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 .............................. 8 Personnel qualification and training....................... 9 Consequences and risks caused by non-compliance with this manual ............ 9 Safety awareness .............................. 9 Safety information for the operator/user ....................... 9 Safety information for maintenance, inspection and installation .............. 10...
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Contents 6.1.3 Checking the shaft seal........................ 31 Operating limits.............................. 31 6.2.1 Pressure limits and temperature limits ..................... 32 6.2.2 Rated current and maximum current .................... 33 6.2.3 Fluid handled ............................. 34 Shutdown/storage/preservation ........................ 35 6.3.1 Measures to be taken for shutdown .................... 35 Returning to service ............................ 36 Servicing/Maintenance ........................
Glossary Glossary ATEX The acronym ATEX is the French abbreviation for "Atmosphère explosible" and refers to the two European Union (EU) directives covering the area of explosion protection: ATEX Equipment Directive 2014/34/EU (also referred to as ATEX 95) and ATEX Workplace Directive 1999/92/EC (also referred to as ATEX 137).
The serial number uniquely describes the product and is used as identification in all further business processes. In the event of damage, immediately contact your nearest KSB service facility 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.
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1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product Movitec 7 of 68...
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...
2 Safety ▪ Only use the pump (set) to handle the fluids described in the data sheet or product literature of the pump model. ▪ Never operate the pump (set) without the fluid to be handled. ▪ Observe the minimum flow rate and maximum flow rate indicated in the data sheet or product literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc.).
2 Safety ▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g. explosive, toxic, hot) so as to avoid any danger to persons and the environment. Adhere to all relevant laws. ▪ Eliminate all electrical hazards. (In this respect refer to the applicable national safety regulations and/or regulations issued by the local energy supply companies.) ▪...
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.
3 Transport/Temporary Storage/Disposal Fig. 1: Transporting the pump set Placing down the pump set WARNING Incorrect positioning/placing down Personal injury and damage to property! ▷ Position the pump set vertically with the motor on top. ▷ Use appropriate means to secure the pump set against tilting and tipping over. ▷...
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 At +20 °C Optional: -10 °C to +55 °C Movitec 13 of 68...
4.2.1 Product information as per Regulation No. 1907/2006 (REACH) For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see http:// www.ksb.com/reach. 4.2.2 Product Information as per Regulation No. 547/2012 (for water pumps with a maximum shaft power of 150 kW) implementing "Ecodesign" Directive 2009/125/EC ▪...
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4 Description of the Pump (Set) Position Code Description Stainless steel 1.4301 Stainless steel / grey cast iron 1.4301 / EN-GJL-250 Stainless steel 1.4301 Stainless steel 1.4404 Connection type Oval flange External thread Round flange Round flange Tri-Clamp fitting Victaulic coupling 11-13 Size 15-16...
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EXM IEC - TBH EXM NEMA EXM IEC - Movitec 230 V, single-phase AC motor 0.37/0.55 [kW], without IE classification 230/400 V - IE3 400/690 V - IE3 230/400 V - IE4/IE5 (KSB SuPremE) 400/690 V - IE4/IE5 (KSB SuPremE) PumpMeter Mit PumpMeter Without PumpMeter Design Standard...
Manufacturer's address Motor rating KSB code Type series, design, size, number of stages, number of reduced stages, and generation KSB order number and order item number VdS-approved flow rate VdS-approved head Required motor rating at 15 m NPSH Rated speed Permissible nominal pressure...
Standard: ▪ Vertical installation Optional: ▪ Horizontal installation Drive ▪ Surface-cooled KSB squirrel-cage motor ▪ 3~230/400 V up to 2.2 kW ▪ 3~400/690 V from 3.0 kW ▪ Thermal class F to IEC 34-1 ▪ Efficiency class IE3 to IEC 60034-30 (for three-phase motors ≥ 0.75 kW) ▪ Enclosure IP55 ▪...
4 Description of the Pump (Set) 4.6 Configuration and function Fig. 3: Sectional drawing Suction nozzle Pump shroud Impeller Discharge nozzle Design The pump is designed with a radial fluid inlet (suction nozzle) and a radial outlet (discharge nozzle) arranged on the same axis. The hydraulic system is rigidly connected to the motor by a shaft coupling.
5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Installation in potentially explosive atmospheres Explosion hazard! ▷ Never install the pump in potentially explosive atmospheres. ▷ Observe the information given in the data sheet and on the name plates of the pump system.
5 Installation at Site 5.4 Piping 5.4.1 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from leakage of hot, toxic, corrosive or flammable fluids! ▷ Do not use the pump as an anchorage point for the piping. ▷...
5 Installation at Site 3. If required, install a filter in the piping (see drawing: Filter in the piping). Fig. 4: Filter in the piping Differential pressure gauge Filter NOTE Use a filter with laid-in wire mesh (mesh width 0.5 mm, wire diameter 0.25 mm) of corrosion-resistant material.
5 Installation at Site Forces and moments at the pump nozzles Table 7: Forces and moments at the pump nozzles of Movitec V(S)F Movitec ∑ F ∑ M [mm] [Nm] [Nm] [Nm] [Nm] 3300 -2400 1700 4400 -210 3300 -2400 1700 4400 -210 3300...
5 Installation at Site 5.6 Electrical connection DANGER Incorrect connection Explosion hazard! ▷ The connection point of the cable ends must be located outside hazardous areas or in an area approved for electrical equipment. DANGER Operating a pump set that has not been fully connected Explosion hazard! Damage to the pump set! ▷...
5 Installation at Site CAUTION Pump (set) overload Damage to the machinery! ▷ Protect the motor by a thermal time-lag overload protection device in accordance with IEC 947 and local regulations. (If the pump is used in a fire protection system as the main fire-fighting pump, the pump must not be tripped automatically by motor protection devices!) ▷...
5 Installation at Site 5.6.2 Earthing DANGER Electrostatic charging Explosion hazard! Damage to the pump set! ▷ Connect the PE conductor to the earthing terminal provided. ▷ Provide for potential equalisation between the pump set and the foundation. 5.7 Checking the direction of rotation DANGER Temperature increase resulting from contact between rotating and stationary components...
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5 Installation at Site Fig. 6: Direction of fluid flow and arrow indicating the direction of rotation Direction of rotation of the motor Direction of fluid flow Movitec 28 of 68...
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 installed correctly. ▪ The pump set has been properly connected to the power supply and is equipped with all protection devices.
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6 Commissioning/Start-up/Shutdown Priming in an open or closed circuit with sufficient supply pressure Fig. 7: Pump with open or closed circuit Shut-off element in the suction line B Shut-off element in the discharge line Filler opening 1. Close the shut-off element in suction line A and the shut-off element in discharge line B.
6 Commissioning/Start-up/Shutdown 4. Close filler opening B. 5. Fully open the shut-off element in discharge line A. Venting The pump can be vented via the corresponding connections when it is not in operation. Fig. 9: Vent connections Vent connections 6.1.3 Checking the shaft seal Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
6 Commissioning/Start-up/Shutdown Table 11: Specified operating range Characteristic Operating range Ambient temperature [°C] -20 to 40 Minimum inlet pressure NPSH + 1 m Viscosity [cSt] 1 - 100 Density [kg/m³] 1000 - 2500 Frequency [Hz] 30 - 60 Maximum number of starts per hour See motor data sheet Permissible particle size [mm] 0,005 - 1...
6 Commissioning/Start-up/Shutdown Mechanical seal Type Material Design Min. Max. [bar] Mechanical seal Shaft seal ring [°C] [°C] Q1 A E G G SiC/Ca/EPDM +120 ✘ Q1 A V G G SiC/Ca/FPM +120 ✘ Q1 A X4 G G SiC/Ca/HNBR ✘ +120 RMG12-G606 Q1 B E G G...
6 Commissioning/Start-up/Shutdown 6.2.3 Fluid handled 6.2.3.1 Density of the fluid handled The power input of the pump set will change in proportion to the density of the fluid handled. CAUTION Impermissibly high density of the fluid handled Motor overload! ▷ Observe the information about fluid density in the data sheet. ▷...
6 Commissioning/Start-up/Shutdown The pump set is removed from the piping and stored ü The checks and maintenance operations have been performed. 1. Spray-coat the inside wall of the pump casing with a preservative. 2. Spray the preservative through the inlet and outlet nozzles of the fluid handled. It is advisable to close the fluid inlet and outlet nozzles afterwards (e.g.
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! ▷ Never open an energised pump set. ▷ Always perform maintenance work on pump sets outside potentially explosive atmospheres only.
7 Servicing/Maintenance 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. Never use force when dismantling and reassembling the pump set.
7 Servicing/Maintenance While the pump is in operation, observe and check the following: ▪ The pump must run quietly and free from vibrations at all times. ▪ Check the shaft seal. Visual inspection while rotating the shaft once by hand. ▪...
7 Servicing/Maintenance 7.2.2.1.3 Grease quantity Use 15 grams of grease per bearing. 7.2.2.1.4 Re-lubricating with grease WARNING Work in the immediate vicinity of rotating parts Risk of hand injuries! ▷ Always have this work performed by trained personnel. ▷ Take particular caution when performing this work. CAUTION Contaminated lubricating nipples Contamination of the lubricating grease!
In the event of damage you can always contact our service departments. 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 Servicing/Maintenance 7.4.2 Preparing the pump set DANGER Power supply not disconnected Danger to life! ▷ Disconnect all electrical connections from the power supply and secure against unintentional start-up. 1. De-energise the pump set and secure it against unintentional start-up. 7.4.3 Removing the motor WARNING Motor tipping over...
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7 Servicing/Maintenance 914.01 914.05 554.02 901.02 901.04 554.04 Fig. 12: Removing the motor (example drawing) ü The motor has been de-energised. 1. Undo hexagon socket head cap screws 914.05. 2. Remove coupling guard 681. 3. Undo hexagon socket head cap screws 914.01. 4.
7 Servicing/Maintenance 7.4.4 Removing the retaining bracket (optional) 89-11.03 914.01 920.01 914.05 554.02 901.02 Fig. 13: Removing retaining bracket 89-11.03 ü The motor has been removed. (ð Section 7.4.3, Page 42) 1. Remove retaining bracket 89-11.03 7.4.5 Removing the mechanical seal 7.4.5.1 Fixed mechanical seal 920.03 412.01 Fig. 14: Removing the mechanical seal (example drawing)
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7 Servicing/Maintenance 7.4.5.2 Easy Access mechanical seal 914.03 412.06 Fig. 15: Removing the mechanical seal (example drawing) ü The motor has been removed. (ð Section 7.4.3, Page 42) 1. Loosen hexagon socket head cap screws 914.03. 2. Remove O-ring 412.06. 3. Remove mechanical seal 433 using tool 969. 7.4.5.3 Cartridge mechanical seal 914.03 412.06...
▷ Reassemble the pump (set) in accordance with the general rules of sound engineering practice. ▷ Use original spare parts only. NOTE Use suitable tools for setting the pump shaft. If necessary, contact KSB. Sequence Always reassemble the pump set in accordance with the corresponding general assembly drawing. Sealing elements ▪ O-rings –...
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7 Servicing/Maintenance 7.5.2.1 Fixed mechanical seal 920.03 412.01 Fig. 17: Installing the mechanical seal (example drawing) 1. Insert mechanical seal 433 and O-rings 412.01. 2. Fit the drive lantern. Screw on nuts 920.03 and tighten them crosswise. 3. Adjust mechanical seal 433. (ð Section 7.5.4, Page 50) 7.5.2.2 Easy Access mechanical seal 914.03 412.06...
Risk of crushing hands and feet! ▷ Suspend or support the motor to prevent it from tipping over. NOTE Using a specially designed KSB motor is recommended. The motor must meet the following conditions: ▪ Reinforced bearing at the driven end (absorbing the axial forces) ▪...
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7 Servicing/Maintenance Table 16: Recommended motor bearings at the drive end Motor rating 1-phase 3-phase 50 Hz 50/60 Hz [kW] 2 poles 4 poles 0,25 6202-2Z-C3 0,37 6202-2Z-C3 6203-2Z-C3 6202-2Z-C3 0,55 6202-2Z-C3 6203-2Z-C3 6202-2Z-C3 0,75 6204-2Z-C3 6204-2Z-C3 6202-2Z-C3 6204-2Z-C3 6204-2Z-C3 6205-2Z-C3 6305-2Z-C3 6305-2Z-C3 6205-2Z-C3 6305-2Z-C3...
5. Fit coupling guard 681. 6. Screw in hexagon socket head cap screws 914.05. 7.5.4 Adjusting the mechanical seal, coupling and pump shaft NOTE Use suitable tools for setting the pump shaft. If necessary, contact KSB. Movitec 50 of 68...
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7 Servicing/Maintenance NOTE Motors ≥ 11 kW: lock rotor before adjusting the coupling. This will prevent the rotor from being lifted out of the bearings. Movitec B – Fixed mechanical seal / Easy Access mechanical seal ü The motor has been mounted on the pump. (ð Section 7.5.3, Page 48) ü...
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7 Servicing/Maintenance 5. Tighten grub screws 904. 6. Raise coupling 862 by 1.5 mm. 7. Tighten hexagon socket head cap screws 914.04. 8. Verify that no clearances remain between the coupling halves, and fasten the coupling in this position. 9. Mount coupling guard 681 and ATEX-compliant external protection device 680, if any.
7 Servicing/Maintenance 3. Mount coupling guard 681. 4. Apply thread-locking agent (e.g. Loctite 2400) to hexagon socket head cap screws 914.05. 7.6 Tightening torques Table 17: Tightening torques [Nm] Part No. Designation Thread [Nm] Flanged motor 903.01 Screw plug G 3/8 903.02 Screw plug G 1/4 914.01...
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7 Servicing/Maintenance Also specify the following data: ▪ Part number and description (ð Section 9.1, Page 57) ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight) Movitec 54 of 68...
▷ For any work performed to remedy faults, observe the relevant information given in this instruction manual and/or in the product literature provided by the accessories manufacturer. If problems occur that are not described in the following table, consultation with the KSB service is required. Table 18: Trouble-shooting Problem Possible cause...
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8 Trouble-shooting Problem Possible cause Remedy Insufficient delivery and/or Valves in suction and discharge lines ▪ Open the shut-off elements. insufficient pressure closed Air in the pump ▪ Vent the pump. Insufficient inlet pressure ▪ Increase inlet pressure. Wrong direction of rotation ▪...
10 EU Declaration of Conformity 10 EU Declaration of Conformity Manufacturer: KSB B.V. Kalkovenweg 13 2401 LJ Alphen aan den Rijn (The Netherlands) This EU Declaration of Conformity is issued under the sole responsibility of the manufacturer. The manufacturer herewith declares that the product:...
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