KSB MK, MKA, MKB, MK2 MK0, MK1 Operating Manual

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Waste Water, Condensate and Heat Transfer Fluid Pump

Installation/Operating Manual

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Legal information/Copyright

Installation/Operating Manual MK

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.

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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

1.6 Key to safety symbols/markings.......................................................................................................................7

2 Safety...................................................................................................................................................... 8

2.1 General..............................................................................................................................................................8

2.2 Intended use .....................................................................................................................................................8

2.2.1 Prevention of foreseeable misuse.......................................................................................................8

2.3 Personnel qualification and training...............................................................................................................8

2.4 Consequences and risks caused by non-compliance with this manual .........................................................9

2.5 Safety awareness ..............................................................................................................................................9

2.6 Safety information for the operator/user.......................................................................................................9

2.7 Safety information for maintenance, inspection and installation ................................................................9

2.8 Unauthorised modes of operation................................................................................................................10

2.9 Explosion protection ......................................................................................................................................10

2.9.1 Marking ..............................................................................................................................................10

2.9.2 Temperature limits.............................................................................................................................10

2.9.3 Monitoring equipment......................................................................................................................11

2.9.4 Operating limits .................................................................................................................................11

3 Transport/Temporary Storage/Disposal............................................................................................. 12

3.1 Checking the condition upon delivery..........................................................................................................12

3.2 Transport.........................................................................................................................................................12

3.3 Storage/preservation......................................................................................................................................12

3.4 Return to supplier...........................................................................................................................................13

3.5 Disposal ...........................................................................................................................................................14

4 Description of the Pump (Set)............................................................................................................. 15

4.1 General description ........................................................................................................................................15

4.2 Designation.....................................................................................................................................................15

4.3 Name plate......................................................................................................................................................15

4.4 Design details..................................................................................................................................................16

4.5 Configuration and function...........................................................................................................................17

4.6 Noise characteristics .......................................................................................................................................19

4.7 Scope of supply...............................................................................................................................................19

5 Installation at Site................................................................................................................................ 20

5.1 Safety regulations...........................................................................................................................................20

5.2 Checks to be carried out prior to installation...............................................................................................20

5.3 Fitting and setting the float switch control (optional) ................................................................................20

5.3.1 Control elements for MK/MKA .........................................................................................................20

5.3.2 Control element for MKY..................................................................................................................23

5.4 Installing the pump set ..................................................................................................................................23

5.5 Connecting the piping ...................................................................................................................................23

5.6 Permissible forces and moments at the pump nozzles ................................................................................24

5.7 Electrical connection ......................................................................................................................................24

5.8 Checking the direction of rotation................................................................................................................25

6 Commissioning/Start-up/Shutdown................................................................................................... 27

6.1 Commissioning/Start-up.................................................................................................................................27

6.1.1 Prerequisites for commissioning/start-up .........................................................................................27

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6.1.2 Filling in lubricants.............................................................................................................................27

6.1.3 Start-up...............................................................................................................................................27

6.1.4 Shutdown ...........................................................................................................................................28

6.2 Operating limits..............................................................................................................................................29

6.2.1 Ambient temperature........................................................................................................................29

6.2.2 Frequency of starts.............................................................................................................................29

6.2.3 Fluid handled .....................................................................................................................................30

6.3 Shutdown/storage/preservation ....................................................................................................................31

6.3.1 Measures to be taken for shutdown ................................................................................................31

6.4 Returning to service .......................................................................................................................................32

7 Servicing/Maintenance........................................................................................................................ 33

7.1 Safety regulations...........................................................................................................................................33

7.2 Servicing/Inspection........................................................................................................................................34

7.2.1 Supervision of operation...................................................................................................................34

7.2.2 Lubrication and lubricant change.....................................................................................................35

7.3 Drainage/cleaning ..........................................................................................................................................39

7.4 Dismantling the pump set..............................................................................................................................40

7.4.1 General information/Safety regulations...........................................................................................40

7.4.2 Removing the pump set from the piping.........................................................................................40

7.4.3 Dismantling the pump section ..........................................................................................................41

7.5 Reassembling the pump set...........................................................................................................................43

7.5.1 General information/Safety regulations...........................................................................................43

7.5.2 Reassembling the pump section .......................................................................................................44

7.6 Tightening torques.........................................................................................................................................48

7.7 Spare parts stock.............................................................................................................................................48

7.7.1 Ordering spare parts..........................................................................................................................48

7.7.2 Recommended spare parts stock for 2 years' operation to DIN24296 ..........................................48

8 Trouble-shooting.................................................................................................................................. 50

9 Related Documents.............................................................................................................................. 52

9.1 General assembly drawings/exploded views with list of components........................................................52

9.1.1 MK, MKA ............................................................................................................................................52

9.1.2 MK, MKA - grease-lubricated............................................................................................................53

9.1.3 MK, MKA - internally lubricated by fluid handled ..........................................................................54

9.1.4 MK, MKA - lubricated by an external fluid ......................................................................................55

9.1.5 MKY ....................................................................................................................................................57

10 EU Declaration of Conformity............................................................................................................. 59

11 Certificate of Decontamination........................................................................................................... 60

Index ..................................................................................................................................................... 61

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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.

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

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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 and size, the main operating data, the order number and the order item number. The order number and order item number clearly 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.

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. (ðSection2.3,Page8)

1.4 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Data sheet Description of the technical data of the pump (set) General arrangement drawing/

outline drawing

Description of mating and installation dimensions for the pump (set), weights

Hydraulic characteristic curve Characteristic curves showing head, NPSH

required

efficiency and power input

General assembly drawing

Sectional drawing of the pump

Sub-supplier product literature1)Operating manuals and other product literature

describing accessories and integrated machinery components

Spare parts lists

Description of spare parts

Piping layout

Description of auxiliary piping

List of components

Description of all pump components

For accessories and/or integrated machinery components, observe the relevant manufacturer's product literature.

1.5 Symbols

Table2: 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 to be included in the scope of supply

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1 General

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Symbol Description

Step-by-step instructions

Note Recommendations and important information on how to handle the product

1.6 Key to safety symbols/markings

Table3: 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.

Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with EU Directive 2014/34/EU (ATEX).

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.

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2 Safety

DANGER

All the information contained in this section refers to hazardous situations. In addition to the present general safety information the action-related safety

information given in the other sections must be observed.

2.1 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.

2.2 Intended use

▪ The pump (set) must only be operated in the fields of application and within the

use limits specified 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 minimum flow rate and maximum flow rate 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.

2.2.1 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 application and operating limits specified in the

data sheet or product literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.3 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain and inspect the machinery this manual refers to.

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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.

2.4 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with these operating instructions 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

2.5 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 regulations and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards, directives and laws

2.6 Safety information for the operator/user

▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪ Do not remove any protective equipment (e.g. 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.

2.7 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the pump (set) are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts/components authorised by the

manufacturer. The use of other parts/components 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.

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▪ Only perform work on the pump set when it has been disconnected from the

power supply (de-energised).

▪ The pump (set) 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. (ðSection6.3,Page31)

▪ 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. (ðSection6.1,Page27)

2.8 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. (ðSection2.2,Page8)

2.9 Explosion protection

DANGER

Always observe the information on explosion protection given in this section when operating the product in potentially explosive atmospheres.

Only pumps/pump sets marked as explosion-proof and identified as such in the data sheet may be used in potentially explosive atmospheres.

Special conditions apply to the operation of explosion-proof pump sets to EU Directive 2014/34/EU (ATEX). Especially adhere to the sections in this manual marked with the symbol opposite and the following sections, (ðSection2.9.1,Page10) to (ðSection2.9.4,Page11) The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. Never operate the pump set outside the limits stated in the data sheet and on the name plate. Prevent impermissible modes of operation at all times.

2.9.1 Marking

Pump The marking on the pump refers to the pump part only.

Example of such marking: II 2 G c TX (EN 13463-1) or II 2G Ex h IIC T5-T1 Gb (ISO 80079-36)

The pump complies with the requirements of type of protection constructional safety "c" to ISO80079-37.

Refer to the data sheet for the applicable temperature class.

Motor The motor has its own marking. The marking is maintained on the condition that the

temperatures the pump causes to develop at the motor flange and motor shaft are permitted by the motor manufacturer. The motors used by KSB on pumps with ATEX certification meet this condition.

2.9.2 Temperature limits

In normal pump operation, the highest temperatures are to be expected at the surface of the pump casing, the pipe assembly, the plain bearings and in the bearing areas. The surface temperature at the pump casing corresponds to the temperature of the fluid handled. If the pump is heated in addition, the operator of the system is responsible for observing the specified temperature class and fluid temperature (operating temperature). The table below lists the temperature classes and the resulting theoretical temperature limits of the fluid handled (a potential temperature rise in the shaft seal area has been taken into account).

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The temperature class specifies the maximum permissible temperature at the surface of the pump set during operation. For the permissible operating temperature of the pump in question refer to the data sheet.

Table4: Temperature limits

Temperature class to EN 13463-1 or ISO

80079-36

Maximum permissible fluid temperature

T1 90°C T2 90°C T3 90°C T4 90°C T5 80°C

Temperature class T5 Temperature class T5 can only be complied with if the bearing temperature is limited

to 80°C. Misuse, malfunctions or non-compliance with the instructions may result in

substantially higher temperatures. If the pump is to be operated at a higher temperature, if there is no data sheet or if

the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature.

2.9.3 Monitoring equipment

The pump (set) must only be operated within the limits specified in the data sheet and on the name plate. If the system operator cannot warrant compliance with these operating limits, appropriate monitoring devices must be used. Check whether monitoring equipment is required to ensure that the pump set functions properly.

Contact KSB for further information on monitoring equipment.

Bearing temperature monitoring

If temperature class T5 is to be complied with, the bearing temperature must be monitored. For this purpose, the pump must be equipped with a temperature sensor at the drive-end fixed bearing (G 1/8 connection, DIN 3852). The temperature sensor must be operated with an ATEX-approved transducer providing explosion protection for the sensor. The bearing temperature must be monitored so as to ensure it does not exceed 80°C.

2.9.4 Operating limits

The minimum flows indicated in (ðSection6.2.3.1,Page30) refer to water and water-like fluids handled. Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures at the pump surface. However, if the physical properties of the fluids handled are different from water, it is essential to check whether an additional heat build-up may occur and if the minimum flow rate must therefore be increased. The calculation formula in (ðSection6.2.3.1,Page30) can be used to check whether additional heat build-up may lead to a dangerous temperature increase at the pump surface.

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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

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.

▷ Observe the information about weights, centre of gravity and fastening points. ▷ Observe the applicable local accident prevention regulations. ▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.

CAUTION

Incorrect transport of the pump

Damage to the shaft seal!

▷ For transport, lock the pump shaft with a suitable transport lock to prevent any

movement of the shaft.

To transport the pump/pump set suspend it from the lifting tackle as shown.

Fig.1: Transporting the complete pump set

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that the following measures be taken for pump (set) storage.

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CAUTION

Damage during storage due to humidity, dirt or vermin

Corrosion/contamination of the pump (set)!

▷ For outdoor storage cover the pump (set) or the packaged pump (set) and

accessories with waterproof material.

CAUTION

Wet, contaminated or damaged openings and connections

Leakage or damage to the pump!

▷ Clean and cover pump openings and connections as required prior to putting

the pump into storage.

Store the pump (set) in a dry, protected room where the atmospheric humidity is as constant as possible.

Rotate the shaft by hand once a month, e.g. via the pump impeller. If properly stored indoors, the equipment is protected for a maximum of 12 months.

New pumps/pump sets are supplied by our factory duly prepared for storage. For storing a pump (set) which has already been operated, observe the instructions in

(ðSection6.3.1,Page31) .

3.4 Return to supplier

1. Drain the pump as per operating instructions. (ðSection7.3,Page39)

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 has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen also neutralise the pump and blow through with anhydrous inert gas to ensure drying.

4. Always complete and enclose a certificate of decontamination when returning the pump. Indicate any safety measures and decontamination measures taken. (ðSection11,Page60)

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 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.

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4 Description of the Pump (Set)

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4 Description of the Pump (Set)

4.1 General description

▪ Waste water, condensate and heat transfer fluid pump

Pump for handling waste water, oils, emulsions, condensate, heat transfer fluids and aggressive fluids.

4.2 Designation

MK A - B 20 - 1/ 100

Table5: Designation key

Code Description

MK Type series A Design

Pump without discharge pipe, without cover plate, with motor

A Pump with square mounting/cover plate and discharge pipe, with

motor

Y Pump with round mounting/cover plate and flanged discharge

pipe, with lantern, gland packing and motor

B Casing material

Grey cast iron B Tin bronze C Chrome nickel molybdenum cast steel

2 Pipe connection

2 Rp 2

0 Design status 1 Power code (defines the impeller diameter)

1 - 6

100 Installation depth [cm]

100, 190, 280

4.3 Name plate

No. 9971402925/ 000200 / 01

Q 10 m3/h H 3 m

n 1450 1/min

Ident.-No. 00 391 209 AN 886-82

2016

MKA-B 20-1/100

Johann-Klein-Straße 9

Deutschland

67227 Frankenthal

KSB SE & Co. KGaA

Fig.2: MK name plate (example)

1 Type series, size and version 2 KSB order number

(ten digits) 3 Flow rate 4 Direction of rotation 5 Year of construction 6 Order item number

(six digits)

2) Blank

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4 Description of the Pump (Set)

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7 Consecutive number

(two digits)

8 Head

9 Speed

4.4 Design details

Design

▪ Volute casing ▪ Vertical installation ▪ Rigid connection between pump and motor ▪ Single-stage

Drive

▪ KSB surface-cooled IEC three-phase current squirrel-cage motor ▪ 230/400V ▪ Type of construction V1 ▪ Enclosure IP55 ▪ Motors integrated in explosion-proof pump sets are supplied in Ex eb IIB / Ex db

eb IIC type of protection.

Shaft seal

MK, MKA:

▪ Vapour barrier

MKY:

▪ Gland packing

Impeller type

▪ Three-channel impeller

Bearings

Drive end:

▪ Radial ball bearing ▪ Greased for life

Impeller end:

▪ Bearing bush ▪ Product-lubricated ▪ Optional:

– Internal lubrication by fluid handled – Grease lubrication – Lubrication by external fluid

Explosion protection

MK, MKA:

▪ Available ▪ For explosion-proof variants one of the optional lubrication types must be used

for the bearing bush.

MKY:

▪ Not available

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4.5 Configuration and function

MKA

13 14

Fig.3: MK, MKA

1 Thrust and radial bearing 2 Radial ball bearing 3 Shaft 4 Support column 5 Discharge pipe 6 Bearing bush 7 Volute casing 8 Motor 9 Cover plate 10 Shaft coupling

11 Vapour barrier 12 Overflow opening 13 Radial bearing 14 Impeller 15 Clearance gap

Design The vertical non-self-priming submerged pump in single-stage, single-entry design

features an axial fluid inlet and a radial fluid outlet. At the drive end the rotor is axially and radially supported by a radial ball bearing

which is greased for life; at the impeller end it is radially supported by a productlubricated bearing bush. It is connected to the motor by a rigid coupling sleeve. Various installation depths can be accommodated by up to three support column sets and matching incremental lengths of the shaft assembly. The required radial bearings are lubricated by the fluid handled. As an alternative, external lubrication can be used. To protect the drive-end radial ball bearing the shaft is enclosed by a vapour barrier below the thrust and radial bearing. For pump sets installed with a cover plate (MKA) the discharge nozzle of the volute casing is connected to the plate via a discharge pipe.

Function The uniformly rotating impeller of the submerged pump transfers mechanical energy

to the fluid passing through. The fluid enters the pump set vertically via the suction nozzle and is accelerated outward by the rotating impeller. In the flow passage of the volute casing the kinetic energy of the fluid handled is converted into pressure energy. The fluid leaves the pump set via the discharge nozzle. The clearance gap minimises the fluid flowing back from the volute casing into the suction nozzle. On the rear side of the impeller, the hydraulic system extends up to the radial bearing with bearing bush. The shaft passes through the radial bearing.

Sealing Apart from a vapour barrier protecting the fixed bearing the pump set is seal-less. A

small amount of leakage flows into the support column at the shaft passage and then through the overflow opening back into the tank.

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MKY

6 7

8 9

14 15

Fig.4: MKY

1 Discharge pipe 2 Bearing bush 3 Volute casing 4 Motor 5 Radial ball bearing 6 Thrust and radial bearing 7 Shaft coupling 8 Drive lantern 9 Shaft seal 10 Shaft

11 Support column 12 Overflow opening 13 Radial bearing 14 Impeller 15 Clearance gap

Design The vertical non-self-priming submerged pump in single-stage, single-entry design

features an axial fluid inlet and a radial fluid outlet. Above the drive lantern the rotor is axially and radially supported by a radial ball

bearing which is greased for life; at the impeller end, it is radially supported by a product-lubricated bearing bush. It is connected to the motor by a rigid coupling sleeve. Various installation depths can be accommodated by up to three support column sets and matching incremental lengths of the shaft assembly. The pump set is installed in a drive lantern. The discharge nozzle of the volute casing is connected to the lantern via a discharge pipe. The discharge pipe ends in a flanged bend.

Function The uniformly rotating impeller of the submerged pump transfers mechanical energy

to the fluid passing through. The fluid enters the pump vertically via the suction nozzle and is accelerated outward by the rotating impeller. In the flow passage of the volute casing the kinetic energy of the fluid handled is converted into pressure energy. The fluid leaves the pump via the discharge nozzle. The clearance gap minimises the fluid flowing back from the volute casing into the suction nozzle. On the rear side of the impeller, the hydraulic system extends up to the radial bearing with bearing bush. The shaft passes through the radial bearing.

Sealing The pump set is sealed towards the fixed bearing with a shaft seal (gland packing).

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4.6 Noise characteristics

Table6: Surface sound pressure level L

Rated power input

PN [kW]

Pump set

1450 rpm

[dB]

2900 rpm

[dB]

0,55 52 0,75 57 64

1,1 - 64 1,5 - 65 2,2 - 66

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Pump

Drive

▪ Surface-cooled IEC frame three-phase squirrel-cage motor

Special accessories

▪ As required

Soleplate

MK:

▪ Without baseplate

MKA:

▪ Baseplate accommodating pump and motor

MKY:

▪ Baseplate integrally cast with the lantern

Monitoring equipment (optional)

▪ Temperature sensor at the drive-end fixed bearing with G 1/8 threaded

connection

Level control system (optional)

▪ Level control system with rod-actuated float switch ▪ Level control system with magnetic float switch ▪ Level control system with EURO float switch

3) Spatial average; as per ISO 3744; valid for pump operation in the Q/Qopt = 0.80 - 1.1 range and for non-cavitating operation. If noise levels are to be guaranteed: add +3dB for measuring and constructional tolerance; the above values apply to the pump set without cover plate. If a cover plate is fitted, this value may increase by up to 2 pA (dB).

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5 Installation at Site

5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheres

Explosion hazard! Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information in the data sheet and on the name plates of pump and

motor.

DANGER

Improper cleaning of coated pump surfaces

Explosion hazard by electrostatic discharge!

▷ When cleaning coated pump surfaces in atmospheres of Explosion groupIIC,

use suitable anti-static equipment.

5.2 Checks to be carried out prior to installation

Check the structural requirements. The structural work required must have been prepared in accordance with the dimensions stated in the outline drawing and/or general arrangement drawing.

5.3 Fitting and setting the float switch control (optional)

5.3.1 Control elements for MK/MKA

5.3.1.1 Rod-actuated float switch control

The pump set is controlled by a switch fitted on the motor flange. The switch is actuated by a float via a switch rod with stop clamps.

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Fitting the rod-actuated float switch

74-4

574

901.52

930.52

575.52

500.50

930.52

920.52

81-45

900.51

550.51 570

900.50

920.50

733.51

481

733.52

68-3

550.51

920.51

575.51

902.12

920.12

710.01

920.11

550.11

400.11

Fig.5: Fitting the rod-actuated float switch

a) b) c)

A A B B C C

Fig.6: Positioning the rod-actuated float switch for installation depth: a) 1000mm; b) 1900mm; c) 2800mm

A 1000 mm B 1900 mm C 2800 mm

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Fig.7: Float switch a) installation position; b) switching position

1. Fasten strip 575.51 to the motor flange and strip 575.52 to the pump casing with hexagon head bolt 901.52, hexagon nut 920.52 and spring washers 930.52.

2. Mount float switch 81-45 on strip 575.51 using hexagon socket head cap screws

900.51, discs 550.51 and nuts 920.51.

3. Fit the lever on float switch 81-45.

4. Assemble guide rod 574 with float 74-4 and the two upper adjusting rings

500.50.

5. Run the guide rod through strip 575.52 and fit adjusting ring 500.50 beneath the strip.

6. Connect the lever and the guide rod using hexagon socket head cap screw

900.50 and hexagon nut 920.50.

7. If applicable, fit bellows 481 and hose clamp 733.51 on the guide rod.

8. Fasten the bellows on cover plate 68-3 with hose clamp 733.52.

9. Position adjusting rings 500.50 in the desired switching levels above and below the float, respectively, to start and stop the pump as required.

10. Adjust the switching mechanism of float switch 81-45 such that the lever is angled 42° off the horizontal in non-actuated position, see illustration of float switch a) installation position. In installed condition, the lever position must be as shown in the illustration of the float switch b) switching position.

ð As the float rises, the lever is lifted into the position shown and contact 15-16

closes.

11. Check that the rod-actuated float switch functions properly.

5.3.1.2 Magnetic float switch control (non-ATEX applications only)

Pump sets for installation depths of 1000 and 1900mm are controlled by a magnetic float switch arrangement. It is equipped with a sensor tube with integrated dry-reed contacts. The float with integrated permanent magnets can move freely along the sensor tube and activates the dry-reed contacts when it reaches the minimum and maximum fluid levels. The fluid levels are permanently pre-set by means of adjusting rings.

Fitting the magnetic float switch control

1. Remove the plug from the G3/4 through-hole in the cover plate.

2. Tightly screw the magnetic float switch arrangement into the G3/4 hole provided.

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NOTE

The switching points - measured from the cover plate - are located at 300mm for "ON" and 800mm (for installation depth 1000mm) or 1700mm (for installation depth 1900mm) for "OFF" and cannot be altered. The max. contact rating is 1 A; for MK pumps separately at the tank.

5.3.1.3 EURO float switch control (non-ATEX applications only)

The pump set is started/stopped by the float switch in response to the fluid level. The free length of the float's connection cable (= length from the attachment point

to the float switch) defines the fluid levels for starting/stopping the pump. Float switches with 5, 10 or 20 m connection cable must only be used for fluids with a

maximum temperature of 70 °C.

5.3.2 Control element for MKY

Pump sets installed in heat transfer fluid and recirculating systems usually do not need any control elements.

If the pump set is used for handling condensate at temperatures of up to 110°C and is installed at installation depths of 1000mm or 1900mm, it can be equipped with magnetic float switch control. (ðSection5.3.1.2,Page22)

5.4 Installing the pump set

ü The installed motor is protected against flooding. ü Motor and (optional) float switch are located outside the pit or tank. ü Motor and (optional) float switch are ventilated and protected against moisture.

1. Remove the transport plugs from the volute casing and the discharge pipe.

2. For pump sets with installation depths of 1900mm and 2800mm without cover plate (MK) fit the pipe union 731, which is supplied separately strapped to the pump. (ðSection9.1.2,Page53) (ðSection9.1.4,Page55)

3. Place the pump set on the floor of a pit (approximately 500x500mm) or, if the pump set is installed in a tank, fit it to the tank edge with a cover plate.

4. If the pump set is installed in a pit without a cover plate and angular frame, secure it to the pit wall using mounting clamps.

5.5 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 on the piping

Destruction of rolling element bearings (pitting effect)!

▷ Never earth the electric welding equipment on the pump or soleplate. ▷ Prevent current flowing through the rolling element bearings.

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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.

NOTE

If the pump is used for automatic drainage, fit a non-return or check valve.

ü The nominal diameters of the pipelines are equal to or greater than the nominal

diameters of the pump nozzles.

ü Adapters to larger nominal diameters are designed with a diffuser angle of

approx. 8° to avoid excessive pressure losses.

ü A flow velocity of 2-3m/s is recommended. 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!

▷ Free the piping from any impurities.

3. If required, fit a suction strainer upstream of the pump nozzle.

4. Connect the discharge-side pump nozzle with the piping.

CAUTION

Aggressive flushing liquid and pickling agent

Damage to the pump!

▷ Match the cleaning operation mode and duration of flushing and pickling to

the casing materials and seal materials used.

5.6 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.

5.7 Electrical connection

DANGER

Incorrect electrical installation

Explosion hazard!

▷ For electrical installation, also observe the requirements of IEC 60079-14. ▷ Observe the manufacturer's product literature supplied with the motor. ▷ Observe the manufacturer's product literature supplied with the float switch if

float switch control is used.

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DANGER

Electrostatic charging

Explosion hazard! Damage to the pump set!

▷ Connect the potential equalisation conductor to the earthing terminal

provided.

▷ Make sure that the connection between pump and baseplate is electrically

conductive.

▷ Screws, bolts, nuts and shims must not be coated or the coating must be

removed.

▷ Provide potential equalisation between the pump set and the foundation.

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, EN60079.

WARNING

Incorrect connection to the mains

Damage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

NOTE

A motor protection device is recommended.

1. Check the available mains voltage against the data on the motor name plate.

2. Select an appropriate starting method.

5.8 Checking the direction of rotation

DANGER

Pump set running dry

Explosion hazard!

▷ Check the direction of rotation of explosion-proof pump sets outside

potentially explosive atmospheres.

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.

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CAUTION

Pump set running dry

Increased vibrations! Damage to mechanical seals and bearings!

▷ Never operate the pump set for more than 60seconds outside the fluid to be

handled.

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 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.

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

▪ 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. ▪ After prolonged shutdown of the pump (set), the activities required for returning

the equipment to service have been carried out.

▪ Float switch control has been installed and set (if applicable).

6.1.2 Filling in lubricants

Thrust and radial bearings The sealed-for-life radial ball bearings are already packed with grease.

Radial bearings The bearing bushes are lubricated by the fluid handled. The start-up point must be

situated above the top bearing. Observe the minimum fluid level (ðSection6.2.3.2,Page30) . For grease lubrication (optional) fill the lubricators with grease. For lubrication by external fluid open the flushing liquid connection. (ðSection7.2.2.2,Page36)

6.1.3 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits due to a clogged intake or if the pump is operated with the discharge line closed.

Explosion hazard! Leakage of hot fluids!

▷ Never operate the pump with the shut-off elements in the discharge line

closed.

▷ Only start up the pump set against a slightly or completely open discharge-side

shut-off element.

▷ Make sure that the intake area is clean and free from foreign objects.

DANGER

Excessive temperatures due to dry running or excessive gas content in the fluid handled

Explosion hazard! Damage to the pump set!

▷ Never operate the pump set without liquid fill. ▷ Prime the pump as per operating instructions. ▷ Always operate the pump within the permissible operating range. ▷ If the pump is in slurp mode, stop the pump immediately. ▷ Provide for fill level monitoring to prevent dry running of the pump.

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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 and the inlet tank, if any, have been vented and primed with the fluid

to be handled.

ü The lines for priming and venting have been closed.

CAUTION

Start-up against open discharge line

Motor overload!

▷ Make sure the motor has sufficient power reserves. ▷ Use a soft starter. ▷ Use speed control.

1. Close or slightly open the shut-off element in the discharge line.

2. Start up the motor.

3. 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 Shutdown

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 non-return or check valve, the shut-off element may remain open provided that the system conditions and system regulations are considered and observed.

NOTE

If shut-off is not possible, the pump will run in reverse direction. The reverse runaway speed must be lower than the rated speed.

For prolonged shutdown periods:

1. Close the auxiliary connections.

CAUTION

Risk of freezing during prolonged pump shutdown periods

Damage to the pump!

▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect

them against freezing.

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6.2 Operating limits

DANGER

Non-compliance with operating limits

Damage to the pump set!

▷ Comply with the operating data specified in the data sheet. ▷ Avoid operation against a closed shut-off element. ▷ Never operate an explosion-proof pump set at ambient temperatures or fluid

temperatures exceeding those specified in the data sheet and/or on the name plate.

▷ Never operate the pump set outside the limits specified below.

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:

Table7: Permissible ambient temperatures

Permissible ambient temperature Value

Maximum 40 °C Minimum - 20 °C

6.2.2 Frequency of starts

DANGER

Excessive surface temperature of the motor

Explosion hazard! Damage to the motor!

▷ In case of explosion-proof motors, observe the frequency of starts specified in

the manufacturer's product literature.

To prevent high temperature increases in the motor and excessive loads on the pump, coupling, motor, seals and bearings, the frequency of starts shall not exceed 20 start-ups per hour (h).

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 Fluid handled

6.2.3.1 Flow rate

Unless specified otherwise in the characteristic curves or in the data sheets, the following applies:

▪ Short-time operation: Q

min

=0.1×Q

opt

▪ Continuous operation: Q

min

=0.3×Q

opt

▪ 2-pole operation: Q

max

=1.1×Q

opt

▪ 4-pole operation: Q

max

=1.25×Q

opt

The data refer to water and water-like fluids. Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface. However, if the physical properties of the fluids handled differ from those of water, the calculation formula below must be used to check if an additional heat build-up may lead to a dangerous temperature increase at the pump surface. If necessary, the minimum flow must be increased.

Table8: Key

Symbol Description Unit

c Specific heat capacity J/kg K g Gravitational constant m/s² H Pump discharge head m T

Fluid temperature °C

Temperature at the casing surface °C Pump efficiency at duty point Temperature difference K

6.2.3.2 Minimum level of fluid handled

DANGER

Pump set running dry

Explosion hazard!

▷ Never allow an explosion-proof pump set to run dry!

CAUTION

Fluid level below the specified minimum

Damage to the pump set by cavitation!

▷ Never allow the fluid level to drop below the specified minimum.

Minimum 120mm above the bottom edge of the casing; if handling condensate ~400mm

Maximum 150mm below the plate

Before start-up, the pump set must always be immersed in the fluid to be handled so it is above the minimum switch-off level (ðSection6.1.2,Page27) .

4) Minimum permissible flow rate

5) Flow rate at best efficiency point

6) Maximum permissible flow rate

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6.2.3.3 Temperature of the fluid handled

CAUTION

Incorrect temperature of the fluid handled

Damage to the pump (set)!

▷ Do not operate the pump (set) outside the specified temperature limits.

Table9: Fluid temperature

Design Temperature [°C]

Minimum Maximum

MK, MKA -10 °C 90 °C

MKY -10 °C 200 °C

6.2.3.4 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!

▷ Observe the information about fluid density in the data sheet. ▷ Make sure the motor has sufficient power reserves.

6.2.3.5 Gas content of fluid handled

DANGER

Excessive temperatures as a result of bearing bushes running hot

Explosion hazard! Fire hazard! Damage to the pump set!

▷ Never pump fluids with excessive gas content. ▷ Allow sufficient time for gases to leave the fluid handled.

6.2.3.6 Abrasive fluids

Do not exceed the maximum permissible solids content specified in the data sheet. When the pump handles fluids containing abrasive substances, increased wear of the hydraulic system and shaft seal are to be expected. In this case, reduce the commonly recommended inspection intervals.

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains installed

ü Sufficient fluid is supplied for the functional check run of the pump.

1. For prolonged shutdown periods, start up the pump (set) regularly between once a month and once every three months for approximately five minutes.

ð This will prevent the formation of deposits within the pump and the pump

intake area.

7) 80 °C for bearing material 1.4571-NBR

8) 200 °C for bearing material EK 3205; 110 °C when handling water; 80 °C for bearing material 1.4571-NBR

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The pump (set) is removed from the pipe and stored

ü The pump has been properly drained. ü The safety instructions for dismantling the pump have been observed.

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 nozzle and discharge nozzle. It is advisable to then close the pump nozzles (e.g. with plastic caps).

3. Oil or grease all exposed machined parts and surfaces of the pump (with silicone-free oil or grease, food-approved if required) to protect them against corrosion. Observe the additional instructions on preservation.

If the pump set is to be stored temporarily, only preserve the wetted components made of low-alloy materials. Commercially available preservatives can be used for this purpose. Observe the manufacturer's instructions for application/removal.

6.4 Returning to service

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.

For returning the equipment to service, observe the sections on commissioning/startup (ðSection6.1,Page27) and the operating limits .

In addition, carry out all servicing/maintenance operations before returning the pump (set) to service. (ðSection7,Page33)

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7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Improper cleaning of coated pump surfaces

Explosion hazard by electrostatic discharge!

▷ When cleaning coated pump surfaces in atmospheres of Explosion groupIIC,

use suitable anti-static equipment.

DANGER

Sparks produced during servicing work

Explosion hazard!

▷ Observe the safety regulations in force at the place of installation! ▷ Always perform maintenance work at an explosion-proof pump (set) outside of

potentially explosive atmospheres.

DANGER

Improperly serviced pump set

Explosion hazard! Damage to the pump set!

▷ Service the pump set regularly. ▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal

and coupling.

The operator ensures that maintenance, inspection and installation is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

WARNING

Unintentional starting of the pump set

Risk of injury by moving components and shock currents!

▷ Ensure that the pump set cannot be started unintentionally. ▷ Always make sure the electrical connections are disconnected before carrying

out work on the pump set.

WARNING

Fluids handled, consumables and supplies which are hot and/or pose a health hazard

Risk of injury!

▷ Observe all relevant laws. ▷ When draining the fluid take appropriate measures to protect persons and the

environment.

▷ Decontaminate pumps which handle fluids posing a health hazard.

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WARNING

Insufficient stability

Risk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent

tilting or tipping over.

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.

NOTE

All maintenance work, service work 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.

Never use force when dismantling and reassembling the pump set.

7.2 Servicing/Inspection

7.2.1 Supervision of operation

DANGER

Impermissibly high temperatures

Explosion hazard! Damage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted

(heating up of the fluid).

▷ Observe the temperature limits in the data sheet and in the section on

operating limits. (ðSection6.2,Page29)

DANGER

Excessive temperatures as a result of bearings running hot or defective bearing seals

Explosion hazard! Fire hazard! Damage to the pump set! Risk of burns!

▷ Regularly check the lubricant level. ▷ Regularly check the rolling element bearings for running noises.

CAUTION

Fluid level below the specified minimum

Damage to the pump set by cavitation! Dry running of the plain bearings!

▷ Never allow the fluid level to drop below the specified minimum.

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. ▪ Check the static sealing elements for leakage.

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▪ Check the rolling element bearings for running noises.

Vibrations, noise and an increase in current input occurring during unchanged operating conditions indicate wear.

▪ Monitor the correct functioning of any auxiliary connections. ▪ Monitor the stand-by pump.

To make sure that stand-by pumps are ready for operation, start them up once a week.

▪ Make sure that the floats of rod-actuated and magnetic float switch

arrangements can always slide along the guide rods without obstruction.

▪ The minimum fluid level must be observed. (ðSection6.2.3.2,Page30) ▪ Monitor the bearing temperature.

The bearing temperature must not exceed 90 °C (measured on the outside of the bearing bracket). For monitoring the bearing temperature, a G 1/8 connection hole (Ø 7 mm) is provided in thrust and radial bearing 303.1 (max. width across corners of fastener used: 18 mm).

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 bearing bracket).

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).

7.2.2 Lubrication and lubricant change

DANGER

Excessive temperatures as a result of bearings running hot or defective bearing seals

Explosion hazard! Fire hazard! Damage to the pump set!

▷ Regularly check the condition of the lubricant.

7.2.2.1 Lubrication of radial ball bearings

The shaft runs in a radial ball bearing in the thrust and radial bearing. The radial ball bearing is fitted with sealing washers on both sides and greased for life.

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Fig.8: Radial ball bearing (thrust and radial bearing)

1 Radial ball bearing 2 Washer 3 Grease fill 4 Nilos ring

Table10: Bearings used

Sizes Motor Radial ball bearing Nilos ring

MK, MKA 20-1 to 5 80M 6006 2 RS ZJV 6006 MK, MKA 20-6 90 S, L 6008 2 RS ZJV 6008 MKY 20-1 to 4 80M 6006 2 RS ZJV 6006 MKY 20-5 and 6 90 S, L 6008 2 RS ZJV 6008

Grease quality ▪ High-performance lithium soap grease to DIN 51825

▪ Free of resin and acid ▪ Not liable to crumble ▪ With good rust-preventive characteristics

Bearing life With this grease, a theoretical bearing life Lh10 of 25,000 h at an operating

temperature of 75 °C can be achieved. If temperatures are higher, grease life will be reduced. A temperature increase of 15 K will reduce grease life by half. However, bearing life may be reduced by vibrations, aggressive gases, humidity, etc.

7.2.2.2 Lubrication of bearing bushes

DANGER

Excessive temperatures as a result of bearing bushes running hot

Explosion hazard! Fire hazard! Damage to the pump set!

▷ Make sure the bearing bushes are properly lubricated. ▷ Regularly check the bearing bushes for correct lubrication.

The bearing bushes (radial bearings) in the support column and volute casing are lubricated by the fluid handled. Bearings must be checked for wear in the following cases:

▪ When the pump has been operated under dry-running or cavitation conditions ▪ When vibrations, noise and an increase in current input occur during unchanged

operating conditions

Internal lubrication by fluid handled

Lubrication by the fluid handled is used for bearing bushes with a risk of dry running. Connect pipe union 731.21 between the discharge pipe and the support column.

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Grease lubrication

CAUTION

Insufficiently filled grease cups

Damage to the pump set by cavitation and ungreased bearings!

▷ The grease cup must be filled with lubricant. ▷ The grease cup must be screwed down regularly.

Provide each bearing bush in the support column with a separate lubricating device including a lubricator.

Grease quality

Optimum grease properties:

Table11: Grease quality to DIN 51825

Soap basis NLGI grade Worked penetration at

25° C in mm/10

Drop point

Lithium 2 to 3 220-295 ≥ 175°C

▪ Free of resin and acid ▪ Not liable to crumble ▪ Rust-preventive characteristics

a) b)

Fig.9: a) Grease lubrication; b) Lubrication by fluid handled

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Lubrication by external fluid

DANGER

Failure of lubrication by external fluid

Explosion hazard!

▷ Monitor lubrication by external fluid.

DANGER

Risk of potentially explosive atmosphere by mixing of incompatible fluids in the auxiliary piping

Risk of burns! Explosion hazard!

▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid

handled.

For lubrication by external fluid provide a flushing water connection which meets the following conditions:

▪ Maximum flushing water temperature: 40°C ▪ Minimum pressure required: 2.5 bar ▪ Fit connection line with shut-off valve and non-return valve. ▪ Control by a solenoid valve connected in parallel with the motor is

recommended.

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Fig.10: Lubrication by external fluid

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!

1. Always flush the pump if it has been used for handling noxious, explosive, hot or other hazardous fluids.

2. Always flush and clean the pump before transporting it to the workshop. Provide a certificate of decontamination for the pump set. (ðSection11,Page60)

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7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

WARNING

Unqualified personnel performing work on the pump (set)

Risk of injury!

▷ Always have repair work 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.

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.

Observe the general safety instructions and information. (ðSection7.1,Page33) 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.

NOTE

DANGER

Insufficient preparation of work on the pump (set)

Risk of personal injury!

▷ Properly shut down the pump set. ▷ Close the shut-off elements in the discharge line. ▷ Drain the pump and release the pump pressure. ▷ Close any auxiliary connections. ▷ Allow the pump set to cool down to ambient temperature.

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.

7.4.2 Removing the pump set from the piping

1. De-energise the pump set and secure it against unintentional start-up.

2. Disconnect the motor from the power supply.

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3. Disconnect and remove all auxiliary pipework.

4. Unbolt the discharge nozzle from the pipeline.

5. Lift the pump set with support column 712 and/or pipe 710.01 and the cover plate out of the tank or pit.

7.4.3 Dismantling the pump section

7.4.3.1 Dismantling the pump set (MK)

ü The notes and steps stated in (ðSection7.4.1,Page40) to

(ðSection7.4.2,Page40) have been observed/carried out.

ü The pump set is kept in a clean and level assembly area.

CAUTION

Damage to the shaft assembly

Warping of the shaft!

▷ Support the shaft assembly if the shaft is long.

1. Undo nuts 920.02.

2. Remove volute casing 102 with casing wear ring 502.

3. Remove grooved pin 561.02 and take impeller 230 off the shaft.

4. Remove radial bearing 303.02 and 303.03 (if any) with bearing bush 545.

5. Undo nuts 920.12.

6. Remove support column 712.01.

CAUTION

Damage to the shaft assembly

Warping of the shaft!

▷ Support the shaft assembly if the shaft is long.

7. For installation depths 1900 mm/2800 mm: Undo hexagon head bolts 901.03 and nuts 920.03 and carefully take support column 712.02/.03 and radial bearings 303.02 and 303.03 (if any) with the respective bearing bush 545 off the shaft.

8. Undo hexagon head bolt 901.01.

9. Remove the motor.

10. Remove the key.

11. Remove grooved pin 561.01 from sleeve 520.

12. Pull shaft 210 out of sleeve 520.

13. Press sleeve 520 out of radial ball bearing 321.

14. Remove radial ball bearing 321 from thrust and radial bearing 303.01.

15. Remove grease-packed ring 500.01.

7.4.3.2 Dismantling the pump set (MKA)

ü The notes and steps stated in (ðSection7.4.1,Page40) to

(ðSection7.4.2,Page40) have been observed/carried out.

ü The pump set is kept in a clean and level assembly area.

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CAUTION

Damage to the shaft assembly

Warping of the shaft!

▷ Support the shaft assembly if the shaft is long.

1. Remove any lubricating lines.

2. Remove level control equipment, if any.

3. Remove screw plug 903.01 with joint ring 411.01 from radial bearing 303.02 and

303.03 (if any).

4. Undo nuts 920.11.

5. Unscrew the discharge pipe from the volute casing 102. Note discs 550.11 and gaskets 400.11.

6. Undo nuts 920.02.

7. Remove volute casing 102 and casing wear ring 502.

8. Undo nuts 920.12.

9. Remove cover plate 68-3.

7.4.3.3 Dismantling the pump set (MKY)

ü The notes and steps stated in (ðSection7.4.1,Page40) to

(ðSection7.4.2,Page40) have been observed/carried out.

ü The pump set is kept in a clean and level assembly area.

1. Remove float switch control equipment, if any.

2. Undo screws 900.61 and remove cover plates 81-92.

3. Undo nut 920.62 at gland follower 452.62 and unscrew pipe 710.01 from volute casing 102.

4. Remove gland follower 452.62, gland packing 461.62 and neck ring 457.

5. Undo nuts 920.02.

6. Remove volute casing 102 with casing wear ring 502.

7. Remove grooved pin 561.02 and take impeller 230 off the shaft.

8. Remove radial bearing 303.03 with bush 545.

9. Undo nuts 920.01.

10. Remove support column 712.01.

CAUTION

Damage to the shaft assembly

Warping of the shaft!

▷ Support the shaft assembly if the shaft is long.

11. For installation depths 1900 mm/2800 mm: Undo the corresponding hexagon head bolt 901.03 and nut 920.03 and carefully take further support column(s)

712.02/.03 and radial bearings 303.02 and 303.03 (if any) with the respective bearing bush 545 off the shaft.

12. Loosen nuts 920.60 at the gland follower.

13. Undo nuts 920.61.

14. Remove drive lantern 341 with gasket 400.60 at the lower end of the shaft.

15. Remove gland follower 452.60 and take out discs 550.60 and gland packing

461.60/.61.

16. Undo hexagon head bolts 901.01 and remove the motor.

17. Remove the key.

18. Drive grooved pin 561.01 out of sleeve 520.

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19. Pull shaft 210 out of sleeve 520.

20. Press sleeve 520 out of radial ball bearing 321.

21. Remove radial ball bearing 321 from thrust and radial bearing 303.01.

22. Remove grease-packed ring 500.01.

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 reassemble the pump in accordance with the corresponding general assembly

drawing.

Sealing elements ▪ Gaskets

– Always use new gaskets, making sure that they have the same thickness as

the old ones.

– Always fit gaskets of asbestos-free materials or graphite without using

lubricants (e.g. copper grease, graphite paste).

▪ O-rings

– Never use O-rings that have been made by cutting an O-ring cord to size and

gluing the ends together.

▪ Packing rings

– Always use pre-compressed packing rings.

CAUTION

Contact of O-ring with graphite or similar material

Fluid could escape!

▷ Do not coat O-ring with graphite or similar material. ▷ Use animal fats or lubricants based on silicone or PTFE.

▪ Assembly adhesives

– For gaskets, avoid the use of assembly adhesives if possible. – If assembly adhesives are required, use a commercially available contact

adhesive (e.g. "Pattex"). – Only apply adhesive at selected points and in thin layers. – Never use quick-setting adhesives (cyanoacrylate adhesives). – Coat the locating surfaces of the individual components and screwed

connections with graphite or similar before reassembly. – Prior to reassembly, screw back any forcing screws and adjusting screws.

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Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.

(ðSection7.6,Page48)

7.5.2 Reassembling the pump section

7.5.2.1 Re-assembling the pump set (MK)

NOTE

If the shaft is worn at the bearing positions, it may be turned upside down and installed again for continued use. At first re-installation in reversed position, the running faces on the shaft are as new. The bearing bushes have to be replaced at the same time.

1. Press sleeve 520 into radial ball bearing 321 in cold condition.

2. Pull shaft 210 into sleeve 520 and secure it with grooved pin 561.01. Make sure it is firmly seated.

CAUTION

Insufficient lubrication

Damage to the bearing! Prior to fitting the Nilos ring, pack its cranked sealing groove with grease.

3. Fit studs 902.01 in thrust and radial bearing 303.01.

4. Pack the cranked sealing groove of ring 500.01 with grease. Then fit the ring in thrust and radial bearing 303.01.

5. Fit radial ball bearing 321 with fitted sleeve 520 and shaft 210 in prepared thrust and radial bearing 303.01.

6. Insert the key into the motor shaft.

7. Slide the motor shaft into sleeve 520.

8. Bolt the motor to thrust and radial bearing 303.01 with hexagon head bolts

901.01.

9. Apply a thin coat of grease to the bearing positions on shaft 210.

10. Press ring 550.01 into the first support column 712.01 following thrust and radial bearing 303.01.

11. Swiftly press bearing bushes 545 into the corresponding radial bearings 303.02 and 303.03 (if any).

CAUTION

Damage to the shaft assembly

Warping of the shaft!

▷ Support the shaft assembly if the shaft is long.

12. Carefully slide first support column 712.01 with fitted ring 550.01 on the shaft. Secure it to radial bearing 303.01 with nut 920.01.

13. Depending on the installation depth, carefully fit further radial bearings 303.02 and 303.03 (if any) with pressed-in bearing bush 545 and support columns

712.02/.03 and secure them with hexagon head bolts 901.03 and nuts 920.03.

14. Slide impeller 230 onto the shaft stub and secure it with grooved pin 561.02. Make sure it is firmly seated.

15. Apply a thin layer of grease to the impeller face 230 at the sealing clearance.

16. Press casing wear ring 502 into volute casing 102. Screw in studs 902.02.

17. Carefully pull prepared volute casing 102 over impeller 230. Screw it to the bottom radial bearing 303.02 and support column 712.02/.03 with hexagon nuts

920.02.

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18. Fit screw plug 903.01 with joint ring 411.01 in radial bearing 303.02 and 303.03 (if any).

19. Install any lubricating lines.

20. Fit float switch control equipment, if any.

NOTE

For lubrication by the fluid handled, the Ermeto pipe fitting to be installed in the support column and the weld-on threaded union with the pipe to be installed in the discharge pipe are supplied but not fitted.

7.5.2.1.1 Installing the shaft seal

The bearing assembly is sealed by washers in the ball bearing of the thrust and radial bearing and a grease-backed ring. The MK/MKA models are additionally equipped with a vapour barrier (PTFE ring) in upper support column 712.01.

Fig.11: Shaft seal MK/MKA

1 Radial ball bearing 2 Grease fill 3 Vapour barrier (PTFE ring) 4 Vent groove 5 Washers 6 Nilos ring

7.5.2.2 Re-assembling the pump set (MKA)

NOTE

1. Press sleeve 520 into radial ball bearing 321 in cold condition.

2. Pull shaft 210 into sleeve 520 and secure it with grooved pin 561.01. Make sure it is firmly seated.

CAUTION

Insufficient lubrication

Damage to the bearing! Prior to fitting the Nilos ring, pack its cranked sealing groove with grease.

3. Fit studs 902.01 in thrust and radial bearing 303.01.

4. Insert studs 902.12 into thrust and radial bearing 303.01.

5. Pack the cranked sealing groove of ring 500.01 with grease. Then fit the ring in thrust and radial bearing 303.01.

6. Fit radial ball bearing 321 with fitted sleeve 520 and shaft 210 in prepared thrust and radial bearing 303.01.

7. Insert the key into the motor shaft.

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8. Slide the motor shaft into sleeve 520.

9. Bolt the motor to thrust and radial bearing 303.01 with hexagon head bolts

901.01.

10. Apply a thin coat of grease to the bearing positions on shaft 210.

11. Press ring 550.01 into the first support column 712.01 following thrust and radial bearing 303.01.

12. Swiftly press bearing bushes 545 into the corresponding radial bearings 303.02 and 303.03 (if any).

CAUTION

Damage to the shaft assembly

Warping of the shaft!

▷ Support the shaft assembly if the shaft is long.

13. Carefully slide first support column 712.01 with fitted ring 550.01 on the shaft. Secure it to radial bearing 303.01 with nut 920.01.

14. Depending on the installation depth, carefully fit further radial bearings 303.02 and 303.03 (if any) with pressed-in bearing bush 545 and support columns

712.02/.03 and secure them with hexagon head bolts 901.03 and nuts 920.03.

15. Slide impeller 230 onto the shaft stub and secure it with grooved pin 561.02. Make sure it is firmly seated.

16. Apply a thin layer of grease to the impeller face 230 at the sealing clearance.

17. Fit cover plate 68-3 and sightly tighten nuts 920.12.

18. Fit volute casing 102 with casing wear ring 502.

19. Tighten nuts 920.02.

20. Run pipe 710.01 through cover plate 68-3 with nut 920.40, disc 550.30 and gasket 400.06 and screw it into the nozzle of casing 102.

21. Secure cover plate 68-3 by tightening nuts 920.12.

22. Secure the pipe above the plate with another nut 920.11 with disc 550.11 and gasket 400.11. N.B.:Make sure the pump is free from stresses and strains when tightening the R2 hexagon nuts.

23. Fit screw plug 903.01 with joint ring 411.01 in radial bearing 303.02 and 303.03 (if any).

24. Install any lubricating lines.

25. Fit float switch control equipment, if any.

NOTE

For lubrication by the fluid handled, screw the pipe union tightly into the support column and connect it via a pipe with the weld-on threaded union of the discharge pipe.

7.5.2.3 Re-assembling the pump set (MKY)

NOTE

1. Press coupling sleeve 520 into radial ball bearing 321 in cold condition.

2. Pull shaft 210 into sleeve 520 and secure it with grooved pin 561.01. Make sure it is firmly seated.

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CAUTION

Insufficient lubrication

Damage to the bearing! Prior to fitting the Nilos ring, pack its cranked sealing groove with grease.

3. Pack the cranked sealing groove of ring 500.01 with grease. Then fit the ring in thrust and radial bearing 303.01.

4. Fit bearing 321 with fitted sleeve 520 and shaft 210 in prepared thrust and radial bearing 303.01 using studs 902.61.

5. Insert the key into the motor shaft.

6. Slide the motor shaft into sleeve 520.

7. Screw the motor to the thrust and radial bearing with hexagon head bolts

901.01.

7.5.2.3.1 Installing the shaft seals

ü The relevant packing chamber has been cleaned meticulously.

1. Fit stud 902.60 in drive lantern and position the gland packing ring 461.60 in outer position and 461.61 in inner position.

2. Insert the first packing ring and push it inwards with gland follower 452.60.

3. Insert subsequent packing rings one at a time, with their joints staggered at approximately 90°. Use gland follower 452.60 to seat each individual packing ring in the packing chamber.

4. Tighten gland follower 452.60 lightly and evenly. It must be easy to rotate the rotor after the final assembly.

5. Fit studs 902.01 in drive lantern 341.

6. Mount the prepared shaft assembly including motor on the drive lantern.

7. Tighten nuts 920.61.

8. Apply a thin coat of grease to the bearing positions on the shaft.

9. Swiftly press bearing bushes 545 into the corresponding radial bearings 303.02 and 303.03 (if any).

10. Carefully slide first support column 712.01 on the shaft. Secure it to drive lantern 341 with nut 920.01.

11. Depending on the installation depth, carefully fit further radial bearings 303.02 and 303.03 (if any) with pressed-in bearing bush 545 and support columns

712.02/.03 and secure them with hexagon head bolts 901.03 and nuts 920.03.

12. Slide impeller 230 onto the shaft stub and secure it with grooved pin 561.02. Make sure it is firmly seated.

13. Apply a thin layer of grease to the impeller face 230 at the sealing clearance.

14. Press casing wear ring 502 into volute casing 102. Screw in studs 902.02.

15. Carefully pull prepared casing 102 over impeller 230. Screw it to the bottom radial bearing 303.02 and support column 712 with nuts 920.02.

16. Fit studs 902.62 in drive lantern 341.

17. Carefully guide pipe 710.01 through gland follower 452.62 with neck ring 457 and gland packing 461.62 and bolt it to volute casing 102 using nuts 920.62.

18. Fit level control equipment, if any.

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7.6 Tightening torques

Fig.12: Tightening points

Table12: Tightening torques [NM] depending on materials

Position Thread Material

[mm] [Nm]

A, B, C, D M10 5.8 22 A, B, C, D M10 8.8 50 A, B, C, D M10 A4-70 35

7.7 Spare parts stock

7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:

▪ Order number ▪ Order item number ▪ Type series ▪ Size ▪ Material variant ▪ Year of construction

Refer to the name plate for all data. Also specify the following data:

▪ Part number and description (ðSection9.1,Page52) ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight)

7.7.2 Recommended spare parts stock for 2 years' operation to DIN24296

Table13: Quantity of spare parts for recommended spare parts stock

Part No. Description Number of pumps (including stand-by pumps)

2 3 4 5 6 and 7 8 and 9 10 and

210 Shaft 1 1 2 2 2 3 30 % 230 Impeller 1 1 1 2 2 3 30 %

9) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20%.

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Part No. Description Number of pumps (including stand-by pumps)

2 3 4 5 6 and 7 8 and 9 10 and

321 Radial ball bearing 1 1 2 2 3 4 50 % 400 Gasket 1 1 2 2 3 4 50 %

550.01 PTFE ring 1 1 2 2 3 4 50 % 457 Neck ring 1 1 2 2 3 4 50 %

461.60/.61 Gland packing, support column

10)

4 6 8 8 9 12 150 %

461.62 Gland packing, discharge pipe

10)

2 3 4 4 6 6 100 % 502 Casing wear ring 2 2 2 3 3 4 50 % 545 Bearing bush

for installation depth 1000 mm for installation depth 1900 mm for installation depth 2800 mm

1 2 3

2 4 6

3 6 9

30% 60% 90%

10) For MKY only

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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 does not start up

B Motor is overloaded

Motor protection switch trips the pump

C Pump delivers insufficient flow rate

D Excessive pump flow rate

E Vibrations during pump operation

F Excessive wear on bearings

Table14: Trouble-shooting

A B C D E F Possible cause Remedy

11)

- - ✘ - - - Wrong direction of rotation ▪ Check the electrical connection of the pump set and the control system, if necessary.

- ✘ ✘ - ✘ - Wear of internal components ▪ Replace worn components by new ones.

- ✘ - ✘ - - System head is lower than specified in the

purchase order.

▪ Re-adjust to duty point by means of the

shut-off valve in the discharge line.

▪ Check whether the impeller could be

turned down.

- ✘ ✘ - - - Density or viscosity of fluid handled higher

than stated in purchase order

▪ Contact the manufacturer.

- ✘ - - - - Gland follower over-tightened or cocked ▪ Tighten gland follower correctly.

- ✘ ✘ - - - Motor is running on two phases only. ▪ Check the electrical cable connections.

▪ Replace the defective fuse.

✘ - - - - - Motor is not running because of lack of

voltage.

▪ Check electrical connections. ▪ Notify the energy supply company.

- ✘ - - - - Switchgear, control unit or overcurrent relay

defective.

Check and replace, if necessary.

▪ Check and replace defective components.

- - ✘ - - - Pump delivers against an excessively high

pressure.

▪ Re-adjust to duty point. ▪ Check system for impurities. ▪ Fit larger impeller.

12)

▪ Increase the speed (turbine, I.C. engine)

- ✘ ✘ - ✘ - Supply line or impeller clogged ▪ Remove deposits in the pump and/or piping.

- ✘ ✘ - ✘ - Insufficient inflow ▪ Check suction openings/screen of the volute casing for dirt accumulation.

11) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

12) Contact KSB.

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A B C D E F Possible cause Remedy

11)

- ✘ - - ✘ ✘ 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.

- ✘ - - ✘ - Defective bearing(s) ▪ Replace the bearing(s). If required, reinstall the shaft upside down.

- ✘ - - - ✘ Pump clogged by sand, dirt in the pump

sump.

▪ Clean the intake, pump components and

lift check valve.

▪ Drain and clean the pit.

- - - - ✘ ✘ Rotor is out of balance, shaft is warped ▪ Clean the impeller.

▪ Re-balance the impeller. ▪ Fit a new shaft.

- ✘ - - - - Current exceeds the value set in the motor

protection switch.

▪ Set the motor protection switch to the

nominal value given on the name plate of the motor.

- - ✘ - - - Excessive temperature of the fluid handled ▪ Lower the fluid temperature.

- - - - - ✘ Aggressive fluid ▪ Use other bearing material.

- - - - - ✘ Abrasive fluid ▪ Use different bearing material, if necessary.

▪ Supply flushing water (lubrication by

external fluid).

- - - - ✘ - Cavitation (rattling noise) ▪ Check steam trap.

▪ Increase suction head. ▪ Reduce condensate temperature. ▪ Increase back pressure by throttling.

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9 Related Documents

9.1 General assembly drawings/exploded views with list of components

9.1.1 MK, MKA

920.11

550.11

400.11

710.01

210

712.01

545

920.02

902.02

303.02

561.02

230

102

502

303.01

68-3

400.12

902.01

920.01

520

801

901.01

903.11

411.11

321

902.12

920.12

500.01

561.01

550.01

903.01

411.01

Fig.13: Illustration of MK, MKA - installation depth 1000mm

Table15: List of components

Part No. Description Part No. Description

102 Volute casing 545 Bearing bush 210 Shaft 550.01/.11 Disc 230 Impeller 561.01/.02 Grooved pin

303.01 Thrust and radial bearing 68-3 Cover plate

303.02 Thrust and radial bearing without vertical hole

710.01 Pipe

321 Radial ball bearing 712.01 Support column without hole

400.11/.12 Gasket 801 Flanged motor

411.01/.11 Joint ring 901.01 Hexagon head bolt

500.01 Ring 902.01/.02/.12 Stud

502 Casing wear ring 903.01/.11 Screw plug 520 Sleeve 920.01/.02/.11/.12 Nut

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9.1.2 MK, MKA - grease-lubricated

920.11

550.11

400.11

710.01

210

712.01

545

920.02

902.02

303.02

561.02

230

102

502

303.01

68-3

400.12

902.01

920.01

520

801

901.01

903.11

411.11

321

500.01

561.01

550.01

902.12

920.12

635

731.30

731.31

710.30

731.32

Fig.14: Illustration of MK, MKA - installation depth 1000mm, grease-lubricated

Table16: List of components

Part No. Description Part No. Description

102 Volute casing 635 Grease cup 210 Shaft 68-3 Cover plate 230 Impeller 710.01 Pipe

303.01 Thrust and radial bearing 710.30 Pipe

303.02 Thrust and radial bearing without vertical hole

712.01

13)

Support column without hole

321 Radial ball bearing 731.30/.31/.32 Pipe union

400.11/.12 Gasket 801 Flanged motor

411.11 Joint ring 81-39 Clamp

500.01 Ring 81-45 Float switch

502 Casing wear ring 901.01 Hexagon head bolt 520 Sleeve 902.01/.02/.12 Stud 545 Bearing bush 903.11 Screw plug

550.01/.11 Disc 920.01/.02/.11/.12 Nut

561.01/.02 Grooved pin

13) Number of support columns 712 without hole, for installation depth ET: 1000mm=0; 1900mm=1;2800mm= 2

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9.1.3 MK, MKA - internally lubricated by fluid handled

920.11

550.11

400.11

712.01

901.01

712.02

545

920.02

902.02

303.03

561.02

230

102

502

303.02

68-3

400.12

902.01

920.01

545

801

901.03

903.11

411.11

321

920.03

500.01

561.01

550.01

903.01

411.01

520

303.01

710.01

903.01

411.01

902.12

920.12

710.21

731.21

Fig.15: Illustration of MK, MKA - installation depth 1900mm, internally lubricated by fluid handled

Table17: List of components

Part No. Description Part No. Description

102 Volute casing 561.01/.02 Grooved pin 230 Impeller 68-3 Cover plate

303.01 Thrust and radial bearing 710.01/.21 Pipe

303.02 Thrust and radial bearing without vertical hole

712.01/.02

14)

Support column without hole

303.03 Thrust and radial bearing with vertical hole

731.21 Pipe union

321 Radial ball bearing 801 Flanged motor

400.11/.12 Gasket 900.46 Screw

411.01/.11 Joint ring 901.01/.03 Hexagon head bolt

500.01 Ring 902.01/.02/.12 Stud

502 Casing wear ring 903.01/.11 Screw plug 520 Sleeve 920.01/.02/.03/.11/.12 Nut 545 Bearing bush 933.01 Split pin

550.11 Disc 99-3 Set of accessories

14) Number of support columns 712 without hole, for installation depth ET: 1000mm=0; 1900mm=1;2800mm= 2

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9.1.4 MK, MKA - lubricated by an external fluid

920.11

550.11

400.11

712.01

901.01

712.03

545

920.02

902.02

303.02

561.02

230

102

502

303.02

68-3

400.12

902.01

920.01

545

801

901.03

731.42

710.01

321

920.03

500.01

561.01

550.01

902.12

920.12

520

303.01

210

710.41

731.43

710.41

731.43

710.40

731.41

903.11

411.11

731.40

731.41

303.02 545

712.02

901.03

920.03

Fig.16: Illustration of MK, MKA - installation depth 2800mm, lubricated by an external fluid

Table18: List of components

Part No. Description Part No. Description

102 Volute casing 550.01/.11 Disc 210 Shaft 561.01/.02 Grooved pin 230 Impeller 68-3 Cover plate

303.01 Thrust and radial bearing 710.01/.40/.41 Pipe

303.02 Thrust and radial bearing without vertical hole

712.01/.02/.03

15)

Support column without hole

321 Radial ball bearing 731.40/.41/.42/.43 Pipe union

400.11/.12 Gasket 801 Flanged motor

411.11 Joint ring 901.01/.03 Hexagon head bolt

500.01 Ring 902.01/.02/.12 Stud

15) Number of support columns 712 without hole, for installation depth ET: 1000mm=0; 1900mm=1;2800mm= 2

Page 56

9 Related Documents

56 of 64

Part No. Description Part No. Description

502 Casing wear ring 903.11 Screw plug 520 Sleeve 920.01/.02/.03/.11/.12 Nut 545 Bearing bush

Page 57

9 Related Documents

57 of 64

9.1.5 MKY

452.62

902.62

920.62

710.01

102

210

230

502

561.02

81-92

902.60

920.60

920.61

902.61

550.60

457

461.62

801

520

901.01

902.01

902.02

920.01

920.02

561.01 321

500.01

303.01

452.60

550.60

461.60

461.61

900.61

81-92 341

400.60

712.01/.02/.03

545

303.02/.03

903.01

411.01

Fig.17: MKY

Table19: List of components

Part No. Description Part No. Description

102 Volute casing 520 Sleeve 210 Shaft 545 Bearing bush 230 Impeller 550.60 Disc

303.01 Thrust and radial bearing 561.01/.02 Grooved pin

303.02 Thrust and radial bearing without vertical hole

710.01 Pipe

303.03 Thrust and radial bearing with vertical hole

712.01 Support column with hole

321 Radial ball bearing 712.02/.03 Support column without hole 341 Drive lantern 801 Flanged motor

400.60 Gasket 81-92 Cover plate

411.01 Joint ring 900.61 Screw

452.60/.62 Gland follower 901.01 Hexagon head bolt

457 Neck ring 902.01/.02/.60/.61/.62 Stud

461.60/.61/.62 Gland packing 903.01 Screw plug

Page 58

9 Related Documents

58 of 64

Part No. Description Part No. Description

500.01 Ring 920.01/.02/.60/.61/.62 Nut

502 Casing wear ring

Page 59

10 EU Declaration of Conformity

59 of 64

10 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

MK, MKA, MKY

KSB order number: ...................................................................................................

▪ 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

Person authorised to compile the technical file:

Name Function Address (company) Address (Street, No.) Address (post or ZIP code, city) (country)

The EU Declaration of Conformity was issued in/on:

Place, date

..............................

16)

.............................

Name

Function

Company

Address

16) A signed, legally binding EU Declaration of Conformity is supplied with the product.

Page 60

11 Certificate of Decontamination

60 of 64

11 Certificate of Decontamination

Type: ................................................................................................................................

Order number/ Order item number

17)

: ................................................................................................................................

Delivery date: ................................................................................................................................

Field of application: ................................................................................................................................

Fluid handled

17)

: ................................................................................................................................

Please tick where applicable

17)

   

Radioactive Explosive Corrosive Toxic

   

Harmful Bio-hazardous Highly flammable Safe

Reason for return

17)

: ................................................................................................................................

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 adapter have also been cleaned.

For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage at the stator can, the stator space has been examined for fluid 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

17) Required fields

Page 61

Index

61 of 64

Index

Abrasive fluids31

Bearing temperature35 Bearings16

Certificate of decontamination60

Design16 Designation15 Direction of rotation26 Dismantling40 Disposal14 Drive16, 19

Event of damage6

Ordering spare parts48

Explosion protection10, 16, 20, 24, 25, 27, 29, 30, 31, 33, 34, 35, 36

Faults

Causes and Remedies50 Fields of application8 Flow rate30

Fluid handled

Density31 Frequency of starts29

Grease lubrication

Grease quality37

Impeller type16 Installation20 Installation at site20 Intended use8

Key to safety symbols/markings7

Maintenance34 Monitoring equipment11

Noise characteristics19

Order number6 Other applicable documents6

Partly completed machinery6 Permissible forces at the pump nozzles24 Preservation13, 32 Product description15

Reassembly40 Return to supplier13 Returning to service32 Running noises34, 35

Safety8 Safety awareness9 Scope of supply19 Shaft seal16 Shutdown28, 32 Soleplate19

Spare part

Ordering spare parts48 Special accessories19 Start-up28 Storage13, 32 Suction strainer24

Temperature limits10 Tightening torques48 Transport12

Warnings7 Warranty claims6

Page 62

Page 63

Page 64

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com

2324.81/19-EN (01317346)

KSB MK, MKA, MKB, MK2 MK0, MK1 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual