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Summary of Contents for KSB Vitastage Series
- Page 1 Hygienic Pump Vitastage Installation/Operating Manual...
- Page 2 All rights reserved. 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 KSB´s express written consent. Subject to technical modification without prior notice.
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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 .................... - Page 4 Contents Electrical connection ..................19 Checking the direction of rotation .............. 20 Commissioning/Start-up/Shutdown ..........22 Commissioning/start-up ................22 Operating limits .................... 24 Shutdown/storage/preservation ..............27 Returning to service ..................27 Servicing/Maintenance ..............28 Safety regulations ..................28 Maintenance/inspection ................28 Drainage/disposal ..................
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Page 5: Glossary
Glossary Glossary Certificate of decontamination Pump A certificate of decontamination certifies that Machine without drive, additional components the pump (set) has been properly drained to or accessories eliminate any environmental and health hazards arising from components in contact Pump set with the fluid handled. -
Page 6: General
(set) and serve as identification for all further business processes. In the event of damage, contact your nearest KSB service centre immediately to maintain the right to claim under warranty. Noise characteristics (⇨ Section 4.6 Page 15) 1.2 Installation of partly completed machinery... - Page 7 1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product Vitastage 7 of 44...
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Page 8: Safety
2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 2.1 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 9: Personnel Qualification And Training
2 Safety ▪ Only use the pump to handle the fluids described in the data sheet or product literature of the pump model. ▪ Never operate the pump without the fluid handled. ▪ Observe the minimum flow rates indicated in the data sheet or product literature (to prevent overheating, bearing damage, etc). -
Page 10: Safety Information For The Operator/User
2 Safety ▪ Safety regulations for handling hazardous substances ▪ Applicable standards and laws 2.7 Safety information for the operator/user ▪ The operator shall fit contact guards for hot, cold or moving parts and check that the guards function properly. ▪... -
Page 11: Transport/Temporary Storage/Disposal
3 Transport/Temporary Storage/Disposal 3 Transport/Temporary Storage/Disposal 3.1 Transport DANGER The pump (set) could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump (set) in horizontal position. ▷ Never attach the suspension arrangement to the free shaft end or the motor eyebolt. -
Page 12: Return To Supplier
4. Always complete and enclose a certificate of decontamination when returning the pump (set). (⇨ Section 11 Page 42) Always indicate any safety and decontamination measures taken. NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.4 Disposal... -
Page 13: Description Of The Pump (Set)
4 Description of the Pump (Set) 4 Description of the Pump (Set) 4.1 General description ▪ Hygienic pump ▪ Multistage centrifugal pump in ring-section design Pump for handling fluids which are not chemically aggressive, are free from solids and do not require hermetic sealing. Hygienic centrifugal pump for the food and beverage industry and the pharmaceutical industry Table 5: Installation type... -
Page 14: Name Plate
Jahr E-Nr 2010 2900 1/min 15 m 90 m Fig. 1: Vitastage name plate Type series, size and version KSB order number Manufacturer's No. Flow rate Head Speed Year of construction 4.4 Design details ▪ High-pressure centrifugal pump ▪ Horizontal/vertical installation ▪... -
Page 15: Configuration And Function
4 Description of the Pump (Set) 4.5 Configuration and function Fig. 2: Sectional drawing of Vitastage Suction nozzle First impeller Stage casing Diffuser Last impeller Discharge casing Motor Shaft seal Discharge nozzle Pump foot Design The pump is installed in either horizontal or vertical position. It is designed with an axial fluid inlet and a radial fluid outlet. -
Page 16: Scope Of Supply
4 Description of the Pump (Set) Size Motor rating Noise characteristic [kW] [dB] VS 05/4 68-71.9 VS 05/5 72.1-74.1 VS 05/6 73-74.6 VS 05/7 75.2-79.1 VS 05/8 76.5-79.4 VS 10/1 75-78.5 VS 10/2 75.2-79.1 VS 10/3 76-79.2 VS 20/1 78.7-83.1 VS 20/2 79.4-84.3 VS 20/3... -
Page 17: Installation At Site
5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Installation in potentially explosive atmospheres Explosion hazard! ▷ Do not install the pump in potentially explosive atmospheres. ▷ Observe the information given in the data sheet and on the name plates of the pump system. - Page 18 5 Installation at Site ✓ The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump nozzles. ✓ Adapters to larger diameters have a diffuser angle of approx. 8° to prevent excessive pressure losses. ✓...
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Page 19: Protective Equipment
Suitable analysing devices must be selected. To monitor the leakage sensor inside the motor, it is recommended to use a special relay available from KSB. 5.6 Electrical connection DANGER... -
Page 20: Checking The Direction Of Rotation
5 Installation at Site NOTE It is recommended to fit a motor protection device. 5.6.1 Setting the time relay CAUTION Switchover between star and delta on three-phase motors with star-delta starting takes too long Damage to the pump (set)! ▷ Keep switch-over intervals between star and delta as short as possible (see table: Time relay settings for star-delta starting). - Page 21 5 Installation at Site CAUTION Incorrect direction of rotation with non-reversible mechanical seal Damage to the mechanical seal and leakage! ▷ Separate the pump from the motor to check the direction of rotation. CAUTION Motor and pump running in the wrong direction of rotation Damage to the pump! ▷...
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Page 22: 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 electric power supply and is equipped with all protection devices. ▪ The pump has been primed with the fluid to be handled. ▪... - Page 23 6 Commissioning/Start-up/Shutdown CAUTION Abnormal noises, vibrations, temperatures or leakage Damage to the shaft! ▷ Switch off the pump (set) immediately. ▷ Eliminate the causes before returning the pump set to service. ✓ The system piping has been cleaned. ✓ The pump, suction line and inlet tank, if any, have been vented and primed with the fluid to be handled.
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Page 24: Operating Limits
6 Commissioning/Start-up/Shutdown CAUTION Risk of freezing during prolonged pump shutdown periods Damage to the pump! ▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect them against freezing. 6.2 Operating limits DANGER Non-compliance with operating limits for pressure, temperature and speed Hot fluid may escape! ▷... - Page 25 6 Commissioning/Start-up/Shutdown 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. Table 11: Key Symbol Description Unit Specific heat capacity J/kg K Gravitational constant m/s²...
- Page 26 6 Commissioning/Start-up/Shutdown Cleaning agents When cleaning in place the system in which the pump set is installed, make sure to comply with the concentration limits, temperature limits and contact times given below for the cleaning agents and disinfectants: Table 12: Cleaning agents for CIP Cleaning agents Concentration Temperature t...
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Page 27: Shutdown/Storage/Preservation
6 Commissioning/Start-up/Shutdown 6.3 Shutdown/storage/preservation 6.3.1 Measures to be taken for shutdown T h e p u m p ( s e t ) r e m a i n s i n s t a l l e d ✓ Sufficient fluid is supplied for the operation check run of the pump. 1. -
Page 28: Servicing/Maintenance
(set) with a minimum of maintenance expenditure and work. NOTE All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the internet at www.ksb.com/ contact". -
Page 29: Drainage/Disposal
7 Servicing/Maintenance CAUTION Increased wear due to dry running Damage to the pump set! ▷ Never operate the pump set without liquid fill. ▷ Never close the shut-off element in the suction line and/or supply line during pump operation. CAUTION Impermissibly high temperature of fluid handled Damage to the pump! ▷... -
Page 30: Dismantling The Pump Set
For dismantling and reassembly observe the exploded views and the general assembly drawing. NOTE All maintenance, service and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the internet at www.ksb.com/ contact". - Page 31 7 Servicing/Maintenance 2. Depending on the pump/motor size, unscrew the bolts that fix the support foot and/or motor foot to the foundation. 3. Remove the complete pump set from the piping. 7.4.4 Dismantling the pump 7.4.4.1 Sizes 10/1 - 10/3, 20/1 - 20/3, 30/1 - 30/3 The dismantling procedure is the same for all sizes.
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Page 32: Reassembling The Pump Set
7 Servicing/Maintenance 14. Dismantle the motor feet, if necessary: Undo nuts (53) and bolts (52) and remove feet (51). 7.5 Reassembling the pump set 7.5.1 General information/Safety regulations CAUTION Improper reassembly Damage to the pump! ▷ Reassemble the pump (set) in accordance with the general rules of sound engineering practice. -
Page 33: Spare Parts Stock
Always quote the following data when ordering replacement or spare parts: ▪ Type series ▪ Material variant ▪ Size ▪ Seal code ▪ KSB order number ▪ Order item number ▪ Consecutive number ▪ Year of construction Refer to the name plate for all data. - Page 34 7 Servicing/Maintenance 7.6.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 14: Quantity of spare parts for recommended spare parts stock Part No. Description Number of pumps (including stand-by pumps) 6 and 7 8 and 9 10 and more Mechanical seal...
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Page 35: Trouble-Shooting
8 Trouble-shooting 8 Trouble-shooting Pump is running but does not deliver Flow rate insufficient Discharge pressure not reached Pump does not withdraw fluid (pump takes in air) Excessive pump power input Leakage at mechanical seal Mechanical seal life too short Mechanical seal damaged Unusual vibrations and/or noises Motor is overloaded... - Page 36 8 Trouble-shooting G H I Possible cause Remedy Fluid or fluid temperature unsuitable for Select type and material of mechanical seal mechanical seal materials used as required. Pump not cleaned sufficiently after it was Drain fluid immediately after pump used for fluids that tend to crystallise operation and perform several cleaning cycles.
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Page 37: Related Documents
9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components, Vitastage 05/1 - 05/8 - horizontal installation Fig. 4: General assembly drawing of Vitastage 05/1 - 05/8 Table 16: List of components Part No. Quantity Description Material Pump casing AISI 316L... -
Page 38: General Assembly Drawing With List Of Components, Vitastage 05/1
9 Related Documents 9.2 General assembly drawing with list of components, Vitastage 05/1 - 05/8 - vertical installation Fig. 5: General assembly drawing of Vitastage 05/1 - 05/8 Table 17: List of components Part No. Quantity Description Material Pump casing AISI 316L Stage casing AISI 316... -
Page 39: General Assembly Drawing With List Of Components, Vitastage 10/1-3; 20/1-3; 30/1-3 - Horizontal Installation
9 Related Documents 9.3 General assembly drawing with list of components, Vitastage 10/1-3; 20/1-3; 30/1-3 - horizontal installation Fig. 6: General assembly drawing of Vitastage 10/1-3; 20/1-3; 30/1-3 Table 18: List of components Part No. Quantity Description Material Pump casing AISI 316L Impeller AISI 316... -
Page 40: General Assembly Drawing With List Of Components, Vitastage 10/1-3; 20/1-3; 30/1-3 - Vertical Installation
9 Related Documents 9.4 General assembly drawing with list of components, Vitastage 10/1-3; 20/1-3; 30/1-3 - vertical installation Fig. 7: General assembly drawing of Vitastage 10/1-3; 20/1-3; 30/1-3 Table 19: List of components Part No. Quantity Description Material Pump casing AISI 316L Impeller AISI 316... -
Page 41: Ec Declaration Of Conformity
67227 Frankenthal (Germany) The manufacturer herewith declares that the pump (set): Vitacast, Vitacast E, Vitaprime, Vitastage KSB order number: ....................▪ is in conformity with the provisions of the following directives as amended from time to time: – Machinery Directive 2006/42/EC –... -
Page 42: 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 43: Index
Index Index Abrasive fluids 25 Operating limits 8, 24 Order number 6 Ordering spare parts 33 Other applicable documents 6 Certificate of decontamination 42 Cleaning 26 Partly completed machinery 6 Permissible forces at the pump nozzles 18 Piping 17 Designation 13 Preservation 12, 27 Direction of rotation 21 Pump casing 14... - Page 44 KSB Aktiengesellschaft 67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com...
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