KSB Magnochem Installation & Operating Manual
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KSB Magnochem Installation & Operating Manual

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Mag-drive Pump
Magnochem
Version with Heat Barrier
Magnochem W
Installation/Operating Manual

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Summary of Contents for KSB Magnochem

  • Page 1 Mag-drive Pump Magnochem Version with Heat Barrier Magnochem W 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 21/03/2022...

  • Page 3: Table Of Contents

    Checks to be carried out prior to installation.................... 25 Installing the pump set .......................... 25 5.3.1 Installation on the foundation...................... 26 5.3.2 Installation without foundation ....................... 27 Piping ................................ 27 5.4.1 Connecting the piping........................ 27 5.4.2 Permissible forces and moments at the pump nozzles.............. 29 5.4.3 Auxiliary connections......................... 31 Enclosure/insulation ............................ 31 Magnochem 3 of 122...
  • Page 4 Mounting the outer rotor on the drive shaft .................. 89 7.5.9 Fitting the bearing bracket with the outer rotor ................ 90 7.5.10 Run-out check ............................ 90 7.5.11 Installing the back pull-out unit ....................... 91 7.5.12 Mounting the motor ......................... 92 Tightening torques............................ 92 Spare parts stock............................. 93 Magnochem 4 of 122...
  • Page 5 For models with ceramic containment shroud only ................... 103 Plain bearings arrangement ........................ 106 Positioning of locking elements and bearing bushes ................ 110 Fitting / removing the shaft seal........................ 112 EU Declaration of Conformity ...................... 117 Certificate of Decontamination...................... 118 Index .............................. 119 Magnochem 5 of 122...

  • Page 6: Glossary

    Pump Machine without drive, additional components or accessories Pump set Complete pump set consisting of pump, drive, additional components and accessories Suction lift line/suction head line The pipeline which is connected to the suction nozzle Magnochem 6 of 122...

  • Page 7: General

    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.

  • Page 8: Symbols

    Warning for persons with pacemaker In conjunction with one of the signal words this symbol indicates a hazard involving magnetic fields and identifies special information for persons with a pacemaker. Magnochem 8 of 122...

  • Page 9: 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. Magnochem 9 of 122...

  • Page 10: 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. Magnochem 10 of 122...

  • Page 11: Unauthorised Modes Of Operation

    The surface temperature at the pump casing corresponds to the temperature of the fluid handled. If the pump is heated, the operator of the system is responsible for observing the specified temperature class. Magnochem 11 of 122...

  • Page 12: Monitoring Equipment

    Any interaction of the fluid handled with the pump materials shall be taken into consideration if necessary. Magnochem 12 of 122...

  • Page 13: Operating Limits

    Accessories available KSB can supply the following equipment on request: ▪ Temperature monitoring, metal containment shroud – Pt100 resistance thermometer –...
  • Page 14 In installed condition the magnetic field is fully shielded so that an assembled pump does not pose a hazard as a result of magnetic fields (even to persons with pacemaker), neither during standstill nor during operation. Magnochem 14 of 122...

  • Page 15: Transport/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 16: Storage/Preservation

    If properly stored indoors, the pump set is protected for a maximum of 12 months. New pumps/pump sets are supplied by our factory duly prepared for storage. For storing a pump (set) which has already been operated, the shutdown measures must be adhered to. (ð Section 6.3.1, Page 52) Magnochem 16 of 122...

  • Page 17: Return To Supplier

    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. Magnochem 17 of 122...

  • Page 18: Description

    Code Description Pump type MACB Magnochem-Bloc MACD Magnochem (long-coupled design) MACW Magnochem (long-coupled design with heat barrier) 5-16 Size, e.g. Nominal suction nozzle diameter [mm] Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Type of impeller Pump casing material Stainless steel 1.4408 / A743CF8M...
  • Page 19 Low-boiling fluids IP-H Low-boiling fluids, heatable IPR- Low-boiling fluids, ring filter IPRH Low-boiling fluids, ring filter, heatable 27-30 IEC motor frame size 090S 090S 100L 100L 112M 112M Number of motor poles Product generation Magnochem Global Pump Magnochem 19 of 122...

  • Page 20: Name Plate

    II 2G Ex h IIC T5-T1 Gb ZN 3823 - 331 Fig. 5: Name plate (example) Type series, size, material, magnetic Customer-specific information coupling size (optional) KSB order and order item number Flow rate Speed Manufacturer's name and address Year of construction Head 4.5 Design details Design ▪...
  • Page 21 Automation Automation options: ▪ PumpDrive ▪ PumpMeter ▪ KSB Guard ▪ Various instrumentation and monitoring devices Pump-end (rolling element bearing 321.01) for PN40 and model with gas-lubricated mechanical seal: 7209B-2RS-TVP Pump-end (rolling element bearing 321.01) for PN40 and model with gas-lubricated mechanical seal: 7209B-JP Pump-end (rolling element bearing 321.01) for PN40 and model with gas-lubricated mechanical seal:...

  • Page 22: Configuration And Function

    (14), and a joint ring (5) between the casing cover (14) and the containment shroud (13). The driving torque is transmitted indirectly from the motor to the pump shaft (12) via the magnetic coupling. The magnetic coupling basically Magnochem 22 of 122...

  • Page 23: Operating Modes

    If pressurised barrier fluid is used, a flow from the magnetic coupling to the main impeller is possible but a return flow back to the magnetic coupling prevented. Magnochem 23 of 122...

  • Page 24: Noise Characteristics

    Surface sound pressure level as per ISO 3744 and DIN EN ISO 20361 ; valid for a pump operating range of Q/ QBEP = 0.8 - 1.1 and non-cavitating operation. If noise levels are to be guaranteed: Add +3 dB for measuring and constructional tolerance. Increase for 60 Hz operation: 3500 rpm +3 dB; 1750 rpm +1 dB; 1160 rpm ±0 dB Magnochem 24 of 122...

  • Page 25: Installation At Site

    ▷ In external circulation (EF) and dead-end configuration (EP) operating modes, vent the rotor space separately via the auxiliary connections at the casing cover. DANGER Improper installation Excessive temperature of oil-lubricated rolling element bearings! ▷ Always install the pump set horizontally and align it. Magnochem 25 of 122...

  • Page 26: Installation On The Foundation

    Perform secondary treatment of the concrete to EN 206. NOTE For low-noise operation contact the manufacturer to check whether the pump set can be installed on anti-vibration mounts. NOTE Expansion joints can be fitted between the pump and the suction line or discharge line. Magnochem 26 of 122...

  • Page 27: Installation Without Foundation

    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. Magnochem 27 of 122...
  • Page 28 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. Magnochem 28 of 122...

  • Page 29: Permissible Forces And Moments At The Pump Nozzles

    100-065-160 2500 1950 1755 3624 1850 1400 1300 1105 1600 2339 1050 100-065-200 2500 1950 1755 3624 1850 1400 1300 1105 1600 2339 1050 100-065-250 2500 1950 1755 3624 1850 1400 1300 1105 1600 2339 1050 Magnochem 29 of 122...
  • Page 30 (1.4408/A743 Gr. CF8M) at 20° C” table. The higher permissible values can be calculated by dividing the indicated values by 0.7. The indicated correction coefficients still have to be taken into account. Magnochem 30 of 122...

  • Page 31: Auxiliary Connections

    ▷ The air flow in the bearing bracket area must not be obstructed by structural measures (e.g. contact guard). ▷ Only electric motors with sufficient air flow axially to the pump must be used. Magnochem 31 of 122...

  • Page 32: Special Measures For Pumping Fluids With Temperatures Exceeding The Temperature Class Of The System

    If measures taken at the site reliably rule out the risk of an explosive atmosphere forming in the space around the containment shroud, inerting is not mandatory. Identifies components where insulation is permitted but does not indicate a specific insulation type or design. Magnochem 32 of 122...

  • Page 33: Inerting The Containment Shroud

    ▷ Always check the coupling after the pump has been installed and connected to the piping. ▷ Also check the coupling of pump sets supplied with pump and motor mounted on the same baseplate. NOTE For fluid temperatures exceeding 200 °C a double Cardan coupling is recommended. Magnochem 33 of 122...
  • Page 34 5 Installation at Site Fig. 13: Non-spacer-type coupling, checking the coupling alignment Straight edge Gauge Fig. 14: Spacer-type coupling, checking the coupling alignment Straight edge Gauge Fig. 15: Double Cardan spacer-type coupling, checking the coupling alignment Straight edge Gauge Magnochem 34 of 122...

  • Page 35: Aligning The Pump And Motor

    5.8 Aligning the pump and motor After having installed the pump set and connected the piping, check the coupling alignment and, if required, re-align the pump set (at the motor). Magnochem 35 of 122...

  • Page 36: Motors With Adjusting Screw

    Risk of injury by rotating shafts! ▷ Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one! ▷ Observe all relevant regulations for selecting a coupling guard.

  • Page 37: Electrical Connection

    Risk of injury by rotating shafts! ▷ Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one! ▷ Observe all relevant regulations for selecting a coupling guard.
  • Page 38 Magnetic coupling selected for ○ ○ ✘ ○ frequency inverter starting Magnetic coupling selected for soft ○ ○ ✘ ✘ starting 1. Check the available mains voltage against the data on the motor name plate. Magnochem 38 of 122...

  • Page 39: Earthing

    Temperature increase 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 set. ▷ Separate the pump from the motor to check the direction of rotation. Magnochem 39 of 122...
  • Page 40 The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. 3. If the motor runs in the wrong direction of rotation, check the electrical connection of the motor and the control system, if applicable. Magnochem 40 of 122...

  • Page 41: Commissioning/Start-Up/Shutdown

    ▷ Regularly check the rolling element bearings for running noises. Fill the bearing bracket with lubricating oil. Oil quality see (ð Section 7.2.3.1.2, Page 61) Oil quantity see (ð Section 7.2.3.1.3, Page 61) Filling the constant level oiler with lubricating oil (oil-lubricated bearings only) ü The constant level oiler has been fitted. Magnochem 41 of 122...
  • Page 42 8. To check the function of the constant level oiler (1), slowly drain some oil via the screw plug (4) until air bubbles can be seen in the oil reservoir. NOTE An excessively high oil level can lead to a temperature rise and to leakage of the fluid handled or oil. Magnochem 42 of 122...

  • Page 43: Priming And Venting The Pump

    Impermissibly high temperatures; dry-running of the plain bearings Damage to plain bearings and magnetic coupling! Explosion hazard! ▷ In dead-end configuration operating mode, vent the rotor space and the heat exchanger separately from the hydraulic system. Magnochem 43 of 122...
  • Page 44 2. Fully open the shut-off element in the suction line. 3. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc.). 4. Check whether the rotor space and the heat exchanger are still completely filled, re-fill if necessary. Magnochem 44 of 122...

  • Page 45: Final Check

    The pump can also be heated, if necessary. The volute casing and the casing cover have heating chambers. The heating chambers can be heated with hot water, steam or thermal oil. The following limits must be observed: ▪ Maximum temperature: 300 °C ▪ Maximum pressure: 20 bar Magnochem 45 of 122...

  • Page 46: Heating Up The Pump (Set) And Keeping It Warm

    Solidifying fluids Take the melting point of the fluid handled into account if the pump is used for handling solidifying fluids. Do not start up the pump set until the pump temperature is higher than the melting point of the fluid handled. Magnochem 46 of 122...

  • Page 47: Start-Up

    ü The shut-off element in the suction line is and remains open. 1. Close the shut-off element in the discharge line. 2. Switch off the motor and make sure the pump set runs down smoothly to a standstill. Magnochem 47 of 122...

  • Page 48: Operating Limits

    (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: Magnochem 48 of 122...

  • Page 49: Frequency Of Starts

    ▪ 6-pole operation: Q = 1,25 × Q -20 °C and 40 °C as per 2014/34/EU; if the ambient temperatures deviate from these specifications, then special variants may be permitted. Consultation with KSB required. Minimum flow rate Best efficiency point Maximum flow rate...

  • Page 50: Leakage Barrier (Optional)

    A shaft seal ring or a gas-lubricated mechanical seal is fitted to seal the drive-end shaft. The shaft seal allows a small amount of leakage as vapour and as liquid. Magnochem 50 of 122...
  • Page 51 Pump not running NOTE For low inlet pressures and low heads, KSB recommends that leakage be monitored by means of a level transmitter (Liquiphant). In the case of higher inlet pressures and heads, containment shroud leakage can also be monitored by means of a pressure gauge.

  • Page 52: Shutdown/Storage/Preservation

    Commercially available preservatives can be used for this purpose. Observe the manufacturer's instructions for application/removal. 6.4 Returning to service For returning the equipment to service observe the sections on commissioning/start- up and the operating limits. (ð Section 6.1, Page 41) (ð Section 6.2, Page 48) Magnochem 52 of 122...
  • Page 53 ▷ As soon as the work is completed, properly re-install and re-activate any safety- relevant devices and protective devices. NOTE If the equipment has been out of service for more than one year, replace all elastomer seals. Magnochem 53 of 122...

  • Page 54: Servicing/Maintenance

    Risk of injury by moving components and shock currents! ▷ Ensure that the pump set cannot be started unintentionally. ▷ Always make sure the electrical connections are disconnected before carrying out work on the pump set. Magnochem 54 of 122...

  • Page 55: Servicing/Inspection

    NOTE All maintenance work, service work and installation work can be carried out by KSB Service or authorised workshops. For contact details refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet.
  • Page 56 Damage to the pump! ▷ Prolonged operation against a closed shut-off element is not permitted (heating up of the fluid). ▷ Observe the temperature limits in the data sheet and in the section on operating limits. (ð Section 6.2, Page 48) Magnochem 56 of 122...
  • Page 57 (model with leakage barrier) 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). Magnochem 57 of 122...

  • Page 58: Inspection Work

    If the clearance is larger than permitted, replace the bearing bushes 545.21, 545.22, thrust bearings 314 or 314.01/.02 and bearing sleeves 529.21, 529.22. NOTE The dimension S1 can be checked by moving the impeller axially with the back pull- out unit removed. UG1450647 D01 Fig. 20: Plain bearing clearances Magnochem 58 of 122...
  • Page 59 Example of functional test To test the correct function of the shaft seal, proceed as follows, for instance: Before starting up the pump, prepare it by fitting an additional connection for the test fluid. Magnochem 59 of 122...
  • Page 60 ▪ As a rule, replace all sealing elements. ▪ Also check all leakage barrier components for corrosion: if corrosion damage is found, replace the bearing bracket lantern, bearing bracket with shaft seal, outer rotor and the rolling element bearings (leakage barrier components ) Magnochem 60 of 122...

  • Page 61: Lubrication And Lubricant Change At Rolling Element Bearings

    Bearing bracket Nominal diameter of Oil quantity [ml] magnetic coupling Bearing bracket Constant level oiler CS40, CS50, CS60 85, 123, 172 CS50, CS60 CS80 172, 235, 265 At least every two years For size 200-200-250: 180 ml Magnochem 61 of 122...
  • Page 62 However, bearing life may be reduced by vibrations, aggressive gases, moisture, etc. 7.2.3.2.2 Grease quality Optimum grease properties for rolling element bearings ▪ High melting point grease ▪ Free of resin and acid ▪ Not liable to crumble ▪ Rust-preventive characteristics Magnochem 62 of 122...

  • Page 63: Drainage/Cleaning

    Utmost care must be taken when highly toxic fluids have been handled. In this case, fluids the complete pump set must be thoroughly flushed through. Always watch out for possible liquid residues even when the pump has been flushed and drained! Magnochem 63 of 122...

  • Page 64: Dismantling The Pump Set

    For any work on the motor, observe the instructions of the motor manufacturer (refer to manufacturer's technical product literature). For dismantling and reassembly observe the exploded views or the general assembly drawing. In case of damage you can always contact KSB Service. Magnochem 64 of 122...

  • Page 65: Preparing The Pump Set

    4. Undo the baseplate fixing bolts at support foot 183 and remove the support foot. 5. Only for versions with clamped casing cover: Fit the casing cover to the bearing bracket lantern with hexagon head bolt 901.31. 6. Undo hexagon nuts 920.01. Magnochem 65 of 122...

  • Page 66: Dismantling The Back Pull-Out Unit

    ü Steps to (ð Section 7.4.1, Page 64) (ð Section 7.4.4, Page 65) have been observed/carried out. 1. Undo hexagon socket head cap screw 901.04. 2. Undo the baseplate fixing bolts at support foot 183 and remove the support foot. 3. Undo hexagon nuts 920.04. Magnochem 66 of 122...
  • Page 67 ▷ Use a suitable guard to protect the containment shroud (see table for manufacturing dimensions of guard). A suitable guard can be manufactured to the following dimensions. Fig. 23: Guard dimensions Table 24: Manufacturing dimensions of the guard Nominal diameter of magnetic coupling [mm] [mm] [mm] [mm] [mm] Magnochem 67 of 122...
  • Page 68 4. Pull sleeve 520 off shaft 210.01. 5. Check the self-locking threaded insert in shaft 210.01 for wear. Replace it if necessary. 6. For models with oil lubrication and without leakage barrier only: Remove joint ring 411.77. Magnochem 68 of 122...
  • Page 69 ü The outer rotor has been removed and is kept in a clean and level, non-magnetic workplace. NOTE The shaft seal lip can only be replaced by KSB. Consultation with KSB is required. 1. Remove keys 940.02 and 940.32. 2. Undo screw 914.01. Pull off shaft seal 430.01 (use the jacking thread if necessary).
  • Page 70 NOTE The shaft seal lip can only be replaced by KSB. Consultation with KSB is required. 1. If the leakage drain is closed, remove screw plug 903.25 and joint ring 411.25. Drain any residual leakage into a suitable container.
  • Page 71 5. Carefully separate containment shroud 82-15 using forcing screws and remove. 6. For models with intermediate piece only: cleanly remove joint ring 411.09 from intermediate piece 132.01. 7. Cleanly remove joint ring 411.08 from casing cover 161. Magnochem 71 of 122...
  • Page 72 10. Place inner rotor assembly (impeller, casing cover, bearing ring carrier, plain bearings, inner rotor) on the face of inner rotor 818.01 and into the guard. Magnochem 72 of 122...
  • Page 73 161. 1. Lift casing cover 161 with bearing ring carrier 391, taper lock ring 515.21, bearing sleeve 529.21, thrust bearing 314 (possibly two-piece bearing), bearing sleeve 529.22 and taper lock ring 515.22 from shaft 210.03. Magnochem 73 of 122...

  • Page 74: Reassembling The Pump Set

    Interference with magnetic data carriers, electronic devices, components and instruments! Uncontrolled magnetic attraction forces between magnet-equipped components, tools or similar! ▷ Keep a safety distance of at least 0.3 m. ▷ Also observe the additional instructions. (ð Section 2.10, Page 13) Magnochem 74 of 122...
  • Page 75 ▪ For gaskets, avoid the use of assembly adhesives if possible. ▪ Should assembly adhesives be required after all, use a commercially available contact adhesive (e.g. "Pattex"). ▪ Only apply adhesive at selected points and in thin layers. Magnochem 75 of 122...

  • Page 76: Fitting The Plain Bearings

    500.61. (ð Section 9.6, Page 110) 2. If necessary, heat up casing cover 161 with locking element 500.61. (ð Table 26) . 3. Press bearing bush 545.21 into casing cover 161. Observe the position of the groove in bearing bush 545.21. (ð Section 9.6, Page 110) Magnochem 76 of 122...
  • Page 77 Fluid temperature Temperature for pressing in [°C] [°C] <180 Room temperature 180-250 >250 CAUTION Dirt particles between conical surfaces of bearing components Damage to the plain bearings! ▷ Thoroughly clean the bearing components prior to reassembly. Magnochem 77 of 122...
  • Page 78 Nominal diameter of magnetic coupling CS40 CS50 CS60 CS80 20. Slide disc spring 950.23 (ð Table 27) onto shaft 210.03. Bearing brackets CS50 and CS60 with nominal magnetic coupling diameters 85 and 123, and bearing bracket CS80 with nominal magnetic coupling diameter Magnochem 78 of 122...

  • Page 79: Fitting The Impeller

    ü It has been checked that the impeller can be easily mounted on the shaft. ü The individual parts have been placed in a clean and level assembly area. ü All dismantled parts have been cleaned and checked for wear. Magnochem 79 of 122...

  • Page 80: Fitting The Containment Shroud

    ü The notes and steps stated in (ð Section 7.5.1, Page 74) to (ð Section 7.5.3, Page 79) have been observed and carried out. ü The individual parts have been placed in a clean and level assembly area. ü All dismantled parts have been cleaned and checked for wear. Magnochem 80 of 122...
  • Page 81 ü Any damaged or worn parts have been replaced by original spare parts. ü The sealing surfaces have been cleaned. ü The inner rotor assembly has been placed on the impeller in a vertical position and secured against tilting. Magnochem 81 of 122...

  • Page 82: Fitting The Bearing Bracket Lantern

    1. For models with leakage barrier only: Insert joint rings 411.11 and 411.15 into bearing bracket lantern 344. 2. Place the containment shroud guard onto containment shroud 82-15. 3. Screw studs 902.15 into casing cover 161. Magnochem 82 of 122...
  • Page 83 Fastening the bearing bracket lantern to the casing cover (model with clamped casing cover)). 4. Mount bearing bracket lantern 344 on casing cover 161 with hexagon head bolts 901.31. Observe the tightening torques. 5. Remove the guard. 6. Fit studs 902.04. Magnochem 83 of 122...

  • Page 84: Fitting The Rolling Element Bearings

    9. For models with leakage barrier only: Proceed with (ð Section 7.5.7, Page 85) 10. For models without leakage barrier only: Slide sleeve 520 onto shaft 210.01. 11. For models without leakage barrier only: Check that the shaft can easily be rotated by hand. Magnochem 84 of 122...

  • Page 85: Fitting The Shaft Seal

    ü The bearing bracket has been placed in a clean and level assembly area. ü The individual parts have been placed in a clean and level assembly area. ü The sealing surfaces have been cleaned. ü Any damaged or worn parts have been replaced by original spare parts. Magnochem 85 of 122...
  • Page 86 7 Servicing/Maintenance NOTE The shaft seal lip can only be replaced by KSB. Consultation with KSB is required. 1. Carefully slide O-ring 412.28 onto shaft 210.01 over the shaft shoulder and fit it in the groove. 2. Lightly wet sleeve 520 at the inside diameter and outside diameter with oil or assembly paste.
  • Page 87 ü Any damaged or worn parts have been replaced by original spare parts. NOTE The shaft seal lip can only be replaced by KSB. Consultation with KSB is required. 1. Carefully slide O-ring 412.28 onto shaft 210.01 over the shaft shoulder and fit it in the groove.
  • Page 88 O-ring 412.55 and the recess of outer rotor 818.02. Make sure that axial contact is established between mating ring 475.54 and the plane surface of the recess. 18. Clean both contact faces. 19. Insert keys 940.32. Magnochem 88 of 122...

  • Page 89: Mounting The Outer Rotor On The Drive Shaft

    4. Insert circlip 932.43 into the groove in outer rotor 818.02. 5. Remove the protective cover. 6. Fit insulation 689, spacer sleeves 525 and cover plate 81-92 in outer rotor 818.02. 7. Tighten screws 914.23. Observe the tightening torques. (ð Section 7.6, Page 92) Magnochem 89 of 122...

  • Page 90: Fitting The Bearing Bracket With The Outer Rotor

    2. Evenly screw back the forcing screws in bearing bracket 330, thus pushing the bearing bracket into lantern 344. 3. Use hexagon nuts 920.04 to fasten bearing bracket 330. 7.5.10 Run-out check After the back pull-out unit has been fitted, check the radial run-out of the pump. Magnochem 90 of 122...

  • Page 91: Installing The Back Pull-Out Unit

    2. Insert studs 902.01 into volute casing 102. 3. Carefully insert gasket 411.10 into volute casing 102. 4. Fit the back pull-out unit into volute casing 102. 5. Tighten nuts 920.01 to the torques given in this manual. Magnochem 91 of 122...

  • Page 92: Mounting The Motor

    Steel 1.4539 G1/2 A Steel 1.4539 914.01 /.02 Hexagon socket head cap 8.8+A2A screw 8.8+A2A 914.03/.28 Hexagon socket head cap 1.7225 screw 1.7225 1.7225 1.7225 914.07 Hexagon socket head cap A4-70 screw 1.4462 1.7709 A4-70 1.4462 1.7709 Magnochem 92 of 122...

  • Page 93: Spare Parts Stock

    Refer to the name plate for all data. Also specify the following data: ▪ Part number and description ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight) Magnochem 93 of 122...

  • Page 94: Recommended Spare Parts Stock For 2 Years' Operation To Din 24296

    For models with gas-lubricated mechanical seal and shaft seal ring as leakage barrier 430.04 Shaft seal ring 150% 433.12 Gas-lubricated mechanical seal 150% Set of sealing elements for gas- 150% lubricated mechanical seal For models with insulation in the outer rotor Insulation Magnochem 94 of 122...

  • Page 95: Trouble-Shooting

    If problems occur that are not described in the following table, consultation with the KSB service is required. A Pump delivers insufficient flow rate B Motor is overloaded...
  • Page 96 Repair necessary. ✘ ✘ - Magnetic coupling out of balance (inner Check balancing. and outer rotor) ✘ Cooling circuit of magnetic coupling Repair necessary. interrupted The fault can also be remedied by changing the impeller diameter. Magnochem 96 of 122...

  • Page 97: Related Documents

    9 Related Documents 9 Related Documents 9.1 General assembly drawing of model with bolted cover Fig. 28: General assembly drawing of model with bolted cover, with intermediate piece Internal circulation, external circulation Low-boiling fluids, dead-end configuration Magnochem 97 of 122...
  • Page 98 9 Related Documents Fig. 29: Fastening of discharge cover on the pump casing on models with bolted cover Magnochem 98 of 122...

  • Page 99: General Assembly Drawing Of Model With Clamped Cover

    9 Related Documents 9.2 General assembly drawing of model with clamped cover Fig. 30: General assembly drawing of model with clamped cover, without intermediate piece Internal circulation, external circulation Low-boiling fluids, dead-end configuration Magnochem 99 of 122...

  • Page 100: Design Variants

    Fig. 31: Fastening of the discharge cover on the pump casing on models with clamped cover 9.3 Design variants UG1452899_D02 Fig. 32: Model with volute casing and ring filter, heating chamber, casing wear ring and impeller wear ring Heating chamber Magnochem 100 of 122...
  • Page 101 9 Related Documents Fig. 33: Model with bearing bracket with grease lubrication and shaft seal ring as leakage barrier Fig. 34: Model with bearing bracket with oil lubrication without shaft seal ring as leakage barrier Magnochem 101 of 122...
  • Page 102 9 Related Documents Fig. 35: Model with bearing bracket with oil lubrication and shaft seal ring as leakage barrier Fig. 36: Model with bearing bracket with oil lubrication and double shaft seal ring as leakage barrier Magnochem 102 of 122...

  • Page 103: For Models With Ceramic Containment Shroud Only

    Comprising Description Volute casing 411.01 /.02 /.03 /.04 Joint ring 502.01 Casing wear ring 902.01 Stud 903.01 /.02 /.03 /.04 Screw plug 920.01 Hexagon nut Casing cover 502.02 502.02 Casing wear ring Not on all models Magnochem 103 of 122...
  • Page 104 Intermediate ring Sleeve 818.01 818.01 Inner rotor 818.02 818.02 Outer rotor 932.43 Circlip 900.08 Special bolt 24)23) 81-92 Cover plate 24)23) Insulation 24)23) Sleeve 24)23) 914.23 Hexagon socket head cap screw 923.43 Circlip For MACW only Magnochem 104 of 122...
  • Page 105 Hexagon socket head cap screw Model with casing cover with ring filter 745.04 745.04 Filter 932.06 932.06 Circlip Model with two shaft seal rings 411.11/.15/.25 411.11/.15/.25 Joint ring 412.08/.28./37/.55 412.08/.28./37/.55 O-ring For ceramic containment shroud only For MACD only Magnochem 105 of 122...

  • Page 106: Plain Bearings Arrangement

    515.11 / 515.12, two-piece Table 36: Overview of plain bearings arrangement Size Bearing Nominal diameter of magnetic coupling [mm] bracket 040-025-160 CS40 040-025-200 CS40 050-032-125 CS40 050-032-125.1 CS40 050-032-160 CS40 Nominal diameter of magnetic coupling as per name plate Magnochem 106 of 122...
  • Page 107 125-080-200.1 CS50 125-080-250 CS50 125-080-315 CS60 125-080-400 CS60 125-100-160 CS50 125-100-200 CS50 125-100-250 CS60 125-100-315 CS60 125-100-400 CS60 150-125-200 CS60 150-125-250 CS60 150-125-315 CS60 150-125-400 CS60 200-150-200 CS60 200-150-250 CS60 200-150-315 CS80 200-150-400 CS80 200-150-500 CS80 Magnochem 107 of 122...
  • Page 108 ▪ Bearing brackets CS50 and CS60 Magnetic coupling 235 Case A22 ▪ Bearing bracket CS80 Magnetic coupling 265 Case A31 ▪ Bearing bracket CS40 Magnetic coupling 85/123 UG1452899 Case B22 ▪ Bearing bracket CS80 Magnetic coupling 172 Magnochem 108 of 122...
  • Page 109 9 Related Documents Description Illustration Case C22 ▪ Bearing bracket CS80 Magnetic coupling 235 Case B21 ▪ Bearing brackets CS50 and CS60 Magnetic couplings 85 and 123 Magnochem 109 of 122...

  • Page 110: Positioning Of Locking Elements And Bearing Bushes

    9.6 Positioning of locking elements and bearing bushes Fig. 39: Positioning of locking elements and bearing bushes on pumps with bearing brackets CS40/CS50/CS60 Marking on casing cover facing upwards Opening of locking element 500.61/.62 Groove in bearing bush 545.21/.22 Axial lubricating groove Magnochem 110 of 122...
  • Page 111 9 Related Documents Fig. 40: Positioning of locking elements and bearing bushes on pumps with bearing bracket CS80 Marking on casing cover facing upwards Opening of locking element 500.61/.62 Groove in bearing bush 545.21/.22 Axial lubricating groove Magnochem 111 of 122...

  • Page 112: Fitting / Removing The Shaft Seal

    9.7 Fitting / removing the shaft seal Fig. 41: Overview of different shaft seal designs Shaft seal ring Double shaft seal ring Gas-lubricated mechanical seal Depending on the individual seal designs, these parts partly differ in characteristics and/or quantity. Magnochem 112 of 122...
  • Page 113 9 Related Documents A / B Fig. 42: Sleeve Shaft seal ring Double shaft seal ring Gas-lubricated mechanical seal Depending on the individual seal designs, these parts partly differ in characteristics and/or quantity. Magnochem 113 of 122...
  • Page 114 9 Related Documents A / C Fig. 43: Shaft seal assembly in the bearing bracket Shaft seal ring Double shaft seal ring Gas-lubricated mechanical seal Depending on the individual seal designs, these parts partly differ in characteristics and/or quantity. Magnochem 114 of 122...
  • Page 115 A1 Shaft seal rings CS40 and CS50/60 A2 Shaft seal rings CS50/60 (magnetic coupling diameter 235) and CS80 Double shaft seal ring Gas-lubricated mechanical seal Depending on the individual seal designs, these parts partly differ in characteristics and/or quantity. Magnochem 115 of 122...
  • Page 116 9 Related Documents A / C Fig. 45: Mating ring Shaft seal ring Gas-lubricated mechanical seal Magnochem 116 of 122...

  • Page 117: 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: Magnochem (MAC), Magnochem-Bloc (MAC-Bloc) KSB order number: ....................▪ is in conformity with the provisions of the following directives / regulations as amended from time to time: –...

  • Page 118: 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 field Magnochem 118 of 122...

  • Page 119: Index

    Oil quality 61 Causes and remedies 95 Oil quantity 61 Filter 28, 59 Operating limits 48 Final check 45 Operating mode Flow rate 49 Dead-end configuration 23 Fluid handled External circulation 23 Density 50 Internal circulation 23 Frequency of starts 49 Low-boiling fluids 23 Function 22 Order number 7 Other applicable documents 7 Magnochem 119 of 122...
  • Page 120 Safety awareness 10 Scope of supply 24 Shaft seal 20 Shutdown 47, 52 Spare part Ordering spare parts 93 Spare parts stock 94 Special accessories 24 Storage 16, 52 Temperature difference 46 Temperature limits 11 Tightening torques 92 Transport 15 Warnings 8 Warranty claims 7 Water cooling 45 Wave spring 84, 85 Magnochem 120 of 122...
  • Page 122 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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