KSB MegaCPK Installation & Operating Manual
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KSB MegaCPK Installation & Operating Manual

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Standardised Chemical Pump
MegaCPK
Installation/Operating Manual

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  • Page 1 Standardised Chemical Pump MegaCPK Installation/Operating Manual...
  • Page 2 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 Aktiengesellschaft, Frankenthal 19.05.2016...

  • Page 3: Table Of Contents

    Configuration and function .........................18 Noise characteristics .............................19 Scope of supply .............................19 Dimensions and weights ..........................19 Installation at Site ........................20 Safety regulations ............................20 Checks to be carried out prior to installation .....................20 Installing the pump set ..........................20 Piping ................................22 MegaCPK 3 of 74...
  • Page 4 Tightening torques ............................58 Spare parts stock ............................60 Trouble-shooting ........................64 Related Documents ........................66 General assembly drawing with list of components ..................66 EU Declaration of Conformity ....................70 Certificate of Decontamination ....................71 Index ............................72 MegaCPK 4 of 74...

  • Page 5: Glossary

    Suction lift line/suction head line Discharge line The pipeline which is connected to the suction The pipeline which is connected to the nozzle discharge nozzle MegaCPK 5 of 74...

  • Page 6: General

    (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. Noise characteristics (⇨ Section 4.6 Page 19) 1.2 Installation of partly completed machinery...
  • Page 7 1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product MegaCPK 7 of 74...

  • Page 8: Safety

    ▪ 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. MegaCPK 8 of 74...

  • Page 9: Personnel Qualification And Training

    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 and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards, directives and laws MegaCPK 9 of 74...

  • Page 10: Safety Information For The Operator/User

    (⇨ Section 2.10.1 Page 11) to (⇨ Section 2.10.4 Page 12) . The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. MegaCPK 10 of 74...
  • Page 11 If the pump is to be operated at a higher temperature, if there is no data sheet or if the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature. 2.10.3...
  • Page 12 Check whether monitoring equipment is required to ensure that the pump set functions properly. Contact KSB for further information on monitoring equipment. 2.10.4 Operating limits The minimum flows indicated in (⇨ Section 6.2.3.1 Page 40) refer to water and water- like fluids handled.

  • Page 13: Transport/Temporary Storage/Disposal

    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 14: Storage/Preservation

    If the pump set has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen, the pump set must also be neutralised, and anhydrous inert gas must be blown through the pump to ensure drying. MegaCPK 14 of 74...

  • Page 15: Disposal

    Always indicate any safety and decontamination measures taken. (⇨ Section 11 Page 71) NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! ▷...

  • Page 16: Description Of The Pump (Set)

    Example: MCPK 50-32-160 CDhix Table 5: Key to the designation Code Description MCPK Type series (full name: MegaCPK) Nominal suction nozzle diameter [mm] Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Casing material, e.g. C = stainless steel Impeller material if different from casing material, e.g. D = duplex Additional description, e.g.
  • Page 17 2 x 7312 CS80 NU216-E 2 x 7216 Economy (oil lubrication) CS40E 6208 C3 6208 C3 CS50E 6310 C3 6310 C3 CS60E 6312 C3 6312 C3 CS80E 6216 C3 6216 C3 Blank FAG designation: B-TVP-UA; SKF designation: BECBP MegaCPK 17 of 74...

  • Page 18: Configuration And Function

    (9 and 10), which are supported by a bearing bracket (5) linked with the pump casing and/or casing cover. Sealing The pump is sealed by a shaft seal (standardised mechanical seal or gland packing). MegaCPK 18 of 74...

  • Page 19: Noise Characteristics

    Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.8 - 1.1 range and for non- cavitating operation. If noise levels are to be guaranteed: add +3 dB for measuring and constructional tolerance. Increase for 60 Hz operation: 3500 rpm +3 dB, 1750 rpm +1 dB, 1160 rpm ±0 dB MegaCPK 19 of 74...

  • Page 20: Installation At Site

    ▷ Install the pump in a horizontal position to ensure self-venting of the pump. 5.3.1 Installation on the foundation Fig. 7: Fitting the shims Bolt-to-bolt distance Shim Shim if (L) > 800 mm Foundation bolt ✓ The foundation has the required strength and characteristics. MegaCPK 20 of 74...
  • Page 21 (on the shaft/discharge nozzle). To adjust any differences in height, loosen the bolts and locknuts (1, 3) of the machine mounts (4). Turn the adjusting nut (2) until any differences in height have been compensated. MegaCPK 21 of 74...

  • Page 22: Piping

    Check that the inside of the pump is free from any foreign objects. Remove any foreign objects. If required, install a filter in the piping (see figure: Filter in the piping). MegaCPK 22 of 74...
  • Page 23 050-032-200 1240 1010 1824 1157 050-032-200.1 1240 1010 1824 1157 050-032-250 1240 1010 1824 1157 050-032-250.1 1240 1010 1824 1157 065-040-125 1600 1300 1105 2339 1050 1000 1425 065-040-160 1600 1300 1105 2339 1050 1000 1425 MegaCPK 23 of 74...
  • Page 24 3350 5250 200 5250 4300 6750 9572 4850 2450 3550 300-250-315 11000 9200 7350 16114 8400 4150 6350 250 7350 6150 9150 13250 6900 3350 5250 Correction coefficients depending on material and temperature (see diagram below). MegaCPK 24 of 74...
  • Page 25 125-100-160 1400 1250 1120 2186 100 1050 1180 1843 125-100-200 1400 1250 1120 2186 100 1050 1180 1843 125-100-250 1400 1250 1120 2186 100 1050 1180 1843 125-100-315 1400 1250 1120 2186 100 1050 1180 1843 MegaCPK 25 of 74...
  • Page 26 Risk of burns! Malfunction of the pump! ▷ Refer to the general arrangement drawing, the piping layout and pump markings (if any) for the quantity, dimensions and locations of auxiliary connections. ▷ Use the auxiliary connections provided. MegaCPK 26 of 74...

  • Page 27: Enclosure/Insulation

    Damage to pump, motor and coupling! ▷ Always check the coupling after the pump has been installed and connected to the piping. ▷ Also check the coupling of pump sets supplied with pump and motor mounted on the same baseplate. MegaCPK 27 of 74...

  • Page 28: Aligning The Pump And Motor

    If alignment is correct, re-install the coupling guard and its footboard, if any. 5.7 Aligning the pump and motor After having installed the pump set and connected the piping, check the coupling alignment and, if required, re-align the pump set (at the motor). MegaCPK 28 of 74...
  • Page 29 Risk of injury by rotating shafts! ▷ Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one! ▷ Observe all relevant regulations for selecting a coupling guard.

  • Page 30: Electrical Connection

    Risk of injury by rotating shafts! ▷ Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one! ▷ Observe all relevant regulations for selecting a coupling guard.
  • Page 31 (looking at the motor shaft stub). The pump's direction of rotation is indicated by an arrow on the pump. Match the motor's direction of rotation to that of the pump. Observe the manufacturer's product literature supplied with the motor. MegaCPK 31 of 74...

  • Page 32: Checking The Direction Of Rotation

    The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. If the motor is running in the wrong direction of rotation, check the electrical connection of the motor and switchgear, if any. MegaCPK 32 of 74...

  • Page 33: Commissioning/Start-Up/Shutdown

    Insufficient quantity of lubricating oil in the reservoir of the constant level oiler Damage to the bearings! ▷ Regularly check the oil level. ▷ Always fill the oil reservoir completely. ▷ Keep the oil reservoir properly filled at all times. MegaCPK 33 of 74...
  • Page 34 Double mechanical seal Prior to starting up the pump, apply barrier pressure as specified in the general arrangement drawing. External liquid feed Apply the quantities and pressures specified in the data sheet and the general arrangement drawing. MegaCPK 34 of 74...
  • Page 35 ▷ Observe the cooling water quality. Observe the following quality data of the cooling water: ▪ Not deposit-forming ▪ Not aggressive ▪ Free from suspended solids ▪ Hardness on average 5 °dH (~1 mmol/l) ▪ pH > 8 MegaCPK 35 of 74...
  • Page 36 Damage to the pump! ▷ Check that the pump is sufficiently warmed up throughout. CAUTION Impermissibly high temperature of the heating medium Fluid or heating medium could escape! ▷ Observe the application limits of the heating media. MegaCPK 36 of 74...
  • Page 37 ✓ 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. MegaCPK 37 of 74...
  • Page 38 Tighten the nuts on the gland follower by 1/6 turn. Monitor the leakage for another five minutes. Excessive leakage: Repeat steps 1 and 2 until the minimum value has been reached. Not enough leakage: Slightly loosen the nuts at the gland follower. MegaCPK 38 of 74...

  • Page 39: Operating Limits

    ▷ 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. MegaCPK 39 of 74...
  • Page 40 ▪ Continuous operation: Q = 0.3 × Q For compliance with 2014/34/EU (ATEX Equipment Directive). Higher ambient temperature possible in individual cases, see data sheet and name plate. Minimum permissible flow rate Flow rate at best efficiency point MegaCPK 40 of 74...

  • Page 41: Shutdown/Storage/Preservation

    Start up the pump (set) regularly between once a month and once every three months for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pump intake area. Maximum permissible flow rate MegaCPK 41 of 74...

  • Page 42: Returning To Service

    Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant and protective devices. NOTE If the pump has been out of service for more than one year, replace all elastomer seals. MegaCPK 42 of 74...

  • Page 43: Servicing/Maintenance

    NOTE All maintenance, service 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.

  • Page 44: Servicing/Inspection

    ▪ The pump must run quietly and free from vibrations at all times. ▪ In case of oil lubrication, ensure the oil level is correct. (⇨ Section 6.1.2 Page 33) ▪ Check the shaft seal. (⇨ Section 6.1.11 Page 38) ▪ Check the static sealing elements for leakage. MegaCPK 44 of 74...
  • Page 45 The clearances given refer to the diameter. Table 17: Clearances between impeller and casing (cover)/between impeller and casing wear ring Impeller Clearances material Maximum G, B 0,3 mm 0,9 mm C, D, E 0,5 mm 1,5 mm MegaCPK 45 of 74...
  • Page 46 7.2.3.1.3 Oil quantity Table 20: Oil quantity Bearing bracket Oil quantity [l] CS40 CS50 CS60 CS80 At least once a year For ambient temperatures below -10 °C use a suitable different type of lubricating oil. Contact KSB. MegaCPK 46 of 74...
  • Page 47 7.2.3.2.2 Grease quality Table 21: Grease quality to DIN 51825 Soap basis NLGI grade Worked penetration Drop point Temperature range at 25 °C in mm/10 Lithium 2 to 3 220-295 ≥ 175 °C -30 °C to 120 °C MegaCPK 47 of 74...

  • Page 48: Drainage/Cleaning

    Use connection 6B to drain the fluid handled (see auxiliary connections). 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 and maintenance work performed by specially trained, qualified personnel. MegaCPK 48 of 74...
  • Page 49 Risk of crushing hands and feet! ▷ Suspend or support the motor to prevent it from tipping over. Disconnect the motor from the power supply. Unbolt the motor from the baseplate. Shift the motor to separate it from the pump. MegaCPK 49 of 74...
  • Page 50 The back pull-out unit is kept in a clean and level assembly area. Pull shaft sleeve 524.01 with the rotating assembly of mechanical seal 433 off the shaft. Undo hexagon head bolts 901.22, if any. Dismantle casing cover 161 with the stationary ring of mechanical seal 433. MegaCPK 50 of 74...
  • Page 51 ▷ Wear heat-resistant protective gloves. ▷ Remove flammable substances from the danger zone. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical roller bearing 322.01 to 80 °C, and pull them off shaft 210. MegaCPK 51 of 74...

  • Page 52: Reassembling The Pump Set

    – For gaskets, avoid the use of assembly adhesives, if possible. – If assembly adhesives are required, use a commercially available contact adhesive (e.g. "Pattex"). – Only apply adhesive at selected points and in thin layers. MegaCPK 52 of 74...
  • Page 53 Tighten slotted round nut 920.21 (⇨ Section 7.6.2 Page 59) to torque M2. Bend back lock washer 931.01. 10. Insert circlip 932.01/932.02 into the bearing bracket. 11. On grease-lubricated models, insert disc 550.24. 12. Fit cylindrical roller bearing 322.01 (roller cage) in the bearing bracket. MegaCPK 53 of 74...
  • Page 54 321.01/.02 into bearing bracket 330. Fit pump-end bearing cover 360.01 with joint ring 400.01; take care not to damage lip seal 421.02. Fit drive-end bearing cover 360.02 with joint ring 400.02; take care not to damage lip seal 421.02. MegaCPK 54 of 74...
  • Page 55 All dismantled parts have been cleaned and checked for wear. ✓ Any damaged or worn parts have been replaced by original spare parts. ✓ The sealing surfaces have been cleaned. Fit thrower 507.01, if any, and align flush with the shaft shoulder. MegaCPK 55 of 74...
  • Page 56 Packing cross-section Packing rings Ø d Ø d CS40 8×8 4 rings and 1 lantern ring CS50 10×10 CS60 10×10 CS80 12,5×12,5 6 rings Pure graphite packings see supplementary operating instructions. Always use pre-compressed packing rings. MegaCPK 56 of 74...
  • Page 57 ▷ Suspend or support the bearing bracket at the pump end. ✓ The notes and steps stated in (⇨ Section 7.5.1 Page 52) to (⇨ Section 7.5.4 Page 57) have been observed/carried out. ✓ Any damaged or worn parts have been replaced by original spare parts. MegaCPK 57 of 74...

  • Page 58: Tightening Torques

    Tightening torques for the pump Fig. 20: a) Tightening points at the pump, b) Model with clamped casing cover Use a torque wrench to tighten the bolted connections (902.01/920.01) between the volute casing and the bearing bracket. MegaCPK 58 of 74...
  • Page 59 CS 80 KM 16 M 80x2 Casing material: G = cast iron; C,V = stainless steel; E = unalloyed steel; D = duplex stainless steel Loosen the screwed connection again after first tightening. Final tightening torque MegaCPK 59 of 74...

  • Page 60: Spare Parts Stock

    Refer to the name plate for all data. Also specify the following data: ▪ Part number and description ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight) MegaCPK 60 of 74...
  • Page 61 Shaft protecting sleeve 50 % Sealing elements for pump 150 % casing (set) Torque-transmitting coupling 30 % elements (set) Versions with mechanical seal: Mechanical seal, complete 25 % Versions with gland packing: 461.01 Gland packing (set) 100 % MegaCPK 61 of 74...
  • Page 62 16 16 125-080-400 CS60 17 17 125-100-250 CS60 17 17 125-100-315 CS60 17 17 On pumps with casing wear ring only On pumps with casing wear ring and impeller wear ring only Depending on mechanical seal type MegaCPK 62 of 74...
  • Page 63 24 24 250-200-500 CS80 17 14 25 25 300-250-315 CS80 19 15 26 26 On pumps with casing wear ring only On pumps with casing wear ring and impeller wear ring only Depending on mechanical seal type MegaCPK 63 of 74...

  • Page 64: Trouble-Shooting

    ▷ For any work to remedy faults observe the relevant information in this manual or in the relevant accessory manufacturer's product literature. If problems occur that are not described in the following table, consultation with the KSB customer service is required. Pump delivers insufficient flow rate Motor is overloaded...
  • Page 65 ✘ ✘ Flow rate is too low. Increase the minimum flow rate. ✘ - Incorrect inflow of circulation liquid Increase the free cross-section. Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. MegaCPK 65 of 74...

  • Page 66: Related Documents

    9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components Fig. 23: General assembly drawing of standard version (oil-lubricated) 901.22 Version with bearing bracket CS40 Model with clamped casing cover Version with labyrinth seal MegaCPK 66 of 74...
  • Page 67 9 Related Documents Version with gland packing Mechanical seal with conical casing cover Mechanical seal with cylindrical casing cover Mechanical seal with cylindrical casing cover (heatable version "h") Grease-lubricated version (medium-duty bearings) Oil-lubricated version (economy bearings) MegaCPK 67 of 74...
  • Page 68 Joint rings 411.10 and 411.15 (411.15 for versions with mechanical seal with seal cover only) depending on the operating temperature. Order separately in spare parts order. Only for clamped cover Not fitted on versions with economy bearings From CS 60 On versions with economy bearings only MegaCPK 68 of 74...
  • Page 69 920.15 Hexagon nut Impeller nut 932.01 932.01 Circlip 932.02 932.02 Circlip The relevant version is indicated in the product literature supplied. On versions with labyrinth seal only On grease-lubricated versions only Not applicable for grease-lubricated versions MegaCPK 69 of 74...

  • Page 70: Eu Declaration Of Conformity

    67227 Frankenthal (Germany) The manufacturer herewith declares that the product: MegaCPK (MCPK) KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: – Pump (set): Machinery Directive 2006/42/EC The manufacturer also declares that ▪...

  • Page 71: 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 MegaCPK 71 of 74...

  • Page 72: Index

    General assembly drawing 66 Pure graphite packing 38 Gland packing 38 Grease lubrication Grease quality 47 Grease quantities 48 Return to supplier 14 Returning to service 42 Running noises 44, 45 Heating 36 Heating speed 37 Heating up 37 MegaCPK 72 of 74...
  • Page 73 Tightening torques 58, 60 Shaft seal 17 Shaft nut 59 Shutdown 39, 42 Transport 13 Spare part Ordering spare parts 60 Spare parts stock 61 Special accessories 19 Water cooling 35 Start-up 37 Storage 14, 42 MegaCPK 73 of 74...
  • Page 74 67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com KSB Bombas Hidráulicas SA Rua José Rabello Portella, 638 13220-540 - Várzea Paulista - SP - Brasil Tel.: +55 11 4596 8500 • Fax: +55 11 4596 8580 www.ksb.com.br...

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