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Summary of Contents for KSB Megabloc
- Page 1 Standardised Pump for General Use Megabloc Installation / Operating Manual...
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Page 2: Technical Information
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 KSB's express written consent. Subject to technical modification without prior notice. -
Page 3: Table Of Contents
Checking the direction of rotation Start-up/shutdown Start-up 6.1.1 Priming 6.1.2 Preparation for starting 6.1.3 Startu-up 6.1.4 Operation 6.1.5 Shutdown procedure Operating limits 6.2.1 Ambient temperature 6.2.2 Frequency of starts 6.2.3 Fluid handled 6.2.3.1 Flow rate 6.2.3.2 Density of the fluid handled Megabloc 3 of 32 ... - Page 4 Assembly Electric motor maintenance and lubrication 7.6.1 Grease type 7.6.2 Relubricaiton interval 7.6.3 Tightening torques 7.6.3.1 Tightening torques for the pump Operation abnormalities and troubleshooting Abnormalities Possible cause Related documents Exploded view Certificate of Decontamination 4 of 32 Megabloc...
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Page 5: Glossary
The complete back pull-out unit can be pulled Discharge line out without having to remove the pump casing The line which is connected to the discharge from the piping nozzle Suction lift line/suction head line The line which is connected to the suction nozzle Megabloc 5 of 32 ... -
Page 6: General
The order number and order item number uniquely identify the pump (set) and serve as identification for all further business processes. In the event of damage, contact your nearest KSB service centre immediately to maintain the right to claim under warranty. -
Page 7: Safety
Observe the minimum flow rates indicated in the data sheet or product literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc). Do not throttle the flow rate on the suction side of the pump (to prevent cavitation damage). Megabloc 7 of 32 ... -
Page 8: Personnel Qualificaton And Training
(set) during pump set installation. 2.8 Safety information for maintenance, inspection and installation work Modifications or alterations of the pump are only permitted with the manufacturer's prior consent. 8 of 32 Megabloc... -
Page 9: Unauthorized 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. (⇨ Section 2.3 Page 7) Megabloc 9 of 32 ... -
Page 10: Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery On transfer of goods, check each packaging unit for damage. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) and the insurer about the damage in writing immediately. -
Page 11: Return To Supplier
Always complete and enclose a certificate of decontamination when returning the pump (set). Always indicate any safety and decontamination measures taken. (⇨ Section 10 Page 32). NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING... -
Page 12: Description Of The Pump Set
- Circulation of condensates - City property installations - Air conditioning - Cooling services - Industries in general 4.2 Designation Code Description Megabloc Model/type Discharge nozzle diameter (mm) Nominal impeller diameter (mm) Motor rating (hp) Number of poles 4.3 Nameplates Fig.5: Nameplates (examples) ... -
Page 13: Design Details
Optional material – Stainless steel upon consult. Mechanical Seal – Standardized for use with water to 90ºC, as well as for most hydrocarbons. For others temperatures and liquids refers to KSB. Standard material – Carbon/ Stainless steel or Ceramics / Stainless steel. -
Page 14: Installation At Site
Correct operation of a pump depends on dimensions and correct arrangement of piping to be used. Suction and discharge pipings shall be supported by suitable means. Herewith, mechanical efforts are prevented to be transferred to pump nozzles. 14 of 32 Megabloc... -
Page 15: Suction Piping
Maximum recommended velocity of 5 m/s. Installation of a check valve after discharge nozzle. Prevent air pockets making up in piping. If that is not possible the highest piping point shall be provided with an air vent device to facilitate air exit. Megabloc 15 of 32 ... -
Page 16: Typical Installation
5 Installation at site 5.3 Typical installation Fig. 3: Example of horizontal installation 16 of 32 Megabloc... -
Page 17: Installation Availability
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 start-up method. NOTE It is recommended to fit a motor protection device. Megabloc 17 of 32 ... -
Page 18: Setting The Time Relay
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. 18 of 32 Megabloc... - Page 19 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. Megabloc 19 of 32 ...
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Page 20: Start-Up/Shutdown
Other priming methods may be used depending on the installation location availability. Most of these methods are based on the creation of a differential pressure between suction piping, the pump and the discharge piping, being used mainly when there is not a foot valve available. 20 of 32 Megabloc... -
Page 21: Preparation For Starting
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. Megabloc 21 of 32 ... -
Page 22: Frequency Of Starts
If necessary, the minimum flow must be increased. + ∆ϑ g x H ∆ϑ ɳ c x ɳ 22 of 32 Megabloc... -
Page 23: Density Of The Fluid Handled
If the pump set is to be stored temporarily, only preserve the wetted components made of low- alloy materials. Commercially available preservatives can be used for this purpose. Observe the manufacturer's instructions for application/removal. Observe any additional instructions and information provided. (⇨ Section 3 Page 10) Megabloc 23 of 32 ... -
Page 24: Returning To Service
_________________________________________________________________________ In case of altitude higher than 1.000 m and or temperature over 40 °C refer to KSB. 24 of 32 ... -
Page 25: Maintenance
Risk of burns! Regularly check the lubricant level. Regularly check the rolling element bearings for running noises. DANGER Incorrectly serviced shaft seal Damage to the pump set! Risk of burns! Fire hazard! Regularly service the shaft seal. Megabloc 25 of 32 ... -
Page 26: Inspection Work
If the clearance is larger than permitted (see the following table), fit a new casing wear ring 502.01 and/or 502.2. The clearances specified refer to the diameter. Table 8: Clearances between impeller and casing/between impeller and casing wear ring Casing material Clearances Maximum permissible enlargement 0,3 mm 0,9 mm 26 of 32 Megabloc... -
Page 27: Cleaning Filters
Should the problem remains refer to nearest authorized dealer. 7.6 Electric motor maintenance and lubrication We recommend the periodical checking of switch contacts preventing worst consequences caused by oxidation, or bad contact of elements. Megabloc 27 of 32 ... -
Page 28: Grease Type
25 Table 10 7.6.3 Tightening torques 7.6.3.1 Tightening torques for the pump Use a torque wrench to tighten the bolted connections between the volute casing, casing cover and electric motor. Fig. 5 Tightening torque 28 of 32 Megabloc... - Page 29 7 Maintenance Position Thread size Nominal value (Nm) 3/8UNC 1/2UNC 3/8UNC 1/2UNC 5/8UNC Table 11: Tightening torques Megabloc 29 of 32 ...
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Page 30: Operation Abnormalities And Troubleshooting
27. Operation with reduced flows. 28. Set fastening in not sufficiently steady. 29. Lack of lubrication on bearings. 30. Excessive grease on bearings. 31. Impurities on bearings or on lubricant. Oxidation of bearings due to water penetration. 30 of 32 Megabloc... -
Page 31: Related Documents
9 Related documents 9 Related documents 9.1 Exploded view Megabloc 31 of 32 ... -
Page 32: Certificate Of Decontamination
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 Required fields 32 of 32 Megabloc... - Page 34 KSB Bombas Hidráulicas SA Rua José Rabello Portella, 638 Várzea Paulista SP 13220-540 Brazil http://www.ksb.com.br Phone: 55 11 4596 8500 Fax: 55 11 4596 8580 –KSB Customer Service e-mail: gqualidade@ksb.com.br Fax: 55 11 4596 8656...
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