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Summary of Contents for KSB KNCPP
- Page 1 Stock pump in back pull-out design KNCPP 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 Limited, Pune, India 2023-01-20...
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Page 3: Table Of Contents
Permissible forces and moments at the pump nozzles: Material variant cast iron .... 25 5.4.2.2 Permissible forces and moments at the pump nozzles: Material variant steel ..... 26 5.4.3 Auxiliary connections........................ 27 Enclosure/insulation ............................ 28 Checking the coupling alignment ......................... 28 KNCPP 3 of 72... - Page 4 Replacing the gland packing ......................... 60 Mounting the motor ............................. 61 Spare parts stock............................. 61 7.8.1 Ordering spare parts ......................... 61 7.8.2 Recommended spare parts stock for 2 years' operation to DIN 24296.......... 62 7.8.3 Interchangeability of pump components .................. 62 KNCPP 4 of 72...
- Page 5 Contents Trouble-shooting.......................... 64 Related Documents .......................... 66 General assembly drawing with list of components .................. 66 EU Declaration of Conformity ...................... 68 Index .............................. 69 KNCPP 5 of 72...
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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 KNCPP 6 of 72... -
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: 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. KNCPP 8 of 72... -
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. KNCPP 9 of 72... -
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. KNCPP 10 of 72... -
Page 11: Unauthorised Modes Of Operation
They include only a general safety margin for the mechanical seal. For single mechanical seals, the safety margin required for specific operating conditions and mechanical seal designs may be substantially higher. If operating conditions differ KNCPP 11 of 72... -
Page 12: 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. 2.9.3 Monitoring equipment The pump (set) must only be operated within the limits specified in the data sheet and on the name plate. -
Page 13: 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 14: Storage/Preservation
4. Always complete and enclose a certificate of decontamination when returning the pump. Indicate any safety measures and decontamination measures taken. NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination KNCPP 14 of 72... -
Page 15: 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. KNCPP 15 of 72... -
Page 16: Description Of The Pump (Set)
Material of wetted components Mechanical seal Bearing bracket Serial number of the casing cover in the bearing bracket 15-20 Nominal discharge nozzle diameter [mm] 4.4 Name plate KNCPP C 42-200 S.No. 9974xxxx62/100 1250 m³/h 1/min 1480 IN 03520 D B 52x74 Fig. 5: Name plate (example) -
Page 17: Design Details
Table 8: Codes of angular contact ball bearings and cylindrical roller bearings Bearing bracket Bearing size Pump end Motor end NUP 307 7308 BECBP NUP 309 7310 BECBP NUP 311 7312 BECBP NUP 313 7314 BECBP NUP 317 7318 BECBP KNCPP 17 of 72... -
Page 18: Configuration And Function
(9 and 10) which are supported by a bearing bracket (5) linked with the pump casing and/or casing cover. Sealing The pump is sealed by a shaft seal (standardised mechanical seal or gland packing). KNCPP 18 of 72... -
Page 19: 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 KNCPP 19 of 72... -
Page 20: Dimensions And Weights
4 Description of the Pump (Set) 4.9 Dimensions and weights For dimensions and weights refer to the general arrangement drawing/outline drawing of the pump/pump set. KNCPP 20 of 72... -
Page 21: Installation At Site
5.3 Installing the pump set Always install the pump set in a horizontal position. DANGER Excessive temperatures due to improper installation Explosion hazard! ▷ Install the pump in a horizontal position to ensure self-venting of the pump. KNCPP 21 of 72... -
Page 22: Installation On A Foundation
Perform secondary treatment of the concrete to DIN 1045. 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. KNCPP 22 of 72... -
Page 23: Installation Without Foundation (European Version)
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. KNCPP 23 of 72... - Page 24 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. KNCPP 24 of 72...
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Page 25: Permissible Forces And Moments At The Pump Nozzles
1780 1260 1460 2620 41-200 2100 1890 2345 3658 1138 805 3340 2980 2700 5220 1780 1260 1460 2620 Based on an operating temperature of 180 °C. See DIN EN ISO 5199 (pages 32, 35, 36, 37, 40). KNCPP 25 of 72... -
Page 26: Permissible Forces And Moments At The Pump Nozzles: Material Variant Steel
10814 31-125 125 2485 2240 2765 4340 1470 1050 1330 150 3500 3150 2835 5495 1750 1225 1435 2555 Based on an operating temperature of 180 °C. See DIN EN ISO 5199 (pages 32, 35, 36, 37, 40). KNCPP 26 of 72... -
Page 27: Auxiliary Connections
Risk of burns! Malfunction of the pump! ▷ Refer to the general arrangement drawing, the piping layout and pump markings (if any) for the quantity, dimensions and locations of auxiliary connections. ▷ Use the auxiliary connections provided. KNCPP 27 of 72... -
Page 28: Enclosure/Insulation
Damage to pump, motor and coupling! ▷ 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. KNCPP 28 of 72... -
Page 29: Aligning The Pump And Motor
5. If alignment is correct, re-install the coupling guard and its footboard, if any. 5.7 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). KNCPP 29 of 72... -
Page 30: 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 31: 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 32: Setting The Time Relay
(looking at the motor shaft stub). The pump's direction of rotation is indicated by an arrow on the pump. 1. Match the motor's direction of rotation to that of the pump. 2. Observe the manufacturer's product literature supplied with the motor. KNCPP 32 of 72... -
Page 33: Earthing
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 switchgear, if any. KNCPP 33 of 72... -
Page 34: Commissioning/Start-Up/Shutdown
CAUTION 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. KNCPP 34 of 72... -
Page 35: Shaft Seal
Double mechanical seal Prior to starting up the pump, apply barrier pressure as specified in the general arrangement drawing. External liquid feed Apply the quantities and pressures specified in the data sheet and the general arrangement drawing. KNCPP 35 of 72... -
Page 36: Priming And Venting The Pump
Check that coupling/shaft can be easily rotated by hand. 4. Fit the coupling guard and its footboard, if any. 5. Check the distance between coupling and coupling guard. The coupling guard must not touch the coupling. KNCPP 36 of 72... -
Page 37: Start-Up
▷ 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. 3. Start up the motor. KNCPP 37 of 72... -
Page 38: Checking The Shaft Seal
The leakage can be reduced. 1. Tighten the nuts on the gland follower by 1/6 turn. 2. Monitor the leakage for another five minutes. Excessive leakage: Repeat steps 1 and 2 until the minimum value has been reached. KNCPP 38 of 72... -
Page 39: Shutdown
Only turn off the cooling liquid supply after the pump has cooled down. 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. KNCPP 39 of 72... -
Page 40: Operating Limits
The frequency of starts depends on the power reserves of the motor in steady-state operation and on the starting conditions (DOL starting, star-delta For compliance with 2014/34/EU (ATEX Equipment Directive). Higher ambient temperature possible in individual cases, see data sheet and name plate. KNCPP 40 of 72... -
Page 41: Fluid Handled
Pump efficiency at duty point Temperature difference 6.2.3.2 Density of the fluid handled The power input of the pump set will change in proportion to the density of the fluid handled. Minimum flow rate Best efficiency point Maximum flow rate KNCPP 41 of 72... -
Page 42: Shutdown/Storage/Preservation
▷ 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. KNCPP 42 of 72... -
Page 43: Servicing/Maintenance
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent tilting or tipping over. A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pump, pump set and pump parts with a minimum of servicing/maintenance expenditure and work. KNCPP 43 of 72... -
Page 44: Servicing/Inspection
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 refer to the enclosed "Addresses" booklet or visit "https://www.ksb.com/en-global/contact" on the Internet. Never use force when dismantling and reassembling the pump set. - Page 45 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). KNCPP 45 of 72...
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Page 46: Inspection Work
7.2.3 Lubrication and lubricant change of rolling element bearings DANGER Excessive temperatures as a result of bearings running hot or defective bearing seals Explosion hazard! Fire hazard! Damage to the pump set! ▷ Regularly check the condition of the lubricant. KNCPP 46 of 72... -
Page 47: Oil Lubrication
▷ When draining the lubricant take appropriate measures to protect persons and the environment. ▷ 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. KNCPP 47 of 72... -
Page 48: Grease Lubrication
▪ LITHON 2 made by HP ▪ Bharat M.P. Grease 3 made by BP ▪ LITHON 3 Bharat Lanthex EP made by HP If the surface temperature of the bearing bracket rises by 15 °C, the re-lubrication interval has to be halved. KNCPP 48 of 72... -
Page 49: Drainage/Cleaning
Use connection 6B to drain the fluid handled (see drawing of auxiliary connections). 7.4 Dismantling the pump set 7.4.1 General information/Safety regulations WARNING Unqualified personnel performing work on the pump (set) Risk of injury! ▷ Always have repair work and maintenance work performed by specially trained, qualified personnel. KNCPP 49 of 72... -
Page 50: Preparing The Pump Set
▷ Suspend or support the motor to prevent it from tipping over. 1. Disconnect the motor from the power supply. 2. Unbolt the motor from the baseplate. 3. Shift the motor to separate it from the pump. KNCPP 50 of 72... -
Page 51: Removing The Back Pull-Out Unit
3. Hold the coupling in place to prevent rotation of shaft 210. 4. Take the impeller off the shaft. To do so, undo the impeller screw and rotate the impeller anti-clockwise. To prevent any damage to the impeller vanes, never use metal rods or similar tools. KNCPP 51 of 72... -
Page 52: Removing The Bearing Unit
1. Firmly clamp the bearing unit with bearing bracket 330 to the workbench with a vice. 2. Pull off coupling half 840 using a puller. Fig. 19: Pulling off the coupling half using a puller 3. Undo hexagon head bolts 901.4. Remove the bearing cover. KNCPP 52 of 72... - Page 53 6. Remove bearings 320.1/.2 from the shaft with a puller or with a hammer and punch. 7. Always remove bearings that have been removed from the shaft by new bearings. Fig. 21: Removing the bearing nut and lock washer KNCPP 53 of 72...
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Page 54: Reassembling The Pump Set
1. Check the centre offset of shaft 210 and shaft protecting sleeve 524. The maximum permissible centre offset is 0.05 mm. 2. Clamp the shaft with the impeller end facing up to the workbench using a vice. To prevent any damage place soft cloths between the vice jaws. KNCPP 54 of 72... - Page 55 5. Fit lock washer 931 on the shaft. 6. Tighten bearing nut 923 with a suitable C-wrench, which moves the rolling element bearings firmly against the shaft shoulder. 7. Bend the lock washer teeth into the bearing nut grooves. KNCPP 55 of 72...
- Page 56 Fasten the bearing cover to the bearing bracket with hexagon head bolts 901.4. Tighten the bolts. 14. Carefully position deflector 507 on the shaft with the tools shown in the illustration. Prior to the installation, grease the rubber lip. KNCPP 56 of 72...
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Page 57: Fitting The Back Pull-Out Unit
3. Fit O-ring 412.4 between impeller 230 and the shaft protecting sleeve. 4. Fasten casing cover 161 to the bearing bracket lantern with hexagon head bolts 901.2. 5. Hold the coupling in place to prevent the shaft from rotating. Mount impeller 230. KNCPP 57 of 72... - Page 58 8. Fasten the support foot of the bearing unit with hexagon head bolts. 9. Heat the coupling flange up to approximately 100 °C. Guide it onto the shaft until its face aligns with the shaft end. Table 23: Tightening torques Bearing unit Bolt size Tightening torque [Nm] Minimum Nominal value KNCPP 58 of 72...
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Page 59: Installing The Back Pull-Out Unit
4. Insert shims underneath the support foot for height compensation if necessary. Do not compensate the height difference by tightening. 5. Fasten support foot 183 to baseplate 890 with hexagon head bolts 901.8. 6. Lubricate the bearing unit with oil or grease. KNCPP 59 of 72... -
Page 60: Replacing The Gland Packing
11. Also insert the last two rings with their joints offset by 180° to each other. Once all packing rings and lantern ring 458 have been inserted, tighten the nuts of stuffing box housing 452 by hand. Observe the steps on commissioning gland packing 461 (ð Section 6.1.7, Page 38) . KNCPP 60 of 72... -
Page 61: Mounting The Motor
Refer to the name plate for all data. Also specify the following data: ▪ Part No. and description ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight) KNCPP 61 of 72... -
Page 62: Recommended Spare Parts Stock For 2 Years' Operation To Din 24296
Volute casing 10 11 12 13 14 15 16 17 Wear plate 10 11 12 13 14 15 16 17 Casing cover Support foot Shaft Impeller 10 11 12 13 14 15 16 17 Rolling element bearing KNCPP 62 of 72... - Page 63 16 16 21 21 21 22 17 18 18 18 18 18 23 20 24 24 25 412.5 O-ring (impeller) Labyrinth ring Gland follower Neck bush Lantern ring Gland packing Thrower Shaft protecting sleeve Adjusting screw Lock washer KNCPP 63 of 72...
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Page 64: 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 65 In the case of persistent overloading, turn down impeller. ✘ - Density or viscosity of fluid handled Contact KSB. higher than stated in purchase order - Gland follower over-tightened or cocked Correct. ✘ ✘ ✘ ✘...
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Page 66: Related Documents
9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components Fig. 32: General assembly drawing of standard version (oil-lubricated) KNCPP 66 of 72... - Page 67 Gland follower Neck bush Lantern ring Gland packing Thrower Shaft protecting sleeve Constant level oiler 901.1/.2/.3/.4/.5/.6/.7/.8/.9 Hexagon head bolt Stud 903.1 Screw plug Adjusting screw Vent plug Hexagon socket head cap screw 920.1/.2 Hexagon nut Lock washer KNCPP 67 of 72...
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Page 68: Eu Declaration Of Conformity
Pune - 411018 (India) The manufacturer herewith declares that the product: KNCPP KSB order number: ....................▪ is in conformity with the provisions of the following directives / regulations as amended from time to time: – Pump (set): 2006/42/EC Machinery Directive The manufacturer also declares that ▪... -
Page 69: Index
Shaft seal 17 Shutdown 39, 42 General assembly drawing 66 Spare part Gland packing 38 Ordering spare parts 61 Spare parts stock 62 Special accessories 19 Impeller type 17 Start-up 37 Installation Storage 14, 42 Installation on a foundation 22 without foundation 23 Installation at site 21 Intended use 9 KNCPP 69 of 72... - Page 70 Index Temperature limits 11 Transport 13 Warnings 8 Warranty claims 7 KNCPP 70 of 72...
- Page 72 KSB Limited Mumbai - Pune Road, Pimpri Pune 411018 (India) Tel : +91 020 2710 1000 Fax : +91 020 2742 6000 www.ksbindia.co.in...
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