in the suction line Damage to the pump Monitor contamination of filter with suitable means e g differentia...

Page 42: ...ating hours 70 C 80 C After 300 operating hours Every 4200 operating hours 80 C 90 C After 300 operating hours Every 2000 operating hours 7 2 3 1 2 Oil quality Quality ISO VG 46 7 2 3 1 3 Oil quantity Table 14 Oil quantity Oil quantity approx 6 ml Drive end Non drive end 880 920 7 2 3 1 4 Changing the oil WARNING Lubricants posing a health hazard and or hot lubricants Hazard to persons and the env...

Page 43: ...ce the bearing housing 3 has been drained re insert and re tighten the screw plug 5 4 Re fill with oil ð Section 6 1 2 Page 29 7 2 3 2 Grease lubrication The bearings are supplied packed with high quality lithium soap grease 7 2 3 2 1 Intervals Size Rotational speed in rpm 1800 2950 3550 100 9000 h 5700 h 3900 h NOTE If re lubrication intervals are short we recommend that the grease be completely ...

Page 44: ... fluids Hazard to persons and the environment Collect and properly dispose of flushing liquid and any residues of the fluid handled Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard Horizontal pumps Remove the drain plugs in the stage casing optional suction casing if any and discharge casing 1 Use a crane to bring...

Page 45: ...es booklet or on the Internet at www ksb com contact DANGER Insufficient preparation of work on the pump set Risk of injury Properly shut down the pump set ð Section 6 1 7 Page 33 Close the shut off elements in suction and discharge line Drain the pump and release the pump pressure Close any auxiliary connections Allow the pump set to cool down to ambient temperature NOTE After a prolonged period ...

Page 46: ...7 4 3 2 Dismantling the rolling element bearing drive end The drive end rolling element bearing are removed without dismantling the plain bearing located at the opposite end of the shaft Removing the coupling half The coupling half must be removed before the drive end rolling element bearing can be dismantled 1 Undo the grub screw in the coupling hub 2 Pull off the coupling half 3 Pull out key 940...

Page 47: ...Oil lubrication of lip seal 903 14 525 1 421 1 412 10 412 6 320 1 360 2 520 1 421 2 520 4 500 1 412 11 940 3 920 6 914 4 550 10 412 12 551 1 Fig 16 Oil lubrication of lip seal ü For oil lubrication The oil has been drained 1 Undo socket head cap screws 914 4 and remove them together with disc 550 10 and O ring 412 12 2 Remove bearing cover 360 2 3 Pull off sleeve 520 4 with ring 500 1 tolerance ri...

Page 48: ...2 Removing the rolling element bearing NOTE When dismantling keywayed nut 920 6 mark all relevant positions such as sequence and orientation of the contact face to ensure identical reassembly 1 Undo nut 920 2 with lockwasher 931 or nuts 920 6 holding onto shaft 210 2 Pull off sleeve 520 1 with rolling element bearing s 320 1 The shaft is centered in the sleeve without locking device CAUTION Incorr...

Page 49: ... seal cover 471 until the spring of the mechanical seal is relaxed 4 Undo nut 920 1 and remove bearing housing 350 1 5 Pull off spacer sleeve 525 1 6 Remove seal cover 471 1 with the mating ring and gasket 400 1 7 Remove primary ring not in case of bellows type seals 8 Remove key 940 2 9 Pull off shaft sleeve 523 1 with the rotating assembly of mechanical seal 433 1 Two holes are provided in the s...

Page 50: ...g the discharge casing ü Rolling element bearings 320 1 have been removed ü The shaft seal has been removed ü The hydraulic system is in vertical position if possible 1 Remove the plain bearing 2 Place the pump in a vertical position with the bare shaft end pointing upwards 3 Support the opposite pump end suction side 4 Start dismantling from the top discharge side 5 Number and match mark the casi...

Page 51: ... 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 glued together from material sold by the metre Always use new O rings Assembly adhesives For gaskets avoid the use of assembly adhesives if possible Should assembly adhesives be required after all use a commercially available con...

Page 52: ...ge numbers applied during dismantling On the 9 2 10 2 11 1 and 12 1 hydraulics impeller 230 3 is the last impeller 9 Fit key 940 2 balance drum 59 4 or spacer sleeve 525 4 and disc 550 3 on the shaft 10 Fit discharge casing 107 with O ring 412 1 foot if any drum bush 540 1 if any and four studs 902 1 11 Insert tie bolts 905 with discs 550 4 and nuts 920 4 12 Slightly tighten tie bolts 905 1 2 3 4 ...

Page 53: ...amage ü The notes and steps stated in ð Section 7 5 1 Page 51 to ð Section 7 5 2 Page 51 have been observed carried out ü The bearing assembly and the individual parts of the mechanical seal are kept in a clean and level assembly area ü All disassembled parts have been cleaned and checked for wear ü Any damaged or worn parts have been replaced by original spare parts ü The sealing surfaces have be...

Page 54: ...assembled bearing as well as the individual parts are kept in a clean and level assembly area ü All disassembled parts have been cleaned and checked for wear ü Any damaged or worn parts have been replaced by original spare parts ü The sealing surfaces have been cleaned 1 Clean the packing chamber 2 Slip the pre stressed packing ring onto shaft protecting sleeve 524 and press it home with the help ...

Page 55: ... Rolling element bearing sizes grease lubricated bearings Size Fixed bearing 320 1 100 2 x 7312 BUA Fig 26 Oil lubricated bearings Table 18 Rolling element bearing sizes oil lubricated bearings Size Fixed bearing 320 1 100 2 x 7312 BUA Fixed bearing The fixed bearing is located at the drive end The pump is fitted with angular contact ball bearings in X arrangement Spacer discs 551 1 provide axial ...

Page 56: ...he pre assembled bearing assembly into bearing housing 350 1 Lift the shaft slightly if necessary 6 Secure the rolling element bearings with shaft nuts 920 2 6 7 On models with two shaft nuts firmly tighten the inner shaft nut first then slightly loosen it again before locking it with the outer shaft nut 7 Bend lockwasher 931 if any to engage it in the groove provided Final check After installatio...

Page 57: ...e shaft nut without a torque wrench If there is no suitable torque wrench available for tightening the shaft nuts proceed as follows depending on the pump version Nut with lockwasher drive end 1 Tighten the shaft nut firmly 2 Loosen the shaft nut again 3 Tighten the shaft nut moderately 4 Bend back the lockwasher Nut with locknut drive end 1 Tighten the first shaft nut firmly 2 Loosen the first sh...

Page 58: ...al complete 2 3 4 5 6 7 90 46111 Gland packing set 4 6 8 8 9 12 150 50212 Casing wear ring set 2 2 2 3 3 4 50 523 Shaft sleeve 2 2 2 3 3 4 50 52411 Shaft protecting sleeve 2 2 2 3 3 4 50 525 Spacer sleeve 2 2 2 3 3 4 50 550 113 Disc set 2 2 2 3 3 4 50 99 20 114 Plain bearing repair kit incl parts No 381 412 2 3 529 550 7 561 1 901 2 931 1 1 1 2 2 3 4 50 99 20 2 Balance drum repair kit incl parts N...

Page 59: ... Multitec A SX Part No Description Number of pumps including stand by pumps 2 3 4 5 6 and 7 8 and 9 10 and more 42316 Labyrinth ring 2 3 4 5 6 7 90 99 9 2 Set of sealing elements incl parts No 411 10 11 412 6 10 11 12 4 8 8 8 9 12 150 ...

Page 60: ...eal X X X Wrong direction of rotation Interchange two phases of the power cable X Speed too low18 Increase speed 18 X X X X Wear of internal parts Replace worn parts by new ones X X Pump back pressure lower than specified in purchase order Re adjust to duty point X X Density or viscosity of fluid handled higher than stated in purchase order 18 X X X Gland follower too tight or askew Correct Increa...

Page 61: ... arrangement drawing X X Motor running on two phases only Replace the defective fuse Check the electric cable connections X X X Rotor out of balance Clean the impeller Re balance the impeller X X X Defective bearing Fit new bearing X X X Insufficient flow rate Increase minimum flow rate X Incorrect inflow of circulation liquid Increase the free cross section X X X X In case of parallel operation c...

Page 62: ...8 Disc 182 1 Foot 551 1 Spacer disc 210 Shaft 561 1 2 Half round head grooved pin 230 1 Impeller 565 Rivet 231 Suction impeller 59 4 Balance drum 320 1 Rolling element bearing 636 Lubricating nipple 350 1 Bearing housing 710 1 2 Pipe 360 1 Bearing cover 731 1 2 3 4 16 18 Pipe union 381 Bearing cartridge 81 92 Cover plate 400 1 Gasket 900 4 Screw 411 1 2 3 4 7 8 13 24 25 Joint ring 901 1 2 Hexagon ...

Page 63: ...Description Part No Description 461 Gland packing 920 1 2 3 4 5 Nut 471 1 Seal cover 931 Lockwasher 502 120 Casing wear ring 932 2 Circlip 507 Thrower 940 1 2 3 Key 520 1 Sleeve 970 1 Plate 523 1 Shaft sleeve19 20 Except for Multitec 65 material code 12 ...

Page 64: ...irectives 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 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 21 Nam...

Page 65: ...carefully drained cleaned and decontaminated inside and outside prior to dispatch placing at your disposal On seal less pumps the rotor has been removed from the pump for cleaning No special safety precautions are required for further handling The following safety precautions are required for flushing fluids fluid residues and disposal We confirm that the above data and information are correct and...

Page 66: ... quality 43 I Impeller type 16 Installation Installation on foundation 21 Installation at site 20 Intended use 9 M Maintenance repair 38 Mechanical seal 32 Misuse 9 Monitoring equipment 12 N Noise characteristics 18 O Oil lubrication Intervals 42 Oil quality 42 Operating limits 9 34 Order number 6 Other applicable documents 6 P Partly completed machinery 6 Permissible forces at the pump nozzles 24...

Page 67: ......

Page 68: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1777 81 03 EN ...

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