KSB Vitacast, Vitacast Bloc Operating Manual
Hygienic Pump
Vitacast / Vitacast Bloc
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual Vitacast / Vitacast Bloc
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 17/09/2018
Contents
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
2.3 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......................................................................................................................................13
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 Designation.....................................................................................................................................................18
4.4 Name plate......................................................................................................................................................21
4.5 Design details..................................................................................................................................................21
4.6 Configuration and function...........................................................................................................................23
4.7 Noise characteristics .......................................................................................................................................23
4.8 Scope of supply...............................................................................................................................................24
4.9 Dimensions and weights ................................................................................................................................24
5 Installation at Site................................................................................................................................ 25
5.1 Checks to be carried out prior to installation...............................................................................................25
5.2 Installing the pump set ..................................................................................................................................25
5.2.1 Installation on a foundation .............................................................................................................26
5.2.2 Installation without foundation .......................................................................................................27
5.3 Piping ..............................................................................................................................................................27
5.3.1 Connecting the piping.......................................................................................................................27
5.3.2 Permissible forces and moments at the pump nozzles....................................................................29
5.3.3 Auxiliary connections.........................................................................................................................29
5.4 Enclosure/insulation .......................................................................................................................................29
5.5 Checking the coupling alignment .................................................................................................................30
5.6 Electrical connection ......................................................................................................................................31
5.6.1 Setting the time relay........................................................................................................................31
5.6.2 Connecting the motor .......................................................................................................................32
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Contents
5.6.3 Earthing..............................................................................................................................................32
5.7 Checking the direction of rotation................................................................................................................32
6 Commissioning/Start-up/Shutdown................................................................................................... 34
6.1 Commissioning/Start-up.................................................................................................................................34
6.1.1 Prerequisites for commissioning/start-up .........................................................................................34
6.1.2 Filling in lubricants.............................................................................................................................34
6.1.3 Priming and venting the pump.........................................................................................................35
6.1.4 Start-up...............................................................................................................................................36
6.1.5 Checking the shaft seal......................................................................................................................37
6.1.6 Shutdown ...........................................................................................................................................37
6.1.7 Seal supply system..............................................................................................................................38
6.2 Operating limits..............................................................................................................................................40
6.2.1 Ambient temperature........................................................................................................................40
6.2.2 Frequency of starts.............................................................................................................................41
6.2.3 Cleaning in place (CIP).......................................................................................................................41
6.2.4 Steaming in place (SIP) ......................................................................................................................42
6.2.5 Fluid handled .....................................................................................................................................42
6.3 Shutdown/storage/preservation ....................................................................................................................43
6.3.1 Measures to be taken for shutdown ................................................................................................43
6.4 Returning to service .......................................................................................................................................44
7 Servicing/Maintenance........................................................................................................................ 45
7.1 Safety regulations...........................................................................................................................................45
7.2 Servicing/Inspection........................................................................................................................................46
7.2.1 Supervision of operation...................................................................................................................46
7.2.2 Inspection work..................................................................................................................................48
7.2.3 Lubrication and lubricant change of rolling element bearings ......................................................49
7.3 Drainage/cleaning ..........................................................................................................................................51
7.4 Dismantling the pump set..............................................................................................................................52
7.4.1 General information/Safety regulations...........................................................................................52
7.4.2 Preparing the pump set.....................................................................................................................53
7.4.3 Removing the complete pump set from the piping ........................................................................53
7.4.4 Removing the pump casing and impeller.........................................................................................53
7.4.5 Removing the mechanical seal..........................................................................................................53
7.4.6 Removing the motor and bearings...................................................................................................56
7.5 Reassembling the pump set...........................................................................................................................57
7.5.1 General information/Safety regulations...........................................................................................57
7.5.2 Installing the bearings.......................................................................................................................58
7.5.3 Installing the mechanical seal ...........................................................................................................59
7.5.4 Fitting the impeller............................................................................................................................62
7.5.5 Adjusting the clearances ...................................................................................................................63
7.5.6 Mounting the pump casing...............................................................................................................64
7.5.7 Mounting the motor..........................................................................................................................64
7.6 Spare parts stock.............................................................................................................................................65
7.6.1 Ordering spare parts..........................................................................................................................65
7.6.2 Recommended spare parts stock for 2 years' operation to DIN24296 ..........................................65
8 Trouble-shooting.................................................................................................................................. 67
9 Related Documents.............................................................................................................................. 69
9.1 General assembly drawings with list of components...................................................................................69
9.1.1 Vitacast ...............................................................................................................................................69
9.1.2 Vitacast-Bloc.......................................................................................................................................73
10 EU Declaration of Conformity............................................................................................................. 76
11 Certificate of Decontamination........................................................................................................... 77
Index ..................................................................................................................................................... 78
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Glossary
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.
CIP (cleaning in place)
Procedure during which the inside of the pump is
cleaned with a cleaning agent. The pump does not
need to be dismantled.
Discharge line
The pipeline which is connected to the discharge
nozzle
Hydraulic system
The part of the pump in which the kinetic energy
is converted into pressure energy
Pool of pumps
Customers/operators’ pumps which are purchased
and stored regardless of their later use.
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
SIP (steaming in place)
Procedure during which the inside of the pump is
sterilised with steam. The pump does not need to
be dismantled.
Suction lift line/suction head line
The pipeline which is connected to the suction
nozzle
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1 General
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. (ðSection2.3,Page8)
1.4 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
General arrangement drawing/
outline drawing
Hydraulic characteristic curve Characteristic curves showing head, NPSH
Description of mating and installation dimensions
for the pump (set), weights
,
required
efficiency and power input
General assembly drawing
1)
Sectional drawing of the pump
Sub-supplier product literature1)Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists
Piping layout
List of components
1)
1)
1)
Description of spare parts
Description of auxiliary piping
Description of all pump components
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.5 Symbols
Table2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨
⇨ Cross-references
Result of an action
1) If agreed to be included in the scope of supply
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1 General
!
DANGER
!
WARNING
CAUTION
Symbol Description
1.
Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
1.6 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
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
2 Safety
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.
2.3 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
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.
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2 Safety
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.
▪ 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.
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2 Safety
!
DANGER
▪ When taking the pump set out of service always adhere to the procedure
described in the manual. (ðSection6.1.6,Page37) (ðSection6.3,Page43)
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page34)
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.
(ðSection2.2,Page8)
2.9 Explosion protection
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, (ðSection2.9.1,Page10) to (ðSection2.9.4,Page11)
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)
Refer to the individual Temperature Limits table for the temperatures permitted for
the individual pump variants.
The pump complies with the requirements of type of protection constructional safety
"c" to ISO80079-37.
Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor The motor must be considered separately.
2.9.2 Temperature limits
In normal pump operation, the highest temperatures are to be expected on the
surface of the pump casing, at the shaft seal 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 possible temperature rise in the shaft seal
area has already been taken into account).
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.
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Motor supplied by the
operator
2 Safety
Table4: Temperature limits
Temperature class to EN 13463-1 or
ISO 80079-36
T1 Temperature limit of the pump
T2 Temperature limit of the pump
T3 130 °C
T4 60 °C
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.
If a pump is supplied without motor (as part of a pool of pumps), the motor specified
in the pump data sheet must meet the following conditions:
▪ The permissible temperature limits at the motor flange and motor shaft must be
higher than the temperatures generated by the pump.
▪ Contact the manufacturer for the actual pump temperatures.
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 about monitoring equipment.
Maximum permissible
fluid temperature
2.9.4 Operating limits
The minimum flows indicated in (ðSection6.2.5.1,Page42) 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
(ðSection6.2.5.1,Page42) 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 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.
Vitacast-Bloc
Vitacast
1. If a motor shroud is fitted, remove it before transporting the pump set.
2. To transport the pump/pump set suspend it from the lifting tackle as shown.
Transporting installation type K
3-point ball feet
Transporting installation type M Transporting installation type L
Transporting installation type K
4-point ball feet
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3 Transport/Temporary Storage/Disposal
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.
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 motor fan.
If properly stored indoors, the pump set 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, the shutdown measures
must be adhered to. (ðSection6.3.1,Page43)
3.4 Return to supplier
1. Drain the pump as per operating instructions. (ðSection7.3,Page51)
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.
(ðSection11,Page77)
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 Transport/Temporary Storage/Disposal
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)
4 Description of the Pump (Set)
4.1 General description
▪ Hygienic pump
Pump for handling fluids which are not chemically aggressive, are free from solids
and do not require hermetic sealing.
Hygienic centrifugal pump for the food and beverage industry and the
pharmaceutical industry
Table5: Installation type
Installation type Illustration Description
Vitacast Bloc
K Horizontal installation, close-coupled pump set
▪ Axial suction nozzle, radial discharge nozzle, adjustable
through 360°
▪ Mounted on 3-point ball feet up to a drive rating of
4kW.
▪ Mounted on 4-point ball feet for drive ratings from 5.5
to 22kW.
M Horizontal installation, close-coupled pump set
▪ Axial suction nozzle, radial discharge nozzle, adjustable
through 360°
▪ Mounted on a motor foot for drive ratings from 0.33 to
22kW.
L Horizontal installation, close-coupled pump set
▪ Axial suction nozzle, radial discharge nozzle, adjustable
through 360°
▪ Connected to the motor via a bearing pedestal for drive
ratings of 30kW.
Vitacast
Fig. 0 (bare shaft) Horizontal installation, pump with bearing bracket
▪ Mounted on a baseplate
▪ Pump shaft and motor shaft connected via a coupling:
– Drive rating > 30 kW: standard
– Drive rating < 30 kW: option
4.2 Designation
Table6: Designation example
Position
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
V A I 0 4 0 - 0 3 2 - 1 4 5 0 4 0 2 G B T 8 1 A E C C S X O A
See name plate and data sheet See data sheet
Table7: Designation key
Position Code Description
1-4 Pump type
VA Vitacast
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4 Description of the Pump (Set)
Position Code Description
1-4 VAI Vitacast Inducer
5-16 Size, e.g.
040 Nominal suction nozzle diameter [mm]
032 Nominal discharge nozzle diameter [mm]
145 Impeller diameter [mm]
17-19 Motor rating PN [kW]
007 0,70
... ...
550 55,00
20 Number of motor poles
21 Scope of supply
G Baseplate
22-23 Shaft seal type
B Single mechanical seal, internal, dead-end arrangement, without
flushing
BQ Single mechanical seal, internal, dead-end arrangement, external
flushing (quench)
DB Double mechanical seal in back-to-back arrangement
I Single mechanical seal, internal, dead-end arrangement, internal
circulation
J Single mechanical seal, external, without flushing
24-26 Seal code, single mechanical seal, internal
T00 GCEGG
T18 U3U3VGG
T19 U3U3EGG
T64 U3Q1EGG
T66 Q1Q1M3GG
T68 U3Q1VGG
T69 BQ1M3GG
T80 BQ1VGG
T81 Q1Q1VGG
T82 BQ1EGG
T83 Q1Q1EGG
T84 Q1U3EGG
T85 Q1U3VGG
Seal code, single mechanical seal, internal, with encapsulated spring
H0D GCVGG
H1 Q1CEGG
H1D Q1CVGG
H2 Q1U3EGG
H2D Q1U3VGG
H3 Q1Q1EGG
H3D Q1Q1VGG
H4 U3U3EGG
H5 Q2Q2EGG**
H7 U2U2VGG*
H8 U3U3VGG
H9 BQ1VGG*
HA U3U3EGG
Seal code, single mechanical seal, external
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4 Description of the Pump (Set)
Position Code Description
24-26 Y06 U3U3EGG
Y07 BU3EGG
Seal code, double mechanical seal in back-to-back arrangement
Q80 BQ1VGG
BGVGG
Q81 Q1Q1VGG
BGVGG
Q82 BQ1EGG
BGEGG
Q83 Q1Q1EGG
BGEGG
Q84 Q1U3EGG
BGEGG
Q85 Q1U3VGG
BGVGG
27 Pipe connection
A Flange APV
B Threaded connection DIN 11864-1A
C Flange DIN 11864-2A
D Clamped connection DIN 11864-3A
E Threaded connection DIN 11853
F Threaded connection RJT
G Flange Varivent
I Threaded connection ISO 2853 (IDF)
L Flange EN 1092-1
M Threaded connection DIN 11851 (hygienic pipe union)
S Threaded connection SMS
T Clamped connection DIN 32676-A
U Clamped connection DIN32676-C (Tri-Clamp)
V Clamped connection ISO 2852
Z Flange ANSI B16.5 Class 150
28 O-ring material (casing/impeller)
E EPDM
K Kalrez
M FEP (encapsulated)
T PTFE
V FPM
29 Pump casing material
C Stainless steel 1.4409
D Super duplex stainless steel 1.4469/ 1.4410
X Hastelloy C276 2.4819
30 Impeller material
C Stainless steel 1.4409
D Super duplex stainless steel 1.4469/ 1.4410
X Hastelloy C276 2.4819
31 Motor shroud
O Without shroud
S With shroud
32 Design
Vitacast / Vitacast Bloc
17 of 80
4 Description of the Pump (Set)
Position Code Description
32
2)
Standard
X Non-standard (BT3D, BT3), including ATEX
33 Draining facility
D Casing drain with plug
O No drain
P Casing drain via piping
V Casing drain via valve
34 Generation
A Vitacast
4.3 Designation
Table8: Designation example
Position
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
V A B 0 3 2 - 0 2 5 - 1 4 5 0 4 0 2 K B T 8 1 M E C C S X O A
See name plate and data sheet See data sheet
Table9: Designation key
Position Code Description
1-4 Pump type
VAB Vitacast Bloc
VABI Vitacast Bloc Inducer
5-16 Size, e.g.
040 Nominal suction nozzle diameter [mm]
025 Nominal discharge nozzle diameter [mm]
200 Nominal impeller diameter [mm]
17-19 Motor rating PN [kW]
007 0,7
... ...
550 55,00
20 Number of motor poles
21 Scope of supply
K Ball feet
L Bearing bracket
M Motor foot
T Round base feet
V Trolley
22-23 Shaft seal type
B Single mechanical seal, internal, dead-end arrangement, without
flushing
BQ Single mechanical seal, internal, dead-end arrangement, external
flushing (quench)
DB Double mechanical seal, external, in back-to-back arrangement
I Single mechanical seal, internal, dead-end arrangement, internal
circulation
J Single mechanical seal, external, without flushing
24-26 Seal code, single mechanical seal, internal
T00 GCEGG
2) Blank
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Vitacast / Vitacast Bloc
4 Description of the Pump (Set)
Position Code Description
24-26 T18 U3U3VGG
T19 U3U3EGG
T64 U3Q1EGG
T66 Q1Q1M3GG
T68 U3Q1VGG
T69 BQ1M3GG
T80 BQ1VGG
T81 Q1Q1VGG
T82 BQ1EGG
T83 Q1Q1EGG
T84 Q1U3EGG
T85 Q1U3VGG
Seal code, single mechanical seal, internal, with encapsulated spring
H0D GCVGG
H1 Q1CEGG
H1D Q1CVGG
H2 Q1U3EGG
H2D Q1U3VGG
H3 Q1Q1EGG
H3D Q1Q1VGG
H4 U3U3EGG
H5 Q2Q2EGG**
HA U3U3EGG
H7 U2U2VGG*
H8 U3U3VGG
H9 BQ1VGG*
Seal code, single mechanical seal, external
Y06 U3U3EGG
Y07 BU3EGG
Seal code, double mechanical seal, external, back-to-back arrangement
Q70 GCEGG
GBEGG
Q71 U3CEGG
GCEGG
Q72 U3U3EGG
U3BGG
Q74 U3U3VGG
BU3VGG
Q78 U3U3VGG
U3U3VGG
Q79 U3U3TGG
U3CTGG
27 Pipe connection
A Flange APV
B Threaded connection DIN 11864-1A
C Flange DIN 11864-2A
D Clamped connection DIN 11864-3A
E Threaded connection DIN 11853
F Threaded connection RJT
Vitacast / Vitacast Bloc
19 of 80
4 Description of the Pump (Set)
Position Code Description
27 G Flange Varivent
I Threaded connection ISO 2853 (IDF)
L Flange EN 1092-1
M Threaded connection DIN 11851 (hygienic pipe union)
S Threaded connection SMS
T Clamped connection DIN 32676-A
U Clamped connection DIN32676-C (Tri Clamp)
V Clamped connection ISO 2852
Z Flange ANSI B16.5 Class 150
28 O-ring material (casing/impeller)
E EPDM
K Kalrez
M FEP (encapsulated)
P PTFE
V FPM
29 Pump casing material
C Stainless steel 1.4409
D Super duplex stainless steel 1.4469/ 1.4410
X Hastelloy C276 2.4819
30 Impeller material
C Stainless steel 1.4409
D Super duplex stainless steel 1.4469/ 1.4410
X Hastelloy C276 2.4819
31 Motor shroud
O Without shroud
S With shroud
32 Design
3)
Standard
X Non-standard (BT3D, BT3), including ATEX
33 Drain
D Casing drain with plug
O No drain
P Casing drain via pipeline
V Casing drain via valve
34 Generation
A Vitacast Bloc
3) Blank
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Vitacast / Vitacast Bloc
4 Description of the Pump (Set)
VAB 032-025-145 0402KB T81ME
E-Nr
Nr
H 20 mQ 8 m
3
/h
Jahr 2016
n 2900 1/min
1
2
4
3
6
7
5
Johann-Klein-Straße 9
Deutschland
67227 Frankenthal
KSB SE & Co. KGaA
4.4 Name plate
Fig.1: Name plate of a Vitacast-Bloc (example)
1 Type series, size and version 2 KSB order number
3 Manufacturer's No. 4 Flow rate
5 Head 6 Speed
7 Year of construction
4.5 Design details
Design
▪ Hygienic centrifugal pump
▪ Single-stage
▪ Close-coupled design and long-coupled design
▪ Non-self-priming
▪ Wetted parts made of stainless steel 1.4404/1.4409 (AISI316L/CF3M)
Pump casing
▪ Volute casing
Impeller type
▪ Open multi-vane impeller
Bearings
▪ Grease-packed deep groove ball bearing
▪ Bearing in oil bath
Shaft seal
▪ Single mechanical seal to EN12756
– Seal typeT5): pump-end seal with non-encapsulated spring surrounded by
fluid handled, uni-directional
– Seal typeH6): pump-end seal with encapsulated spring, polished surface, bi-
directional
– Seal type Y: external seal
– Double mechanical seal to EN12756
– Seal type Q: back-to-back arrangement (pressurised barrier fluid)
4)
4) Vitacast only
5) Hygienic design
6) Sterile design
Vitacast / Vitacast Bloc
21 of 80
4 Description of the Pump (Set)
Drive
Standard design:
▪ KSB surface-cooled IEC three-phase current squirrel-cage motor
▪ 50Hz winding, 220-240V/ 380-420V ≤2.20kW
▪ 50Hz winding, 380-420V/ 660-725V ≥3.00kW
▪ 60Hz winding, 440-480V ≤2.60kW
▪ 60Hz winding, 440-480V ≥3.60kW
▪ Type of construction IMV1 ≤4.00kW
▪ Type of construction IMV15 ≥5.50kW
▪ Enclosure IP55
▪ Duty cycle: continuous duty S1
▪ Thermal class F with temperature sensor, 3 PTC thermistors
Explosion-proof version:
▪ KSB surface-cooled IEC three-phase current squirrel-cage motor
▪ 50Hz winding, 220-240V/ 380-420V ≤1.85kW
▪ 50Hz winding, 380-420V/ 660-725V ≥2.50kW
▪ Type of construction IMV1 ≤3.30kW
▪ Type of construction IMV15 ≥4.60kW
▪ Enclosure IP55 or IP54
▪ Duty cycle: continuous duty S1
▪ Type of protection EEx e II
▪ Temperature class T3
Automation
Automation options:
▪ PumpDrive
▪ PumpMeter
Connections
▪ Axial suction nozzle, tangential discharge nozzle
▪ Adjustable through 360°
Types of connection:
▪ Threaded connection to DIN11851 (hygienic pipe union)
▪ Threaded connection to DIN11853
▪ Threaded connection to DIN11864-1-GS-A
▪ Threaded connection to SMS standard
▪ Threaded connection to ISO2853 (IDF)
▪ Threaded connection to RJT standard
▪ Clamped connection to DIN32676-C (Tri-Clamp/Tri-Clover fitting)
▪ Clamped connection to DIN11864-3-NKS-A
▪ Clamped connection to DIN32676-A
▪ Clamped connection to ISO2852
▪ Flange to EN1092-1
▪ Flange to DIN11864-2-NF-A
▪ Flange to ANSI B16.5 Class 150
▪ APV flange
▪ Varivent flange
▪ Other connection types on request
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Vitacast / Vitacast Bloc
4 Description of the Pump (Set)
7
8
9 10 11
12
1
2
3
4
5 6
4.6 Configuration and function
Fig.2: Sectional drawing of a Vitacast Bloc
1 Volute channel 2 Discharge nozzle
3 Clamping piece 4 Pump shaft
5 Rolling element bearing for pump
shaft
7 Suction nozzle 8 Impeller
9 Casing cover 10 Shaft seal
11 Bearing assembly 12 Drive
Design The pump is designed with an axial fluid inlet and a radial outlet. The hydraulic
system is rigidly connected to the motor via a stub shaft.
Function The fluid enters the pump via the suction nozzle (7) and is accelerated outward in a
radial flow by the rotating impeller (8). In the flow passage of the pump casing (1)
the kinetic energy is converted into pressure energy. The fluid is pumped to the
discharge nozzle (2), where it leaves the pump. At the rear side of the impeller, the
shaft (4) enters the hydraulic system via the casing cover (9). The shaft passage
through the cover is sealed to atmosphere with a dynamic shaft seal (10). The pump
shaft runs in a rolling element bearing (5), which is supported by a bearing assembly
(11). The motor shaft is inserted into the pump shaft (stub shaft). The drive (12) is
connected to the pump via the drive lantern (6).
Sealing The pump is sealed by a mechanical seal.
6 Drive lantern
4.7 Noise characteristics
Table10: Surface sound pressure level LpA [dB]
Size Pump set
1450 rpm 2900 rpm
032-025-145 < 70 71 - 75
032-025-175 < 70 71 - 75
7)
7) Measured at a distance of 1 metre, 1.6 metres above the installation surface
Vitacast / Vitacast Bloc
23 of 80
4 Description of the Pump (Set)
Size Pump set
1450 rpm 2900 rpm
040-032-110 < 70 71 - 75
040-032-145 < 70 71 - 75
040-032-175 < 70 71 - 75
040-032-210 < 70 76 - 80
050-032-260 < 70 050-040-145 < 70 76 - 80
050-040-175 < 70 76 - 80
050-040-210 < 70 76 - 80
050-040-260 < 70 065-050-145 < 70 76 - 80
065-050-175 < 70 76 - 80
065-050-210 < 70 76 - 80
065-050-260 < 70 81 - 85
080-065-145 < 70 81 - 85
080-065-175 < 70 81 - 85
080-065-210 < 70 86 - 90
080-065-260 71 - 75 86 - 90
100-080-175 71 - 75 81 - 85
100-080-210 71 - 75 86 - 90
100-080-260 71 - 75 86 - 90
100-080-310 71 - 75 125-100-210 71 - 75 86 - 90
125-100-310 71 - 75 150-125-350 71 - 75 200-150-350 71 - 75 -
4.8 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪ Pump
▪ Drive
▪ Frequency inverter
▪ Motor shroud
▪ Pump foot or foot base (e.g. 3-point ball feet)
▪ Trolley with switch and power cable
4.9 Dimensions and weights
For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump/pump set.
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Vitacast / Vitacast Bloc
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