5.3.2 Permissible forces and moments at the pump nozzles.............. 29 5.3.3 Auxiliary connections......................... 29 Enclosure/insulation ............................ 29 Checking the coupling alignment ......................... 30 Electrical connection ............................ 31 5.6.1 Setting the time relay ........................ 31 5.6.2 Connecting the motor ........................ 32 Vitacast / Vitacast Bloc 3 of 80...
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Recommended spare parts stock for 2 years' operation to DIN 24296 .......... 65 Trouble-shooting.......................... 67 Related Documents .......................... 69 General assembly drawings with list of components................... 69 9.1.1 Vitacast ............................... 69 9.1.2 Vitacast-Bloc ............................ 73 EU Declaration of Conformity ...................... 76 Certificate of Decontamination...................... 77 Index .............................. 78 Vitacast / Vitacast Bloc 4 of 80...
Procedure during which the inside of the pump is sterilised with steam. The pump does not need to be dismantled. Suction lift line/suction head line The pipeline which is connected to the suction nozzle Vitacast / Vitacast Bloc 5 of 80...
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.
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. Vitacast / Vitacast Bloc 7 of 80...
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. Vitacast / Vitacast Bloc 8 of 80...
▪ 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. Vitacast / Vitacast Bloc 9 of 80...
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. Vitacast / Vitacast Bloc 10 of 80...
60 °C 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. Motor supplied by the...
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.
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 77) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination Vitacast / Vitacast Bloc 13 of 80...
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. Vitacast / Vitacast Bloc 14 of 80...
Single mechanical seal, internal, dead-end arrangement, external flushing (quench) Double mechanical seal, external, in back-to-back arrangement Single mechanical seal, internal, dead-end arrangement, internal circulation Single mechanical seal, external, without flushing 24-26 Seal code, single mechanical seal, internal GCEGG Blank Vitacast / Vitacast Bloc 18 of 80...
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Seal code, double mechanical seal, external, back-to-back arrangement GCEGG GBEGG U3CEGG GCEGG U3U3EGG U3BGG U3U3VGG BU3VGG U3U3VGG U3U3VGG U3U3TGG U3CTGG Pipe connection Flange Threaded connection DIN 11864-1A Flange DIN 11864-2A Clamped connection DIN 11864-3A Threaded connection DIN 11853 Threaded connection Vitacast / Vitacast Bloc 19 of 80...
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2.4819 Motor shroud Without shroud With shroud Design Standard Non-standard (BT3D, BT3), including ATEX Drain Casing drain with plug No drain Casing drain via pipeline Casing drain via valve Generation Vitacast Bloc Blank Vitacast / Vitacast Bloc 20 of 80...
67227 Frankenthal Deutschland VAB 032-025-145 0402KB T81ME Jahr E-Nr 2016 20 m 2900 1/min Fig. 1: Name plate of a Vitacast-Bloc (example) Type series, size and version KSB order number Manufacturer's No. Flow rate Head Speed Year of construction 4.5 Design details Design ▪...
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4 Description of the Pump (Set) Drive Standard design: ▪ KSB surface-cooled IEC three-phase current squirrel-cage motor ▪ 50 Hz winding, 220 - 240 V / 380 - 420 V ≤ 2.20 kW ▪ 50 Hz winding, 380 - 420 V / 660 - 725 V ≥ 3.00 kW ▪ 60 Hz winding, 440 - 480 V ≤ 2.60 kW ▪ 60 Hz winding, 440 - 480 V ≥ 3.60 kW ▪ Type of construction IM V1 ≤ 4.00 kW ▪...
4 Description of the Pump (Set) 4.6 Configuration and function 2 3 4 5 6 9 10 Fig. 2: Sectional drawing of a Vitacast Bloc Volute channel Discharge nozzle Clamping piece Pump shaft Rolling element bearing for pump Drive lantern shaft...
▪ Pump foot or foot base (e.g. 3-point ball feet) ▪ Trolley with switch and power cable 4.9 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump/pump set. Vitacast / Vitacast Bloc 24 of 80...
For pump sets with a motor rating > 30 kW installation without a foundation is not recommended. Always install the pump set in a horizontal position. Table 11: Installation type Motor size Installation type 71 ... 180 Ball feet 71 ... 180 Motor foot Vitacast / Vitacast Bloc 25 of 80...
In this case, only fasten the flexible elements at the baseplate after the piping has been connected. NOTE Expansion joints can be fitted between the pump and the suction/discharge line. Vitacast / Vitacast Bloc 26 of 80...
Incorrect earthing during welding work at the piping Destruction of rolling element bearings (pitting effect)! ▷ Never earth the electric welding equipment on the pump or baseplate. ▷ Prevent current flowing through the rolling element bearings. Vitacast / Vitacast Bloc 27 of 80...
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Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of corrosion-resistant material. Use a filter with a filter area three times the cross-section of the piping. Conical filters have proved suitable. 5. Connect the pump nozzles to the piping. Vitacast / Vitacast Bloc 28 of 80...
Explosion hazard! ▷ Make sure the space between the casing cover/discharge cover and the bearing cover is sufficiently vented. ▷ Never close or cover the perforation of the bearing bracket guards (e.g. by insulation). Vitacast / Vitacast Bloc 29 of 80...
ü The coupling guard and its footboard, if any, have been removed. 1. Loosen the support foot and re-tighten it without transmitting any stresses and strains. 2. Place the straight-edge axially on both coupling halves. Vitacast / Vitacast Bloc 30 of 80...
▷ Keep switch-over intervals between star and delta as short as possible. Table 12: Time relay settings for star-delta starting: Motor rating Y time to be set [kW] ≤ 30 < 3 > 30 < 5 Vitacast / Vitacast Bloc 31 of 80...
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. Vitacast / Vitacast Bloc 32 of 80...
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5. If the motor is running in the wrong direction of rotation, check the electrical connection of the motor and the control system, if any. 6. Fasten motor shroud 683 with screws 900.1. Vitacast / Vitacast Bloc 33 of 80...
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. Vitacast / Vitacast Bloc 34 of 80...
▷ The pump internals in contact with the fluid to be handled, including the seal chamber and auxiliary systems must be filled with the fluid to be handled at all times. ▷ Provide sufficient inlet pressure. ▷ Provide an appropriate monitoring system. Vitacast / Vitacast Bloc 35 of 80...
ü The system piping has been cleaned. ü Pump, suction line and inlet tank, if any, have been vented and primed with the fluid to be pumped. ü The lines for priming and venting have been closed. Vitacast / Vitacast Bloc 36 of 80...
1. Close the shut-off element in the suction line. 2. Close any auxiliary lines. If the fluid to be handled is fed in under vacuum, also supply the shaft seal with barrier fluid during standstill. Vitacast / Vitacast Bloc 37 of 80...
Periodically check the quench liquid for contamination (replace quench liquid and clean quench system if necessary). 6.1.7.3.1.3 Applications For seal types T and H, operating mode BQ Make sure the circulation line diameter is ≥ ¼". Vitacast / Vitacast Bloc 38 of 80...
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The flow rate of the barrier fluid system depends on the shaft diameter, speed and fluid temperature. Valid for unbalanced mechanical seals flushed with clean water of 20 °C. Vitacast / Vitacast Bloc 39 of 80...
(e.g. fill level monitoring). 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. Observe the following parameters and values during operation: Vitacast / Vitacast Bloc 40 of 80...
+45 to +60 Flushing Washing lye +70 to +95 20 to 30 Intermediate flushing Water +60 max. 5 to 10 Flushing See table below 10 to 15 Flushing Water +15 to +25 10 to 15 Vitacast / Vitacast Bloc 41 of 80...
≈ 25 % of Q opt. The calculation formula below can be used to check if an additional heat build-up could lead to a dangerous temperature increase at the pump surface. Best efficiency point Vitacast / Vitacast Bloc 42 of 80...
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. Vitacast / Vitacast Bloc 43 of 80...
If the equipment has been out of service for more than one year, replace all elastomer seals before returning the equipment to service. Verify that the type of the new elastomers (material, certification) corresponds with that of the previous ones. Vitacast / Vitacast Bloc 44 of 80...
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. Vitacast / Vitacast Bloc 45 of 80...
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.
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– The bearing temperature must not exceed 100 °C (measured in the oil sump). CAUTION Operation outside the permissible bearing temperature Damage to the pump! ▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured on the outside of the motor housing). Vitacast / Vitacast Bloc 47 of 80...
▷ Clean filter at appropriate intervals. 7.2.2.4 Checking the flushing liquid Periodically check the flushing liquid for contamination. If necessary, drain the flushing liquid. Clean the flushing system and fill it with new flushing liquid. Vitacast / Vitacast Bloc 48 of 80...
▷ Wear safety clothing and a protective mask if required. ▷ Collect and dispose of any lubricants. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard. At least once a year Vitacast / Vitacast Bloc 49 of 80...
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Motor size < 160 / 11 kW The bearings are grease-packed for life. Motor size ≥ 160 / 11 kW Fig. 10: Arrangement of lubricating nipples (1) Vitacast-Bloc, up to motor size 180 Vitacast-Bloc, motor size 200 Depending on the pump size and rotational speed, re-lubricate the rolling element bearings or replace the grease at regular intervals.
2. Always flush the pump if it has been used for handling harmful, explosive and hot fluids or other fluids posing a risk. Always flush and clean the pump before transporting it to the workshop. Provide a certificate of decontamination for the pump. Vitacast / Vitacast Bloc 51 of 80...
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.
7.4.4 Removing the pump casing and impeller 1. Undo clamping piece 81-44. ð On Vitacast 150-125-350 and Vitacast 200-150-350 pump casing 101 is screwed on. In this case, undo studs 902.1 and nuts 920.1 instead of clamping piece 81-44.
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ð Pull the spring together with the seal off shaft 210. 433.1 5. If applicable, remove pipe 710.2 for the flushing connection of casing cover 161 from drive lantern 341. Fig. 14: Removing the mechanical seal Vitacast / Vitacast Bloc 54 of 80...
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7 Servicing/Maintenance 7.4.5.5 Seal type Q, operating mode DB (Vitacast) 901.5 710.2 ü The pump casing and impeller have been removed. 1. Remove both pipes 710.2 of the flushing connections. 2. Undo and remove hexagon head bolts 901.4 on the rear side of seal cover 471.
210 or gently tap shaft 210 with a rubber mallet. Take care not to damage shaft 210. 11. Clean rolling element bearings 320.1/.2 with a degreasing agent. Check for any damage. 12. If rolling element bearings 320.1/.2 need to be replaced: ð Undo nut 920.1. Vitacast / Vitacast Bloc 56 of 80...
▷ 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...
320.1. 3. Slide rolling element bearing 320.2 onto shaft 210 from the drive end. To do so, exert gentle pressure on the inner ring of bearing 320.2. Vitacast / Vitacast Bloc 58 of 80...
2. Fit casing cover 161 on shaft 210 and gently slide it into its specified location on drive lantern 341. 3. Slide the primary ring of mechanical seal 433.1, fitted with spacer discs 551, onto shaft 210. Move it into its specified location. Fig. 20: Installing the mechanical seal Vitacast / Vitacast Bloc 59 of 80...
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3. If applicable, fit pipe 710.2 for the flushing connection. 4. Fit casing cover 161 on shaft 210 and gently slide it into its specified location on drive lantern 341. 433.1 Fig. 22: Installing the mechanical seal Vitacast / Vitacast Bloc 60 of 80...
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7 Servicing/Maintenance 7.5.3.5 Seal type Q, operating mode DB (Vitacast) CAUTION The keyway could damage the seal faces and O-rings Damage to the mechanical seal! ▷ Always handle seal faces with utmost care. 901.5 710.2 ü The rolling element bearings have been properly installed.
7 Servicing/Maintenance 7.5.3.6 Seal type Q, operating mode DB (Vitacast-Bloc) CAUTION The keyway could damage the seal faces and O-rings Damage to the mechanical seal! ▷ Always handle seal faces with utmost care. 412.2 ü The rolling element bearings have been properly installed.
3. Fasten motor 801 to bearing housing 350 with hexagon head bolts 901.2. 4. Align the pump horizontally. 5. Fit the flushing connections. Applies to: versions T and H, operating mode BQ; version Q, operating mode DB Vitacast / Vitacast Bloc 64 of 80...
25 % shaft 320.1 + 320.2 Set of rolling element bearings, pump 25 % shaft 320.1 + 320.2 Set of rolling element bearings, bearing 25 % pedestal 412.1 O-ring, casing 150 % Vitacast only Vitacast / Vitacast Bloc 65 of 80...
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30 % Only version Q, operating mode DB and versions T and H, operating mode BQ Only Vitacast 150-125-350 and 200-150-350, seal type T, operating mode BQ Only Vitacast 150-125-350 and 200-150-350, seal type T Motor size 160 and larger...
If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Pump is running, but does not deliver B Insufficient flow rate...
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✘ Rolling element bearings lubricated Replace bearings. Provide correct grease insufficiently. or oil quantity. Observe maintenance intervals. ✘ Water enters pump bearings. Clean the bearings. Fill in new lubricants. Replace joint rings. Vitacast / Vitacast Bloc 68 of 80...
9.1 General assembly drawings with list of components 9.1.1 Vitacast 81-44 81-92 81-92 914.2 412.3 901.2 320.2 940.2 940.1 412.1 903.2 901.1 433.1 914.1 320.1 554.3 901.3 421.1 Fig. 31: General assembly drawing, shaft diameter 28 mm, 43 mm Vitacast / Vitacast Bloc 69 of 80...
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554.3 421.1 Fig. 32: General assembly drawing, shaft diameter 55 mm 931 710.3 Version with inducer Seal type T, Seal type T, operating mode I, operating mode I, shaft diameter: 28 mm, 43 mm shaft diameter: 55 mm Vitacast / Vitacast Bloc 70 of 80...
900.2 81-92 412.3 914.2 182.2 909.1 320.1 909.2 412.1 182.1 920.3 901.2 914.1 920.2 914.4 Fig. 33: General assembly drawing, motor size IEC 71-112 421.1 909.2 920.2 182.2 Fig. 34: General assembly drawing, motor size IEC 132-180 Vitacast / Vitacast Bloc 73 of 80...
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Fig. 35: General assembly drawing, motor size IEC 200 551.1 Version with inducer Seal type T, Seal type H, operating mode I, operating mode I, shaft diameter: 20 mm, 28 mm, shaft diameter: 20 mm, 28 mm, 43 mm 43 mm Vitacast / Vitacast Bloc 74 of 80...
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Joint ring (V-ring) 901.1/.2 Hexagon head bolt 412.1/.2/.3/.4/.6/.7 O-ring 909.1/.2 Adjusting screw 421.1/.2 Lip seal 914.1/.2/.3/.4/.5 Hexagon socket head cap screw Mechanical seal Plug Shaft seal housing 920.1/.2/.3 Seal cover Impeller nut Thrower Vitacast / Vitacast Bloc 75 of 80...
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: Vitacast, Vitacast-Bloc, Vitaprime, Vitastage KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: –...
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 Vitacast / Vitacast Bloc 77 of 80...
Spare part Grease lubrication Ordering spare parts 65 Grease quality 51 Intervals 50 Start-up/commissioning 36 Storage 13, 44 Impeller type 21 Installation Temperature limits 10, 11 Installation on a foundation 26 Transport 12 without foundation 27 Installation at site 25 Intended use 8 Warnings 7 Warranty claims 6 Vitacast / Vitacast Bloc 78 of 80...
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