KSB Vitaprime Operating Manual

Hygienic Pump

Vitaprime

Hygienic Side Channel Pump
for the Highest Requirements
on Cleanability

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual Vitaprime

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 13/08/2018

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

2.3 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 ...........................................................................................................................................................13

4 Description of the Pump (Set)............................................................................................................. 14

4.1 General description ........................................................................................................................................14

4.2 Designation.....................................................................................................................................................14

4.3 Name plate......................................................................................................................................................16

4.4 Design details..................................................................................................................................................17

4.5 Configuration and function...........................................................................................................................19

4.6 Noise characteristics .......................................................................................................................................19

4.7 Scope of supply...............................................................................................................................................20

4.8 Dimensions and weights ................................................................................................................................20

5 Installation at Site................................................................................................................................ 21

5.1 Checks to be carried out prior to installation...............................................................................................21

5.2 Installing the pump set ..................................................................................................................................21

5.3 Piping ..............................................................................................................................................................21

5.3.1 Connecting the piping.......................................................................................................................21

5.3.2 Permissible forces and moments at the pump nozzles....................................................................23

5.3.3 Auxiliary connections.........................................................................................................................23

5.4 Enclosure/insulation .......................................................................................................................................23

5.5 Electrical system..............................................................................................................................................24

5.5.1 Operation on a frequency inverter...................................................................................................24

5.6 Electrical connection ......................................................................................................................................24

5.6.1 Setting the time relay........................................................................................................................25

5.6.2 Connecting the motor .......................................................................................................................25

5.6.3 Earthing..............................................................................................................................................25

5.7 Checking the direction of rotation................................................................................................................26

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

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

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

6.1.2 Filling in lubricants.............................................................................................................................27

6.1.3 Priming and venting the pump.........................................................................................................27

6.1.4 Start-up...............................................................................................................................................28

6.1.5 Checking the shaft seal......................................................................................................................29

6.1.6 Shutdown ...........................................................................................................................................30

6.1.7 Seal supply system..............................................................................................................................30

6.2 Operating limits..............................................................................................................................................33

6.2.1 Ambient temperature........................................................................................................................33

6.2.2 Frequency of starts.............................................................................................................................33

6.2.3 Cleaning in place (CIP).......................................................................................................................34

6.2.4 Steaming in place (SIP) ......................................................................................................................34

6.2.5 Fluid handled .....................................................................................................................................35

6.3 Shutdown/storage/preservation ....................................................................................................................36

6.3.1 Measures to be taken for shutdown ................................................................................................36

6.4 Returning to service .......................................................................................................................................37

7 Servicing/Maintenance........................................................................................................................ 38

7.1 Safety regulations...........................................................................................................................................38

7.2 Servicing/Inspection........................................................................................................................................39

7.2.1 Supervision of operation...................................................................................................................39

7.2.2 Inspection work..................................................................................................................................41

7.2.3 Lubrication and lubricant change of rolling element bearings ......................................................42

7.3 Drainage/cleaning ..........................................................................................................................................43

7.4 Dismantling the pump set..............................................................................................................................43

7.4.1 General information/Safety regulations...........................................................................................43

7.4.2 Preparing the pump set.....................................................................................................................44

7.4.3 Removing the complete pump set from the piping ........................................................................44

7.4.4 Removing the pump casing and impeller.........................................................................................44

7.4.5 Removing the mechanical seal..........................................................................................................46

7.4.6 Dismantling the bearing assembly....................................................................................................48

7.5 Reassembling the pump set...........................................................................................................................49

7.5.1 General information/Safety regulations...........................................................................................49

7.5.2 Adjusting the clearances ...................................................................................................................50

7.5.3 Fitting the bearing assembly.............................................................................................................50

7.5.4 Installing the mechanical seal ...........................................................................................................51

7.5.5 Fitting the impeller and the pump casing........................................................................................53

7.6 Spare parts stock.............................................................................................................................................55

7.6.1 Ordering spare parts..........................................................................................................................55

7.6.2 Recommended spare parts stock for 2 years' operation to DIN24296 ..........................................55

8 Trouble-shooting.................................................................................................................................. 56

9 Related Documents.............................................................................................................................. 57

9.1 General assembly drawing with list of components (single-stage pumps).................................................57

9.1.1 Pump size 40-146, motor size 90.......................................................................................................57

9.1.2 Pump size 50-164, motor size 132.....................................................................................................58

9.1.3 Pump size 60/65-200, motor size 160................................................................................................59

9.1.4 Pump size 80-240, motor size 160.....................................................................................................60

9.2 General assembly drawing with list of components (two-stage pumps)....................................................61

9.2.1 Pump size 42-146, motor size 112.....................................................................................................61

9.2.2 Pump size 52-164, motor size 132.....................................................................................................62

10 EU Declaration of Conformity............................................................................................................. 63

11 Certificate of Decontamination........................................................................................................... 64

Index ..................................................................................................................................................... 65

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.

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

IE3

Efficiency class to IEC60034-30: 3=Premium
Efficiency (IE = International Efficiency)

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

Self-priming ability

Ability of a filled pump to evacuate a suction line,
i.e. to self-prime from an unfilled suction line.

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

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
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power input
General assembly drawing

1)

Sectional drawing of the pump
Sub-supplier product literature1)Operating manuals and other product literature

describing accessories and integrated machinery

components
Spare parts lists

1)

Description of spare parts
Piping layout

1)

Description of auxiliary piping
List of components

1)

Description of all pump components
Drawing for assembly

1)

Sectional drawing of the installed shaft seal

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

1.5 Symbols

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 upon in scope of supply

1 General

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Symbol Description

1.

2.

Step-by-step instructions

Note
Recommendations and important information on how to handle
the product

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. (ðSection1.4,Page6)

▪ 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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2.4 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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▪ When taking the pump set out of service always adhere to the procedure

described in the manual. (ðSection6.1.6,Page30) (ðSection6.3,Page36)

▪ 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)

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 ISO80079-37.

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 at the
surface of the pump casing and at the shaft seal.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated, 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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Table4: Temperature limits

Temperature class to EN 13463-1 Maximum permissible fluid

temperature

T1 Pump temperature limit
T2 Pump temperature limit
T3 100 °C
T4 90 °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.

Motor supplied by the

operator

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.

2.9.4 Operating limits

The minimum flows indicated in (ðSection6.2.5.1,Page35) 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6.2.5.1,Page35) can be used to check whether additional heat build-up
may lead to a dangerous temperature increase at the pump surface.

3 Transport/Temporary Storage/Disposal

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3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.

3.2 Transport

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.

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

Fig.1: Transporting the pump set

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that the
following measures be taken 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.

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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. (ðSection6.3.1,Page36)

3.4 Return to supplier

1. Drain the pump as per operating instructions. (ðSection7.3,Page43)

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64)

NOTE

If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination

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.

4 Description of the Pump (Set)

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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 side channel pump for the food and beverage industry and the
pharmaceutical industry

All pumps of this type series are fitted with standardised mechanical seals to
EN12756. This ensures reliable operation and interchangeability.

When different standardised mechanical seals are used, verify the axial length of the
seal.
Type and material of the mechanical seal are specifically selected to match the nature
and composition of the fluid to be handled.

NOTE

Before using the pump for any fluids different from those originally specified, check
that the mechanical seals and joint rings are suitable for that fluid.
If certified seal types and/or materials are used, make sure that the replacement
seals also meet the certification requirements.

Design

▪ Seal typeT: internal single mechanical seal (standard design)
▪ Seal type VT: internal single mechanical seal with flushing system (quench,

unpressurised)

▪ Seal typeQ: external double mechanical seal with flushing system, with

pressurised barrier fluid

▪ Seal typeH: internal single mechanical seal, enclosed spring, balanced
▪ Seal type VH: internal single mechanical seal with flushing system (quench,

unpressurised), enclosed spring, balanced

4.2 Designation

Table5: 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

V P 8 0 - 2 4 0 - 1 1 0 4 0 4 K B Q T 8 2 M E C C O O A

See name plate and data sheet See data

sheet

Table6: Designation key

Position Code Description

1-4 Pump type

VP Vitaprime

5-13 Size, e.g.

80 Nominal nozzle diameter [mm]
240 Nominal impeller diameter [mm]
11 Load range

14-16 Motor rating PN [kW]

007 0,70
040 4,00

185 18,50
17 Number of motor poles
18 Scope of supply

4 Description of the Pump (Set)

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Position Code Description

18 K Ball feet

M Motor foot

T Round base feet

V Trolley
19-20 Shaft seal type

B Single mechanical seal, dead-end arrangement, without flushing

BQ Single mechanical seal, dead-end arrangement, external flushing

(quench)

DB Double mechanical seal in back-to-back arrangement
21-23 Seal code, single mechanical seal

T00 BGEGG

T18 U2U2VGG

T19 U2U2EGG

T64 U2Q1EGG

T66 Q1Q1M3GG

T68 U2Q1VGG

T69 BQ1M3GG

T80 BQ1VGG

T81 Q1Q1VGG

T82 BQ1EGG

T83 Q1Q1EGG

T84 Q1U2EGG

T85 Q1U2VGG

Seal code, double mechanical seal in back-to-back arrangement

Q70 BGEGG

BGEGG

Q71 BU2EGG

BGEGG

Q72 U2U2EGG

BU2EGG

Q74 U2U2VGG

BU2VGG

Q78 U2U2VGG

U2U2EGG

Q79 U2U2M3GG

BU2EGG

24 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 DIN32676-C (Tri-Clamp)

4 Description of the Pump (Set)

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Vitaprime

Position Code Description

24 V Clamped connection ISO 2852

Z Flange ANSI B16.5 Class 150
25 O-ring material (casing/impeller)

E EPDM

F FFKM (Kaflon)

K FFKM (Kalrez)

M FEP (encapsulated)

P PTFE

V FPM
26 Pump casing material

C Stainless steel 1.4409
27 Impeller material

C Stainless steel 1.4409
28 Motor shroud

S With shroud

O Without shroud
29 Design

2)

Standard

X Non-standard (BT3D, BT3), including ATEX
30 Drain

O No drain

P Casing drain via pipeline

V Casing drain via valve

D Casing drain with plug
31 Product generation

A Vitaprime

4.3 Name plate

VP 80-240-11040KBQT82ME

E-Nr

Nr

H 20 m

Q 10 m

3

/h

Jahr 2016

n 1450 1/min

1

2

4

3

6

7

5

Johann-Klein-Straße 9

Deutschland

67227 Frankenthal

KSB SE & Co. KGaA

Fig.2: Name plate Vitaprime (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

2) Blank

4 Description of the Pump (Set)

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Vitaprime

4.4 Design details

Design

▪ Standard design with materials to Regulation (EC) No.1935/2004
▪ Design to ATEX

Design

▪ Side channel pump
▪ Horizontal installation
▪ One or two stages
▪ Self-priming

Pump casing

▪ Casing with transfer passages

Impeller type

▪ Open star impeller

Bearings

▪ Grease-packed deep groove ball bearing

Shaft seal

▪ Single mechanical seal to EN12756

– Seal typeT3): pump-end seal with non-encapsulated spring surrounded by

fluid handled, uni-directional

▪ Double mechanical seal to EN12756

– Seal type Q: back-to-back arrangement (pressurised barrier fluid)

Drive

▪ Efficiency class IE3 to IEC60034-30

Standard design:

▪ KSB surface-cooled IEC three-phase current squirrel-cage motor
▪ 50Hz winding, 220-240V/ 380-420V ≤2.20kW
▪ 50Hz winding, 380-420V/ 660-725V ≥3.00kW
▪ 60Hz winding, 440-480V ≤2.60kW
▪ 60Hz winding, 440-480V ≥3.60kW
▪ Type of construction IMV1 ≤4.00kW
▪ Type of construction IMV15 ≥5.50kW
▪ 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
▪ 50Hz winding, 220-240V/ 380-420V ≤1.85kW
▪ 50Hz winding, 380-420V/ 660-725V ≥2.50kW
▪ Type of construction IMV1 ≤3.30kW
▪ Type of construction IMV15 ≥4.60kW
▪ Enclosure IP55 or IP54

3) Hygienic design

4 Description of the Pump (Set)

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Vitaprime

▪ Duty cycle: continuous duty S1
▪ Type of protection EEx e II
▪ Temperature class T3

Automation

Automation options:

▪ PumpDrive

Connections

▪ Axial suction nozzle, tangential discharge nozzle

Types of connection:

▪ Threaded connection to DIN11851 (hygienic pipe union)
▪ Threaded connection to DIN11853
▪ Threaded connection to DIN11864-1-GS-A
▪ Threaded connection to SMS standard
▪ Threaded connection to ISO2853 (IDF)
▪ Threaded connection to RJT standard
▪ Clamped connection to DIN32676-C (Tri-Clamp/Tri-Clover fitting)
▪ Clamped connection to DIN11864-3-NKS-A
▪ Clamped connection to DIN32676-A
▪ Clamped connection to ISO2852
▪ Flange to EN1092-1
▪ Flange to DIN11864-2-NF-A
▪ Flange to ANSI B16.5 Class 150
▪ APV flange
▪ Varivent flange
▪ Other connection types on request

4 Description of the Pump (Set)

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Vitaprime

4.5 Configuration and function

Fig.3: Sectional drawing of Vitaprime

1 Suction nozzle 2 Inlet casing
3 Impeller casing 4 Discharge nozzle
5 Impeller 6 Shaft seal
7 Rolling element bearing 8 Drive shaft
9 Side channel 10 Bearing assembly
11 Motor

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 inlet casing (2) of the pump via the suction nozzle (1) and then

passes through an opening into the impeller casing (3). The rotating impeller (5)
conveys the fluid into the side channel (9), so that a liquid ring is formed in the
casing. Owing to the conical geometry of the side channel, i.e. a change in volume
(positive displacement effect), the fluid is drawn from the inlet casing (2) and
transferred to the discharge nozzle (4), where it leaves the pump. The drive shaft (8)
enters the casing through an opening at the rear. The shaft passage is sealed with a
dynamic shaft seal (6). The drive shaft runs in a rolling element bearing (7), which is
supported by a bearing assembly (10). The motor shaft is inserted into the drive shaft
(stub shaft). The motor (11) is bolted to the pump casing. The pump is self-priming
once the inlet casing has been filled.

Sealing The pump is sealed by a mechanical seal.

Various seal designs can be used.

4.6 Noise characteristics

Table7: Surface sound pressure level L

pA

4)

Size Noise characteristic

[dB]

Vitaprime 40-146 < 80
Vitaprime 42-146 81 - 85
Vitaprime 50-164 81 - 85
Vitaprime 52-164 86 - 90

4) Measured at a distance of 1 metre, 1.6 metres above the installation surface

4 Description of the Pump (Set)

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Vitaprime

Size Noise characteristic

[dB]

Vitaprime 60-200 86 - 90
Vitaprime 65-200 86 - 90
Vitaprime 80-240 86 - 90

4.7 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
▪ Noise reduction valve

4.8 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump/pump set.

5 Installation at Site

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Vitaprime

5 Installation at Site

5.1 Checks to be carried out prior to installation

Place of installation

WARNING

Installation on mounting surface which is unsecured and cannot support the load

Personal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets the

requirements of exposure class XC1 to EN206-1.

▷ The mounting surface must be set, flat, and level.
▷ Observe the weights indicated.

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

5.2 Installing the pump set

Always install the pump set in a horizontal position.

DANGER

Excessive temperatures due to improper installation

Explosion hazard!

▷ Install the pump in a horizontal position to ensure self-venting of the pump.

CAUTION

Ingress of leakage into the motor

Damage to the pump!

▷ Never install the pump set with the "motor below".

1. Align the pump set with the help of a spirit level placed on the discharge
nozzle.

5.3 Piping

5.3.1 Connecting the piping

DANGER

Impermissible loads acting on the pump nozzles

Danger to life from leakage of hot, toxic, corrosive or flammable fluids!

▷ Do not use the pump as an anchorage point for the piping.
▷ Anchor the pipes in close proximity to the pump and connect them properly

without transmitting any stresses or strains.

▷ Take appropriate measures to compensate for thermal expansion of the piping.

5 Installation at Site

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Vitaprime

CAUTION

Incorrect earthing during welding work at the piping

Destruction of rolling element bearings (pitting effect)!

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

NOTE

Installing check and shut-off elements in the system is recommended, depending on
the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.

CAUTION

When handling gaseous fluids or fluids which tend to froth, the pump will not be
self-priming.

Pump is running, but does not deliver!

▷ Install a check valve in the suction line.

ü Suction lift lines have been laid with a rising slope, suction head lines with a

downward slope towards the pump.

ü A flow stabilisation section having a length equivalent to at least twice the

diameter of the suction flange has been provided upstream of the suction flange.

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

diameters of the pump nozzles.

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

approx. 8° to avoid excessive pressure losses.

ü The pipelines have been anchored in close proximity to the pump and connected

without transmitting any stresses or strains.

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).

2. Before installing the pump in the piping, remove the flange covers on the
suction and discharge nozzles of the pump.

CAUTION

Welding beads, scale and other impurities in the piping

Damage to the pump!

▷ Remove any impurities from the piping.
▷ If necessary, install a filter.
▷ Observe the information in (ðSection7.2.2.2,Page41) .

NOTE

Use a filter with laid-in wire mesh (mesh width 0.5mm, wire diameter 0.25mm) of
corrosion-resistant material.
Use a filter with a filter area three times the cross-section of the piping.
Conical filters have proved suitable.

3. Connect the pump nozzles to the piping.

5 Installation at Site

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Vitaprime

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.

5.3.2 Permissible forces and moments at the pump nozzles

No piping-induced forces and moments (from warped pipelines or thermal
expansion, for example) must act on the pump.

5.3.3 Auxiliary connections

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.

CAUTION

Failure to use or incorrect use of auxiliary connections (flushing liquid)

Malfunction of the pump!

▷ Use and install any auxiliary connections in such a way that a proper flow is

ensured.

If a shaft seal with flush connection is used, fit the flushing liquid reservoir in the
immediate vicinity of the pump set approximately 1metre above the pump
centreline. Fluid circulation is ensured by thermosyphon effect or forced circulation.

When mounting the pipe unions comply with the instructions provided by the pipe
union manufacturer.

NOTE

The flushing liquid feed line must be laid with a continuously rising slope towards
the flushing liquid reservoir.

Make sure that the flushing liquid (if any) circulates properly also before starting up
and after shutting down the pump (until the pump set comes to a complete stop).

5.4 Enclosure/insulation

WARNING

The volute casing and casing/discharge cover take on the same temperature as the
fluid handled

Risk of burns!

▷ Insulate the volute casing.
▷ Fit protective equipment.

5 Installation at Site

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Vitaprime

CAUTION

Heat build-up in the bearing bracket

Damage to the bearing!

▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover.

5.5 Electrical system

5.5.1 Operation on a frequency inverter

The pump set is suitable for operation on a frequency inverter as per IEC60034-17.

Selection When selecting a frequency inverter, check the following details:

▪ Data provided by the manufacturer
▪ Electrical data of the pump set, particularly the rated current
▪ Only voltage source inverters (VSI) with pulse width modulation (PWM) and

carrier frequencies between 1 and 16kHz are suitable.

Setting Observe the following instructions for setting a frequency inverter:

▪ Set the current limit to max. 1.2 times the rated current. The rated current is

indicated on the name plate.

Start-up Observe the following instructions for starting the frequency inverter:

▪ Ensure short start ramps (maximum 5 seconds).
▪ Only start variable speed control after 2minutes at the earliest.

Pump start-up with long start ramps and low frequency may cause clogging.

Operation Observe the following limits during operation on a frequency inverter:

▪ Only utilise up to 95% of the motor rating P2 indicated on the name plate.
▪ Frequency range 25 to 60Hz

Electromagnetic

compatibility

Operation on a frequency inverter produces interference emissions whose level varies
depending on the inverter used (type, interference suppression, make). To prevent
the drive system, consisting of a submersible motor and a frequency inverter, from
exceeding any given limits always observe the EMC information provided by the
inverter manufacturer. If the inverter manufacturer recommends a shielded power
cable, make sure to use a submersible motor pump with shielded power cables.

Interference immunity The submersible motor pump generally meets interference immunity requirements.

For monitoring the sensors installed the operator must ensure sufficient interference
immunity by appropriately selecting and laying the power cables in the plant. No
modifications are required on the power/control cable of the submersible motor
pump. Suitable analysing devices must be selected. To monitor the leakage sensor
inside the motor using a special relay available from KSB is recommended.

5.6 Electrical connection

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.

5 Installation at Site

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WARNING

Incorrect connection to the mains

Damage to the mains network, short circuit!

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

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

2. Select an appropriate starting method.

NOTE

A motor protection device is recommended.

5.6.1 Setting the time relay

CAUTION

Switchover between star and delta on three-phase motors with star-delta starting
takes too long.

Damage to the pump (set)!

▷ Keep switch-over intervals between star and delta as short as possible.

Table8: Time relay settings for star-delta starting:

Motor rating Y time to be set

≤ 30 kW < 3 s

5.6.2 Connecting the motor

NOTE

In compliance with IEC 60034-8, three-phase motors are always wired for clockwise
rotation (looking at the motor shaft stub).

The pump's direction of rotation is indicated by an arrow on the pump.

1. Match the motor's direction of rotation to that of the pump.

2. Observe the manufacturer's product literature supplied with the motor.

5.6.3 Earthing

DANGER

Electrostatic charging

Explosion hazard!
Damage to the pump set!

▷ Connect the PE conductor to the earthing terminal provided.
▷ Provide for potential equalisation between the pump set and foundation.

5 Installation at Site

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Vitaprime

5.7 Checking the direction of rotation

DANGER

Temperature increase resulting from contact between rotating and stationary
components

Explosion hazard!
Damage to the pump set!

▷ Never check the direction of rotation by starting up the unfilled pump set.
▷ Separate the pump from the motor to check the direction of rotation.

WARNING

Hands inside the pump casing

Risk of injuries, damage to the pump!

▷ Always disconnect the pump set from the power supply and secure it against

unintentional start-up before inserting your hands or other objects into the
pump.

CAUTION

Incorrect direction of rotation with non-reversible mechanical seal

Damage to the mechanical seal and leakage!

▷ Separate the pump from the motor to check the direction of rotation.

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 switchgear, if any.

6 Commissioning/Start-up/Shutdown

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the following
conditions are met:

▪ The quality of the concrete foundation complies with the regulations.
▪ The pump set has been installed and aligned in accordance with the tolerances

specified.

▪ The pump set has been properly connected to the power supply and is equipped

with all protection devices. (ðSection5.6,Page24)

▪ The pump has been primed with the fluid to be handled. The pump has been

vented.

▪ The direction of rotation has been checked. (ðSection5.7,Page26)
▪ All auxiliary connections required are connected and operational.
▪ The lubricants have been checked.
▪ The lock washers, if any, have been removed from the shaft groove.
▪ The pump (set) has been installed and connected as described in this manual.
▪ After prolonged shutdown of the pump (set), the activities required for returning

the equipment to service have been carried out. (ðSection6.4,Page37)

6.1.2 Filling in lubricants

Grease-lubricated bearings

The bearings have been packed with grease at the factory.

6.1.3 Priming and venting the pump

DANGER

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

Explosion hazard!
Damage to the pump set!

▷ Prime the pump as per operating instructions.

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.

6 Commissioning/Start-up/Shutdown

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Vitaprime

DANGER

Risk of potentially explosive atmosphere inside the pump

Explosion hazard!

▷ The pump internals in contact with the fluid to be handled, including the seal

chamber and auxiliary systems must be filled with the fluid to be handled at all
times.

▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.

CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

1. Vent the pump and suction line and prime both with the fluid to be handled.

2. Fully open the shut-off element in the suction line.

3. Fully open all auxiliary feed lines (barrier fluid, flushing liquid, etc.), if any.

NOTE

For design-inherent reasons some unfilled volume in the hydraulic system cannot be
excluded after the pump has been primed for commissioning/start-up. However,
once the motor is started up the pumping effect will immediately fill this volume
with the fluid handled.

6.1.4 Start-up

DANGER

Formation of a potentially explosive atmosphere inside the pump

Explosion hazard!

▷ The fluid for priming the pump must not be combustible.
▷ When the fluid for priming the pump is taken from a potentially explosive

atmosphere, make sure that no potentially explosive atmosphere can enter the
pump.

DANGER

Non-compliance with the permissible pressure and temperature limits if the pump
is operated with the suction and/or discharge line closed.

Explosion hazard!
Hot or toxic fluids escaping!

▷ Never operate the pump with the shut-off elements in the suction line and/or

discharge line closed.

▷ Only start up the pump set with the discharge-side shut-off element slightly or

fully open.

6 Commissioning/Start-up/Shutdown

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Vitaprime

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.

CAUTION

Abnormal noises, vibrations, temperatures or leakage

Damage to the pump!

▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.

ü The system piping has been cleaned.
ü The pump, suction line and inlet tank, if 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. Fully open the shut-off element in the suction head/suction lift line.

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

3. If a mechanical seal with flushing system is used, make sure that the flushing
liquid circulates properly.

4. Start up the motor.

5. 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. When the operating temperature has been reached and/or if there is any
leakage, check the clamping ring/screw connection between casing and casing
cover. If required, re-tighten it.

6.1.5 Checking the shaft seal

Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.

Mechanical seals are maintenance-free.

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6.1.6 Shutdown

CAUTION

Heat build-up inside the pump

Damage to the shaft seal!

▷ Depending on the type of installation, the pump set requires sufficient after-

run time – with the heat source switched off – until the fluid handled has
cooled down.

CAUTION

Backflow of fluid handled is not permitted

Motor or winding damage! Mechanical seal damage!

▷ Close the shut-off elements.

ü The shut-off element in the suction line is and remains open.

1. Close the shut-off element in the discharge line.

2. Switch off the motor and make sure the pump set runs down smoothly to a
standstill.

NOTE

If the discharge line is equipped with a non-return or check valve, the shut-off
element may remain open provided that the system conditions and system
regulations are considered and observed.

For prolonged shutdown periods:

1. Close the shut-off element in the suction line.

2. Close any auxiliary lines.
If the fluid to be handled is fed in under vacuum, also supply the shaft seal with
barrier fluid during standstill.

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.

6.1.7 Seal supply system

6.1.7.1 Application

In order to function properly, the mechanical seals require a flushing liquid. The
flushing liquid completely fills the space between the inboard and the outboard
mechanical seal.

6.1.7.2 Requirements to be met by the seal supply system

Pipework routing

requirements

When routing pipework and flexible tubing, prevent any high points or ensure that
high points can be vented separately to prevent dry running of the mechanical seal.
The connecting pipes between the main pipe and the pump must be routed with a
continuously rising slope to assure self-venting of the pipe and the mechanical seal,
respectively.

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6.1.7.3 Types of seal supply systems

Which of the two types of seal supply systems is used depends on the mechanical
seal:

6.1.7.3.1 Quench liquid

6.1.7.3.1.1 Applications

A quench liquid is used in the following cases:

▪ Where a single mechanical seal without supportive measures would not work at

all or unsatisfactorily.

▪ Where a double mechanical seal design with pressurised barrier fluid is not

required.

6.1.7.3.1.2 Quench liquid requirements

The quench liquid should preferably form a solution with the fluid handled and be
environmentally compatible.

Typical quench liquids ▪ Water with a conductivity of 100 - 800 µS/cm

▪ Water/glycol mixture

▪ Glycerine

5)

The quench liquid should be supplied to the mechanical seals unpressurised (at
atmospheric pressure), if possible. Positive pressures of up to 0.5 bar are acceptable.

The one-way quench supply should be adjusted to a constant flow ≥0.4l/min.
Periodically check the quench liquid for contamination (replace quench liquid and

clean quench system if necessary).

6.1.7.3.1.3 Applications

For seal types T and H, operating mode BQ

6.1.7.3.2 Barrier fluid system

6.1.7.3.2.1 Applications

Barrier fluid systems serve to:

▪ Dissipate friction heat
▪ Prevent the fluid handled from entering the sealing gap

6.1.7.3.2.2 Barrier fluid requirements

The barrier fluid should preferably form a solution with the fluid handled and be
environmentally compatible. The barrier fluid should be monitored: Any ingress of
the fluid handled can be identified at an early stage by the barrier fluid becoming
turbid.

The temperature differences between the barrier fluid and the fluid handled must
not exceed 5°C. A general minimum temperature of 0°C applies to the barrier fluid.

The barrier fluid system must be set to a pressure which exceeds the pressure inside
the pump by approximately 0.5 to 1bar.

General rule: The maximum permissible pressure inside the barrier fluid system
equals 10bar. Actual maximum permissible pressure depending on the material
combination and shaft diameter:

5) Make sure the circulation line diameter is ≥¼".

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Vitaprime

0

Pressure in flushing system [bar]

Shaft diameter [mm]

0

1

2

3

4

1

2

3

4

5

6

7

8

9

10

10

20 30 40 50

60 70 80

90 100

110

120 130

140 150

11

12

13

14

15

Fig.4: Application limits for mechanical seals6) 2900rpm

1 Hard-soft combination (steel/carbon) 2 Hard-soft combination (ceramic/

carbon)

3 Hard-soft combination (silicon

carbide/carbon; tungsten carbide/
carbon)

4 Hard-hard combination (silicon

carbide/silicon carbide; tungsten
carbide/tungsten carbide)

The flow rate of the barrier fluid system depends on the shaft diameter, speed and
fluid temperature.

Table9: Flow rate of the flushing liquid

Material combination of seal
faces

Hard-soft combination Hard-hard combination

Pump speed 1450

[rpm]

2900

[rpm]

1450

[rpm]

2900

[rpm]

Mechanical seal diameter

[mm]

Flow rate flushing

liquid

[l/min]

Flow rate flushing

liquid

[l/min]

Flow rate flushing

liquid

[l/min]

Flow rate flushing

liquid

[l/min]

20 0,4-1,0 0,7-1,9 0,4-1,2 0,9-2,2
28 0,6-1,2 1,0-2,4 0,7-1,6 1,3-3,1
43 1,0-1,9 1,8-3,8 1,2-2,8 2,2-5,4
55 1,0-2,4 2,0-4,6 1,3-3,4 2,6-6,7

The lower flushing limit refers to a temperature of the fluid handled of 25°C and a
barrier pressure of 1bar. The upper flushing limit refers to a temperature of the fluid
handled of 100°C and a barrier pressure of 10bar. The flow rate of the flushing
liquid must be adjusted to the actual conditions (pressure, temperature). The data
refer to a temperature difference of 5°C between the inlet and outlet of the flushing
liquid.

6.1.7.3.2.3 Applications

For seal type Q, operating mode DB

6) Valid for unbalanced mechanical seals flushed with clean water of 20°C.

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6.2 Operating limits

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled and
speed

Explosion hazard!
Hot or toxic fluid could escape!

▷ Comply with the operating data indicated in the data sheet.
▷ Never use the pump for handling fluids it is not designed for.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures, pressures or rotational speeds

exceeding those specified in the data sheet or on the name plate unless the
written consent of the manufacturer has been obtained.

DANGER

Formation of a potentially explosive atmosphere inside the pump

Explosion hazard!

▷ When draining tanks take suitable measures to prevent dry running of the

pump (e.g. fill level monitoring).

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10: Permissible ambient temperatures

Permissible ambient temperature Value

Maximum 40 °C
Minimum See data sheet.

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.

The frequency of starts is usually determined by the maximum temperature increase
of the motor. This largely depends on the power reserves of the motor in steady­state operation and on the starting conditions (DOL, star-delta, moments of inertia,
etc). If the starts are evenly spaced over the period indicated, the pump set can be
started up six times per hour (h) with the discharge-side gate valve slightly open.

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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.

6.2.3 Cleaning in place (CIP)

CAUTION

Elastomers do not have sufficient resistance

Damage to the pump!

▷ Effect cleaning/sterilisation only if the elastomer components used in the pump

(e.g. O-rings, mechanical seals) are made of EPDM or other approved materials.

Conditions CIP may be effected with the pump running or with the pump stopped.

Recommended flow velocity: between 2.5 and 3m/s

Cleaning agent, cleaning

process

When performing CIP in the system the pump set is installed in, comply with the
concentration limits, temperature limits and contact times given below for the
cleaning agents and disinfectants:

Table11: Cleaning sequence

Step Process Cleaning agent Temperature Contact time

[°C] [min]

1 Pre-flushing Water +15 to +25 10 to 15
2 Flushing Water +45 to +60 10
3 Flushing Washing lye +70 to +95 20 to 30
4 Intermediate flushing Water +60 max. 5 to 10
5 Flushing See table below 10 to 15
6 Flushing Water +15 to +25 10 to 15

Table12: Agent for cleaning step5 "Flushing"

Cleaning agent Concentration Temperature

[%] [°C]

Sodium hydroxide (soda lye) 1 to 3 +70 to +90
Phosphoric acid 0,5 +45
Lye, alkaline 5 +95
Nitric acid 1 to 2.5 +45
Citric acid 0.5 to 3 +70

6.2.4 Steaming in place (SIP)

WARNING

Pump casing takes on the same temperature as the sterilisation fluid

Risk of burns!

▷ Fit additional protective devices.
▷ Observe the general safety rules and regulations for steam applications.

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CAUTION

Elastomers do not have sufficient resistance

Damage to the pump!

▷ Effect cleaning/sterilisation only if the elastomer components used in the pump

(e.g. O-rings, mechanical seals) are made of EPDM or other approved materials.

CAUTION

SIP with the pump running

Damage to the mechanical seals!

▷ Effect SIP (cleaning using superheated steam) only during standstill of the

pump set.

Conditions Only effect SIP during standstill of the pump set.

Limits Table13: SIP temperature requirements

Elastomer Saturated steam Chemical

EPDM 121°C 82°C
FPM/FKM 149°C 82°C

6.2.5 Fluid handled

6.2.5.1 Flow rate

Table14: Flow rate

Temperature range (t) Minimum flow rate Maximum flow rate

0 to +70 ℃ ≈ 15 % of Q

opt.

7)

See hydraulic characteristic

curves.

> 70 °C ≈ 25 % of Q

opt.

7)

The calculation formula below can be used to check if an additional heat build-up
could lead to a dangerous temperature increase at the pump surface.

×

×

×

Table15: Key

Symbol Description Unit

c Specific heat capacity J/kg K

g Gravitational constant m/s²
H Pump discharge head m
T

f

Fluid temperature °C

T

O

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

6.2.5.2 Density of the fluid handled

The pump input power changes in proportion to the density of the fluid handled.

7) Best efficiency point

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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.

6.2.5.3 Viscosity of the fluid handled

The discharge head, flow rate and power input of the pump are influenced by the
viscosity of the fluid handled.

CAUTION

The fluid handled has a higher viscosity than permitted.

Risk of motor overload!

▷ Observe the viscosity limits for the fluid handled given in the data sheet.
▷ Make sure the motor has sufficient power reserves.

6.2.5.4 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 operation 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.

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. (ðSection3.3,Page12)

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

Observe any additional instructions and information provided. (ðSection3,Page12)

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6.4 Returning to service

For returning the equipment to service observe the sections on commissioning/start­up and the operating limits. (ðSection6.1,Page27) (ðSection6.2,Page33)

In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (ðSection7,Page38)

WARNING

Failure to re-install or re-activate protective devices

Risk of injury from moving parts or escaping fluid!

▷ As soon as the work is completed, re-install and re-activate any safety-relevant

devices and protective devices.

NOTE

If the pump has been out of service for more than one year, replace all elastomer
seals.

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7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Sparks produced during servicing work

Explosion hazard!

▷ Observe the safety regulations in force at the place of installation!
▷ Always perform maintenance work on explosion-proof pump sets outside

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 and shaft

seal.

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.

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.

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

Risk of potentially explosive atmosphere inside the pump

Explosion hazard!

▷ The pump internals in contact with the fluid to be handled, including the seal

chamber and auxiliary systems must be filled with the fluid to be handled at all
times.

▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.

DANGER

Incorrectly serviced shaft seal

Explosion hazard!
Hot, toxic fluid escaping!
Damage to the pump set!
Risk of burns!
Fire hazard!

▷ Regularly service the shaft seal.

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 rolling element bearings for running noises.

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CAUTION

Increased wear due to dry running

Damage to the pump set!

▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during

pump operation.

CAUTION

Impermissibly high temperature of fluid handled

Damage to the pump!

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

(heating up of the fluid).

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

operating limits. (ðSection6.2,Page33)

While the system is in operation, observe or check the following:

▪ The pump must run quietly and free from vibrations at all times.
▪ Check the shaft seal. (ðSection6.1.5,Page29)
▪ In case of oil lubrication, ensure the oil level is correct.
▪ Check the static sealing elements for leakage.
▪ Check the rolling element bearings for running noises.

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

▪ 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.

▪ Monitor the bearing temperature.

– The bearing temperature must not exceed 90°C (measured at the motor

housing).

CAUTION

Operation outside the permissible bearing temperature

Damage to the pump!

▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured

on the outside of the motor housing).

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).

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7.2.2 Inspection work

DANGER

Excessive temperatures caused by friction, impact or frictional sparks

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

▷ Regularly check the cover plates, plastic components and other guards of

rotating parts for deformation and sufficient distance from rotating parts.

DANGER

Static charging due to insufficient potential equalisation

Explosion hazard!

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

conductive.

7.2.2.1 Checking the clearances

1. Remove pump casing 101.

2. Examine pump casing 101 and impeller vanes for signs of seizure or rubbing
contact.

3. Smoothen any signs of seizure or rubbing contact using a polishing cloth.

4. Remove any burrs from the impeller vane.

5. Re-adjust the axial clearance / distance between pump casing 101 and impeller

230. (ðSection7.5.2,Page50)

6. Mount pump casing 101. (ðSection7.5,Page49)

7.2.2.2 Cleaning filters

CAUTION

Insufficient inlet pressure due to clogged filter in the suction line

Damage to the pump!

▷ Monitor contamination of filter with suitable means (e.g. differential pressure

gauge).

▷ Clean filter at appropriate intervals.

7.2.2.3 Checking the flushing liquid

Periodically check the flushing liquid for contamination. If necessary, drain the
flushing liquid. Clean the flushing system and fill it with new flushing liquid.

7.2.2.4 Checking the bearing seals

DANGER

Excessive temperatures caused by mechanical contact

Risk of explosion!
Damage to the pump set!

▷ Check correct seating of axial seal rings mounted on the shaft.

Only gentle contact of the sealing lip shall be established.

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7.2.3 Lubrication and lubricant change of rolling element bearings

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.

7.2.3.1 Grease lubrication

The bearings are supplied packed with high-quality lithium-soap grease.

7.2.3.1.1 Intervals

NOTE

On some pump designs (motor ≤ 132) the rolling element bearings are lubricated
for life. These pumps are not provided with a lubricating nipple on the bearing
bracket.

The rolling element bearings of the pump must be re-lubricated or the grease in the
bearings replaced at regular intervals.

The re-lubrication interval is 4000 hours for all sizes.
For correct re-lubrication the bearings must be removed, carefully cleaned and

packed with new grease (up to half the volume).

7.2.3.1.2 Grease quality

Optimum grease properties for rolling element bearings

Table16: 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

If required, the bearings may be lubricated with greases of other soap bases.
Make sure to remove any old grease and rinse the bearings thoroughly.

7.2.3.1.3 Changing the grease

CAUTION

Mixing greases of differing soap bases

Changed lubricating qualities!

▷ Thoroughly clean the bearings.
▷ Adjust the re-lubrication intervals to the grease used.

ü The pump has been dismantled for changing the grease.

1. Only half-fill the bearing cavities with grease.

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7.3 Drainage/cleaning

WARNING

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

Hazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any fluid residues.
▷ Wear safety clothing and a protective mask if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. For draining the fluid handled use the pump connections or a valve for residual
drainage, if fitted.

2. Always flush the pump if it has been used for handling harmful, explosive and
hot fluids or other fluids posing a risk.
Always flush and clean the pump before transporting it to the workshop.
Provide a certificate of decontamination for the pump.

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.

Always observe the safety instructions and information. (ðSection7.1,Page38)
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

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.

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DANGER

Insufficient preparation of work on the pump (set)

Risk of injury!

▷ Properly shut down the pump set. (ðSection6.1.6,Page30)
▷ Close the shut-off elements in the suction line and discharge line.
▷ Drain the pump and release the pump pressure.
▷ Shut off any auxiliary feed lines.
▷ 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 an appropriate pull-off device, if possible.

7.4.2 Preparing the pump set

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

2. Reduce pressure in the piping by opening a consumer installation.

3. Disconnect and remove all auxiliary pipework.

7.4.3 Removing the complete pump set from the piping

1. Disconnect the discharge nozzle and suction nozzle from the piping.

2. Depending on the pump size and motor size, unscrew the bolts that fix the
support foot or motor foot to the foundation.

3. Remove the complete pump set from the piping.
Alternative: Leave pump casing 101 installed in the piping. Undo clamping piece
81-44. Pull the remaining back pull-out unit out towards the back (back pull-out
design).

7.4.4 Removing the pump casing and impeller

7.4.4.1 Sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15

1. For mechanical seal designT with operating modeBQ, or mechanical seal
designQ with operating modeDB: Remove quench connections 710.

2. Undo screws 900.1 and remove shroud 683 if fitted.

3. Undo hexagon head bolts 901.1 to remove motor 801.

4. Carefully pull motor 801 out of bearing housing 350/shaft 210.

NOTE

Remove the foot base if necessary.
Ball feet:
Motors <IEC112: Undo nuts 920.1 and hexagon socket head cap screws 914.1.
Remove the foot base.
Motors >IEC112: Undo nuts 920.1 and hexagon socket head cap screws 914.1.
Remove the front foot base. Remove foot 182.2.
Motor feet:
Undo nuts (82) and bolts (81). Remove the feet.

5. Undo and remove clamping piece 81-44.

6. Remove pump casing 101.2 and O-ring 412.2.

7. Unscrew impeller nut 922 in anti-clockwise direction. Remove it together with
O-ring 412.1.

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8. Remove impeller 230 and key 940.

9. Remove spacer discs 551.

7.4.4.2 Sizes 42-146 and 52-164

1. For mechanical seal designT with operating modeBQ, or mechanical seal
designQ with operating modeDB: Remove quench connections 710.

2. Undo screws 900.1 and remove shroud 683 if fitted.

3. Undo hexagon head bolts 901.1 to remove motor 801.

4. Carefully pull motor 801 out of bearing housing 350/shaft 210.

NOTE

Remove the foot base if necessary.
Ball feet:
Motors <IEC112: Undo nuts 920.1 and hexagon socket head cap screws 914.1.
Remove the foot base.
Motors >IEC112: Undo nuts 920.1 and hexagon socket head cap screws 914.1.
Remove the front foot base. Remove foot 182.2.
Motor feet:
Undo nuts (82) and bolts (81). Remove the feet.

5. Undo screw 900.

6. Remove pump casing 101.2.

7. Remove first impeller 230 and key 940.

8. Remove the interstage plate with guide vanes 172 and O-ring 412.2.

9. Remove second impeller 230 and key 940.

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7.4.5 Removing the mechanical seal

7.4.5.1 Mechanical seal designT, operating modeB

a) b)

101.1

101.1

433

433

101.2 412.1

210

210

551 230 940 922

554 940 172

932 230 172

Fig.5: Mechanical seal designT, operating modeB
a) Sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15
b) Sizes 42-146 and 52-164

1. Slide back the ring retainer 8). Remove circlip 932 from shaft 210.

2. Remove the primary ring of mechanical seal 433. To do so, rotate the primary
ring and the spring in clockwise direction while pulling them off the end of the
shaft.

3. Undo hexagon socket head cap screws 914.2. Take pump casing 101.1 carefully
off bearing housing 350.

4. Take the mating ring of mechanical seal 433 out of its seat in pump casing

101.1.

5. Pull thrower 507 off shaft 210.

8) Sizes 42-146 and 52-164 only

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7.4.5.2 Mechanical seal designT, operating modeBQ

a) b)

101.1

101.1

412.3

210

210

902

421.2 710 471.2

421.2 710 412.3

471.2 902

Fig.6: Mechanical seal designT, operating modeBQ
a) Sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15
b) Sizes 42-146 and 52-164

1. Slide back the ring retainer9). Remove circlip 932 from shaft 210.

2. Remove the primary ring of mechanical seal 433. To do so, rotate the primary
ring and the spring in clockwise direction while pulling them off the end of the
shaft.

3. Undo hexagon socket head cap screws 914.2. Take pump casing 101.1 carefully
off bearing housing 350.

4. Undo nuts 920.4 and studs 902.

5. Carefully remove seal cover 471.2 from pump casing 101.1.

6. Remove lip seal 421.2 from seal cover 471.2.

7. Take the mating ring of mechanical seal 433 out of its seat in pump casing

101.1.

9) Sizes 42-146 and 52-164 only

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7.4.5.3 Mechanical seal designQ, operating modeDB

a) b)

101.1 412.1

210 433

471.1

412.5

922

101.2

902

230

940

433

A

471.1

210 940

Fig.7: Mechanical seal designQ, operating modeDB
a) Sectional drawing
b) Installation dimensionA

1. On sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15: Undo nuts
(69) and studs 902.
On sizes 42-146 and 52-164: Undo grub screws 904.4.

2. Move back seal cover 471.1 to separate it from pump casing 101.1.

3. Undo hexagon socket head cap screws 914.2. Take pump casing 101.1 carefully
off bearing housing 350.

4. Remove the mating ring of mechanical seal 433 from the rear section of pump
casing 101.1.

NOTE

Observe distance "A" when re-installing the mechanical seal. Note down this
distance to be able to re-install the mechanical seal accurately.

5. Undo the grub screws at the primary ring and pull the primary ring off shaft

210.

6. Remove seal cover 471.1.

7. Press the mating ring of mechanical seal 433 out of seal cover 471.1. Remove O­ring 412.5.

8. Pull thrower 507 off shaft 210.

7.4.6 Dismantling the bearing assembly

1. If applicable, undo screws 900.2 and remove holder 732.

2. Undo hexagon head bolts 901.2.

3. Remove bearing cover 360.

4. Press the assembly consisting of shaft 210 and rolling element bearing 320 and –
for motor sizes IEC160 and above – lip seal 421.1 out of bearing housing 350.

5. Undo and remove nut 920.3.

6. Guide shaft 210 out of rolling element bearing 320. Remove lip seal 421.1 if
fitted.

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7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

DANGER

Wrong selection of motor

Explosion hazard!

▷ Use an original motor or a motor of identical design from the same

manufacturer.

▷ The permissible temperature limits at the motor flange and motor shaft must

be higher than the temperatures generated by the pump. (Contact KSB for
temperatures).

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 or exploded view.

Sealing elements Always use new O-rings.

Never use O-rings that have been made by cutting an O-ring cord to size and gluing
the ends together.

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).

Assembly adhesives Avoid the use of assembly adhesives, if possible.

Match the lubricants to the fluid handled (e.g. water for foodstuff applications).

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

Tightening torque of the impeller nut: 70-80 Nm

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7.5.2 Adjusting the clearances

C
B

A

Fig.8: Pump clearances

A Rear side of impeller,

distance between impeller and
pump casing

B Distance between pump casing and

pump inlet casing

C Distance between front side of

impeller and pump inlet casing

Explanation:
Distance C is set at the factory; distance B is achieved by using spacer discs which are

fitted to adjust distance A (on the rear side of the impeller).
Should any problems occur, particularly verify distance A as this is the most

significant value. The only distance for which a deviation is permissible is distance B.

Table17: Impeller and casing clearances

Size A B C

40-146 0,15 0,15 -­50-164 0,15 0,15 2,85
60-200 0,20 0,20 2,80
65-200 0,20 0,20 2,80
80-240-11 0,30 0,30 4,20
80-240-11 0,30 0,30 4,20

7.5.3 Fitting the bearing assembly

1. Check shaft 210 for any wear. Clean it thoroughly.

2. Fit rolling element bearing 320 on shaft 210.

3. Fit and tighten nut 920.3.

4. Insert the assembly consisting of shaft 210 and rolling element bearing 320 into
bearing housing 350. For motor size IEC160 and above: Fit lip seal 421.1.

5. Fit bearing cover 360. Fasten it with hexagon head bolts 901.2.

6. Slide thrower 507 onto shaft 210.

7. Fit holder 732 (if applicable). Fasten screws 900.2.

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7.5.4 Installing the mechanical seal

7.5.4.1 Mechanical seal designT, operating modeB

CAUTION

The keyway could damage the seal faces and O-rings

Damage to the mechanical seal!

▷ Always handle seal faces with utmost care.

a) b)

101.1

101.1

433

433

101.2 412.1

210

210

551 230 940 922

554 940 172

932 230 172

Fig.9: Mechanical seal designT, operating modeB
a) Sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15
b) Sizes 42-146 and 52-164

1. Carefully insert the mating ring of mechanical seal 433 into pump casing 101.1.

2. Place pump casing 101.1 on bearing housing 350. Slide the seal carefully over
shaft 210.

3. Fasten pump casing 101.1 with hexagon socket head cap screws 914.2 to bearing
housing 350 .

4. Slide the primary ring of mechanical seal 433 onto shaft 210.

5. Fit the ring retainer

10)

on shaft 210. Use the ring retainer to compress the spring

of mechanical seal 433. Lock the spring with circlip 932.

7.5.4.2 Mechanical seal designT, operating modeBQ

CAUTION

The keyway could damage the seal faces and O-rings

Damage to the mechanical seal!

▷ Always handle seal faces with utmost care.

10) For sizes 42-146 and 52-164 only.

7 Servicing/Maintenance

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a) b)

101.1

101.1

412.3

210

210

902

421.2 710 471.2

421.2 710 412.3

471.2 902

Fig.10: Mechanical seal designT, operating modeBQ
a) Sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15
b) Sizes 42-146 and 52-164

1. Fit lip seal 421.2 in seal cover 471.2.

2. Fit studs 902 in pump casing 101.1. Tighten the studs.

3. Place seal cover 471.2 on studs 902. Fasten the studs with nuts (69).

4. Carefully insert the mating ring of mechanical seal 433 into pump casing 101.1.

5. Place pump casing 101.1 on bearing housing 350. Make sure not to damage lip
seal 421.2 and mating ring.

6. Fit and tighten hexagon socket head cap screws 914.2.

7. Slide the primary ring of mechanical seal 433 onto shaft 210.

8. Fit the ring retainer

11)

on shaft 210. Use the ring retainer to compress the spring

of mechanical seal 433. Lock the spring with circlip 932.

7.5.4.3 Mechanical seal designQ, operating modeDB

CAUTION

The keyway could damage the seal faces and O-rings

Damage to the mechanical seal!

▷ Always handle seal faces with utmost care.

11) For sizes 42-146 and 52-164 only.

7 Servicing/Maintenance

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a) b)

101.1 412.1

210 433

471.1

412.5

922

101.2

902

230

940

433

A

471.1

210 940

Fig.11: Mechanical seal designQ, operating modeDB
a) Sectional drawing
b) Installation dimensionA

1. Fit O-ring 412.5 in seal cover 471.1.

2. Insert the mating ring (motor end) of mechanical seal 433 into seal cover 471.1.

3. On sizes 42-146 and 52-164: Fit hexagon head bolts 901.4 in seal cover 471.1.
On sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15: Fit and
tighten studs 902 in pump casing 101.1.

4. Fit seal cover 471.1 on shaft 210. Slide it right to the end of the shaft.

5. Slide the primary rings of mechanical seal 433 onto shaft 210.

6. Check distance A: This value must be observed to make sure the load on the
mechanical seal is evenly distributed.
Correct values:
Size 40-146: A = 16mm
Size 50-164: A = 17.5mm
Size 60-200: A = 15.5mm
Size 65-200: A = 15.5mm
Size 80 240-11: A = 19.5mm
Size 80 240-15: A = 19.5mm

7. If value A is correct, tighten the grub screws of the primary ring.

8. Fit the mating ring (pump end) into the rear end of pump casing 101.1.

9. Carefully place pump casing 101.1 on bearing housing 350. Make sure not to
damage the seal.

10. Fasten pump casing 101.1 to bearing housing 350 with hexagon socket head cap
screws 914.2.

11. Slide seal cover 471.1 right against pump casing 101.1. Fasten the seal cover.

12. On sizes 42-146 and 52-164: Fasten it with hexagon head bolts 901.4.
On sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15: Fasten it with
nuts (69).

7.5.5 Fitting the impeller and the pump casing

7.5.5.1 Sizes 40-146, 50-164, 60-200, 65-200, 80-240-11 and 80-240-15

1. Slide a suitable spacer disc 551 onto shaft 210.

2. Insert key 940 into the keyway of shaft 210. Fit impeller 230.

3. Fit O-ring 412.1 in impeller nut 922. Secure impeller 230 with the nut.

4. Fit O-ring 412.2 in the groove of pump casing 101.1.

5. Fit pump casing 101.2. Secure it with clamping piece 81-44.

7 Servicing/Maintenance

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NOTE

Fit the foot base if applicable.
Ball feet:
Motors <IEC112: Fasten the foot base to pump casing 101.1 with hexagon socket
head cap screws 914.1 and nuts 920.1.
Motors >IEC112: Fasten the front foot base to pump casing 101.1 with hexagon
socket head cap screws 914.1 and nuts 920.1. Fasten foot 182.2 to motor 801.
Motor feet:
Fasten the feet to motor 801 with bolts (81) and nuts (82).

6. Mount motor 801. To do so, insert the motor shaft into shaft 210. Fasten motor
801 with hexagon head bolts 901.1.

7. If applicable, place shroud 683 onto the motor. Fasten it to holder 732 with
screws 900.1.

8. For mechanical seal designT with operating modeBQ and mechanical seal
designQ with operating modeDB: Fit quench connections 710 in seal cover

471.1/.2.

7.5.5.2 Sizes 42-146 and 52-164

1. Insert the first key 940. Slide the first impeller 230 onto shaft 210.

2. Insert O-ring 412.2 into the groove in the pump casing. Then fit interstage plate
with guide vane 172.

3. Insert O-ring 412 in interstage plate with guide vane 172. Fit the second
interstage plate with guide vane 172.

4. Insert the second key 940. Slide the second impeller 230 onto shaft 210.

5. Insert O-ring 412 in interstage plate with guide vane 172. Fasten pump casing

101.2 with screws 900.

NOTE

Fit the foot base if applicable.
Ball feet:
Motors <IEC112: Fasten the foot base to pump casing 101.1 with hexagon socket
head cap screws 914.1 and nuts 920.1.
Motors >IEC112: Fasten the front foot base to pump casing 101.1 with hexagon
socket head cap screws 914.1 and nuts 920.1. Fasten foot 182.2 to motor 801.
Motor feet:
Fasten the feet to motor 801 with bolts (81) and nuts (82).

6. Mount motor 801. To do so, insert the motor shaft into shaft 210. Fasten motor
801 with hexagon head bolts 901.1.

7. If applicable, place shroud 683 onto the motor. Fasten it to holder 732 with
screws 900.1.

8. For mechanical seal designT with operating modeBQ and mechanical seal
designQ with operating modeDB: Fit quench connections 710 in seal cover

471.1/.2.

7 Servicing/Maintenance

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7.6 Spare parts stock

7.6.1 Ordering spare parts

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

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

Refer to the name plate for all data. (ðSection4.3,Page16)
Also specify the following data:

▪ Part number and description (ðSection9.1,Page57)
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)

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

Table18: 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

more

230 Impeller 1 1 1 2 2 2 20%
210 + 940 Shaft with key 1 1 1 2 2 2 20%
433 Mechanical seal set 2 3 4 5 6 7 90%
320 Rolling element bearing set 1 1 2 2 2 3 25%

412.1 O-ring (impeller nut) 4 6 8 8 9 10 100%

412.2 O-ring (casing) 4 6 8 8 9 12 150%

412.5 O-ring (seal housing) 4 6 8 8 9 10 100%

421.1 Lip seal set 4 6 8 8 9 10 100%

421.2 Lip seal set 4 6 8 8 9 10 100%

8 Trouble-shooting

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8 Trouble-shooting

WARNING

Improper work to remedy faults

Risk of injury!

▷ For any work performed to remedy faults, observe the relevant information

given in this operating manual and/or in the product literature provided by the
accessories manufacturer.

If problems occur that are not described in the following table, consultation with the
KSB customer service is required.

A Pump is running, but does not deliver

B Insufficient flow rate
C Discharge pressure below specified value

D Excessive power consumption

E Excessive current consumption

Table19: Trouble-shooting

A B C D E Possible cause Remedy

✘ ✘ - - - Air ingress into the suction line Check integrity of all pipe connections and re-

seal if necessary.

✘ - - - - Suction line not submerged in fluid Check fill level.
✘ ✘ ✘ - - Clearance tolerances between impeller and

casing exceeded

Re-adjust impeller or replace if worn.

✘ - - - - No fluid inside the pump casing Fill in fluid.
✘ - - - - Cavitation caused by excessive suction lift Reduce suction lift.
✘ - - - - Air pocket in discharge line Fit a vent valve.
✘ - - - - Pump does not prime. Check the points mentioned in section

(ðSection6.1,Page27) .

✘ - - - - Wrong direction of rotation Change electrical connection of motor.
✘ ✘ - - - Suction line clogged Check suction line and clean if necessary.
✘ - - - - The shut-off valves are closed. Open all valves.

- ✘ - - - System pressure too high Check discharge-side piping; increase nominal
piping diameter if necessary.

- ✘ - - - Air intake at the mechanical seal Check mechanical seal arrangement.

- ✘ - - - Fluid viscosity is higher than specified for pump

selection.

Consult the manufacturer.

- - ✘ - - System pressure lower than specified Throttle the discharge-side valve.

- - - ✘ - Power input lower than permitted Check all system conditions.

- - - ✘ - Pump speed too high (frequency inverter

operation)

Reduce speed.

- - - ✘ - Impeller does not rotate freely. Eliminate clogging, re-adjust impeller.

- - - ✘ - Viscosity and/or density of fluid higher than

specified

Consult the manufacturer.

- - - ✘ - Bearings run sluggishly. Replace rolling element bearings, replace
lubricant.

- - - - ✘ Flow rate too high Check items listed above.

- - - - ✘ Excessive drop of electrical voltage Check voltage supply (trained specialist
personnel only).

- - - - ✘ Fault in electrical system Shut down pump.

9 Related Documents

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9 Related Documents

9.1 General assembly drawing with list of components (single-stage pumps)

9.1.1 Pump size 40-146, motor size 90

683 801 920.3

360

914.2

900.1 732

900.2

916

210 101.1

101.2

922940562433

182.1

920.2

909.2

901.2

901.1
350

320

507

914.1

909.1

920.1
551

412.2
81-44

230

412.1

Fig.12: Size 40-146, motor 90

Table20: List of components for pump size 40-146, motor size 90

Part No. Description Part No. Description

81-44 Clamping piece 562 Parallel pin

101.1/.2 Pump casing 683 Shroud

182.1 Foot 732 Holder
210 Shaft 801 Flanged motor
230 Impeller 900.1/.2 Bolt/screw
320 Rolling element bearing 901.1/.2 Hexagon head bolt
350 Bearing housing 909.1/.2 Adjusting screw
360 Bearing cover 914.1/.2 Hexagon socket head cap

screw

412.1/.2 O-ring 916 Plug
433 Mechanical seal 920.1/.2/.3 Nut
507 Thrower 922 Impeller nut
551 Spacer disc 940 Key

9 Related Documents

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9.1.2 Pump size 50-164, motor size 132

683

801

920.3

360

914.2 900.1

732900.2

916

210

101.1 101.2

922

940

562

433

182.2

920.2

909.2 901.2

901.1

350

320 507

914.1 909.1

920.1

551

412.2

81-44230

412.1

182.1

Fig.13: Pump size 50-164 / motor size 132

Table21: List of components for pump size 50-164, motor size 132

Part No. Description Part No. Description

81-44 Clamping piece 562 Parallel pin

101.1/.2 Pump casing 683 Shroud

182.1/.2 Foot 732 Holder
210 Shaft 801 Flanged motor
230 Impeller 900.1/.2 Bolt/screw
320 Rolling element bearing 901.1/.2 Hexagon head bolt
350 Bearing housing 909.1/.2 Adjusting screw
360 Bearing cover 914.1/.2 Hexagon socket head cap

screw

412.1/.2 O-ring 916 Plug
433 Mechanical seal 920.1/.2/.3 Nut
507 Thrower 922 Impeller nut
551 Spacer disc 940 Key

9 Related Documents

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9.1.3 Pump size 60/65-200, motor size 160

683

801

920.3

360

914.2

900.1

732900.2

421.1

210

101.1

101.2

922

940

562433

182.1 920.2

909.2 901.2

901.1

350

320

507

914.1 909.1

920.1

551

412.2

81-44

230

412.1

182.2 636

Fig.14: Pump size 60/65-200, motor size 160

Table22: Pump size 60/65-200, motor size 160

Part No. Description Part No. Description

81-44 Clamping piece 562 Parallel pin

101.1/.2 Pump casing 636 Lubricating nipple

182.1/.2 Foot 683 Shroud
210 Shaft 732 Holder
230 Impeller 801 Flanged motor
320 Rolling element bearing 900.1/.2 Bolt/screw
350 Bearing housing 901.1/.2 Hexagon head bolt
360 Bearing cover 909.1/.2 Adjusting screw

412.1/.2 O-ring 914.1/.2 Hexagon socket head cap
screw

421.1 Lip seal 920.1/.2/.3 Nut

433 Mechanical seal 922 Impeller nut
507 Thrower 940 Key
551 Spacer disc

9 Related Documents

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9.1.4 Pump size 80-240, motor size 160

683

801

920.3

360

914.2

900.1

732900.2

421.1

210101.1

101.2

922

940

562

433

182.1

920.2

909.2 901.2

901.1

350

320

507

914.1 909.1

81-92

551

412.2

81-44

230

412.1

182.2

636

81-92

901.3

Fig.15: Pump size 80-240, motor size 160

Table23: List of components for pump size 80-240, motor size 160

Part No. Description Part No. Description

81-44 Clamping piece 551 Spacer disc
81-92 Cover plate 562 Parallel pin

101.1/.2 Pump casing 636 Lubricating nipple

182.1/.2 Foot 683 Shroud

210 Shaft 732 Holder
230 Impeller 801 Flanged motor
320 Rolling element bearing 900.1/.2 Bolt/screw
350 Bearing housing 901.1/.2/.3 Hexagon head bolt
360 Bearing cover 909.1/.2 Adjusting screw

412.1/.2 O-ring 914.1/.2 Hexagon socket head cap
screw

421.1 Lip seal 920.2/.3 Nut

433 Mechanical seal 922 Impeller nut
507 Thrower 940 Key

9 Related Documents

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9.2 General assembly drawing with list of components (two-stage pumps)

9.2.1 Pump size 42-146, motor size 112

683

801

920.3

360 914.2 900.1

732

900.2

210

101.1

101.2

932

940

562

433

182.1920.2

909.2

901.2

901.1

350

320

507

914.1 909.1

554

412.2

920.1

230

564

182.2 900

916 172

172

412

914

Fig.16: Pump size 42-146, motor size 112

Table24: List of components for pump size 42-146, motor size 112

Part No. Description Part No. Description

101.1/.2 Pump casing 564 Pin

172 Interstage plate with guide

vane

683 Shroud

182.1/.2 Foot 732 Holder

210 Shaft 801 Flanged motor
230 Impeller 900.1/.2 Bolt/screw
320 Rolling element bearing 901.1/.2 Hexagon head bolt
350 Bearing housing 909.1/.2 Adjusting screw
360 Bearing cover 914.1/.2 Hexagon socket head cap

screw

412.2 O-ring 916 Plug

433 Mechanical seal 920.1./2/.3 Nut
507 Thrower 932 Circlip
554 Washer 940 Key
562 Parallel pin

9 Related Documents

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9.2.2 Pump size 52-164, motor size 132

683

801

920.3

360

914.2

900

932

900.1
507

210

101.1

101.2

732

940

564

433

182.1920.1

909.2 901.2

901.1
350

320

914.1 909.1
554

412.2 172

230

172

182.2

916

900.2

412

Fig.17: Pump size 52-164, motor size 132

Table25: List of components for pump size 52-164, motor size 132

Part No. Description Part No. Description

101.1/.2 Pump casing 564 Pin
172 Interstage plate with guide

vane

683 Shroud

182.1/.2 Foot 732 Holder
210 Shaft 801 Flanged motor
230 Impeller 900.1/.2 Bolt/screw
320 Rolling element bearing 901.1/.2 Hexagon head bolt
350 Bearing housing 909.1/.2 Adjusting screw
360 Bearing cover 914.1/.2 Hexagon socket head cap

screw

412.1/.2 O-ring 916 Plug
433 Mechanical seal 920.1/.3 Nut
507 Thrower 932 Circlip
554 Washer 940 Key

10 EU Declaration of Conformity

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10 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Vitacast, Vitacast-Bloc, Vitaprime, Vitastage

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

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Pump (set): EC Machinery Directive 2006/42/EC
– Pump (set): Regulation 1935/2004/EG on Materials and Articles Intended to Come into Contact with Food

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

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

12)

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

Name

Function

Company

Address

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

11 Certificate of Decontamination

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11 Certificate of Decontamination

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

Order number/
Order item number

13)

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

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

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

Fluid handled

13)

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

Please tick where applicable

13)

:

   

Radioactive Explosive Corrosive Toxic

   

Harmful Bio-hazardous Highly flammable Safe

Reason for return

13)

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

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

13) Required fields

Index

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Vitaprime

Index

A

Abrasive fluids36
Automation18

B

Bearing temperature40
Bearings17

C

Certificate of decontamination64
Cleaning34, 35
Commissioning27
Connections18

D

Design17
Direction of rotation26
Dismantling43
Disposal13
Drive17

E

Electromagnetic compatibility24
Event of damage6

Ordering spare parts55

Explosion protection10, 21, 25, 26, 27, 28, 29, 33, 38,
39, 41, 42

F

Faults

Causes and remedies56
Fields of application8
Filter41

Fluid handled

Density35
Frequency of starts33

G

Grease lubrication

Grease quality42

I

Impeller type17
Installation at site21
Intended use8
Interference immunity24

K

Key to safety symbols/markings7

M

Maintenance39
Mechanical seal29
Monitoring equipment11

N

Name plate16
Noise characteristics19

O

Operating limits33
Operation on a frequency inverter24
Order number6
Other applicable documents6

P

Partly completed machinery6
Permissible forces at the pump nozzles23
Piping22
Preservation13, 36
Product code14
Product description14
Pump casing17

R

Reassembly43, 49
Return to supplier13
Returning to service37

S

Safety8
Safety awareness9
Scope of supply20
Shaft seal17
Shutdown36

Spare part

Ordering spare parts55
Start-up29
Storage13, 36

T

Temperature limits10
Transport12

W

Warnings7
Warranty claims6

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. [phone]
www.ksb.com

1969.84/05-EN