Page 1
Multistage Horizontal Centrifugal Pump
Comeo
Installation/Operating Manual
Page 2
Legal information/Copyright
Installation/Operating Manual Comeo
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 B.V., Alphen aan den Rijn, Nederland 15/05/2017
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Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Installation of partly completed machinery....................................................................................................6
1.3 Target group.....................................................................................................................................................6
1.4 Other applicable documents............................................................................................................................6
1.5 Symbols .............................................................................................................................................................6
2 Safety...................................................................................................................................................... 8
2.1 Key to safety symbols/markings.......................................................................................................................8
2.2 General..............................................................................................................................................................8
2.3 Intended use .....................................................................................................................................................8
2.4 Personnel qualification and training...............................................................................................................9
2.5 Consequences and risks caused by non-compliance with this manual .........................................................9
2.6 Safety awareness ..............................................................................................................................................9
2.7 Safety information for the operator/user.......................................................................................................9
2.8 Safety information for maintenance, inspection and installation ..............................................................10
2.9 Unauthorised modes of operation................................................................................................................10
3 Transport/Temporary Storage/Disposal............................................................................................. 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
3.3 Storage/preservation......................................................................................................................................12
3.4 Disposal ...........................................................................................................................................................13
3.5 Return to supplier...........................................................................................................................................13
4 Description of the Pump (Set)............................................................................................................. 14
4.1 General description ........................................................................................................................................14
4.2 Designation.....................................................................................................................................................14
4.3 Name plate......................................................................................................................................................14
4.4 Design details..................................................................................................................................................14
4.5 Configuration and function...........................................................................................................................15
4.6 Noise characteristics .......................................................................................................................................16
4.7 Scope of supply...............................................................................................................................................16
4.8 Dimensions and weights ................................................................................................................................16
5 Installation at Site................................................................................................................................ 17
5.1 Safety regulations...........................................................................................................................................17
5.2 Checks to be carried out prior to installation...............................................................................................17
5.3 Installing the pump set ..................................................................................................................................17
5.4 Piping ..............................................................................................................................................................18
5.4.1 Connecting the piping.......................................................................................................................18
5.5 Fitting a bypass ..............................................................................................................................................19
5.6 Electrical system..............................................................................................................................................19
5.6.1 Information for planning the electrical connection ........................................................................ 19
5.6.2 Electrical connection.......................................................................................................................... 20
5.7 Checking the direction of rotation................................................................................................................21
6 Commissioning/Start-up/Shutdown................................................................................................... 23
6.1 Commissioning/Start-up.................................................................................................................................23
6.1.1 Prerequisites for commissioning/start-up ......................................................................................... 23
6.1.2 Priming and venting the pump.........................................................................................................23
6.1.3 Start-up............................................................................................................................................... 25
6.2 Operating limits..............................................................................................................................................25
6.2.1 Minimum flow rate / maximum flow rate........................................................................................26
6.3 Shutdown/storage/preservation ....................................................................................................................26
6.3.1 Measures to be taken for shutdown ................................................................................................26
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6.4 Returning to service .......................................................................................................................................27
7 Servicing/Maintenance........................................................................................................................ 28
7.1 Safety regulations...........................................................................................................................................28
7.2 Servicing/inspection........................................................................................................................................28
7.3 Drainage/cleaning ..........................................................................................................................................28
7.4 Tightening torques.........................................................................................................................................29
8 Trouble-shooting.................................................................................................................................. 30
9 Related Documents.............................................................................................................................. 31
9.1 General assembly drawing with list of components ....................................................................................31
9.2 Wiring diagrams .............................................................................................................................................32
10 EU Declaration of Conformity............................................................................................................. 33
11 Certificate of Decontamination........................................................................................................... 34
Index ..................................................................................................................................................... 35
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Glossary
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Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid 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
IE3
Efficiency class to IEC60034-30: 3=Premium
Efficiency (IE = International Efficiency)
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, drive,
additional components and accessories
Suction lift line/suction head line
The pipeline which is connected to the suction
nozzle
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1 General
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1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Observe the noise characteristics, indicated as surface sound pressure level.
(ðSection4.6,Page16)
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.4,Page9)
1.4 Other applicable documents
Table1: 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 Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing
1)
Sectional drawing of the pump
Sub-supplier product literature1)Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists
1)
Description of spare parts
Piping layout
1)
Description of auxiliary piping
List of components
1)
Description of all pump components
Drawing for assembly
1)
Sectional drawing of the installed shaft seal
For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
1.5 Symbols
Table2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1) If agreed upon in scope of supply
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1 General
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Symbol Description
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
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2 Safety
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2 Safety
!
DANGER
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
!
DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!
WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with 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 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 complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
2.3 Intended use
▪ The pump (set) must only be operated within the operating limits described in
the other applicable documents. (ðSection1.4,Page6)
▪ 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 sheet or product literature
(to prevent overheating, bearing damage, etc.).
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▪ Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc.)
▪ Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪ Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪ Never open the discharge-side shut-off elements further than permitted.
– The maximum flow rates specified in the product literature or data sheet
would be exceeded.
– Risk of cavitation 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 transport, 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 operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with this manual
▪ Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪ Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards, directives and laws
2.7 Safety information for the operator/user
▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any contact guards during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
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▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪ If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation
▪ Modifications or alterations of the pump are only permitted with the
manufacturer's prior 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 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 supply (de-energised).
▪ The pump casing must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pump set out of service always adhere to the procedure
described in the manual. (ðSection6.3,Page26)
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page23)
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
(ðSection2.3,Page8)
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3 Transport/Temporary Storage/Disposal
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
Transporting the pump set
DANGER
Improper transport
Danger to life from falling parts!
Damage to the pump set!
▷ Use the attachment point provided for attaching the lifting accessory.
▷ Never suspend the pump set by its power cable.
▷ Use the lifting chain/rope included in the scope of supply exclusively for
lowering or lifting the pump set into/out of the pump sump.
▷ Securely attach the lifting chain/rope to the pump and crane.
▷ Use tested, marked and approved lifting accessories only.
▷ Observe the regional transport regulations.
▷ Observe the product literature supplied by the lifting accessory manufacturer.
▷ The load-carrying capacity of the lifting accessory must be higher than the
weight indicated on the name plate of the pump set to be lifted. Take into
account any additional system components to be lifted.
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
To transport the pump/pump set suspend it from the lifting tackle as shown.
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Fig.1: Transporting the pump set
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
▪ Store the pump set in dry, vibration-free conditions and, if possible, in its original
packaging.
▪ Fill some antifreeze (e.g. glycol) into the pump to protect it from frost/freezing.
▪ Manually rotate the shaft once every three months as well as shortly before start-
up.
▪ Spray the inside of the mechanical seal chamber with a preservative to prevent
seizure of the mechanical seal.
Table4: Ambient conditions for storage
Ambient condition Value
Relative humidity 5% to 80%
2)
(non-condensing)
Ambient temperature -10°C to +40°C
3)
2) At +20°C
3) Optional: -10°C to +55°C
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3.4 Disposal
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Hazard to persons and the environment!
▷ Collect and properly 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. 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 regulations or in another
controlled manner.
3.5 Return to supplier
1. Drain the pump as per operating instructions. (ðSection7.3,Page28)
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 set has handled fluids whose residues could lead to corrosion
damage in the presence of atmospheric humidity or could ignite upon contact
with oxygen, the pump set must also be neutralised, and anhydrous inert gas
must be blown through the pump to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump.
Indicate any safety measures and decontamination measures taken.
(ðSection11,Page34)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
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4 Description of the Pump (Set)
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4 Description of the Pump (Set)
4.1 General description
▪ Multistage horizontal centrifugal pump
Pump for handling clean or slightly aggressive aqueous fluids.
4.2 Designation
Example: Comeo C 2/2
Table5: Designation key
Code Description
Comeo Type series
C Material variant
C Pump casing made of cast stainless steel
G Pump casing made of cast iron
2 Size, flow rate [m³/h] at BEP
2, 4, 6
2 Number of stages
4)
4.3 Name plate
Comeo C 4/6 B
1.1kW 50 Hz
KSB B.V.
QH
4.3 m³/h 40.4 m
Hmin
9.0 m
n fix.
2880rpm
SN
01/2017 1234657-123
Eff.
59.7%
Seal.
code 32
ID
48239965
PO
700113778
P/T
PN10 - 15/60°C
Kalkovenweg 13
Alphen aan den Rijn NL
www.ksb.com
5
6
7
8
12
13
3
4
1
2
9
10
11
14
Made in NL
EAC
Fig.2: Name plate (example) Comeo
1 Designation 2 Power required
3 Rated frequency 4 Flow rate
5)
5 Head
5)
6 Minimum head
7 Rated speed 8 Efficiency
9 Mechanical seal code 10 Maximum pressure
11 Permissible fluid temperature 12 KSB material number
13 Week/year of production, serial
number
14 KSB purchase order number
4.4 Design details
Design
▪ Centrifugal pump
▪ Multistage
▪ Close-coupled design
▪ Extended motor shaft
▪ Maximum pressure class PN 10
4) Default: stages 2, 4 und 6; optional: intermediate stages 1, 3 and 5
5) At best efficiency point (Qopt)
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4 Description of the Pump (Set)
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Installation
▪ Horizontal installation
Drive
▪ Single-phase AC motor or three-phase motor
▪ To IEC60034-7
▪ Efficiency class IE3 to IEC60034-30 (for three-phase motors ≥0.75kW)
▪ Frequency 50/60 Hz
▪ 2 poles
▪ Thermal class F
▪ IP55 enclosure
▪ Duty cycle: continuous duty S1
▪ Thermal circuit breaker with automatic reset and start-up for single-phase AC
motor
Shaft seal
▪ Mechanical seal
▪ To EN12756
▪ Uncooled
▪ Maintenance-free
4.5 Configuration and function
1
2
3
4
5
6
Fig.3: Sectional drawing
1 Suction nozzle 2 Impeller
3 Pump shroud 4 Discharge nozzle
5 Screw plug for filling 6 Screw plug for draining
Design
The horizontal multistage centrifugal pump is designed for handling clean or slightly
aggressive fluids containing water. The pump is easy to install, commission and
operate. The hydraulic assembly is driven by an electric motor. All hydraulic system
components of the pump are made of stainless steel. The pump casings are available
in stainless steel or cast iron.
The pump is suitable for transporting cold and warm water and boosting the
pressure thereof without any wear on the components within the specified operating
range. Fluids whose viscosity or density differ from water can also be transported. In
this case, a motor with adjusted rating might be required.
The pump is designed with openings for measuring, draining and venting. These
openings are closed with screw plugs. Connection (5) serves to fill and vent the pump
or measure the inlet pressure and suction pressure using a G1/4 connection.
Connection (6) serves to drain the pump or measure the discharge pressure using a
G1/4 connection.
Function
The rotating impeller causes the pressure to drop at the impeller inlet. This pressure
drop makes the fluid enter the suction nozzle (1). Each stage (2) consists of an
impeller and a diffuser. The flow rate of the pump is determined by the free passage
of the stage. The pressure at the stage depends on the impeller diameter. Given the
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4 Description of the Pump (Set)
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modular design system, the number of impellers can be selected to ideally match the
required duty point. After the fluid has left the last impeller, it is guided back
through the pump in the passage between the pump stages and the pump casing (3)
and leaves the pump at the discharge nozzle (4).
Sealing
The pump is sealed by a standardised mechanical seal.
4.6 Noise characteristics
The noise characteristics given refer to the motor. See motor literature supplied.
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪ Pump
▪ Electric motor
4.8 Dimensions and weights
For dimensions and weights refer to the general arrangement drawing/outline
drawing or data sheet of the pump set.
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5 Installation at Site
5.1 Safety regulations
DANGER
Installation in potentially explosive atmospheres
Explosion hazard!
▷ Never install the pump in potentially explosive atmospheres.
▷ Observe the information given in the data sheet and on the name plates of the
pump system.
WARNING
Pump with long-term preservation: Harmful preservatives in drinking water
systems
Danger of poisoning!
▷ Flush the system prior to commissioning.
▷ If necessary, dismantle the pump and thoroughly remove the preservative from
all wetted components.
▷ Observe the data given in the order confirmation.
5.2 Checks to be carried out prior to installation
Place of installation
WARNING
Installation on mounting surface which is unsecured and cannot support the load
Personal injury and damage to property!
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN206-1.
▷ The mounting surface must have set and must be completely horizontal and
even.
▷ 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 Installing the pump set
CAUTION
Ingress of leakage into the motor
Damage to the pump!
▷ Never install the pump set with the "motor below".
1. Install and fasten the pump set on a sturdy and level foundation in a dry, frost-
proof room.
2. Make sure that sufficient air can reach the fan opening of the motor.
(The clearance above the fan opening must measure at least 1/4 of the diameter
of the fan cover air intake.)
3. Place a spirit level on the discharge nozzle to align the pump set.
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5.4 Piping
5.4.1 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 an anchorage point for the piping.
▷ Anchor the pipes in close proximity to the pump and connect them properly
without transmitting any stresses or strains.
▷ Take appropriate measures to compensate for thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.
NOTE
Installing check and shut-off elements in the system is recommended, depending on
the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
NOTE
VdS-certified pumps must be connected in compliance with current information
from VdS CEA 4001.
ü The suction lift line has been laid with a rising slope, the suction head line with a
downward slope towards the pump.
ü A flow stabilisation section having a length equivalent to at least twice the
diameter of the suction flange has been provided upstream of the suction flange.
ü The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
As far as the nominal diameters in the suction and discharge line, and installation
of check valves and shut-off elements in a fire protection system are concerned,
observe the sizing specifications in the relevant directives.
ü Adapters to larger nominal diameters are designed with a diffuser angle of
approx. 8° to avoid excessive pressure losses.
ü The pipelines have been anchored in close proximity to 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 from the piping.
▷ If necessary, install a filter.
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3. If required, install a filter in the piping (see figure: Filter in the piping).
1
2
Fig.4: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter)
made of corrosion-resistant material.
Use a filter with a filter area three times the cross-section of the piping.
Conical filters have proved suitable.
4. Connect the pump nozzles to the piping.
CAUTION
Aggressive flushing and pickling agents
Damage to the pump!
▷ Match the cleaning operation mode and duration for flushing and pickling
service to the casing and seal materials used.
5.5 Fitting a bypass
NOTE
If the pump is operated against a closed valve, installing a bypass is recommended.
The bypass capacity must correspond to at least 10 % of the optimum volume flow
rate.
5.6 Electrical system
5.6.1 Information for planning the electrical connection
Rated current
The permissible rated current of the motor is shown on the motor name plate. It
indicates the operating range of the motor. The motor protection switch can be preset to this value to protect the motor. By measuring the actual current of the pump
during operation the motor protection switch can be pre-set to a specific value for
protecting the pump/motor combination. This current value can also be used to select
appropriate electrical equipment such as drives with frequency inverter, master
switch, conductor diameter, etc.
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5.6.2 Electrical connection
DANGER
Incorrect connection
Explosion hazard!
▷ The connection point of the cable ends must be located outside hazardous
areas or in an area approved for electrical equipment.
DANGER
Operating a pump set that has not been fully connected
Explosion hazard!
Damage to the pump set!
▷ Never start up a pump set with power cables that have not been fully
connected or non-operational monitoring devices.
DANGER
Connection of damaged power cables
Danger of death from electric shock!
▷ Check the power cables for damage before connecting them.
▷ Never connect damaged power cables.
▷ Replace damaged power cables.
DANGER
Electrical connection work by unqualified personnel
Risk of fatal injury due to electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, .
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
CAUTION
Improper routing of power cable
Damage to the power cables!
▷ Never move the power cables at temperatures below - 25 ℃.
▷ Never kink or crush the power cables.
▷ Never lift the pump set by the power cables.
▷ Adjust the length of the power cables to the site requirements.
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CAUTION
Motor overload
Damage to the motor!
▷ Protect the motor by a thermal time-lag overload protection device in
accordance with IEC 947 and local regulations.
(If the pump is used in a fire protection system as the main fire-fighting pump,
the pump must not be tripped automatically by motor protection devices!)
▷ Make sure that the motor's specifications match those of the power supply it
will be connected to.
For electrical connection observe the wiring diagrams in the Annex and the
information for planning the control system.
If a motor of a different make is used, observe the relevant operating instructions.
The pump set is supplied with power cables as standard. Always use all cables
provided and connect all marked cores of the control cable.
The permissible rated current of the motor supplied is shown on the motor name
plate.
It describes the permissible operating range of the motor and can be used for setting
the overload protection device. If the actual power input is measured during
operation, the motor protection switch can be pre-set to a lower value to protect the
pump set.
This current value can also be used to select appropriate electrical equipment such as
frequency inverter, master switch, conductor diameter, etc.
5.7 Checking the direction of rotation
DANGER
Temperature increase resulting from contact between rotating and stationary
components
Damage to the pump set!
▷ Never check the direction of rotation by starting up the unfilled pump set.
▷ Separate the pump from the motor to check the direction of rotation.
WARNING
Hands inside the pump casing
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
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 electrical connection and
correct the direction of rotation.
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5 Installation at Site
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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 direction
of rotation on the pump.
3. If the motor is running in the wrong direction of rotation, check the electrical
connection of the motor and the control system, if applicable.
1
Fig.5: Arrow indicating the direction of rotation on the pump for three-phase motors
1 Direction of rotation of the motor
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6 Commissioning/Start-up/Shutdown
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6 Commissioning/Start-up/Shutdown
6.1 Commissioning/Start-up
6.1.1 Prerequisites for commissioning/start-up
Before commissioning/starting up the pump set, make sure that the following
conditions are met:
▪ The pump set has been installed correctly.
▪ The pump set has been properly connected to the power supply and is equipped
with all protection devices.
▪ The direction of rotation has been checked.
▪ All auxiliary connections required are connected and operational.
▪ Pump shaft and motor shaft are running smoothly and without any excessive
noise.
▪ After prolonged shutdown of the pump (set), the activities required for returning
the pump (set) to service have been carried out. (ðSection6.4,Page27)
6.1.2 Priming and venting the pump
DANGER
Formation of a potentially explosive atmosphere inside the pump
Explosion hazard!
▷ Before starting up the pump set, vent the pump and suction line and prime
both with the fluid to be handled.
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.
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Priming in an open or closed circuit with sufficient supply pressure
A
B
C
Fig.6: Pump with open or closed circuit
A Shut-off valve in suction line B Shut-off valve in discharge line
C Filler nozzle (G 1/4) with screw plug
1. Close the shut-off valve in suction line A and the shut-off valve in discharge line
B.
2. Remove the screw plug of filler nozzleC.
3. Open the shut-off valve in suction lineA gradually until fluid escapes from filler
nozzle C.
4. Close filler nozzleC with the screw plug.
5. Open the shut-off valve in suction line A.
6. Open the shut-off valve in discharge line B.
Priming in open circuit with fluid level below the pump
A
BC
Fig.7: Pump with open circuit and fluid level below the pump
A Shut-off valve in discharge line B Filler nozzle (G 1/4) with screw plug
C Valve in the suction line
(foot valve with integrated swing
check valve)
ü The valve in suction lineC is fully submerged.
1. Remove the screw plug of filler nozzleB.
2. Close the shut-off valve in discharge line A.
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3. Fill fluid into the pump casing through filler nozzleB until the fluid reaches the
maximum fill level.
4. Close the filler nozzleB with the screw plug.
5. Open the shut-off valve in discharge line A.
Venting
While the pump is in operation it cannot be vented via the corresponding
connection.
A
Fig.8: Vent connection
A Vent connection
6.1.3 Start-up
1. Start up the motor.
2. Slowly open the shut-off valve in the discharge line.
3. If the pump does not start up flawlessly within 20seconds, switch off the motor.
4. Prime the pump again.
5. Start up the motor again.
6. When the pump has been running continuously for 30seconds, stop and start
up the motor 2 to 3 times.
7. Make sure that all air has been evacuated from the pump.
6.2 Operating limits
DANGER
Non-compliance with operating limits
Damage to the pump set!
▷ Comply with the operating data indicated in the data sheet.
▷ Avoid operation against a closed shut-off element.
▷ Never operate the pump set outside the limits specified below.
DANGER
Non-compliance with operating limits for the fluid handled
Explosion hazard!
▷ Never use the pump to handle different fluids which might react chemically
with each other.
▷ Never use the pump to handle a flammable fluid with a fluid temperature
above the ignition temperature.
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6 Commissioning/Start-up/Shutdown
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CAUTION
Excessive temperature difference between the fluid handled and the pump
Damage to the machinery!
▷ The temperature difference between the fluid handled and the pump must
never exceed 60°C.
▷ If the temperature difference between the pump and the fluid handled exceeds
30°C, prime/heat up the pump slowly to avoid any risk of thermal shock.
The operating range depends on the application as well as on the combination of
pressure and temperature.
Table6: Operating limits
Characteristic Value
Flow rate Q [m³/h] ≤ 10.8
Head H [m] ≤ 79.5
Fluid temperature T [°C] -10 to +60
Ambient temperature T [°C] -20 to +40
6)
Pressure class PN [bar] 10
6.2.1 Minimum flow rate / maximum flow rate
A minimum flow rate must be ensured to protect the pump against overheating and
to prevent gas pockets, cavitation, etc.
Table7: Minimum flow rate / maximum flow rate Q[m³/h] at a fluid temperature
≤20°C
Size 50Hz 60 Hz
Min. Max. Min. Max.
2 0,2 3,3 0,2 4,0
4 0,4 6,5 0,5 7,8
6 0,6 9,0 0,8 10,8
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 regularly once a month or once every three months for
approximately five minutes during prolonged shutdown periods.
This will prevent the formation of deposits within the pump and the pump
intake area.
CAUTION
Danger of freezing during prolonged pump shutdown periods
Damage to the pump!
▷ The temperature maintenance equipment must remain in operation also during
pump shutdown periods.
6) Optional: -20 to +55°C
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6 Commissioning/Start-up/Shutdown
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The pump set is removed from the piping and stored
ü The checks and maintenance operations have been performed.
1. Spray-coat the inside wall of the pump casing with a preservative.
2. Spray the preservative through the inlet and outlet nozzles of the fluid handled.
It is advisable to close the fluid inlet and outlet nozzles afterwards (e.g. with
plastic caps or similar).
Observe any additional instructions and information provided. (ðSection3,Page11)
6.4 Returning to service
For returning the equipment to service, observe the sections on commissioning/startup (ðSection6.1,Page23) and the operating limits. (ðSection6.2,Page25)
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (ðSection7,Page28)
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.
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7 Servicing/Maintenance
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7 Servicing/Maintenance
7.1 Safety regulations
DANGER
Power supply not disconnected
Danger to life!
▷ Pull the mains plug and secure the pump against unintentional start-up.
DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
▷ Have pump components modified and dismantled by authorised personnel
only.
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.
WARNING
Fluids handled, consumables and supplies posing a health hazard
Hazard to persons and the environment!
▷ Clean the pump prior to any maintenance and installation work.
▷ Make sure persons cannot come into contact with the fluid handled.
7.2 Servicing/inspection
The pump is practically maintenance-free.
It will suffice to clean the pump once a year and carry out visual inspections of the
condition of the pump and supply line.
7.3 Drainage/cleaning
WARNING
Fluids handled, consumables and supplies which are hot and/or pose a health
hazard
Hazard to persons and the environment!
▷ Collect and properly 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.
If the fluids handled by the pump (set) leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might ignite
when coming into contact with oxygen, the pump (set) must be flushed through,
neutralised, and anhydrous inert gas must be blown through the pump for drying
purposes.
The pump is fitted with a drainage nozzle.
Draining the pump while in operation is impermissible!
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7 Servicing/Maintenance
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A
Fig.9: Connection for draining the pump
1 Connection for draining the pump
7.4 Tightening torques
A
B
Fig.10: Connections
A Filler nozzle with screw plug
B Drain with screw plug
Table8: Tightening torques
Position Thread Tightening torque
Comeo C Comeo G
[Nm] [Nm]
A, B G1/4 15 3
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8 Trouble-shooting
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8 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work performed to remedy faults, observe the relevant information
given in this operating manual and/or in the product literature provided by the
accessories manufacturer.
If problems occur that are not described in the following table, consultation with the
KSB customer service is required.
Table9: Trouble-shooting
Problem Possible cause Remedy
Motor is not running. No electrical voltage at the terminal ▪ Check the power cable.
▪ Check the motor protection switch.
Motor protection switch has tripped. ▪ Disconnect the motor from the
power supply.
▪ Let the motor cool down.
▪ Wait for the motor protection switch
to be reset automatically and the
motor to re-start.
▪ Check the ambient temperature and
fluid temperature.
▪ If the problem keeps recurring,
contact the manufacturer.
Motor running but pump does
not start.
Internal fault ▪ Contact the manufacturer.
Pump vibrates and causes
running noises.
Pump not primed ▪ Prime and vent the pump.
No or insufficient inflow ▪ Provide sufficient supply.
▪ Check inlet line for clogging.
Motor bearing defective ▪ Contact the manufacturer.
NPSH available too low (cavitation) ▪ Improve suction conditions.
Pump not working in its operating
range.
▪ Adjust system to operation within
operating range or select different
pump.
Insufficient delivery and/or
insufficient pressure
Shut-off valve in suction line or
discharge line closed
▪ Open shut-off valves.
Air in the pump ▪ Vent the pump.
No or insufficient inflow ▪ Increase suction pressure.
Wrong direction of rotation ▪ Check electrical connection.
Foot valve clogged ▪ Clean foot valve.
Suction line not vented ▪ Vent suction line.
An air bubble remains in the suction
line.
▪ Lay suction line with a rising slope
towards the pump.
Pump takes in air due to leakage in
suction line.
▪ Repair.
Insufficient flow rate of pump leads to
air remaining in the pump.
▪ Use smaller pump.
▪ Increase flow rate.
Diameter of suction line too small ▪ Increase diameter of suction line.
Flow rate of water meter in supply line
too low
▪ Increase flow rate of water meter.
Leakage Leakage at the pump. ▪ Contact the manufacturer.
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9 Related Documents
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9 Related Documents
9.1 General assembly drawing with list of components
101
800
341
400.04
433
525.05
525.03
525.01
950 108.05
108.01
108.04
230
412.01
10-6
905
920.03
554.01
903.05
412.03
914.02
160
930.02
932
920.02
580.02
Fig.11: General assembly drawing
Table10: List of components
Part No. Description Part No. Description
10-6 Pump shroud 554.01 Washer
101 Pump casing 580.02 Cap
108.01/.04/.05 Stage casing 800 Motor
160 Cover 903.05 Screw plug
230 Impeller 905 Tie bolt
341 Drive lantern 914.02 Hexagon socket head cap screw
400.04 Gasket 920.02/.03 Nut
412.01/.03 O-ring 930.02 Safety device
433 Mechanical seal 932 Circlip
525.01/.03/.05 Spacer sleeve 950 Spring
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9 Related Documents
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9.2 Wiring diagrams
1)
2)
3)
Fig.12: Wiring diagram, depending on selected motor
1 1~230V with motor protection
2 3~230V
3 3~400V
Page 33
10 EU Declaration of Conformity
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10 EU Declaration of Conformity
Manufacturer: KSB B.V.
Kalkovenweg 13
2401 LJ Alphen aan den Rijn (The Netherlands)
The manufacturer herewith declares that the product:
Comeo
Serial numbers: 13/2017 1000000-001 - 52/2018 9999999-999
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): EC Machinery Directive 2006/42/EC
– Pump (set): Ecodesign Directive 2009/125/EC, Regulation 547/2012
(for water pumps with a maximum shaft power of 150kW)
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
Person authorised to compile the technical file:
Menno Schaap
Manager Product Development
KSB B.V.
(Subsidiary D.P. Industries B.V.)
Kalkovenweg 13
2401 LJ Alphen aan den Rijn (The Netherlands)
The EU Declaration of Conformity was issued in/on:
Alphen aan den Rijn, 01.04.2017
Menno Schaap
Manager Product Development
KSB B.V.
Kalkovenweg 13
2401 LJ Alphen aan den Rijn
Page 34
11 Certificate of Decontamination
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11 Certificate of Decontamination
Type: ................................................................................................................................
Order number/
Order item number7): ................................................................................................................................
Delivery date: ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled7): ................................................................................................................................
Please tick where applicable7):
Radioactive Explosive Corrosive Toxic
Harmful Bio-hazardous Highly flammable Safe
Reason for return7): ................................................................................................................................
Comments: ................................................................................................................................
................................................................................................................................
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.
For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, 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 intermediate piece 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 leakage; if fluid handled has penetrated the stator space, it has
been removed.
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 with the
relevant legal provisions.
.................................................................... ....................................................... .......................................................
Place, date and signature Address Company stamp
7) Required fields
Page 35
Index
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Index
A
Applications8
C
Certificate of decontamination34
Commissioning23
D
Design14, 15
Designation14
Direction of rotation22
Disposal13
Drive15
E
Electrical connection21
Explosion protection20
F
Fault/malfunction30
Function15
I
Installation15
Installation on a foundation17
Installation at site17
Intended use8
M
Misuse9
N
Name plate14
O
Other applicable documents6
P
Partly completed machinery6
Piping18
Preservation12, 27
Product description14
R
Return to supplier13
Returning to service27
S
Safety8
Safety awareness9
Scope of supply16
Shaft seal15
Shutdown27
Storage12, 27
T
Tightening torques29
Page 36
KSB B.V.
Kalkovenweg 13
2401 LJ Alphen aan den Rijn
1799.8/03-EN
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