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Summary of Contents for KSB MK
- Page 1 Waste Water, Condensate and Heat Transfer Fluid Pump 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 SE & Co. KGaA, Frankenthal 11/10/2018...
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Page 3: Table Of Contents
Installation at Site .......................... 20 Safety regulations............................ 20 Checks to be carried out prior to installation.................... 20 Fitting and setting the float switch control (optional) ................ 20 5.3.1 Control elements for MK/MKA ...................... 20 5.3.2 Control element for MKY........................ 23 Installing the pump set .......................... 23 Connecting the piping ........................... 23 Permissible forces and moments at the pump nozzles ................ 24... - Page 4 General assembly drawings/exploded views with list of components ............ 52 9.1.1 MK, MKA ............................ 52 9.1.2 MK, MKA - grease-lubricated...................... 53 9.1.3 MK, MKA - internally lubricated by fluid handled ................ 54 9.1.4 MK, MKA - lubricated by an external fluid .................. 55 9.1.5 MKY .............................. 57 EU Declaration of Conformity ...................... 59 Certificate of Decontamination......................
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Page 5: Glossary
Glossary Glossary Certificate of decontamination A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled. -
Page 6: General
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. -
Page 7: Key To Safety Symbols/Markings
1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product 1.6 Key to safety symbols/markings Table 3: Definition of safety symbols/markings Symbol Description DANGER DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury. -
Page 8: Safety
2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 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. -
Page 9: Consequences And Risks Caused By Non-Compliance With This Manual
2 Safety 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. -
Page 10: Unauthorised Modes Of Operation
The motors used by KSB on pumps with ATEX certification meet this condition. 2.9.2 Temperature limits In normal pump operation, the highest temperatures are to be expected at the surface of the pump casing, the pipe assembly, the plain bearings and in the bearing areas. -
Page 11: Monitoring Equipment
If the pump is to be operated at a higher temperature, if there is no data sheet or if the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature. 2.9.3 Monitoring equipment The pump (set) must only be operated within the limits specified in the data sheet and on the name plate. -
Page 12: Transport/Temporary Storage/Disposal
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. -
Page 13: Return To Supplier
4. Always complete and enclose a certificate of decontamination when returning the pump. Indicate any safety measures and decontamination measures taken. (ð Section 11, Page 60) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 13 of 64... -
Page 14: Disposal
3 Transport/Temporary Storage/Disposal 3.5 Disposal WARNING Fluids handled, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! ▷ Collect and properly dispose of flushing fluid and any fluid residues. ▷ Wear safety clothing and a protective mask if required. ▷... -
Page 15: Description Of The Pump (Set)
▪ Waste water, condensate and heat transfer fluid pump Pump for handling waste water, oils, emulsions, condensate, heat transfer fluids and aggressive fluids. 4.2 Designation MK A - B 20 - 1/ 100 Table 5: Designation key Code Description Type series... -
Page 16: Design Details
▪ Vertical installation ▪ Rigid connection between pump and motor ▪ Single-stage Drive ▪ KSB surface-cooled IEC three-phase current squirrel-cage motor ▪ 230/400 V ▪ Type of construction V1 ▪ Enclosure IP55 ▪ Motors integrated in explosion-proof pump sets are supplied in Ex eb IIB / Ex db eb IIC type of protection. -
Page 17: Configuration And Function
4 Description of the Pump (Set) 4.5 Configuration and function Fig. 3: MK, MKA Thrust and radial bearing Radial ball bearing Shaft Support column Discharge pipe Bearing bush Volute casing Motor Cover plate Shaft coupling Vapour barrier Overflow opening Radial bearing... - Page 18 4 Description of the Pump (Set) Fig. 4: MKY Discharge pipe Bearing bush Volute casing Motor Radial ball bearing Thrust and radial bearing Shaft coupling Drive lantern Shaft seal Shaft Support column Overflow opening Radial bearing Impeller Clearance gap Design The vertical non-self-priming submerged pump in single-stage, single-entry design features an axial fluid inlet and a radial fluid outlet.
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Page 19: Noise Characteristics
4 Description of the Pump (Set) 4.6 Noise characteristics Table 6: Surface sound pressure level L Rated power input Pump set [kW] 1450 rpm 2900 rpm [dB] [dB] 0,55 0,75 4.7 Scope of supply Depending on the model, the following items are included in the scope of supply: ▪... -
Page 20: Installation At Site
5.3 Fitting and setting the float switch control (optional) 5.3.1 Control elements for MK/MKA 5.3.1.1 Rod-actuated float switch control The pump set is controlled by a switch fitted on the motor flange. The switch is actuated by a float via a switch rod with stop clamps. - Page 21 5 Installation at Site Fitting the rod-actuated float switch 81-45 900.51 550.51 900.50 920.50 733.51 920.11 550.11 400.11 733.52 68-3 550.51 920.51 575.51 710.01 902.12 920.12 74-4 901.52 930.52 575.52 500.50 930.52 920.52 Fig. 5: Fitting the rod-actuated float switch Fig. 6: Positioning the rod-actuated float switch for installation depth: a) 1000 mm; b) 1900 mm; c) 2800 mm 1000 mm 1900 mm 2800 mm...
- Page 22 5 Installation at Site Fig. 7: Float switch a) installation position; b) switching position 1. Fasten strip 575.51 to the motor flange and strip 575.52 to the pump casing with hexagon head bolt 901.52, hexagon nut 920.52 and spring washers 930.52. 2.
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Page 23: Control Element For Mky
1. Remove the transport plugs from the volute casing and the discharge pipe. 2. For pump sets with installation depths of 1900 mm and 2800 mm without cover plate (MK) fit the pipe union 731, which is supplied separately strapped to the pump. (ð Section 9.1.2, Page 53) (ð Section 9.1.4, Page 55) 3. -
Page 24: Permissible Forces And Moments At The Pump Nozzles
5 Installation at Site NOTE Installing check and shut-off elements in the system is recommended, depending on the type of plant and pump. However, such elements must not obstruct proper drainage or hinder disassembly of the pump. NOTE If the pump is used for automatic drainage, fit a non-return or check valve. ü... -
Page 25: Checking The Direction Of Rotation
5 Installation at Site DANGER Electrostatic charging Explosion hazard! Damage to the pump set! ▷ Connect the potential equalisation conductor to the earthing terminal provided. ▷ Make sure that the connection between pump and baseplate is electrically conductive. ▷ Screws, bolts, nuts and shims must not be coated or the coating must be removed. - Page 26 5 Installation at Site CAUTION Pump set running dry Increased vibrations! Damage to mechanical seals and bearings! ▷ Never operate the pump set for more than 60 seconds outside the fluid to be handled. CAUTION Drive and pump running in the wrong direction of rotation Damage to the pump! ▷...
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Page 27: Commissioning/Start-Up/Shutdown
6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/Start-up 6.1.1 Prerequisites for commissioning/start-up ▪ The pump set has been properly connected to the power supply and is equipped with all protection devices. ▪ The direction of rotation has been checked. ▪ All auxiliary connections required are connected and operational. ▪... -
Page 28: Shutdown
6 Commissioning/Start-up/Shutdown CAUTION Abnormal noises, vibrations, temperatures or leakage Damage to the pump! ▷ Switch off the pump (set) immediately. ▷ Eliminate the causes before returning the pump set to service. ü The system piping has been cleaned. ü The pump and the inlet tank, if any, have been vented and primed with the fluid to be handled. -
Page 29: Operating Limits
6 Commissioning/Start-up/Shutdown 6.2 Operating limits DANGER Non-compliance with operating limits Damage to the pump set! ▷ Comply with the operating data specified in the data sheet. ▷ Avoid operation against a closed shut-off element. ▷ Never operate an explosion-proof pump set at ambient temperatures or fluid temperatures exceeding those specified in the data sheet and/or on the name plate. -
Page 30: Fluid Handled
6 Commissioning/Start-up/Shutdown 6.2.3 Fluid handled 6.2.3.1 Flow rate Unless specified otherwise in the characteristic curves or in the data sheets, the following applies: ▪ Short-time operation: Q = 0.1 × Q ▪ Continuous operation: Q = 0.3 × Q ▪ 2-pole operation: Q = 1.1 × Q ▪ 4-pole operation: Q = 1.25 × Q The data refer to water and water-like fluids. -
Page 31: Shutdown/Storage/Preservation
▷ Do not operate the pump (set) outside the specified temperature limits. Table 9: Fluid temperature Design Temperature [°C] Minimum Maximum MK, MKA -10 °C 90 °C -10 °C 200 °C 6.2.3.4 Density of the fluid handled The pump input power changes in proportion to the density of the fluid handled. -
Page 32: Returning To Service
6 Commissioning/Start-up/Shutdown 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. -
Page 33: Servicing/Maintenance
7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations DANGER Improper cleaning of coated pump surfaces Explosion hazard by electrostatic discharge! ▷ When cleaning coated pump surfaces in atmospheres of Explosion group IIC, use suitable anti-static equipment. DANGER Sparks produced during servicing work Explosion hazard! ▷... -
Page 34: Servicing/Inspection
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. -
Page 35: Lubrication And Lubricant Change
7 Servicing/Maintenance ▪ 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. - Page 36 Washer Grease fill Nilos ring Table 10: Bearings used Sizes Motor Radial ball bearing Nilos ring MK, MKA 20-1 to 5 80 M 6006 2 RS ZJV 6006 MK, MKA 20-6 90 S, L 6008 2 RS ZJV 6008 MKY 20-1 to 4 80 M...
- Page 37 7 Servicing/Maintenance Grease lubrication CAUTION Insufficiently filled grease cups Damage to the pump set by cavitation and ungreased bearings! ▷ The grease cup must be filled with lubricant. ▷ The grease cup must be screwed down regularly. Provide each bearing bush in the support column with a separate lubricating device including a lubricator.
- Page 38 7 Servicing/Maintenance Lubrication by external fluid DANGER Failure of lubrication by external fluid Explosion hazard! ▷ Monitor lubrication by external fluid. DANGER Risk of potentially explosive atmosphere by mixing of incompatible fluids in the auxiliary piping Risk of burns! Explosion hazard! ▷...
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Page 39: Drainage/Cleaning
7 Servicing/Maintenance Fig. 10: Lubrication by external fluid 7.3 Drainage/cleaning WARNING Fluids handled, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! ▷ Collect and properly dispose of flushing fluid and any fluid residues. ▷... -
Page 40: Dismantling The Pump Set
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. -
Page 41: Dismantling The Pump Section
5. Lift the pump set with support column 712 and/or pipe 710.01 and the cover plate out of the tank or pit. 7.4.3 Dismantling the pump section 7.4.3.1 Dismantling the pump set (MK) ü The notes and steps stated in (ð Section 7.4.1, Page 40) to (ð Section 7.4.2, Page 40) have been observed/carried out. - Page 42 7 Servicing/Maintenance CAUTION Damage to the shaft assembly Warping of the shaft! ▷ Support the shaft assembly if the shaft is long. 1. Remove any lubricating lines. 2. Remove level control equipment, if any. 3. Remove screw plug 903.01 with joint ring 411.01 from radial bearing 303.02 and 303.03 (if any).
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Page 43: Reassembling The Pump Set
7 Servicing/Maintenance 19. Pull shaft 210 out of sleeve 520. 20. Press sleeve 520 out of radial ball bearing 321. 21. Remove radial ball bearing 321 from thrust and radial bearing 303.01. 22. Remove grease-packed ring 500.01. 7.5 Reassembling the pump set 7.5.1 General information/Safety regulations WARNING Improper lifting/moving of heavy assemblies or components... -
Page 44: Reassembling The Pump Section
Tightening torques For reassembly, tighten all screws and bolts as specified in this manual. (ð Section 7.6, Page 48) 7.5.2 Reassembling the pump section 7.5.2.1 Re-assembling the pump set (MK) NOTE If the shaft is worn at the bearing positions, it may be turned upside down and installed again for continued use. - Page 45 7.5.2.1.1 Installing the shaft seal The bearing assembly is sealed by washers in the ball bearing of the thrust and radial bearing and a grease-backed ring. The MK/MKA models are additionally equipped with a vapour barrier (PTFE ring) in upper support column 712.01.
- Page 46 7 Servicing/Maintenance 8. Slide the motor shaft into sleeve 520. 9. Bolt the motor to thrust and radial bearing 303.01 with hexagon head bolts 901.01. 10. Apply a thin coat of grease to the bearing positions on shaft 210. 11. Press ring 550.01 into the first support column 712.01 following thrust and radial bearing 303.01.
- Page 47 7 Servicing/Maintenance CAUTION Insufficient lubrication Damage to the bearing! Prior to fitting the Nilos ring, pack its cranked sealing groove with grease. 3. Pack the cranked sealing groove of ring 500.01 with grease. Then fit the ring in thrust and radial bearing 303.01. 4.
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Page 48: Tightening Torques
7 Servicing/Maintenance 7.6 Tightening torques Fig. 12: Tightening points Table 12: Tightening torques [NM] depending on materials Position Thread Material [mm] [Nm] A, B, C, D A, B, C, D A, B, C, D A4-70 7.7 Spare parts stock 7.7.1 Ordering spare parts Always quote the following data when ordering replacement or spare parts: ▪... - Page 49 7 Servicing/Maintenance Part No. Description Number of pumps (including stand-by pumps) 6 and 7 8 and 9 10 and more Radial ball bearing 50 % Gasket 50 % 550.01 PTFE ring 50 % Neck ring 50 % 461.60/.61 Gland packing, support column 150 % 461.62 Gland packing, discharge pipe...
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Page 50: Trouble-Shooting
If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Pump does not start up B Motor is overloaded... - Page 51 8 Trouble-shooting A B C D E F Possible cause Remedy ✘ ✘ ✘ Pump is warped or sympathetic vibrations in ▪ Check pipeline connections and secure the piping. fixing of pump; if required, reduce the distances between the pipe clamps. ▪...
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Page 52: Related Documents
500.01 920.01 561.01 550.01 710.01 712.01 920.02 902.02 303.02 561.02 903.01 411.01 Fig. 13: Illustration of MK, MKA - installation depth 1000 mm Table 15: List of components Part No. Description Part No. Description Volute casing Bearing bush Shaft 550.01/.11 Disc Impeller 561.01/.02 Grooved pin 303.01... -
Page 53: Mk, Mka - Grease-Lubricated
920.01 561.01 710.01 550.01 710.30 712.01 920.02 902.02 303.02 561.02 731.32 Fig. 14: Illustration of MK, MKA - installation depth 1000 mm, grease-lubricated Table 16: List of components Part No. Description Part No. Description Volute casing Grease cup Shaft 68-3 Cover plate Impeller 710.01... -
Page 54: Mk, Mka - Internally Lubricated By Fluid Handled
411.01 712.02 731.21 710.21 920.02 902.02 903.01 303.03 411.01 561.02 Fig. 15: Illustration of MK, MKA - installation depth 1900 mm, internally lubricated by fluid handled Table 17: List of components Part No. Description Part No. Description Volute casing 561.01/.02 Grooved pin Impeller... -
Page 55: Mk, Mka - Lubricated By An External Fluid
901.03 920.03 731.43 303.02 712.03 710.41 920.02 902.02 303.02 731.42 561.02 Fig. 16: Illustration of MK, MKA - installation depth 2800 mm, lubricated by an external fluid Table 18: List of components Part No. Description Part No. Description Volute casing 550.01/.11 Disc Shaft 561.01/.02... - Page 56 9 Related Documents Part No. Description Part No. Description Casing wear ring 903.11 Screw plug Sleeve 920.01/.02/.03/.11/.12 Bearing bush 56 of 64...
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Page 57: Mky
9 Related Documents 9.1.5 MKY 901.01 561.01 500.01 920.62 303.01 452.62 452.60 461.62 550.60 550.60 461.61 461.60 920.61 902.61 902.62 900.61 902.60 920.60 81-92 400.60 902.01 81-92 920.01 710.01 712.01/.02/.03 920.02 561.02 303.02/.03 902.02 903.01 411.01 Fig. 17: MKY Table 19: List of components Part No. - Page 58 9 Related Documents Part No. Description Part No. Description 500.01 Ring 920.01/.02/.60/.61/.62 Casing wear ring 58 of 64...
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Page 59: Eu Declaration Of Conformity
10 EU Declaration of Conformity 10 EU Declaration of Conformity Manufacturer: KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: MK, MKA, MKY KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: –... -
Page 60: Certificate Of Decontamination
11 Certificate of Decontamination 11 Certificate of Decontamination Type: ..........................Order number/ Order item number ..........................Delivery date: ..........................Field of application: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ Radioactive Explosive Corrosive Toxic ⃞ ⃞ ⃞... -
Page 61: Index
Index Index Abrasive fluids 31 Noise characteristics 19 Bearing temperature 35 Order number 6 Bearings 16 Other applicable documents 6 Certificate of decontamination 60 Partly completed machinery 6 Permissible forces at the pump nozzles 24 Preservation 13, 32 Design 16 Product description 15 Designation 15 Direction of rotation 26 Dismantling 40 Reassembly 40 Disposal 14 Return to supplier 13 Drive 16, 19 Returning to service 32 Running noises 34, 35... - Page 64 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
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