Page 1
Multistage Horizontal Centrifugal Pump
Emporia MB
Installation/Operating Manual
Page 2
Legal information/Copyright
Installation/Operating Manual Emporia MB
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 09/01/2018
Page 3
Contents
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Emporia MB
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...................................................................................................................................................... 7
2.1 Key to safety symbols/markings.......................................................................................................................7
2.2 General..............................................................................................................................................................7
2.3 Intended use .....................................................................................................................................................8
2.4 Personnel qualification and training...............................................................................................................8
2.5 Consequences and risks caused by non-compliance with this manual .........................................................8
2.6 Safety awareness ..............................................................................................................................................9
2.7 Safety information for the operator/user.......................................................................................................9
2.8 Safety information for maintenance, inspection and installation ................................................................9
2.9 Unauthorised modes of operation..................................................................................................................9
3 Transport/Temporary Storage/Disposal............................................................................................. 10
3.1 Checking the condition upon delivery..........................................................................................................10
3.2 Transport.........................................................................................................................................................10
3.3 Storage/preservation......................................................................................................................................11
3.4 Return to supplier...........................................................................................................................................11
3.5 Disposal ...........................................................................................................................................................12
4 Description of the Pump (Set)............................................................................................................. 13
4.1 General description ........................................................................................................................................13
4.2 Designation.....................................................................................................................................................13
4.3 Name plate......................................................................................................................................................13
4.4 Design details..................................................................................................................................................14
4.5 Configuration and function...........................................................................................................................14
4.6 Noise characteristics .......................................................................................................................................15
4.7 Scope of supply...............................................................................................................................................15
4.8 Dimensions and weights ................................................................................................................................15
5 Installation at Site................................................................................................................................ 16
5.1 Checking the site before installation ............................................................................................................16
5.2 Installing the pump set ..................................................................................................................................16
5.3 Piping ..............................................................................................................................................................16
5.3.1 Connecting the piping.......................................................................................................................16
5.3.2 Permissible forces and moments at the pump nozzles....................................................................17
5.4 Electrical connection ......................................................................................................................................17
5.5 Checking the direction of rotation................................................................................................................19
6 Commissioning/Start-up/Shutdown................................................................................................... 20
6.1 Commissioning/Start-up.................................................................................................................................20
6.1.1 Prerequisites for commissioning/start-up ......................................................................................... 20
6.1.2 Priming and venting the pump.........................................................................................................20
6.1.3 Start-up............................................................................................................................................... 20
6.1.4 Checking the shaft seal......................................................................................................................21
6.1.5 Shutdown ...........................................................................................................................................21
6.2 Operating limits..............................................................................................................................................22
6.2.1 Ambient temperature........................................................................................................................22
6.2.2 Frequency of starts.............................................................................................................................22
6.2.3 Maximum operating pressure ........................................................................................................... 23
6.2.4 Fluid handled .....................................................................................................................................23
6.3 Shutdown/storage/preservation ....................................................................................................................23
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6.4 Returning to service .......................................................................................................................................24
7 Servicing/Maintenance........................................................................................................................ 25
7.1 Safety regulations...........................................................................................................................................25
7.2 Servicing/inspection........................................................................................................................................26
7.2.1 Supervision of operation ................................................................................................................... 26
7.3 Drainage/cleaning ..........................................................................................................................................27
7.4 Dismantling the pump set..............................................................................................................................27
7.4.1 General information/Safety regulations...........................................................................................27
7.5 Reassembling the pump set...........................................................................................................................28
7.5.1 General information/Safety regulations...........................................................................................28
7.6 Tightening torques.........................................................................................................................................29
7.7 Spare parts stock.............................................................................................................................................29
7.7.1 Ordering spare parts.......................................................................................................................... 29
8 Trouble-shooting.................................................................................................................................. 30
9 Related Documents.............................................................................................................................. 32
9.1 Exploded view and list of components .........................................................................................................32
10 EU Declaration of Conformity............................................................................................................. 34
11 EU Declaration of Conformity............................................................................................................. 35
12 Certificate of Decontamination........................................................................................................... 36
Index ..................................................................................................................................................... 37
Page 5
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
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
Page 6
1 General
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Emporia MB
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 operating manual describes the proper and safe use
of this equipment in all phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics see (ðSection4.6,Page15)
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,Page8)
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 dimensions and installation
dimensions for the pump (set), weights
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing
1)
Sectional drawing of the pump
Spare parts lists
1)
Description of spare parts
List of components
1)
Description of all pump components
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.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1) If agreed to be included in the scope of supply
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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 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 be read and completely understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
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 manual.
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2 Safety
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2.3 Intended use
▪ The pump (set) must not be used in potentially explosive atmospheres.
▪ The pump (set) must not be operated on a frequency inverter.
▪ The pump (set) must only be operated within the operating limits described in
the other applicable documents.
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate the pump (set) in partially assembled condition.
▪ Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model or variant.
▪ Never operate the pump without the fluid to be handled.
▪ Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪ 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
▪ Observe all safety information and instructions in this manual.
▪ 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.
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
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2 Safety
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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.
▪ 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.
▪ Any work on the pump set shall only be performed 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.
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning. (ðSection6.1,Page20)
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.
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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 (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in the specified position.
▷ Never attach 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
Improper pump transport
Damage to the pump!
▷ Never suspend the pump/pump set from the power cable.
▷ Prevent the pump (set) from getting knocked or dropped.
To transport the pump/pump set suspend it from the lifting tackle as shown.
Fig.1: Transporting the pump set
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3 Transport/Temporary Storage/Disposal
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3.3 Storage/preservation
The pump set remains installed
1. Properly shut down the pump set.
CAUTION
Damage during storage by frost, humidity, dirt, UV radiation or vermin
Corrosion/contamination of the pump!
▷ Store the pump (set) in a dry, dark, frost-proof room not exposed to sunlight
where the atmospheric humidity is as constant as possible.
2. Properly cover the pump set.
The pump set is removed from the system
1. Properly shut down the pump set.
2. Remove the suction line and discharge line from the pump.
WARNING
Fluids posing a health hazard
Hazard to persons and the environment!
▷ Collect and properly dispose of flushing liquid and any residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of substances posing a health
hazard.
3. Drain the pump as per operating instructions.
4. Store the pump (set) in a dry, dark, frost-proof room not exposed to sunlight
where the atmospheric humidity is as constant as possible.
3.4 Return to supplier
1. Drain the pump as per operating instructions.
2. Always 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 (set).
Always indicate any safety and decontamination measures taken.
(ðSection12,Page36)
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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3.5 Disposal
WARNING
Fluids, 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 residues of the fluid
handled.
▷ Wear safety clothing and a protective mask if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
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.
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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 to turbid water not containing aggressive, abrasive or solid
substances.
4.2 Designation
Example: Emporia MB-152 M
Table4: Designation key
Code Description
EmporiaMB Type series
152 Size
M Type of current
M 1~230 V
T2 3~230 V
T3 3~400 V
4.3 Name plate
1,17 kW
C = 20 µF/ 450 V
230 V~
Tmax = 90°C
Hmax = 90 mQmax = 15m3/h
ElectroPump ~ 1
Class F
Overload protection
Yes
No
2016
Made in EU
Continuous Duty
02503163
IP 44
2800 min
-1
50 Hz
2,3 A
2016w12 Emporia MB-101M
L
WA
70 dB
1
2
5
4
987
171819
6
3
16
15
14
13
12
11
10
KSB SE & Co. KGaA
67227 Frankenthal
Deutschland
Johann-Klein-Straße 9
Fig.2: Name plate (example)
1 Type series, size 2 Flow rate
3 Nominal voltage 4 Nominal current
5 Mains type 6 Material number (if applicable)
7 Thermal class 8 Mode of operation
9 Year of construction 10 External overload protection
11 Enclosure 12 Sound power [dB]
13 Nominal speed 14 Motor rating
15 Maximum fluid temperature 16 Series code
17 Maximum head 18 Run capacitor
19 Nominal frequency - -
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4 Description of the Pump (Set)
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4.4 Design details
Design
▪ Close-coupled design
▪ 2 stages
Drive
▪ 1~230VAC, 50Hz
▪ Thermal overload protection
▪ 3~230/400 VAC, 50Hz
▪ Thermal class F
▪ IP44 enclosure
Impeller type
▪ Closed radial impeller
Bearings
▪ Deep groove ball bearings
▪ Grease-lubricated for life
Shaft seal
▪ Mechanical seal
4.5 Configuration and function
1
2
Fig.3: Emporia MB
1 Suction nozzle 2 Discharge nozzle
Design
Multistage, non-self-priming centrifugal pump in close-coupled design with axial
fluid inlet and vertical fluid outlet. The hydraulic system runs in common bearings
and is connected to the motor via a shaft.
Function
The fluid enters the pump via the suction nozzle (1) and is accelerated outward by
the rotating impellers. In the flow passage of the pump casing the kinetic energy of
the fluid is converted into pressure energy. The fluid is pumped to the discharge
nozzle (2), where it leaves the pump. The shaft passage is sealed by a shaft seal. The
shaft runs in rolling element bearings.
Sealing
The pump is sealed by a standardised mechanical seal. A thrower protects the
bearing and the motor in the event of leakage.
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4 Description of the Pump (Set)
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4.6 Noise characteristics
Sound pressure level < 70 dB(A)
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪ Pump
▪ Drive
4.8 Dimensions and weights
Dimensions
For dimensions refer to the outline drawings of the pump.
Weights
Table5: Weights
Size Weight
[kg]
MB-101M 15,3
MB-101T2 15,3
MB-152M 24,7
MB-152T2 24,7
MB-202T2 25,6
MB-302T2 25,6
MB-400T2 41
MB-550T2 44,8
MB-751T2 50,5
MB-751T3 50,5
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5 Installation at Site
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5 Installation at Site
5.1 Checking the site before installation
Place of installation
WARNING
Installation on mounting surfaces which are 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 X0 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.
5.2 Installing the pump set
WARNING
Excessive temperatures due to improper installation
Burns from touching hot surfaces!
Damage to the pump set!
▷ Install the pump set at distance of at least 30 mm from the wall in a dry, well-
ventilated room that is not at risk of flooding.
ü The place of installation has been properly prepared.
1. Install the pump set in a horizontal position.
2. Bolt the pump set to its place of installation with the feet provided for this
purpose.
5.3 Piping
5.3.1 Connecting the piping
WARNING
Impermissible loads acting on the pump nozzles
Burns from contact with fluid handled!
Damage to the pump set!
▷ Do not use the pump as an anchorage point for the piping.
▷ Anchor the pipes in close proximity to the pump casing.
▷ Observe the permissible forces and moments at the pump nozzles.
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5 Installation at Site
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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.
ü Suction lift lines have been laid with a rising slope, suction head lines with a
downward slope towards the pump.
ü A flow stabilisation section having a length equivalent to at least twice the inside
diameter of the suction flange has been provided upstream of the suction flange.
ü The nominal diameters of the pipes are equal to or greater than the nominal
diameters of the pump nozzles.
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 connection covers on the
suction nozzle and discharge nozzle of the pump.
3. Check that the inside of the pump is free from any foreign objects. Remove any
foreign objects.
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.
5.3.2 Permissible forces and moments at the pump nozzles
No piping-induced forces and moments (from warped pipelines or thermal
expansion, for example) must act on the pump.
5.4 Electrical connection
DANGER
Electrical connection work by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC60364.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
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5 Installation at Site
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CAUTION
Small parts in the motor space
Damage to the pump set!
▷ Never drop small parts into the motor space.
▷ After the electrical connection work on the the pump set has been completed,
check that no small parts have fallen into the motor space. If they have, remove
them.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method. Pump sets with a nominal current >10A
must be wired for star-delta starting.
NOTE
A motor protection device is recommended.
Star-delta starting
Fig.4: Circuit diagram for star-delta starting
Pump sets, single-phase
Fig.5: Circuit diagram of single-phase pump sets
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Pump sets, three-phase
Fig.6: Circuit diagram of three-phase pump sets
5.5 Checking the direction of rotation
WARNING
Temperature increase caused by rotating parts
Risk of injuries! Damage to the pump set!
▷ Never check the direction of rotation by starting up the unfilled pump set.
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.
The correct direction of rotation of 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.
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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 properly connected to the power supply and is equipped
with all protection devices.
▪ The pump has been primed with the fluid to be handled. The pump has been
vented.
▪ The direction of rotation has been checked.
▪ After prolonged shutdown of the pump (set), the activities required for returning
the equipment to service have been carried out. (ðSection6.4,Page24)
6.1.2 Priming 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 both with the fluid to be handled.
2. Fully open the shut-off element (if any) in the suction line.
NOTE
For design-inherent reasons some unfilled 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 pumping effect will immediately fill this volume
with the fluid handled.
6.1.3 Start-up
DANGER
Non-compliance with the permissible pressure and temperature limits if the pump
is operated with the suction and discharge lines closed
Leakage of hot or toxic fluids!
▷ Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷ Only start up the pump set with the discharge-side gate valve slightly or fully
open.
DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid
handled
Damage to the pump set!
▷ Never operate the pump set without a liquid fill.
▷ Prime the pump as per operating instructions.
▷ Always operate the pump within the permissible operating range.
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6 Commissioning/Start-up/Shutdown
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CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
ü The system piping has been cleaned.
ü The pump, suction line and inlet tank, if fitted, have been vented and primed
with the fluid to be pumped.
ü The lines for priming and venting have been closed.
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. Start up the motor.
4. Immediately after the pump has reached full rotational speed, slowly open the
shut-off element in the discharge line and adjust it to comply with the duty
point.
6.1.4 Checking the shaft seal
Mechanical 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-up inside the pump
Damage to the shaft seal!
▷ Depending on the type of installation, the pump set requires sufficient after-
run time – with the heat source switched off – until the fluid handled has
cooled down.
ü The shut-off element in the suction line is and remains open.
1. Close the shut-off element in the discharge line.
2. Switch off the motor and make sure the pump set runs down smoothly to a
standstill.
NOTE
If the discharge line is equipped with a check valve, the shut-off element in the
discharge line may remain open, provided the site's requirements and regulations
are taken into account and 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 protect it against freezing.
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6.2 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature, fluid handled and
speed
Hot fluids escaping!
▷ Comply with the operating data indicated in the data sheet.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at product temperatures exceeding those specified in
the data sheet or on the name plate.
6.2.1 Ambient temperature
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
▷ Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
Table6: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 40 °C
Minimum 1°C
6.2.2 Frequency of starts
CAUTION
Excessive surface temperature of the motor
Damage to the motor!
▷ Observe the frequency of starts specified in the motor manufacturer's product
literature.
The frequency of starts is usually determined by the maximum temperature increase
of the motor. This largely depends on the power reserves of the motor in steadystate operation and on the starting conditions (DOL, star-delta, moments of inertia,
etc). If the starts are evenly spaced over the period indicated, the following limits
serve as orientation for start-up with the discharge-side gate valve slightly open:
Table7: Frequency of starts
Motor rating
[kW]
Maximum No. of start-ups
[Start-ups/hour]
< 4 15
> 5 10
CAUTION
Re-starting while motor is still running down
Damage to the pump (set)!
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
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6.2.3 Maximum operating pressure
CAUTION
Permissible operating pressure exceeded
Damage to connections and seals!
▷ Never exceed the operating pressure specified in the data sheet.
Table8: Maximum operating pressure
Size Maximum permissible operating pressure
[bar]
MB-101 6
MB-152 to MB-751 10
6.2.4 Fluid handled
6.2.4.1 Fluid temperature
CAUTION
Incorrect temperature of the fluid handled
Damage to the pump (set)!
▷ Do not operate the pump (set) outside the specified temperature limits.
Do not operate the pump at temperatures higher than 90°C.
6.2.4.2 Density of the fluid handled
The pump input power changes in proportion to the density of the fluid handled.
CAUTION
Impermissibly high density of the fluid handled
Motor overload!
▷ Make sure the motor has sufficient power reserves.
6.2.4.3 Abrasive fluids
When the pump handles fluids containing abrasive substances, increased wear of the
hydraulic system and the shaft seal are to be expected. In this case, reduce the
commonly recommended inspection intervals.
6.3 Shutdown/storage/preservation
DANGER
Electrical connection work by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC60364.
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Emporia MB
DANGER
Power supply not disconnected
Danger to life!
▷ Pull the mains plug or disconnect all electrical connections and secure against
unintentional start-up.
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 minutes during prolonged shutdown periods.
This will prevent the formation of deposits within the pump and the pump
intake area.
The pump (set) is removed from the pipe and stored
ü The pump has been properly drained and the safety instructions for dismantling
the pump have been observed. (ðSection7.4.1,Page27)
1. Spray-coat the inside wall of the pump casing and, in particular, the impeller
clearance areas with a preservative.
2. Spray the preservative through the suction and discharge nozzles.
It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).
3. Oil or grease all exposed machined parts and surfaces of the pump (with
silicone-free oil and grease, food-approved if required) to protect them against
corrosion.
Observe the additional instructions .
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 instructions and information provided. (ðSection3,Page10)
6.4 Returning to service
For returning the equipment to service, observe the sections on commissioning/startup (ðSection6.1,Page20) and the operating limits. (ðSection6.2,Page22)
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (ðSection7,Page25)
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant
and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer
seals.
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7 Servicing/Maintenance
7.1 Safety regulations
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. For contact details please refer to the enclosed "Addresses"
booklet or visit "www.ksb.com/contact" on the Internet.
The operator ensures that maintenance, inspection and installation is performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.
DANGER
Electrical connection work by unqualified personnel
Danger of death from electric shock!
▷ Always have electrical work performed by a trained and qualified electrician
only.
▷ Observe regulations IEC60364 and HD637S1.
WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set.
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure.
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
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
Insufficient stability
Risk of crushing hands and feet!
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.
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A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump, pump set and pump parts with a
minimum of servicing/maintenance expenditure and work.
7.2 Servicing/inspection
7.2.1 Supervision of operation
DANGER
Incorrectly serviced shaft seal
Fire hazard!
Hot fluids escaping!
Damage to the pump set!
▷ Regularly service the shaft seal.
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing
seals
Fire hazard!
Damage to the pump set!
▷ Regularly check the rolling element bearings for running noises.
CAUTION
Increased wear due to dry running
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during
pump operation.
CAUTION
Impermissibly high temperature of fluid 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. (ðSection6.2,Page22)
While the pump is in operation, observe and check the following:
▪ The pump must run quietly and free from vibrations at all times.
▪ Check the shaft seal. (ðSection6.1.4,Page21)
▪ Check the static sealing elements for leakage.
▪ Check the rolling element bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured
on the outside of the motor housing).
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NOTE
After commissioning, increased temperatures may occur at grease-lubricated rolling
element bearings due to the running-in process. The final bearing temperature is
only reached after a certain period of operation (up to 48 hours depending on the
conditions).
7.3 Drainage/cleaning
WARNING
Fluids, 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 residues of the fluid
handled.
▷ Wear safety clothing and a protective mask if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Use the suction nozzle or discharge nozzle to drain the fluid handled.
2. Always flush the system if it has been used for handling noxious, explosive, hot
or other hazardous fluids.
Always flush and clean the pump before transporting it to the workshop.
Provide a certificate of decontamination for the pump. (ðSection12,Page36)
7.4 Dismantling the pump set
7.4.1 General information/Safety regulations
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set.
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure.
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
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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.
Always observe the safety instructions and information.
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly observe the exploded views and the general
assembly drawing. (ðSection9.1,Page32)
In the event of damage, you can always contact our service department.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. For contact details please refer to the enclosed "Addresses"
booklet or visit "www.ksb.com/contact" on the Internet.
NOTE
After a prolonged period of operation the individual components may be hard to
pull off the shaft. If this is the case, use a brand name penetrating agent and/or - if
possible - an appropriate puller.
7.5 Reassembling the pump set
7.5.1 General information/Safety regulations
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.
CAUTION
Improper reassembly
Damage to the pump!
▷ Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
▷ Use original spare parts only.
Sequence
Always re-assemble the pump in accordance with the corresponding general
assembly drawing or exploded view. (ðSection9.1,Page32)
Sealing elements
▪ O-rings
– Check O-rings for any damage and replace by new O-rings if required.
– Never use O-rings that have been made by cutting an O-ring cord to size and
gluing the ends together.
▪ Gaskets
– Always use new gaskets, making sure that they have the same thickness as
the old ones.
▪ Assembly adhesives
– Avoid the use of assembly adhesives if possible.
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Tightening torques
For reassembly, tighten all screws and bolts as specified in this manual.
(ðSection7.6,Page29)
7.6 Tightening torques
Table9: Tightening torques for bolted/screwed connections
Position Nominal value
[Nm]
Pump casing 10
Tie bolt 15
Impeller nut 10
7.7 Spare parts stock
7.7.1 Ordering spare parts
Always quote the following data when ordering replacement or spare parts:
▪ Type series
▪ Size
▪ Order number
▪ Order item number
▪ Series code
▪ Year of construction
Refer to the name plate for all data.
Also specify the following data:
▪ Part number and description
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)
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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.
A
Pump delivers insufficient flow rate
B
Motor is overloaded
C
Leakage at the pump
D
Excessive leakage at the shaft seal
E
Vibrations during pump operation
F
Impermissible temperature increase in the pump
Table10: Trouble-shooting
A B C D E F Possible cause Remedy
2)
✘ - - - - - ▪ Pump delivers against an excessively
high pressure.
▪ Check system for impurities.
✘ - - - ✘ ✘ ▪ Pump and/or piping are not
completely vented and/or primed.
▪ Vent and/or prime.
✘ - - - - - ▪ Supply line or impeller clogged ▪ Remove deposits in the pump and/or piping.
✘ - - - - - ▪ Formation of air pockets in the
piping
▪ Alter piping layout.
▪ Fit a vent valve.
✘ - - - - - ▪ Air intake at the shaft seal ▪ Supply external barrier fluid and/or increase its
pressure.
▪ Fit new shaft seal.
✘ - - - - - ▪ Wrong direction of rotation ▪ Check the electrical connection of the motor and
the control system, if any.
✘ - - - ✘ - ▪ Wear of internal components ▪ Replace worn components by new ones.
- ✘ - - ✘ - ▪ Pump back pressure is lower than
specified in the purchase order.
▪ Re-adjust to duty point.
- ✘ - - - - ▪ Density or viscosity of fluid handled
higher than stated in purchase order
▪ Contact KSB.
- - ✘ - - - ▪ Tie bolts/sealing element defective ▪ Replace sealing element at pump casing.
▪ Re-tighten the bolts.
- - - ✘ - - ▪ Worn shaft seal ▪ Fit new shaft seal.
- - - ✘ - - ▪ Dismantle to find out. ▪ Remedy.
▪ Fit new shaft seal, if required.
- - - ✘ ✘ - ▪ Pump is warped or sympathetic
vibrations in the piping.
▪ Check pipeline connections and secure fixing of
pump; if required, reduce the distances between
the pipe clamps.
▪ Fix the pipelines using anti-vibration material.
✘ ✘ - - - - ▪ Motor is running on 2 phases only. ▪ Replace the defective fuse.
▪ Check the electrical cable connections.
- - - - ✘ - ▪ Rotor out of balance ▪ Clean the impeller.
- - - - ✘ - ▪ Defective bearing(s) ▪ Replace.
2) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
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A B C D E F Possible cause Remedy
2)
✘ ✘ - - - ✘ ▪ Thermal motor protection device has
tripped.
▪ Verify that mains voltage matches the voltage
indicated on the name plate.
▪ Ensure that the motor ventilation openings are
clear.
✘ - - - - - ▪ Excessive pressure loss in the piping ▪ Check whether piping diameter is too small or
piping is clogged.
Page 32
9 Related Documents
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9 Related Documents
9.1 Exploded view and list of components
Fig.7: Exploded view (size MB-101-751)
Table11: List of components
Part No. Description
101 Pump casing
130 Casing part
182 Foot
210 Shaft
232 Clockwise impeller
233 Counter-clockwise impeller
321 Radial ball bearing
400 Gasket
412 O-ring
433 Mechanical seal
525 Spacer sleeve
529 Bearing sleeve
551 Spacer disc
81-22 Terminal box cover
82-26 Fan
811 Motor housing
812 Motor housing cover
Page 33
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Part No. Description
826 Cable gland
832 Fan hood
833 Terminal box
836 Terminal strip
837 Capacitor
900 Screw
901 Hexagon head bolt
903 Screw plug
905 Tie bolt
913 Vent plug
921 Shaft nut
932 Circlip
940 Key
941 Woodruff key
Page 34
10 EU Declaration of Conformity
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Emporia MB
10 EU Declaration of Conformity
Manufacturer: KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the product:
Emporia CP, Emporia MB, Emporia PD (T..., 3~)
Series code range: 2016w39 - 2018w52
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
– EN 60034-1, EN 60034-5/A1
Person authorised to compile the technical file:
Dr. Lutz Urban
Head of Product Development Standardised Water Pumps
KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The EU Declaration of Conformity was issued in/on:
Frankenthal, 1February2018
Thomas Heng
Head of Product Development Series Pumps
KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal
Page 35
11 EU Declaration of Conformity
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Emporia MB
11 EU Declaration of Conformity
Manufacturer: KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the product:
Emporia CP, Emporia MB, Emporia PD (M..., 1~)
Series code range: 2016w39 - 2018w52
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
– EN 60034-1, EN 60034-5/A1
– EN 60335-1/A1, EN 60335-2-41
Person authorised to compile the technical file:
Dr. Lutz Urban
Head of Product Development Standardised Water Pumps
KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The EU Declaration of Conformity was issued in/on:
Frankenthal, 1February2018
Thomas Heng
Head of Product Development Series Pumps
KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal
Page 36
12 Certificate of Decontamination
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Emporia MB
12 Certificate of Decontamination
Type: ................................................................................................................................
Order number/
Order item number3): ................................................................................................................................
Delivery date: ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled3): ................................................................................................................................
Please tick where applicable3):
Radioactive Explosive Corrosive Toxic
Harmful Bio-hazardous Highly flammable Safe
Reason for return3): ................................................................................................................................
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
3) Required fields
Page 37
Index
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Emporia MB
Index
A
Abrasive fluids23
Applications8
Assembly28
B
Bearings14
C
Certificate of decontamination36
Commissioning20
D
Design14
Designation13
Direction of rotation19
Dismantling28
Disposal12
Drive14
E
Event of damage
Ordering spare parts29
F
Faults30
Fluid handled
Density23
Frequency of starts22
I
Impeller type14
Installation16
Installation at site16
Intended use8
M
Mechanical seal21
Misuse8
N
Name plate13
O
Operating limits22
Operating pressure23
Order number6
Other applicable documents6
P
Partly completed machinery6
Permissible forces at the pump nozzles17
Piping17
Preservation24
Product description13
R
Reassembly28
Return to supplier11
Returning to service24
S
Safety7
Safety awareness9
Scope of supply15
Shaft seal14
Shutdown24
Spare part
Ordering spare parts29
Start-up21
Storage11, 24
T
Tightening torques29
Transport10
Page 38
Page 39
Page 40
KSB SE & Co. KGaA
Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com
5132.84/02-EN
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