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Summary of Contents for KSB Sewabloc Series
- Page 1 Dry-installed Volute Casing Pump Sewabloc 50 / 60 Hz DIN / IEC motors Installation/Operating Manual Mat. No.: 01104323...
- 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 24/08/2018...
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Page 3: Table Of Contents
Contents Contents Glossary .............................. 5 General.............................. 6 Principles ................................ 6 Installation of partly completed machinery.................... 6 Target group.............................. 6 Other applicable documents.......................... 6 Symbols ................................ 6 Safety .............................. 8 Key to safety symbols/markings........................ 8 General................................ 8 Intended use .............................. 9 Personnel qualification and training....................... 9 Consequences and risks caused by non-compliance with this manual ............ 10 Safety awareness ............................ 10 Safety information for the operator/user ..................... 10 Safety information for maintenance, inspection and installation .............. 10... - Page 4 Contents 6.1.3 Shutdown ............................ 28 Operating limits.............................. 28 6.2.1 Maximum operating pressure ...................... 29 6.2.2 Frequency of starts.......................... 30 6.2.3 Fluid handled ............................. 30 Shutdown/storage/preservation ........................ 30 Returning to service ............................ 31 Servicing/Maintenance ........................ 32 Safety regulations............................ 32 Servicing/Inspection............................ 33 7.2.1 Supervision of operation ........................ 33 7.2.2 Inspection work.......................... 34 7.2.3 Lubrication and lubricant change..................... 35 Drainage/cleaning ............................ 38 Dismantling the pump set.......................... 38...
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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 1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product Sewabloc 7 of 60...
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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 Key to safety symbols/markings Table 3: Definition of safety symbols/markings Symbol Description... -
Page 9: Intended Use
2 Safety 2.3 Intended use ▪ The pump set must only be operated within the operating limits described in the other applicable documents. ▪ Only operate pump sets which are in perfect technical condition. ▪ Do not operate partially assembled pump sets. ▪... -
Page 10: Consequences And Risks Caused By Non-Compliance With This Manual
2 Safety Training on the pump (set) must always be supervised by technical specialist personnel. 2.5 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. ▪... -
Page 11: Unauthorised Modes Of Operation
2 Safety ▪ When taking the pump set out of service always adhere to the procedure described in the manual. ▪ Decontaminate pumps which handle fluids posing a health hazard. (ð Section 7.3, Page 38) ▪ As soon as the work has been completed, re-install and re-activate any safety- relevant devices and protective devices. -
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: Storage/Preservation
3 Transport/Temporary Storage/Disposal Horizontal transport Horizontal transport Close-coupled pump Close-coupled pump without motor 3.3 Storage/preservation If commissioning is to take place some time after delivery, we recommend that the following measures be taken: CAUTION Damage during storage due to humidity, dirt or vermin Corrosion/contamination of the pump (set)! ▷... -
Page 14: Disposal
Indicate any safety measures and decontamination measures taken. (ð Section 11, Page 57) 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! ▷... -
Page 15: Description Of The Pump (Set)
4 Description of the Pump (Set) 4 Description of the Pump (Set) 4.1 General description Pump for handling untreated sewage and all types of waste water. ▪ Close-coupled pump with shaft seal ▪ Directly flanged standardised motor ▪ Direct drive electric motor Table 6: Installation types Installation Illustration... -
Page 16: Designation
Type series Impeller type Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Material variant Installation type 4.3 Name plate KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal Deutschland SNr. 24 17 41 2016 SEWABLOC F 100 - 250 P-No. -
Page 17: Configuration And Function
4 Description of the Pump (Set) 4.5 Configuration and function Fig. 2: Sectional drawing Sewabloc with K impeller Clearance gap Discharge nozzle Discharge cover Shaft Bearing bracket Suction nozzle Impeller Shaft seal Rolling element bearing Motor Design The hydraulic system and the motor are firmly connected and form a close-coupled unit. -
Page 18: Scope Of Supply
4 Description of the Pump (Set) Rated power input Pump set 2900 / 3500 rpm 1450 / 1750 rpm 960 /1160 rpm 760 / 875 rpm [kW] [dB] [dB] [dB] 68,5 62,0 60,5 70,0 63,5 63,0 71,0 65,0 63,5 11,0 72,5 67,0 65,5... -
Page 19: Installation At Site
5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Excessive temperatures in the shaft seal area Explosion hazard! ▷ Never operate a pump (set) with gland packing in potentially explosive atmospheres. 5.2 Checks to be carried out prior to installation Place of installation WARNING Installation on mounting surface which is unsecured and cannot support the load... - Page 20 5 Installation at Site Fastening ▪ Fasten the pump feet or foundation rails, soleplate or suction duckfoot bend to a concrete foundation with chemical anchors. ü The foundation has the required strength and characteristics. ü The foundation has been prepared in accordance with the dimensions given in the outline drawing/general arrangement drawing.
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Page 21: Piping
5 Installation at Site Table 10: Curing times of mortar cartridge Floor temperature Curing time [°C] [min] -5 to 0 0 to +10 +10 to +20 > +20 5.4 Piping 5.4.1 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from escaping hot, toxic, corrosive or flammable fluids! ▷... -
Page 22: Permissible Forces And Moments At The Pump Nozzles
5 Installation at Site 5.4.2 Permissible forces and moments at the pump nozzles The values correspond with those specified in EN ISO 5199 for horizontal installation (installation type 1A), for cast iron and 20 °C. The values also apply to Sewabloc pumps installed vertically. Forces and moments at the pump nozzles The data on forces and moments apply to static piping loads only. -
Page 23: Vacuum Balance Line
5 Installation at Site Flanges Forces at suction nozzle Moments at suction Forces at discharge Moments at discharge nozzle nozzle nozzle DN1 DN2 Fy ∑F ∑M ∑F ∑M 125 - 315 F, K B03 125 1100 1400 1250 2150 550 1050 1100 1400 1250 2150 550 1050 150 - 253 D... -
Page 24: Auxiliary Connections
5 Installation at Site 5.5 Auxiliary connections WARNING Screw plugs subjected to pressure Risk of injuries by parts flying off and escaping fluid! ▷ Never use screw plugs for releasing pressure from the pump casing. ▷ Always use suitable venting devices (e.g. vent valve). The following auxiliary connections are available: 1M.1 1M.1... -
Page 25: Electrical Connection
5 Installation at Site Lubrication of mechanical seals The lubricant reservoirs have been filled at the factory. Before commissioning the pump set, check the lubricant level. Fig. 6: Checking the lubricant level ü The pump set has been installed as specified. 1. -
Page 26: Checking The Direction Of Rotation
5 Installation at Site 5.8 Checking the direction of rotation DANGER Temperature increases 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. WARNING Hands inside the pump casing Risk of injuries, damage to the pump! -
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 Before commissioning/starting up the pump set, make sure that the following conditions are met: ▪ The pump set has been properly connected to the power supply and is equipped with all protection devices. (ð Section 5.7, Page 25) ▪... -
Page 28: Shutdown
6 Commissioning/Start-up/Shutdown WARNING Abnormal noises, vibrations, temperatures or leakage Damage to the pump! Risk of personal injury! ▷ Switch off the pump (set) immediately. ▷ Eliminate the causes before returning the pump set to service. ü The pump, suction line and discharge line have been vented and primed with the fluid to be handled. -
Page 29: Maximum Operating Pressure
6 Commissioning/Start-up/Shutdown 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 Maximum operating pressure CAUTION Permissible operating pressure exceeded Damage to connections and seals! ▷... -
Page 30: Frequency Of Starts
6 Commissioning/Start-up/Shutdown 6.2.2 Frequency of starts To prevent high temperature increases in the motor and excessive loads on the pump, motor, seals and bearings, the frequency of starts shall not exceed the following number of start-ups per hour. Table 14: Frequency of starts Rated motor power Maximum frequency of starts [kW]... -
Page 31: Returning To Service
6 Commissioning/Start-up/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... -
Page 32: Servicing/Maintenance
7 Servicing/Maintenance 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! -
Page 33: 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 34: Inspection Work
7 Servicing/Maintenance While the system is in operation, observe and check the following: ▪ The pump must run quietly and free from vibrations at all times. ▪ 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 35: Lubrication And Lubricant Change
7 Servicing/Maintenance 900.02 920.17 550.04 164.02 412.05 Fig. 7: Inspection hole in the casing Opening the inspection hole ▪ Close the shut-off element on the suction side. ▪ Switch off the drive and make sure it cannot be re-started unintentionally. ▪ Close the shut-off element on the discharge side. ▪... - Page 36 7 Servicing/Maintenance WARNING Lubricants posing a health hazard and/or hot lubricants Hazard to persons and the environment! ▷ When draining the lubricant take appropriate measures to protect persons and the environment. ▷ Wear safety clothing and a protective mask if required. ▷...
- Page 37 7 Servicing/Maintenance Size Bearing bracket Lubricant quantity 065 - 252 065 - 252 065 - 253 065 - 253 080 - 215 080 - 216 080 - 217 080 - 250 080 - 252 080 - 253 080 - 315 080 - 316 080 - 317 100 - 215...
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Page 38: Drainage/Cleaning
7 Servicing/Maintenance 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. ▷... -
Page 39: Preparations For Dismantling
7 Servicing/Maintenance 7.4.2 Preparations for dismantling DANGER Insufficient preparation of work on the pump (set) Risk of injury! ▷ Properly shut down the pump set. ▷ Close the shut-off elements in the suction line and discharge line. ▷ Drain the pump and release the pump pressure. (ð Section 7.3, Page 38) ▷... -
Page 40: Removing The Pump Set
A forcing screw is required to remove the impeller. The forcing screw is not included in the scope of supply. It can be ordered separately from KSB. ü The notes and steps stated in (ð Section 7.4.5, Page 40) have been observed/ carried out. - Page 41 7 Servicing/Maintenance Size Impeller type Forcing screw (ADS) Thread Designation 065 - 216 M 12 ADS 7 065 - 217 M 10 ADS 6 065 - 250 F, K M 16 ADS 1 065 - 252 B01 M 16 ADS 1 065 - 252 B02 M 20 ADS 2...
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Page 42: Dismantling The Mechanical Seal
7 Servicing/Maintenance 7.4.7 Dismantling the mechanical seal 433.02 433.01 515 / 932.03 Fig. 10: Dismantling the mechanical seal 7.4.7.1 Dismantling the pump-end mechanical seal ü The back pull-out unit and the impeller have been removed as described above. 1. Pull the rotating assembly of mechanical seal 433.01 off shaft 210. 2. -
Page 43: Removing Shaft And Rolling Element Bearing
7 Servicing/Maintenance 7.4.7.3 Removing the KSB double cartridge seal 101-47 914.52 Fig. 11: Removing the KSB double cartridge seal 412.28 932.59 Fig. 12: Removing the mechanical seal ü The back pull-out unit and the impeller have been removed as described above. 1. Fix discharge cover 163 to bearing bracket 330 using suitable bolts/screws and washers. -
Page 44: Removing The Wear Plate (For D Type Impellers Only)
7 Servicing/Maintenance 7.4.9 Removing the wear plate (for D type impellers only) 914.12 Fig. 13: Removing the wear plate ü The inside of the casing has been cleaned. ü The wear plate needs to be replaced as a result of visual inspection. 1. -
Page 45: Installing The Shaft And Rolling Element Bearings
7 Servicing/Maintenance 7.5.2 Installing the shaft and rolling element bearings When re-installing the shaft, replace deep groove ball bearing 321.01 if required. 1. Press deep groove ball bearing 321.01 onto shaft 210 unit it abuts against the shaft shoulder. 2. Insert circlip 932.20 into shaft 210. 3. - Page 46 150 - 317 38,5 200 - 315 D, K 38,5 200 - 316 38,5 200 - 317 38,5 200 - 318 38,5 7.5.3.2 Installing the KSB double cartridge seal 101-47 Fig. 15: Installing the KSB double cartridge seal Sewabloc 46 of 60...
- Page 47 ü The back pull-out unit of the pump has been placed in a clean and level assembly area. ü The KSB 4STQ double cartridge seal is fully assembled and undamaged. 1. Insert circlip 932.59 in the shaft groove and make sure that circlip 932.59 is positioned correctly in the shaft groove.
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Page 48: Fitting The Impeller
7 Servicing/Maintenance Table 19: Reference dimension "K" Size Reference dimension "K" 50-215/216 24+/- 0.5 65-215/217 80-215/216/217 100-215 65-216 32+/- 0.5 80-216 50-250 38+/- 0.5 65-250/252/253 80-250/252 100-250/252/254 50-251 41+/- 0.5 65-253 80-253/315/316 100-251/253/255/315/316/317 125-315/317 150-315/317 200-315/316/317/318 7.5.4 Fitting the impeller ü The shaft and rolling element bearings have been properly installed. ü... -
Page 49: Installing The Back Pull-Out Unit
7 Servicing/Maintenance Size Impeller type Thread Tightening torque [Nm] 100 - 251 M 16 100 - 252 M 10 100 - 253 D, E, F, K M 10 100 - 254 F, K M 10 100 - 255 M 16 100 - 316 125 - 315 F, K... -
Page 50: Leak Test
7 Servicing/Maintenance 914.12 412.34 914.24 412.33 Fig. 19: Fitting the wear plate 1. Equip wear plate 135 with two new O-rings 412.33/34. 2. Insert wear plate 135 into pump casing 101. 3. Fasten wear plate 135 to pump casing 101 with hexagon socket head cap screws 914.12. -
Page 51: Spare Parts Stock
7 Servicing/Maintenance 7.7 Spare parts stock 7.7.1 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 ▪... -
Page 52: Trouble-Shooting
If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Pump delivers insufficient flow rate B Motor is overloaded... - Page 53 Fit new shaft seal. ✘ ✘ - Vibrations during pump operation Correct the suction conditions. Re-align the pump. Re-balance the impeller. Increase pressure at the pump suction nozzle. ✘ - Operating voltage too low. Increase the voltage. Contact KSB. Sewabloc 53 of 60...
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Page 54: Related Documents
9 Related Documents 9 Related Documents 9.1 General assembly drawing – Sewabloc 411.02 903.02 902.01 920.01 903.90 903.03 932.02 411.90 321.01 411.03 433.01 433.02 914.10 / 906 550.23* 515 / 932.03 904.01** 932.20 901.57 920.57 550.57 901.99 903.01 411.01 412.15 412.04 903.46 411.46... -
Page 55: Exploded View Of A Sewabloc
9 Related Documents 9.2 Exploded view of a Sewabloc 903.02 411.02 914.73 515.02 411.03 412.15 903.03 903.90 932.02 920.01 321.01 411.90 902.01 411.01 932.20 903.01 433.01 412.04 920.57 411.22 550.57 411.46 903.22 901.57 903.46 433.02 550.23 914.10 Fig. 21: Exploded view of a Sewabloc Table 25: List of components Part No. -
Page 56: 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: Sewabloc, Sewatec KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: –... -
Page 57: 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 58: Index
Index Index Applications 9 Partly completed machinery 6 Permissible forces and moments at the pump nozzles 22 Piping 21 Bearings 16 Preservation 13 Priming and venting 26 Product description 15 Certificate of decontamination 57 Commissioning 27 Reassembly 38 Return to supplier 13 Design 16 Returning to service 31 Designation 16 Direction of rotation 26 Dismantling 38 Safety 8 Disposal 14 Safety awareness 10 Scope of supply 18... - Page 60 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
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