KSB Meganorm Operation Manual

Operating Instructions
Nº A2742.8E/8

KSB Meganorm

Centrifugal pump for general use

1. Application

The KSB MEGANORM centrifugal pump is suitable for
handling chemical products, aggressive organic and
inorganic liquids, oil, water, condensate and other liquids,
and it is mainly used in the following applications:

- Sugar and alcohol industry

- Water supply

- Irrigation

- Air conditioning

- Fire fighting

- Drainage

2. Design

Horizontal, single-stage, end suction with top centerline
discharge. The “back-pull-out”design allows maintenance
and repair services through the backside, without
dismantling piping supports.
Dimensionally built to ISO 2858/DIN 24256 and
mechanically to ANSI B73.1.

Line :
Standard :

Mega

ISO 2858

3. Designation

Trade Mark
Model / Type
Discharger Nozzle Diameter (mm)
Nominal Impeller Diameter(mm)

KSB Meganorm 80 - 200

4. Operating data

Sizes - DN 25 up to 150 ( 1 ¼” to 6’)
Flow - up to 3,082 gpm (700 m3/h)
Head - to 460 ft (140 m)
Temperature - to 221ºF (105º C)
Max. Suction pressure - to 145 psi (10 bar)
Speed - to 3,500 rpm

5. Introduction

KSB has supplied you with equipment that has been
designed and manufactured with the most advanced
technology. Due to its simple and tough construction it will
not need much maintenance. With the aim of provid ing our
clients with a satisfactory, trouble free operation, we
recommend to install and care our equipment according to
the instructions contained in this service manual.

Place for description
of type and size of
the pump.

Meganorm

This manual has been prepared to inform the end user
about the construction and operation of our pumps,
describing the adequate procedures for handling and
maintenance. We recommend that this manual should be
handled by the maintenance supervision.
This equipment should be used in the operational
conditions for which it was selected as to: flow rate, total
head, speed, voltage, frequency, and temperature of
pumped liquid

Place for description
of manufacturer data.

Place for order number

Fig. 1 –Nameplate

For requests about the product, or when ordering spare
parts, please indicate the type of pump and the Production
Order nº (serial nº). This information can be obtained from
the nameplate on the actual pump. If the nameplate is not
available, the PO nº is engraved in low relief on the suction
flange, and on the discharge flange you may find the

Attention

instructions and recommendations. Its careful reading
is an obligation before installation, electrical
connections, first starting and maintenance.

: This manual contains very important

impeller diameter.

Contents

Denomination Chapter Denomination Chapter

Application
Design
Designation
Operating data
Introduction
Technical data
Transportation
Preservation and storage of idle pumps

1
2
3
4
5
6
7
8

Installation
Operation
Maintenance
Explode view/Parts list
Recommended spare parts
Special recommendations
Pressure limit x Maximum temperature
Wearing areas maintenance

9
10
11
12
13
14
15
16

2

Meganorm

6. Technical data

Pump sizes

Units.

100-250 *

100-315

100-400 e

125-200 *

125-250

125-315

125-400 e

150-200

150-250

100-160

100-200 d

65-315

80-315

40-315

50-315

80-200 d

65-250 d

50-125

32-160

32-200.1 d

32-200 d

40-125

32-125.1

32-125

Technical data
Bearing bracket A 30 A 40 A 50 A60

25-150

32-160.1

25-200 d

40-160

40-200 d

50-160

32-250 d

50-200 d

80-160

65-160

65-200 d

50-250 d

40-250 d

65-125

32-250.1 d

80-250 d

80-400 e

150-315

150-400 e

mm

Width of impeller
passage

WR2 with water

Max. rot. speed rpm 3500 1750 3500 1750
Max. suction pressure bar/(psi) 10 / (145) d e

Max. discharge pressure
x Temp.

Packing

Shaft
Seal

Mech. seal f inch 1 3/8 1 3/4 2 3/8 2 3/4

Axial thrust balance ­Min./max. flow - 0.1 Qopt / 1.1 Qopt 0.15 Qopt / 1.1 Qopt
Flanges - ANSI B 16.1 125 Lb FF 250 Lb FF
Rotation direction - Clockwise, seen from driver end

Bearings

inch

kg m²

lb.ft

bar/(psi) See table 7

mm 10 12,5
inch 3/8 1/2

Ball bearings 2x

6 7 9 5 5 6 6

5,5

3/16

4/16

0.0214

0.0591

2

0.127

0.350

c

4/16

6/16

0.0140

0.0142

0.083

0.084

14

12 9 20

3/16

3/16

4/16

4/16

9/16

8/16

6/16

13/16

0.0224

0.0238

0.0760

0.0786

0.0144

0.0336

0.0640

0.0189

0.132

0.141

0.451

0.466

0.085

0.199

0.379

0.112

6306 C 3 6308 C 3 6310 C 3

16

11

7/16 1 5/16

10/16

0.0394

0.0750

0.233

0.445

8 8 8

25

0.0263

0.1800

0.156

1.068

12

21

17

5/16

5/16

8/16

13/16

11/16

0.1820

0.1880

0.1920

0.0521

0.0985

1.079

1.115

1.139

0.309

0.584

By bored hole on impeller

125LbFF

9

31

6/16

1 4/16

0.0641

0.4396

0.380

2.608

y y y yy

9

13

6/16

8/16

0.4800

0.2232

2.847

1.324

23

19

14/16

12/16

0.1568

0.2904

0.930

1.722

36

32

1 7/16

1 4/16

0.1040

0.1800

0.617

1.067

13

18

13

27

23

8/16

8/16

10/16

14/16

1 1/16

0.5120

0.5696

1.2788

0.3172

0.6100

3.037

3.379

7.587

1.881

3.619

ANSI B 16.1 125 Lb FF

17

40

11/16

1 9/16

1.3832

0.2230

8.206

1.323

37

30

1 7/16

1 3/16 1 2 5/16

0.4100

0.7740

2.432

4.592

25

59

1.6912

0.2918

1.731

10.033

48

39

1 9/16

1 14/16

0.4656

0.8680

2.762

5.149

6312 C 3

33

1 5/16

1.8600

11.035

Drive (P/n value)
Shaft SAE 1045

Weight Cast iron

Lubrication

HP/rpm 0.0176 0.0458 0.100

kg

32

40

34

35

34

34

42

44

38

38

49

40

42

47

49

68

68

73

lb

70

88

75

77

75

75

92

97

84

84

88

92

108

104

108

150

150

161

72

159

70

154

Oil

61

134

89

196

104

229

108

238

89

196

92

202

106

233

105

231

108

238

126

278

132

291

162

357

132

291

142

313

178

392

136

300

157

346

156

344

Table 1 y125Lb FF yy250 Lb FF
*For sizes 100-250 and 125-200 max. speed = 2.900 rpm.

cFor size 25-200 by bored holes on impeller, for sizes 25-150; 32-125.1 and 32-12 5 without axial thrust balance.
deThe maximum suction pressure for pumps with mechanical seal is 5 bar (73 psi), except for sizes d in 3500 rpm
and e in 1750 rpm which are limited by sum of inlet pressure and work pressure not exceeding 10 bar (145 psi).
fMaterials: stationary face in ceramic, rotating face in carbon, seals in Buna-N.

Not recommended for liquids containing solids.
Other materials upon request.

193

425

183

403

192

423

3

0.158

246

542

280

617

7. Transportation

Skilled, trained personnel should perform the transportation
of the pump-motor assembly or bare shaft pump. Even so,
safety regulations should be observed. On lifting, the motor
lug should be used to carry the motor only and never the
pump-motor assembly.

Fig. 2 – Transportation of the pump through the discharge

flange.

Fig. 3 – Transportation of the pump-motor assembly

Be sure that the coupling guard and foundation bolts

NOTE:

are not lost or damaged during transportation.

8. Preservation and storage of idle
pumps

Following procedures of preservation and storage are made
by KSB and its Dealer Network and protect the equipm ent
up to 6 months in an indoor environment. It is client
responsibility to keep these procedures after receiving the
pump.
When the pump is not subjected to a performance test after
its sale, the areas in contact with the pumped liquid which
are not painted (i.e. stuffing box housing, wear rings, flange
sealing areas, etc), receive an application of RUST ILO DW­301 by brush.
When the pump is equipped with packing and is subjected to
a performance test, it is drained after the test without

Meganorm

disassembling it, and then filled up with RUSTILO DW-

301 rotating its rotor assembly in order to improve
RUSTILO application. After this operation, the pump
should be drained again.
Exposed shaft areas (i.e. shaft end, area between the
gland cover and the bearing bracket) receive a brush
application of TECTYL 506.
On oil lubricated bearing brackets, the bearings receive
a layer of MOBILARMA 524 by spray.
The pump must be protected against material damage,
humidity, dust and aggressive environment i n an i ndoor
place.

8.1 Additional procedures of preservation and
storage of idle pumps

- Pumps stored for periods exceeding one year
should be serviced every 12 months. They should
be disassembled, cleaned and the whole
preservation process described below should be
repeated.

- PACKING equipped pumps should have their
packing removed before storage.

- MECHANICAL SEALS should be cleaned by
compressed air. No other liquid or material
should be applied to them in order to prevent
damage to the secondary sealings as to o-ring
gaskets.

- All connections as inlets for liquids from external
sources, priming, draining, flushing and cooling
should be closed. SUCTION AND DISCHARGE
FLANGES SHOULD BE COVERED to prevent the
entry of strange bodies.

- Assembled pumps waiting to be installed or to start
operation should be turned manually every 15
days. If it is difficult to move them by hand, use a
box spanner, protecting the shaft surface at the
point of application.

- Before conservation liquids application, areas
should be washed with gasoline or kerosene until
they are completely cleaned.

4

Characteristics of the protecting liquids used for pump preservation purposes:

Protecting liquid

Thickness of the applied

layer (μm)

Drying time Removal Manufacturer

Meganorm

TECTIL 506 from 80 to 100 ½ up to 1 hour

RUSTILO DW 301 from 6 to 10 1 up to 2 hours Gasoline, benzene Castrol

MOBILARMA 524

≤ 6

Table 2 – Protecting liquids

9. Installation

Our pumps should be installed, leveled and aligned b y skill ed
and trained personnel. When this service is done incorrectly,
it will originate operational troubles, premature wear and
damage beyond repair.

9.1 Base grouting

Place the foundation bolts in the holes or slots of the
foundation block according to boring design as shown on the
foundation drawing.
Between the base and the foundation block and beside the
foundation bolts, metallic chocks of the same height should
be fixed with grout together with the foundation bolts, to
serve as support for the base.
In order to achieve a perfect adherence to the grout, the
chock blocks and foundation bolts should be free of any
grease or oil residues. After the grout set is compl eted, place
the base on the foundation block (non-shrinking mortar is
highly recommended). Please see Fig. 4.

does not dry Not necessary Mobil Oil

.

Note: After leveling the base and before concrete fulfill, the
motor-pump set must be pre-aligned according to the
instructions of item 9.4.

9.3 Grouting

In order to get a good, vibration-free operation, the pump
base plate must be filled with grout.
Grout should be made of specific compounds available in the
civil construction market, which prevent shrinkage through
grout setting process as well as full base filling and does not
allow blanks or gaps. Please see Fig. 6a

Gasoline, benzene

diesel Oil

Fig. 5 – Base leveling

Brascola

Fig. 4 – Base grouting

9.2 Base leveling

Check if the base plate is equally resting on its chock blocks,
if it is correctly set, place and tighten uniformly the nuts on
the foundation bolts. With the help of a precision lev el, check
the leveling of the base longitudinally and transversally.
If the base plate is out of level, loosen the foundation bolt
nuts and insert shims, as necessary, between the metallic
chock block and the base, in order to correct the leveling.
Please see fig.5.

Fig. 6a-Base fulfill with grout

9.3.1 Execution with adjustment screws

When adjustment screws are used under motor side
surrounding areas should be free of concrete. Protecting
tubes should be used, in order permit future adjustments to
align the equipments. See fig.6b.

5