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Summary of Contents for KSB Movitec
- Page 1 High-pressure In-line Pump Movitec 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 Aktiengesellschaft, Frankenthal 24.11.2015...
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Page 3: Table Of Contents
Configuration and function .........................18 Noise characteristics .............................18 Scope of supply .............................18 Dimensions and weights ..........................18 Installation at Site ........................19 Safety regulations ............................19 Checks to be carried out prior to installation .....................19 Installing the pump set ..........................19 Piping ................................20 Movitec 3 of 62... - Page 4 Spare parts stock ............................48 Trouble-shooting ........................49 Related Documents ........................51 General assembly drawings/exploded views with list of components ............51 Wiring diagram .............................57 EC Declaration of Conformity ....................58 Certificate of Decontamination ....................59 Index ............................60 Movitec 4 of 62...
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Page 5: Glossary
Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Noise characteristics The noise emission to be expected, indicated as sound pressure level LpA in dB(A) Movitec 5 of 62... -
Page 6: General
The serial/series number uniquely identify the system and serve as identification in all further business processes. In the event of damage, immediately contact your nearest KSB service centre to maintain the right to claim under warranty. Noise characteristics: (⇨ Section 4.7 Page 18) 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 Movitec 7 of 62...
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Page 8: Safety
▪ Never operate the pump without the fluid to be handled. ▪ Observe the minimum flow rates indicated in the data sheet or product literature (to prevent overheating, bearing damage, etc). Movitec 8 of 62... -
Page 9: Personnel Qualification And Training
▪ The operator shall fit contact guards for hot, cold and moving parts and check that the guards function properly. ▪ Do not remove any contact guards during operation. ▪ Provide the personnel with protective equipment and make sure it is used. Movitec 9 of 62... -
Page 10: Safety Information For Maintenance, Inspection And Installation
Never operate the pump (set) outside the limits stated in the data sheet and in this manual. The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use. (⇨ Section 2.3 Page 8) Movitec 10 of 62... -
Page 11: Transport/Temporary Storage/Disposal
On transfer of goods, check each packaging unit for damage. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) and the insurer about the damage in writing immediately. -
Page 12: Storage/Preservation
▪ Fill some antifreeze (e.g. glycol) into the pump to protect it from frost/freezing. ▪ Manually rotate the shaft once every three months as well as shortly before start- ▪ Spray the inside of the mechanical seal chamber with a preservative to prevent seizure of the mechanical seal. Movitec 12 of 62... -
Page 13: Disposal
(set). Always indicate any safety and decontamination measures taken. (⇨ Section 11 Page 59) NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination At +20 °C Movitec 13 of 62... -
Page 14: Description Of The Pump (Set)
▪ Information on dismantling, recycling and disposal after decommissioning: (⇨ Section 3.4 Page 13) ▪ Information on benchmark efficiency or benchmark efficiency graph for MEI = 0.70 (0.40) for the pump based on the model shown in the Figure are available at: http://www.europump.org/efficiencycharts Movitec 14 of 62... -
Page 15: Designation
4 Description of the Pump (Set) 4.3 Designation Example: Movitec VCF 90/2-1 B Table 5: Designation key Code Description Movitec Type series Version Pump casing made of stainless steel Hydraulic system of the pump made of stainless steel Pump casing made of stainless steel / grey cast iron... -
Page 16: Name Plate
4 Description of the Pump (Set) 4.4 Name plate NOTE If pumps with VdS certification are supplied, the details on the Movitec – VdS design name plate must be observed. Movitec VCF 90/2-1 B KSB B.V. Frame 160 (12,2kW) 50 Hz 9972040368 Seal. -
Page 17: Design Details
▪ "Fixed" design – Mechanical seal in standard design – Unbalanced bellows-type seal – ≤ 25 bar – Fitted as standard for Movitec 2B, 4B, 6B, 10B, 15B ▪ "Easy access" design – Easy to replace – Unbalanced bellows-type seal –... -
Page 18: Configuration And Function
Depending on the model, the following items are included in the scope of supply: ▪ Pump ▪ Electric motor 4.9 Dimensions and weights For dimensions and weights refer to the general arrangement drawing/outline drawing or data sheet of the pump set. Movitec 18 of 62... -
Page 19: Installation At Site
Make sure that sufficient air can reach the fan opening of the motor. (The clearance above the fan opening must measure at least of the diameter of the fan cover air intake.) Place a spirit level on the discharge nozzle to align the pump set. Movitec 19 of 62... -
Page 20: Piping
Welding beads, scale and other impurities in the piping Damage to the pump! ▷ Remove any impurities from the piping. ▷ If necessary, install a filter. If required, install a filter in the piping (see figure: Filter in the piping). Movitec 20 of 62... - Page 21 Horizontal, at a right angle to the pump axis Direction of moments Around the horizontal axis, parallel to the pump axis Around the vertical nozzle axis Around the horizontal axis, at a right angle to the pump axis Movitec 21 of 62...
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Page 22: Fitting A Bypass
5 Installation at Site Forces and moments at the pump nozzles Table 6: Forces and moments at the pump nozzles of Movitec V(S)F ∑ F ∑ M Movitec [mm] [Nm] [Nm] [Nm] [Nm] V(S)F 2B 3300 -2400 1700 4400 -210... - Page 23 The pump set is supplied with power cables as standard. Always use all cables provided and connect all marked cores of the control cable. Movitec B The permissible rated current of the motor supplied is shown on the motor name plate.
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Page 24: Checking The Direction Of Rotation
This current value can also be used to select appropriate electrical equipment such as frequency inverter, master switch, conductor diameter, etc. Movitec A The permissible rated current of the motor supplied is indicated on the motor name plate as I This maximum permissible current indicates the motor's maximum operating range and can be used for setting the overload protection device. - Page 25 If the motor is running in the wrong direction of rotation, check the electrical connection of the motor and the control system, if applicable. Fig. 6: Direction of fluid flow and arrow indicating the direction of rotation Direction of rotation of the motor Direction of fluid flow Movitec 25 of 62...
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Page 26: Commissioning/Start-Up/Shutdown
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. Movitec 26 of 62... - Page 27 Remove the plug of filler opening B from the upper pump bracket. Close the shut-off valve in discharge line A. Fill fluid into the pump casing through filler opening B until the fluid reaches the maximum fill level. Movitec 27 of 62...
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Page 28: Operating Limits
▷ If the temperature difference between the pump and the fluid handled exceeds 30 °C, prime/heat up the pump slowly to avoid any risk of thermal shock. The operating range depends on the application as well as on the combination of pressure and temperature. Movitec 28 of 62... - Page 29 Maximum number of start-ups per hour Permissible particle size [mm] 0,005 - 1 Forced cooling Cooling 6.2.1 Minimum/maximum flow rate Table 10: Minimum/maximum flow rate (Q) at a fluid temperature ≤ 20 °C Movitec Q [m³/h] 50 Hz 60 Hz 2-pole 4-pole 2-pole 4-pole min.
- Page 30 6 Commissioning/Start-up/Shutdown 6.2.2 Pressure and temperature limits 6.2.2.1 Movitec A, B Movitec A Table 11: Pressure and temperature limits Movitec [bar] [°C] LHS6 Movitec B The pump's pressure and temperature limits are indicated on the name plate. (⇨ Section 4.4 Page 16) 6.2.2.2...
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Page 31: Shutdown/Storage/Preservation
6 Commissioning/Start-up/Shutdown 6.2.3 Rated/maximum current Movitec B The permissible rated current of the motor supplied is shown on the motor name plate. It describes the permissible operating range of the motor and can be used for setting the overload protection device. If the actual power input is measured during operation, the motor protection switch can be pre-set to a lower value to protect the pump set. - Page 32 Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant and protective devices. NOTE If the pump has been out of service for more than one year, replace all elastomer seals. Movitec 32 of 62...
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Page 33: Servicing/Maintenance
NOTE All maintenance, service 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. -
Page 34: Servicing/Inspection
No leakage from the seals is allowed. ▪ Check the rolling element bearings for running noises. Vibrations, noise and an increase in current input occurring during unchanged operating conditions indicate wear. ▪ Monitor the correct functioning of any auxiliary connections. Movitec 34 of 62... - Page 35 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. Movitec 35 of 62...
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Page 36: Drainage/Cleaning
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 and maintenance work performed by specially trained, qualified personnel. Movitec 36 of 62... - Page 37 In the event of damage, you can always contact our service department. NOTE All maintenance, service 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.
- Page 38 Unscrew and remove hexagon head bolts 901.02 or 901.04 and washer 554.02 or 554.04. Lift the motor off the pump. 7.4.4 Removing the retaining bracket (optional) ✓ The motor has been removed. (⇨ Section 7.4.3 Page 38) Remove retaining bracket 89-11.03 Movitec 38 of 62...
- Page 39 Fixed seal 920.03 412.01 Fig. 14: Removing the mechanical seal ✓ The motor has been removed. (⇨ Section 7.4.3 Page 38) Undo nuts 920.03 and lift off the drive lantern. Remove mechanical seal 433 and O-rings 412.01. Movitec 39 of 62...
- Page 40 7.4.5.3 Cartridge seal 914.03 412.06 Fig. 16: Removing the mechanical seal ✓ The motor has been removed. (⇨ Section 7.4.3 Page 38) Undo hexagon socket head cap screws 914.03. Remove mechanical seal 433. Remove O-ring 412.06. Movitec 40 of 62...
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Page 41: Reassembling The Pump Set
▷ 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! Consult KSB if necessary. Sequence Always reassemble the pump set in accordance with the corresponding general assembly drawing. ▪ O-rings Sealing elements –... - Page 42 Adjust mechanical seal 433. 7.5.2.2 Easy access seal 914.03 412.06 Fig. 18: Fitting the mechanical seal Insert the mechanical seal 433 using tool 969. Insert O-ring 412.06. Screw in hexagon socket head cap screws 914.03. Adjust mechanical seal 433. Movitec 42 of 62...
- Page 43 Risk of crushing hands and feet! ▷ Suspend or support the motor to prevent it from tipping over. NOTE It is recommended to use a specially designed KSB motor. The motor must meet the following conditions: ▪ Reinforced bearing at the driven end (absorbing the axial forces) ▪...
- Page 44 37,0 7312-BEP 45,0 7313-BEP 914.01 554.02 914.05 901.02 901.04 554.04 Fig. 20: Mounting the motor ✓ Retaining bracket 89-11.03 (if applicable) has been removed. (⇨ Section 7.4.4 Page 38) Align the motor on the drive lantern. Movitec 44 of 62...
- Page 45 Adjusting the mechanical seal, coupling and pump shaft NOTE Use suitable tools for setting the pump shaft! Consult KSB if necessary. NOTE Motors ≥ 11 kW: lock rotor before adjusting the coupling. This will prevent the rotor from being lifted out of the bearings.
- Page 46 Fixed seal / Easy access seal Cartridge seal Verify that no clearances remain between the coupling halves, and fasten the coupling in this position. Movitec A ✓ The motor has been mounted on the pump. ✓ Coupling 862 has been fastened with pin 560 and screws 914.01.
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Page 47: Tightening Torques
M6 steel head cap screw M8 steel / grey cast iron M8 aluminium 914.02 Hexagon socket head cap screw 914.03 Hexagon socket head cap screw 920.02 920.03 For Movitec 45, 65 and LHS 6 = 10 Nm Movitec 47 of 62... -
Page 48: Spare Parts Stock
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) Movitec 48 of 62... -
Page 49: Trouble-Shooting
▷ For any work to remedy faults observe the relevant information in this manual or in the relevant accessory manufacturer's product literature. If problems occur that are not described in the following table, consultation with the KSB customer service is required. Table 16: Trouble-shooting Fault/malfunction... - Page 50 ▪ Increase diameter of suction line. Diameter of suction line too small ▪ Clean foot valve. Foot valve clogged. ▪ Clean pump. Impeller or diffuser clogged ▪ Replace O-ring with O-ring made of O-ring not resistant to fluid handled suitable material. Movitec 50 of 62...
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Page 51: Related Documents
525.03 525.01 412.03 108.04 525.04 920.02 903.02 412.04 554.03 901.03 Fig. 21: General assembly drawing of Movitec 2B, 4B, 6B Table 17: List of components Part No. Description Part No. Description 10-6 Pump shroud Pump casing Coupling guard Stage casing... - Page 52 525.03 412.03 525.01 108.04 525.01 525.04 920.02 544.03 903.02 901.03 412.04 Fig. 22: General assembly drawing of Movitec 10B, 15B Table 18: List of components Part No. Description Part No. Description 10-6 Pump shroud Washer Pump casing Stage casing Coupling guard...
- Page 53 108.01 525.03 525.02 10-6 108.02 525.01 509.03 525.04 920.02 903.02 412.04 Fig. 23: General assembly drawing of Movitec 25B, 40B, 60B Table 19: List of components Part No. Description Part No. Description 10-6 Pump shroud Washer Pump casing Stage casing...
- Page 54 525.01 230.01 525.02 108.01 525.03 230.01 412.01 525.04 920.02 903.02 412.04 Fig. 24: General assembly drawing of Movitec 90B Table 20: List of components Part No. Description Part No. Description Stage casing Cover Coupling guard Impeller Double-flanged taper Drive lantern...
- Page 55 108.01 525.03 108.02 525.02 108.04 525.01 412.01 920.02 525.04 411.04 920.02 Fig. 25: General assembly drawing of Movitec LHS 6 Table 21: List of components Part No. Description Part No. Description 10-6 Pump shroud Pump casing Coupling guard Stage casing...
- Page 56 81-37 800/801 900.01 412.01 82-5 900.02 400.03 0,37 - 1,1 kW 400.02 81-55 900.03 Fig. 26: Exploded view of Movitec motor Table 22: List of components Part No. Description Part No. Description Gasket Fan impeller Motor Fan hood Flanged motor...
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Page 57: Wiring Diagram
9 Related Documents 9.2 Wiring diagram Fig. 27: Wiring diagram, depending on selected motor Movitec 57 of 62... -
Page 58: Ec Declaration Of Conformity
10 EC Declaration of Conformity 10 EC Declaration of Conformity Manufacturer: KSB B.V. Kalkovenweg 13 2401 LJ Alphen aan den Rijn (The Netherlands) The manufacturer herewith declares that the product: Movitec Serial number: 18/2012 1000000-0001 - 52/2016 9999999-9999 ▪ is in conformity with the provisions of the following Directives as amended from time to time: –... -
Page 59: 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 fields Movitec 59 of 62... -
Page 60: Index
Scope of supply 18 Shaft seal 17 Shutdown 31 Grease lubrication Spare part Grease quality 35 Ordering spare parts 48 Intervals 35 Storage 12, 31 Installation Tightening torques 47 Installation on a foundation 19 Transport 11 Movitec 60 of 62... - Page 62 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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