KSB Vitastage Installation & Operating Manual Download Page 1

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Hygienic Pump

Vitastage

Installation/Operating Manual

Summary of Contents for Vitastage

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

Page 2: ...ents 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 15 12 2017 ...

Page 3: ...Disposal 13 4 Description of the Pump Set 14 4 1 General description 14 4 2 Designation 14 4 3 Name plate 15 4 4 Design details 15 4 5 Configuration and function 16 4 6 Noise characteristics 16 4 7 Scope of supply 17 4 8 Dimensions and weights 17 5 Installation at Site 18 5 1 Safety regulations 18 5 2 Checks to be carried out prior to installation 18 5 3 Piping 18 5 3 1 Connecting the piping 18 5 ...

Page 4: ...nformation Safety regulations 32 7 4 2 Preparing the pump set 33 7 4 3 Removing the complete pump set from the piping 33 7 4 4 Dismantling the pump 33 7 5 Reassembling the pump set 34 7 5 1 General information Safety regulations 34 7 5 2 Reassembling the pump 34 7 6 Spare parts stock 35 7 6 1 Ordering spare parts 35 7 6 2 Recommended spare parts stock for 2 years operation to DIN 24296 35 8 Troubl...

Page 5: ... be dismantled Discharge line The pipeline which is connected to the discharge nozzle Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Noise characteristics The noise characteristics are indicated as surface sound pressure level in dB A Pump Machine without drive additional components or accessories Pump set Complete pump set consisting of pump dr...

Page 6: ... 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 weights Drawing of auxiliary connections Description of auxiliary connections Hydraulic characteristic curve Characteristi...

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

Page 8: ...achine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions 2 2 General This operating manual contains general installation operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property The safety information in all sections of this manual must be ...

Page 9: ... install operate maintain and inspect the machinery this manual refers to The responsibilities competence and supervision of all personnel involved in transport installation operation maintenance and inspection must be clearly defined by the operator Deficits in knowledge must be rectified by means of training and instruction provided by sufficiently trained specialist personnel If required the op...

Page 10: ...f other parts can invalidate any liability of the manufacturer for resulting damage The operator ensures that maintenance inspection and installation 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 Only perform work on the pump set when it has been disconnected from the power sup...

Page 11: ...ttach the suspension arrangement to the free shaft end or the motor eyebolt Give due attention to the weight data and the centre of gravity Observe the applicable local health and safety regulations Use suitable permitted lifting accessories e g self tightening lifting tongs CAUTION Deformation of motor shroud during transport Damage to the pump set Remove motor shroud if included in scope of supp...

Page 12: ...ied by our factory duly prepared for storage For storing a pump set which has already been operated the shutdown measures must be adhered to ð Section 6 3 1 Page 28 3 4 Return to supplier 1 Prior to returning the product to the supplier flush and clean it particularly if it has been used in noxious explosive hot or other hazardous fluids 2 If the product has been used in fluids whose residues coul...

Page 13: ...luid 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 r...

Page 14: ...rge nozzle 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 verify the axial length of the seal Type and material of the mechanical seal are specifically selected to match the nature and composition of the fluid to be handled NOTE Before using the pump...

Page 15: ... Manufacturer s No 4 Flow rate 5 Head 6 Speed 7 Year of construction 4 4 Design details Design Standard design with materials to Regulation EC No 1935 2004 Design High pressure centrifugal pump Ring section design Multistage Installation Horizontal installation vertical installation Impeller type Closed radial impeller with multiply curved vanes Shaft seal Standardised mechanical seal to EN 12756 ...

Page 16: ...ng 3 the kinetic energy of the fluid is converted into pressure energy The fluid is pumped to the next impeller via the diffuser 4 This process is repeated in all stages until the fluid has passed the last impeller 5 The fluid is then pumped 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 mo...

Page 17: ...1 74 1 VS 05 6 5 5 73 74 6 VS 05 7 5 5 75 2 79 1 VS 05 8 5 5 76 5 79 4 4 7 Scope of supply Depending on the model the following items are included in the scope of supply Pump Electric motor Installation parts 4 8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing outline drawing of the pump pump set ...

Page 18: ...el 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 arrangement drawing 5 3 Piping 5 3 1 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from leakage of hot toxic corrosive or flammable fluids Do not use the pump as...

Page 19: ...the pump and connected without transmitting any stresses or strains 1 Thoroughly clean flush and blow through all vessels pipelines and connections especially of new installations 2 Before installing 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 Remove any impurities...

Page 20: ...ter check the following details Data provided by the manufacturer Electrical data of the pump set particularly the rated current Only voltage source inverters VSI with pulse width modulation PWM and carrier frequencies between 1 and 16 kHz are suitable Setting Observe the following instructions for setting a frequency inverter Set the current limit to max 1 2 times the rated current The rated curr...

Page 21: ...ave the electrical connections installed by a trained and qualified electrician Observe regulations IEC 60364 WARNING Incorrect connection to the mains Damage to the mains network short circuit Observe the technical specifications of the local energy supply companies 1 Check the available mains voltage against the data on the name plate 2 Select an appropriate start up method NOTE A motor protecti...

Page 22: ...e pump 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 Drive and pump running in the wrong direction of rotation Damage to the pump Refer to the arrow indicating the direction of rotation on the pump Check the direction of rotation If required check the ...

Page 23: ...ming and venting the pump 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 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 some...

Page 24: ...against open discharge line Motor overload Make sure the motor has sufficient power reserves Use a soft starter Use speed control 1 Fully open the shut off element in the suction head suction lift line 2 Close or slightly open the shut off element in the discharge line 3 If a mechanical seal with quench is used make sure that the quench liquid circulates properly 4 Start up the motor 5 Immediately...

Page 25: ...nd observed For prolonged shutdown periods 1 Close the shut off element in the suction line CAUTION Risk of freezing during prolonged pump shutdown periods Damage to the pump Drain the pump and the 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 Hot fluids es...

Page 26: ...o the pump Effect cleaning sterilisation only if the elastomer components used in the pump e g O rings mechanical seals are made of EPDM or other approved materials Conditions CIP may be effected with the pump running or with the pump stopped Recommended flow velocity between 2 5 and 3 m s Cleaning agent cleaning process When performing CIP in the system the pump set is installed in comply with th...

Page 27: ...ing using superheated steam only during standstill of the pump set Conditions Only effect SIP during standstill of the pump set Limits Table 12 SIP temperature requirements Elastomer Saturated steam Chemical EPDM 121 C 82 C FPM FKM 149 C 82 C 6 2 5 Fluid handled 6 2 5 1 Flow rate Table 13 Flow rate Temperature range t Minimum flow rate Maximum flow rate 0 to 70 15 of Qopt 3 See hydraulic character...

Page 28: ...e hydraulic system and shaft seal are to be expected In this case reduce the commonly recommended inspection intervals 6 3 Shutdown storage preservation 6 3 1 Measures to be taken for shutdown The pump set remains installed ü Sufficient fluid is supplied for the operation check run of the pump 1 Start up the pump set regularly between once a month and once every three months for approximately five...

Page 29: ...ning to service For returning the equipment to service observe the sections on commissioning start up ð Section 6 1 Page 23 and the operating limits ð Section 6 2 Page 25 In addition carry out all servicing maintenance operations before returning the pump set to service ð Section 7 Page 30 WARNING Failure to re install or re activate protective devices Risk of injury from moving parts or escaping ...

Page 30: ...WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents Ensure that the pump set cannot be started unintentionally Always make sure the electrical connections are disconnected before carrying out work on the pump set WARNING Fluids handled consumables and supplies which are hot and or pose a health hazard Risk of injury Observe all relevant laws When d...

Page 31: ...ng pump operation CAUTION Impermissibly high temperature of fluid handled 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 25 While the pump is in operation observe and check the following The pump must run quietly and free from...

Page 32: ...tted 2 Always flush the pump if it has been used for handling harmful explosive and hot fluids or other fluids posing a risk Always flush and clean the pump before transporting it to the workshop Provide a certificate of decontamination for the pump 7 4 Dismantling the pump set 7 4 1 General information Safety regulations WARNING Unqualified personnel performing work on the pump set Risk of injury...

Page 33: ... all electrical connections from the power supply and secure against unintentional start up 1 De energise the pump set and secure it against unintentional start up 7 4 3 Removing the complete pump set from the piping 1 Disconnect the discharge nozzle and suction nozzle from the piping 2 Depending on the pump size and motor size unscrew the bolts that fix the support foot or motor foot to the found...

Page 34: ...ineering practice Use original spare parts only Sequence Always reassemble the pump in accordance with the corresponding general assembly drawing or exploded view Sealing elements Always use new O rings Never use O rings that have been made by cutting an O ring cord to size and gluing the ends together Always use new gaskets making sure that they have the same thickness as the old ones Always fit ...

Page 35: ...p nuts 38 13 For versions with motor shroud Fasten motor shroud 44 with bolts screws 45 to adapter 43 14 Reassemble the motor feet if necessary Fasten motor feet 51 on motor 55 with bolts 52 and nuts 53 7 6 Spare parts stock 7 6 1 Ordering spare parts Always quote the following data when ordering replacement or spare parts Order number Order item number Consecutive number Type series Size Material...

Page 36: ...ned enough Check suction line remove any foreign matter and check all valves NPSHavailable smaller than pump s NPSHrequired Improve suction and flow conditions Reduce flow rate with discharge side control valve Suction side foot valve does not close properly and liquid column drops Repair or replace foot valve Flow losses in system exceed specified discharge head of pump Reduce pipe friction losse...

Page 37: ...al of mechanical seal as required Pump not cleaned sufficiently after it was used for fluids that tend to crystallise Drain fluid immediately after pump operation and perform several cleaning cycles Mechanical seal installed incorrectly Re install mechanical seal correctly Incorrect direction of rotation of pump with non reversible mechanical seal Change the direction of rotation Dry running of pu...

Page 38: ... 920 1 412 230 2 940 1 433 507 901 1 801 Fig 4 General assembly drawing Vitastage 05 1 05 8 Table 17 List of components Part No Description Part No Description 101 Pump casing 683 Shroud 108 Stage casing 732 Cover 161 Casing cover 801 Flanged motor 230 1 2 Impeller 900 Bolt screw 412 O ring 901 1 Hexagon head bolt 433 Mechanical seal 905 Tie bolt 474 Thrust ring 920 1 2 Nut 507 Thrower 940 1 Key 5...

Page 39: ...4 1 940 2 412 230 2 940 1 433 507 801 901 1 Fig 5 General assembly drawing Vitastage 05 1 05 8 Table 18 List of components Part No Description Part No Description 101 Pump casing 507 Thrower 108 Stage casing 554 1 2 Washer 161 Casing cover 801 Flanged motor 230 1 2 Impeller 901 1 Hexagon head bolt 412 O ring 905 Tie bolt 433 Mechanical seal 920 1 2 Nut 474 Thrust ring 940 1 2 Key ...

Page 40: ...p set EC Machinery Directive 2006 42 EC Pump set Regulation 1935 2004 EG 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 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 ...

Page 41: ... 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 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 le...

Page 42: ...5 Installation at site 18 Intended use 8 Interference immunity 21 K Key to safety symbols markings 8 M Maintenance 31 Mechanical seal 24 Misuse 9 N Name plate 15 Noise characteristics 16 O Operating limits 25 Operation on a frequency inverter 20 Order number 6 Other applicable documents 6 P Partly completed machinery 6 Permissible forces at the pump nozzles 20 Piping 19 Preservation 12 29 Product ...

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Page 44: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1969 85 03 EN 01532022 ...

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