KSB Vitachrom Installation & Operating Manual
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KSB Vitachrom Installation & Operating Manual

Hygienic pump in close-coupled design
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Hygienic Pump in Close-coupled Design
Vitachrom
Installation/Operating Manual

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Summary of Contents for KSB Vitachrom

  • Page 1 Hygienic Pump in Close-coupled Design Vitachrom 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 13/07/2018...

  • Page 3: Table Of Contents

    5.3.1 Connecting the piping........................ 24 5.3.2 Permissible forces and moments at the pump nozzles.............. 25 5.3.3 Vacuum balance line.......................... 25 5.3.4 Auxiliary connections......................... 26 Enclosure/insulation ............................ 27 Electrical connection ............................ 27 5.5.1 Setting the time relay ........................ 28 5.5.2 Connecting the motor ........................ 28 Vitachrom 3 of 72...
  • Page 4 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 .......... 51 Trouble-shooting.......................... 53 Related Documents .......................... 55 Exploded view / List of components...................... 55 9.1.1 Vitachrom standard design ....................... 55 9.1.2 Vitachrom with inducer........................ 59 9.1.3 Mechanical seal variants........................ 61 9.1.4 Supply system for mechanical seals in tandem arrangement ............ 63 EU Declaration of Conformity ......................

  • Page 5: Glossary

    Quench liquid supply Unpressurised liquid between the inboard and outboard shaft seal SIP (steaming in place) Procedure during which the inside of the pump is sterilised with steam. The pump does not need to be dismantled. Vitachrom 5 of 72...

  • 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

    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. Vitachrom 7 of 72...

  • Page 8: Safety

    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. Vitachrom 8 of 72...

  • Page 9: Consequences And Risks Caused By Non-Compliance With This Manual

    ▪ 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. Vitachrom 9 of 72...

  • Page 10: Unauthorised Modes Of Operation

    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. Vitachrom 10 of 72...

  • Page 11: Monitoring Equipment

    If the pump is to be operated at a higher temperature, the data sheet is missing or if the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature. Motor supplied by the...

  • 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 66) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination Vitachrom 13 of 72...

  • Page 14: Disposal

    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. Vitachrom 14 of 72...

  • Page 15: Description Of The Pump (Set)

    E M S See name plate and data sheet See data sheet Table 6: Designation key Position Code Description Pump type Vitachrom Vitachrom Inducer Inducer Without inducer Inducer 0 Inducer 1 Inducer 2 5-16 Size, e.g. Nominal suction nozzle diameter [mm]...
  • Page 16 DIN 11851 (hygienic pipe union) Flange Neumo Flange DIN 2633 (EN 1092-1) with recess Threaded connection Clamped connection EN 32676-A O-ring material EPDM Viton PTFE 26-28 Motor rating P [kW] 7,50 10,00 Number of motor poles 30-31 Explosion protection With explosion-proof motor Vitachrom 16 of 72...

  • Page 17: Name Plate

    Q 100 m n 2900 1/min l 2016 Id-No. 00 117 385 ZN 3804 - C 37 x 52 Fig. 4: Name plate Vitachrom (example) Type series, size and version KSB order number (ten digits) Flow rate Speed Kinematic viscosity of the fluid...
  • Page 18 ▪ Winding 50 Hz, 220 - 240 V / 380 - 420 V ≤ 2.20 kW; 380 - 420 V / 660 -  725 V ≥ 3.00 kW ▪ 60 Hz winding, 440 - 480 V 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 ▪...

  • Page 19: Mounting Arrangements

    ▪ Motor frame size 90 to 280 Pump set ball feet mounted ▪ Motor frame size 90 to 280 ▪ Alternatively mounted on rubber-padded round base feet Pump set soleplate mounted ▪ Motor frame size 90 to 280 Vitachrom 19 of 72...

  • Page 20: Configuration And Function

    4 Description of the Pump (Set) 4.6 Configuration and function Fig. 5: Vitachrom sectional drawing Clearance gap Discharge nozzle Discharge cover Shaft Motor housing Suction nozzle Impeller Shaft seal Drive lantern Rolling element bearing Rolling element bearing 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.

  • Page 21: Scope Of Supply

    ▪ Motor shroud (only in combination with vertically adjustable ball feet) ▪ Mechanical seal in tandem arrangement (quench arrangement) 4.9 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump/pump set. Vitachrom 21 of 72...

  • Page 22: Installation At Site

    3. Remove discharge cover 163 and set it aside. 4. Pull the back pull-out unit out of the pump casing and place it on a clean, level surface. 5. Remove the foam insert from the pump casing. Vitachrom 22 of 72...
  • Page 23 Fitting the motor shaft stub on shaft 210) 7. Fasten the shaft to the motor shaft using the locking ring. Applies to Vitachrom 50-50-125/160/200, 65-65-125/160/200 and 80-80-125/160 Applies to Vitachrom 50-50-250, 65-65-250, 80-80-250, 100-100-200 and 125-125-200 Vitachrom 23 of 72...

  • Page 24: Installing The Pump Set

    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) . Vitachrom 24 of 72...

  • Page 25: Permissible Forces And Moments At The Pump Nozzles

    Where fluid has to be pumped out of a vessel under vacuum, installing a vacuum balance line is recommended. The following rules apply to vacuum balance lines: ▪ Minimum nominal line diameter 25 mm. ▪ The line extends above the highest permissible fluid level in the vessel. Vitachrom 25 of 72...

  • Page 26: Auxiliary Connections

    Suitable fittings are available as accessories. When mounting the fittings comply with the instructions provided by the fitting manufacturers. Quench fluid supply Connections ▪ Pipe to DIN 2391 ▪ Compression-type fitting to DIN 2353 Vitachrom 26 of 72...

  • Page 27: Enclosure/Insulation

    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. Vitachrom 27 of 72...

  • Page 28: Setting The Time Relay

    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. Vitachrom 28 of 72...
  • Page 29 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 the control system if applicable. Vitachrom 29 of 72...

  • Page 30: Commissioning/Start-Up/Shutdown

    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. Vitachrom 30 of 72...

  • Page 31: Start-Up

    ▷ 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. Vitachrom 31 of 72...

  • Page 32: Checking The Shaft Seal

    ▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect them against freezing. 6.1.6 Quench liquid supply Permissible quench liquids The quench liquid should preferably form a solution with the fluid handled and be environmentally compatible. Vitachrom 32 of 72...

  • Page 33: Operating Limits

    Observe the following parameters and values during operation: Table 12: Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 °C Minimum See data sheet. Make sure the circulation line diameter is ≥ ¼". Depending on quench liquid used. Vitachrom 33 of 72...

  • Page 34: Frequency Of Starts

    6.2.4 SIP (steaming in place) 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. Vitachrom 34 of 72...

  • Page 35: Fluid Handled

    Temperature at the casing surface °C Pump efficiency at duty point Temperature difference 6.2.5.2 Density of the fluid handled The pump input power changes in proportion to the density of the fluid handled. Best efficiency point Vitachrom 35 of 72...

  • Page 36: Shutdown/Storage/Preservation

    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. Vitachrom 36 of 72...

  • Page 37: Returning To Service

    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. Vitachrom 37 of 72...

  • Page 38: Servicing/Maintenance

    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. Vitachrom 38 of 72...

  • Page 39: 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 40 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). Vitachrom 40 of 72...

  • Page 41: Inspection Work

    ▷ Clean filter at appropriate intervals. 7.2.2.3 Checking the quench liquid Periodically check the quench liquid for contamination. Drain the quench liquid, if required. Clean the quench system and fill with new quench liquid. Between pump casing and impeller vane Vitachrom 41 of 72...

  • Page 42: Drainage/Cleaning

    ▷ 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. Vitachrom 42 of 72...

  • Page 43: Preparing The Pump Set

    In case of damage you can always contact KSB Service. 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 44: Dismantling The Motor

    3. Remove impeller 230.01 with an impeller removal device. 4. Place impeller 230.01 on a clean and level surface. 5. Remove key 940.01 from shaft 210.01. 6. Remove O-ring 412.03 from impeller hub and/or pull V-ring 411.05 off shaft 210.01. Vitachrom 44 of 72...

  • Page 45: Removing The Mechanical Seal

    ▷ 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...

  • Page 46: Installing The Mechanical Seal

    8. Insert O-ring 412.03 in impeller. 9. Slip rotating assembly of the primary mechanical seal 433.01 onto impeller 230. 10. Slip impeller 230 onto shaft 210.01. 11. Insert O-ring 412.02 in impeller nut. 12. Fit and tighten impeller nut 922. Vitachrom 46 of 72...
  • Page 47 Table 21: Key to materials Code Material Carbon, resin-impregnated (FDA-approved) Q1/Q12 Silicon carbide, sintered without pressure (FDA-approved) Q2/Q22 Silicon carbide, reaction-bonded (FDA-approved) E1-04 EPDM (FDA-approved, 3-A, USP VI) FPM (FDA-approved, 3-A, USP VI) PTFE (FDA-approved) CrNiMo steel DIN EN 12756 Vitachrom 47 of 72...

  • Page 48: Fitting The Impeller

    3. Insert the back pull-out unit into pump casing 103. 4. Depending on the pump size and motor size, fit support foot 183. 5. Tighten hexagon nut 920.02 and hexagon head bolt 901.02 at the pump casing. Tightening torque (ð Section 7.6.1, Page 50) Vitachrom 48 of 72...

  • Page 49: Adjusting The Clearance Gaps

    5. Firmly fix the impeller using clamping ring 515.01 and hexagon socket head cap screw 914.01. Make sure that the shaft slot of shaft 210.01 aligns with the slot of locking ring 515.01, and that they are located opposite the keyway of the motor shaft end. Starting torque (ð Section 7.6.1, Page 50) Vitachrom 49 of 72...

  • Page 50: Checking Inducer Run-Out

    Maximum run-out: 0.15 mm 7.6 Tightening torques 7.6.1 Tightening torques for the pump set Fig. 10: Tightening points Table 22: Tightening torques [NM] for bolted/screwed connections at the pump Position Thread Spacer plates can be purchased from KSB. Vitachrom 50 of 72...

  • Page 51: Spare Parts Stock

    210.01 Shaft 30 % 230.01 Impeller 30 % 412.01 O-ring (casing) 90 % 412.02 O-ring (impeller nut) 90 % 412.03 O-ring (impeller) 90 % 433.01 Mechanical seal (primary) 90 % 433.02 Mechanical seal (secondary) 90 % Vitachrom 51 of 72...
  • Page 52 7 Servicing/Maintenance Part No. Description Number of pumps (including stand-by pumps) 6 and 7 8 and 9 10 and more 411.01 Joint ring (suction side) 90 % 411.02 Joint ring (discharge side) 90 % Vitachrom 52 of 72...

  • Page 53: Trouble-Shooting

    If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Impeller rubs on the casing B Pump delivers insufficient flow rate...
  • Page 54 Re-adjust to duty point. ✘ ✘ ✘ specified in the purchase order. ✘ - Density or viscosity of fluid handled Contact KSB. higher than stated in purchase order - Defective gasket Fit new gasket between pump casing and ✘ discharge cover.

  • Page 55: Related Documents

    9 Related Documents 9.1 Exploded view / List of components 9.1.1 Vitachrom standard design The standard design (without inducer) of the Vitachrom hygienic pump is available in two size groups which differ in design details. Size group I ▪ 50-125, 50-160, 50-200 ▪...
  • Page 56 9 Related Documents 9.1.1.1 Exploded view, Vitachrom, size group I This view applies to the following pump sizes: 050-050-125 065-065-125 080-080-125 050-050-160 065-065-160 080-080-160 050-050-200 065-065-200 [ Supplied in packaging units only 940.01 411.02 914.01 412.01 412.02 412.03 433.02 412.02 71-14.01/.02 914.01...
  • Page 57 9 Related Documents Part number Description Part number Description 68-3.01/.02 Cover plate Impeller nut Guard 940.01 Hood Vitachrom 57 of 72...
  • Page 58 9 Related Documents 9.1.1.2 Exploded view, Vitachrom, size group II This view applies to the following pump sizes: 050-050-250 065-065-250 080-080-250 100-100-200 125-125-200 [ Supplied in packaging units only 71-14.01/.02 411.02 940.01 411.03 412.01 412.02 433.01 433.02 (73-1.13/.14) 412.02 914.01 (731.34/.33) (710.13/.14)

  • Page 59: Vitachrom With Inducer

    9 Related Documents 9.1.2 Vitachrom with inducer Fig. 13: Size 65-160-Ind Fig. 14: Size 80-250-Ind Vitachrom 59 of 72...
  • Page 60 Pipe union 970.03 Information plate (rotational arrow) Support foot up to motor size 112 M On pumps with double mechanical seal only Not fitted on pumps with double mechanical seal Only in connection with ball foot 182.2 Vitachrom 60 of 72...

  • Page 61: Mechanical Seal Variants

    Circular casing 412.03 O-ring Discharge cover 433.01 Mechanical seal (inboard) Shaft Impeller nut Impeller Quench liquid outlet (G1/8 411.05 V-ring Quench liquid inlet (G1/8 412.02 O-ring Size group I only To ISO 228/1 Size group II only Vitachrom 61 of 72...
  • Page 62 Supply systems for mechanical seals in tandem arrangement: (ð Section 9.1.4, Page 63) Anti-rotation device 163.02 163.02 Fig. 17: Single or double mechanical seal a) without anti-rotation device, b) with anti- rotation device Part No. Description Part No. Description 163.02 Discharge cover Parallel pin of anti-rotation device Vitachrom 62 of 72...

  • Page 63: Supply System For Mechanical Seals In Tandem Arrangement

    Fig. 18: Supply system with quench pot Primary mechanical seal (inboard) Secondary mechanical seal (outboard) Filling up quench liquid Difference in height between pump shaft and quench pot approx. 1.5 m Quench liquid inlet Quench liquid outlet Connection 24E Connection 24A Vitachrom 63 of 72...
  • Page 64 Disc 741.02 Solenoid valve 550.03 Disc 757.01 Throttle 719.01 Corrugated pipe hose 901.01 Hexagon head bolt 720.01 Nipple joint 901.02 Hexagon head bolt 720.02 Nipple joint 920.01 731.01 Reducing nipple Quench outlet 731.02 Socket Quench inlet Vitachrom 64 of 72...

  • Page 65: 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: Etabloc, Etabloc SYT, Etaline, Etaline SYT, Etaline Z, Etachrom B, Etachrom L, Etanorm, Etanorm SYT, Etanorm V, Etaprime L, Etaprime B, Vitachrom...

  • Page 66: 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 Vitachrom 66 of 72...

  • Page 67: Index

    Frequency of starts 34 Shutdown 37 Spare part Function 20 Ordering spare parts 51 Start-up 31 Storage 13, 37 Impeller type 18 Installation Strainer 42 Installation on a foundation 24 Installation at site 22 Intended use 8 Temperature limits 10 Tightening torques 50 Transport 12 Key to safety symbols/markings 7 Transport lock 22 Vitachrom 67 of 72...
  • Page 68 Index Warnings 7 Warranty claims 6 Vitachrom 68 of 72...
  • Page 72 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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