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KSB Vitastage 10/3/75 2 B T, Installation & Operating Manual

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Summary of Contents for Vitastage 10/3/75 2 B T

Page 1: ...Hygienic Pump Vitastage Installation Operating Manual ...

Page 2: ...eserved 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 KSB s express written consent Subject to technical modification without prior notice KSB Aktiengesellschaft Frankenthal 07 04 2011 ...

Page 3: ...ormation for maintenance inspection and installation work 10 2 9 Unauthorised modes of operation 10 3 Transport Temporary Storage Disposal 11 3 1 Transport 11 3 2 Storage preservation 11 3 3 Return to supplier 12 3 4 Disposal 12 4 Description of the Pump Set 13 4 1 General description 13 4 2 Designation 13 4 3 Name plate 14 4 4 Design details 14 4 5 Configuration and function 15 4 6 Noise characte...

Page 4: ...32 7 6 Spare parts stock 33 8 Trouble shooting 35 9 Related Documents 37 9 1 General assembly drawing with list of components Vitastage 05 1 05 8 horizontal installation 37 9 2 General assembly drawing with list of components Vitastage 05 1 05 8 vertical installation 38 9 3 General assembly drawing with list of components Vitastage 10 1 3 20 1 3 30 1 3 horizontal installation 39 9 4 General assemb...

Page 5: ...arge line The line which is connected to the discharge nozzle Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Pump Machine without drive additional components or accessories Pump set Complete pump set consisting of pump drive additional components and accessories Steaming in place SIP The pump is sterilised using steam while it is not running out...

Page 6: ...l 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 connections Hydraulic characteristic curve Characteri...

Page 7: ...Symbol Description 1 2 Step by step instructions Note Recommendations and important information on how to handle the product 1 General Vitastage 7 of 44 ...

Page 8: ...ge 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 ensure safe pump operation and prevent personal injury and damage to property The safety information in all sections of this manual must be complied with This manual must...

Page 9: ...ntain and inspect the machinery this manual refers to The responsibilities competence and supervision of all personnel involved in installation operation maintenance and inspection must be clearly defined by the operator Deficits in knowledge must be rectified by sufficiently trained specialist personnel training and instructing the personnel who will carry out the respective tasks If required the...

Page 10: ...uthorised 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 standstill of the pump The pump casing must have cooled d...

Page 11: ...motor shroud during transport Damage to the pump set Remove motor shroud if included in scope of supply for transport To transport the pump pump set suspend it from the lifting tackle as shown below Table 4 Transporting the pump set Without motor foot Motor foot Ball feet Vertical model 3 2 Storage preservation If commissioning is to take place some time after delivery we recommend that the follow...

Page 12: ...idity or which might ignite when coming into contact with oxygen the pump set must also 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 Section 11 Page 42 Always indicate any safety and decontamination measures taken NOTE If required a blank certificate of decontamin...

Page 13: ...zzle For sizes 05 10 20 and 30 All pumps of this type series are fitted with standardised mechanical seals to EN 12756 This ensures reliable operation and interchangeability When different standardised mechanical seals are used the axial length of the seal has to be verified Type and materials of the mechanical seal are specifically selected to match the nature and composition of the fluid to be h...

Page 14: ...me plate 1 Type series size and version 2 KSB order number 3 Manufacturer s No 4 Flow rate 5 Head 6 Speed 7 Year of construction 4 4 Design details High pressure centrifugal pump Horizontal vertical installation Multistage Pump casing Casing in ring section design Impeller type Closed radial impeller with multiply curved vanes Shaft seal Standardised mechanical seal to EN 12756 Drive Three phase m...

Page 15: ... is routed to the next impeller 11 via the diffuser 4 This process is repeated in all stages until the fluid has passed the last impeller 5 The fluid then passes through the discharge casing 6 to the discharge nozzle 9 where it leaves the pump The drive shaft enters the casing at the rear of the last impeller 11 The motor 7 is bolted to the casing The shaft passage through the casing is sealed wit...

Page 16: ... 7 83 1 VS 20 2 7 5 79 4 84 3 VS 20 3 11 79 5 84 VS 30 1 5 5 79 8 85 VS 30 2 11 80 85 7 VS 30 3 15 81 2 86 3 4 7 Scope of supply Depending on the model the following items are included in the scope of supply Pump Electric drive Installation parts 4 8 Dimensions and weights For dimensions and weights refer to the general arrangement drawing outline drawing of the pump set 4 Description of the Pump ...

Page 17: ...ons stated in the outline drawing general arrangement drawing 5 3 Piping 5 3 1 Connecting the piping DANGER Excessive loads acting on the pump nozzles Danger to life from leakage of hot toxic corrosive or flammable fluids Do not use the pump as an anchorage point for the piping Anchor the pipelines in close proximity to the pump and connect them without transmitting any stresses or strains Take ap...

Page 18: ... install a filter Observe the instructions in Section 7 2 2 1 Page 29 3 If required install a filter in the piping see illustration Filter in the piping 1 2 Fig 3 Filter in the piping 1 Differential pressure gauge 2 Filter NOTE Use a filter with laid in wire mesh mesh width 0 5 mm wire diameter 0 25 mm of corrosion resistant material Use a filter with a filter area three times the cross section of...

Page 19: ...d in EN 50081 always observe the EMC information provided by the inverter manufacturer If the inverter manufacturer recommends a shielded power cable make sure to use a pump set with a shielded power cable The pump set generally meets the interference immunity requirements to EN 50082 For monitoring the sensors installed the operator must ensure sufficient interference immunity by appropriately se...

Page 20: ... Change the motor s direction of rotation to match that of the pump 2 Observe the manufacturer s product literature supplied with the motor 5 6 3 Earthing DANGER Electrostatic charging Explosion hazard Fire hazard Damage to the pump set Connect the PE conductor to the earthing terminal provided 5 7 Checking the direction of rotation DANGER Temperature increase resulting from contact between rotati...

Page 21: ...ired 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 motor 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 direction of rotation on the pump...

Page 22: ...lement in the suction line and or supply line during pump operation 1 Vent the pump and suction line and prime them with the fluid to be handled 2 Fully open the shut off element in the suction line NOTE For design inherent reasons a remaining gas volume in the hydraulic system cannot be excluded after the pump has been primed for commissioning start up However once the motor is started up the pum...

Page 23: ...t it to comply with the duty point 6 When the operating temperature has been reached and or in the event of leakage check the connection of the individual stage casings with the pump casing and re tighten if necessary 6 1 4 Checking the shaft seal The mechanical seal only leaks slightly or invisibly as vapour during operation Mechanical seals are maintenance free 6 1 5 Shutdown CAUTION Heat build ...

Page 24: ...ring operation Table 9 Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 C Minimum See data sheet 6 2 2 Frequency of starts The start up frequency is usually determined by the maximum temperature increase of the motor This largely depends on the power reserves of the motor in steady state operation and on the starting conditions DOL star delta moments of inertia etc...

Page 25: ...nced by the viscosity of the fluid handled CAUTION The fluid handled has a higher viscosity than permitted Risk of motor overload Observe the viscosity limits for the fluid handled given in the data sheet Make sure the motor has sufficient power reserves 6 2 6 Abrasive fluids Do not exceed the maximum permissible solids content specified in the data sheet When the pump handles fluids containing ab...

Page 26: ...ally flush with cold water for 10 to 15 minutes until all cleaning agents have been removed 6 2 8 Steaming in place SIP WARNING Pump casing takes on the same temperature as the sterilisation fluid Risk of burns Fit additional protective devices Observe the general safety rules and regulations for steam applications CAUTION Elastomers do not have sufficient resistance Damage to the pump Effect clea...

Page 27: ...d approved if required to protect them against corrosion Observe the additional instructions Section 3 2 Page 11 If the pump set is to be stored temporarily only preserve the wetted components made of low alloy materials Commercially available preservatives food approved if required can be used for this purpose Observe the manufacturer s instructions for application removal Observe any additional ...

Page 28: ...ing a health hazard 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 handling fluids posing a health hazard A regular maintenance schedule will help avoid expensive repairs and contribute to trouble free reliable operation of the pump set with a minimum of maintenance expendi...

Page 29: ... are ready for operation start them up once a week 7 2 2 Inspection work DANGER Excessive temperatures caused by friction impact or frictional sparks Explosion hazard Fire hazard Damage to the pump set Regularly check the cover plates plastic components and other guards of rotating parts for deformation and sufficient distance from rotating parts 7 2 2 1 Cleaning filters CAUTION Insufficient inlet...

Page 30: ...vant motor manufacturer For dismantling and reassembly observe the exploded views and the general assembly drawing NOTE All maintenance service and installation work can be carried out by KSB Service Find your contact in the attached Addresses 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 Sec...

Page 31: ...screws 39 separate pump casing 1 from flange 49 and remove joint ring 31 13 Remove mating ring of mechanical seal 13 from pump casing 1 14 Dismantle the motor feet if necessary Undo nuts 53 and bolts 52 and remove feet 51 7 4 4 2 Sizes 05 1 05 8 The dismantling procedure is the same for all sizes It only differs in the number of stages to be dismantled 1 Undo and remove cap nuts 38 incl washers 37...

Page 32: ...ffected in reverse order to dismantling 1 Carefully insert mating ring of mechanical seal 13 into pump casing 1 2 Place joint ring 31 into pump casing 1 and connect pump casing to flange 49 by tightening screws 39 3 Pull splash guard 27 onto motor shaft 50 4 Carefully pull pump casing 1 with flange 49 onto motor shaft 50 and bolt to motor 55 using bolts 40 and washers 42 5 Slide primary ring of me...

Page 33: ...eassembled 9 After the last impeller 5 has been fitted screw on and tighten impeller nut 14 10 Fit grub screws 36 11 Fit joint ring 30 and O ring 16 of the last stage and suction cover 7 vertically installed pumps foot with suction cover 7 12 Fit washers 37 and lock suction cover 7 in position with cap nuts 38 13 Pumps with motor shroud Fasten motor shroud 44 to adapter 43 with bolts 45 14 Reassem...

Page 34: ...uantity of spare parts for recommended spare parts stock Part No Description Number of pumps including stand by pumps 2 3 4 5 6 and 7 8 and 9 10 and more 13 Mechanical seal 2 3 4 5 6 7 90 16 O ring casing set per pump stage 4 8 8 8 9 12 150 7 Servicing Maintenance 34 of 44 Vitastage ...

Page 35: ...ed observe motor rating X X X X Impeller clogged by foreign matter on pumps with closed impeller Remove foreign matter clean impeller if required X X X Excessive wear of mechanical seal Replace complete mechanical seal X X X Excessive wear of impeller or clogged impeller Replace impeller or remove foreign matter X X X Fluid viscosity higher than expected Verify suitability of pump selection X X Ex...

Page 36: ...tains solids Select type and material of mechanical seal as required X Excessive fluid temperature or thermal shock Observe permissible temperature limits increase fluid temperature slowly and prevent abrupt temperature changes X Impeller out of balance Foreign matter in the impeller replace impeller if required X Flow rate too low Open discharge side control valve further to reduce flow losses in...

Page 37: ...n cover AISI 316L 13 1 Mechanical seal 14 1 Nut self locking AISI 316 16 16 O ring EPDM7 24 1 Key AISI 316L 27 1 Splash guard NBR 30 16 Joint ring AISI 316 36 4 Pin AISI 304 37 4 Washer AISI 304 38 4 Cap nut AISI 304 40 4 Hexagon head bolt AISI 304 42 4 Washer AISI 304 438 1 Shroud adapter AISI 304 448 1 Motor shroud AISI 304 458 3 Pan head screw AISI 304 55 1 Motor 5 Between 0 and 7 depending on ...

Page 38: ...ler 2nd stage AISI 316 7 1 Suction cover foot AISI 316L 13 1 Mechanical seal 14 1 Nut self locking AISI 316 16 110 O ring EPDM11 24 1 Key AISI 316L 27 1 Splash guard NBR 28 1 2nd key AISI 316L 30 110 Joint ring AISI 316 36 4 Pin AISI 304 37 4 Washer AISI 304 38 4 Cap nut AISI 304 40 4 Hexagon head bolt AISI 304 42 4 Washer AISI 304 55 1 Motor 9 Between 0 and 7 depending on number of stages 10 Betw...

Page 39: ...ocking AISI 316 16 313 O ring EPDM14 24 313 Key AISI 316L 27 1 Splash guard NBR 30 213 Joint ring AISI 316 31 1 Joint ring NBR 36 6 Pin AISI 304 37 6 Washer AISI 304 38 6 Cap nut AISI 304 39 3 Socket head cap screw AISI 304 40 4 Hexagon head bolt AISI 304 42 4 Washer AISI 304 49 1 Flange AISI 304 50 1 Motor shaft AISI 316 51 2 Foot AISI 304 52 4 Hexagon head bolt AISI 304 53 4 Hexagon nut AISI 304...

Page 40: ...r foot AISI 316L 13 1 Mechanical seal 14 1 Nut self locking AISI 316 16 316 O ring EPDM17 24 316 Key AISI 316L 27 1 Splash guard NBR 30 216 Joint ring AISI 316 31 1 Joint ring NBR 36 6 Pin AISI 304 37 6 Washer AISI 304 38 6 Cap nut AISI 304 39 3 Socket head cap screw AISI 304 40 4 Hexagon head bolt AISI 304 42 4 Washer AISI 304 49 1 Flange AISI 304 55 1 Motor 15 Between 0 and 2 depending on number...

Page 41: ...rective 2006 42 EC Regulation 1935 2004 EC on Materials and Articles Intended to Come into Contact with Food The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 1 A1 ISO 12100 2 A1 ISO 14121 1 EN 809 A1 EN 13951 Frankenthal 29 December 2009 Daniel Wetter Product Manager Life Science Applications Responsible for compiling the technical do...

Page 42: ... 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 complete and that dispatch is effected in accordance w...

Page 43: ...8 Interference immunity 19 M Mechanical seal 23 Misuse 9 N Name plate 14 Noise characteristics 15 O Operating limits 8 24 Order number 6 Ordering spare parts 33 Other applicable documents 6 P Partly completed machinery 6 Permissible forces at the pump nozzles 18 Piping 17 Preservation 12 27 Pump casing 14 R Reassembly 30 32 Return to supplier 12 Returning to service 27 S Safety 8 Safety awareness ...

Page 44: ...KSB Aktiengesellschaft 67225 Frankenthal Johann Klein Str 9 67227 Frankenthal Germany Tel 49 6233 86 0 Fax 49 6233 86 3401 www ksb com 1969 85 EN ...

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