Operating Instructions Mega

Centrifugal Pump

Serial No. : ____________________________

Type Series Mega: ______________________

KSB Ajax Pumps Pty Ltd

 Mega

Contents
Page
0 General 3
0.1 Handling 3

1 Installation 3
1.1 Foundation 3
1.2 Mounting 3
1.3 Aligning Pump/Motor 3
1.4 Connecting the Piping 4
1.4.1 Auxiliary Connections 4
1.4.2 Vacuum Balance 4
1.5 Coupling Guard 4
1.6 Final Check 4

2 Startup/Commissioning, Shutdown 4
2.1 Preparations 4
2.1.1 Lubricant 4
2.1.2 Shaft Seal 4
2.1.3 Priming the Pump and Associated Checks 4
2.1.4 Checking the Direction of Rotation 5
2.2 Startup 5
2.3 Shutdown 5

3 Maintenance and Lubrication 5

3.1 Supervision of Operation 5
3.2 Lubrication 5
3.2.1 Grease (supplied as standard) 5
3.2.2 Oil (optional) 5

4 Dismantling and Reassembly 6

4.1 General 6
4.2 Dismantling 6
4.2.1 Mechanical Seal 6
4.3 Deep Groove Ball Bearing/Lubricant Fill 6
4.3.1 Grease Change 6
4.4 Reassembly 6
4.4.1 Pump 6
4.4.2 Shaft Seal 7
4.4.2.1 Stuffing Box Compartment 7
4.4.2.2 Packing Ring Cut to Size 7
4.4.2.3 Gland Leakage 7
4.4.2.4 Flushing Arrangement 8
4.4.2.5 Mechanical Seal 8
4.5 Spare Parts 8
4.5.1 Ordering Spare Parts 8
4.5.2 Exploded View 9
4.5.3 List of Components 10
4.5.4 Recommended List of Spare Parts 10
for 2 years Continuous Operation
4.5.5 Recommended Impeller Nut Torques 10

5 Faults 11/12

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0 General 0.1 Handling

When handling the complete pumpset, attach ropes to
Centrifugal pumps will give trouble-free, satisfactory the pump and motor as shown (not through the motor
service if they are properly installed and maintained. eyebolt) or onto the lifting lugs supplied.

Follow the instructions in this manual carefully. Do not

run the pumps under operating instructions which differ
from those specified by us.

This manual does not take into account any on site

safety regulations which may apply. The nameplate
attached to the pump indicates the type series/size,
identification number, impeller dimension and serial
number. Please always indicate this data in case of
inquiries, supplement orders and especially when or-
dering spare parts.

Fig. 1 Pump and motor and common baseplate

Do not operate this pumpset above the 1 Installation (Installation on site)

limit values for capacity, speed, pressure
and temperature etc. shown on the
nameplate.
1.1 Foundation
Make sure the concrete foundation has set before
mounting the pumpset. The surface of the foundation
must be completely horizontal and perfectly flat.

Ensure that operation is in accordance with 1.2 Mounting

the instructions contained in this manual
(contract documentation). It is essential that
the electrical connection values are as speci-
fied and that the instructions on installation
and maintenance are followed.
Position the pumpset on the foundation and align using
a precision spirit level (on the discharge nozzle).
Always fit shims to left and right of the anchor bolts
near the bolts, between the baseplate/foundation frame
and the foundation. If the shims are more than 800mm
apart, position extra shims equal distant between them.
All shims must be perfectly flush.

Operation of this unit beyond the above condi-

tions may result in excess load and subse-
quent failure. Failure to heed these warnings
can result in personal injury and damage to
equipment.

N.B. Fig. 2 Fitting shims

The instructions and descriptions in this man-
ual refer to the industrial pump model. This
manual does not cover all details or eventuali-
ties which might occur during installation, op-
erating or maintenance. The pump set must
only be handled by skilled, trained personnel.
For any information and instructions not con-
tained in this manual, please contact KSB Ajax
Pumps. The manufacturer accepts no liability
for the pumpset if the instructions in this man-
ual are not complied with.
Uniformly tighten up securing means.
Baseplates have to be grouted with non-shrinking mor-
tar up to the upper edge of the frame after having been
fixed in position.
1.3 Aligning Pump/Motor
The coupling must be checked and the pumpset re-
aligned even if the pump and motor are supplied ready
mounted on a common baseplate.
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1.4 Connecting the Piping

A Main shutoff valve
Never use the pump as anchorage point for the piping.
B Vacuum balance line
C Shutoff valve
Suction lift lines should be run with a rising slope to-
E Vacuum-tight shutoff valve
wards the pump, positive suction lines with a down-
R Non-return flap valve
ward slope towards the pump to avoid the formation of
V Vacuum vessel
air locks.
Z Intermediate flange
The pipes should be supported very near the pump
Fig. 3 Suction line and vacuum balance line
and connected without transmitting any stresses and
strains to it. The pump must not bear the weight of the 1.5 Coupling Guard
piping. Safety regulations specify that the pump must be fitted
with a coupling guard.
The nominal diameters of short pipelines should at
1.6 Final Check
least correspond to those of the pump connections. In
Recheck alignment as described in 1.3.
case of long pipelines, the most economical nominal
diameter is to be determined for the application. It must be possible to rotate the coupling easily by
hand. Check the integrity of all connections.
Adaptors to larger nominal diameters should be de-
signed with an extension angle of approx. 8˚ to avoid 2 Startup/Commissioning, Shutdown
increased pressure losses.
2.1 Preparations
The installation of non-return devices and suction and 2.1.1 Lubricant
discharge valves is recommended according to the Grease lubricated bearings
type of plant and pump. Bearings are already packed with grease.
Standard Grease for life bearings.
Thermal expansion of the pipework should be accom-
modated by suitable means so as not to impose any Oil lubricated bearings (optional)
extra load on the pump. Fill the bearing bracket with IS viscosity grade 68 or
equivalent lubricating oil suitable for rolling element
Before commissioning a new installation, thoroughly bearings.
clean, flush and blow through all vessels, piping and Procedure
connections. Remove vent plug. Pour oil in through the hole left by
vent plug until oil appears in the vertical section of the
Welding beads, scale and other impurities frequently elbow connecting the bearing bracket and the reser-
only become dislodged after a certain period of time; it voir. Fill up the reservoir and place back in position.
is necessary to fit a strainer in the suction line to pre- Replace the vent plug. After a short time check
vent these entering the pump. The total cross-section whether the oil level in the reservoir has dropped. The
of the holes in the strainer should be three times the reservoir must always be kept topped up.
cross-section of the piping in order to avoid excessive
pressure loss across the strainer due to clogging.
Shaft
A* B
Unit
1.4.1 Auxiliary Connections A30 1 28.6
The size and locations of all auxiliary connections for A40 2 35
sealing, flushing and leakage liquid are shown in the A50 0 44.9
general arrangement drawing or piping diagram. A60 0 53

1.4.2 Vacuum Balance
If the pump has to pump from a vessel under vacuum it
is advisable to fit a vacuum balance line. This line
should have a minimum diameter of 25mm and be ar-
ranged to lead into the vessel above the maximum ad-
visable level.
An additional pipeline that can be shut off - a pump
discharge nozzle vacuum balance line - facilitates the
venting of the pump prior to start up.
4
*Tolerance +1,-0.
2.1.2 Shaft Seal
For information on shaft seal please refer to 4.2.1 and
4.4.2.
2.1.3 Priming the Pump and Associated Checks
Vent and prime the pump and suction line before start
up. The shutoff valve in the suction line must be com-
pletely open.
Fully open all auxiliary lines (sealing, flushing liquid)
and check they are functioning properly. Open the
shutoff valve in the vacuum line (if fitted) and close the
vacuum tight shutoff valve ‘E’ (Fig 3).
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2.1.4 Checking the Direction of Rotation
The direction of rotation of the driver must match the
arrow on the pump. Check this by switching the pump
on and immediately switching it off again. Fit the cou-
pling guard.
If the gland is leaking too heavily after a long period of
operation, uniformly tighten the gland nuts up by 1/6 of
a turn, then observe the leakage. If the nuts cannot be
tightened up any further, install a new packing ring. It is
usually not necessary to replace the complete packing.

Pumps with mechanical seals experience minor or in-

2.2 Startup
Start the set up against a closed discharge valve only.
Once the pump has reached full speed slowly open the
valve and set to the duty point.
After the pump has reached its working tempera-
ture and/or if leakage occurs, tighten nuts (920)
with the set disconnected.
visible (vapour) leakage. The seal is maintenance free.
Standby pumps should be started up and run for ten
minutes once a week to keep them operational. Also
check the integrity of the auxiliary connections.
Flexible parts of the coupling which show signs of wear
should be replaced in good time.

2.3 Shutdown 3.2 Lubrication

Close the discharge gate valve.
The discharge gate valve can remain open if the dis-
charge line is fitted with a non return device and pres-
sure is maintained in the discharge pipe.
3.2.1 Grease (supplied as standard)
Mega pumps are fitted as standard with grease lubri-
cated - sealed for life bearings.

Switch off the motor, making sure the pumpset runs Grease Nipple (Option)
down smoothly and evenly to a stand-still. Item 636 - Bearing Cap fitted with Grease Nipple.

If the pumpset is to remain out of service for long peri-

ods, close the shut-off valve in the suction line and
close all auxiliary connections.
On pumps supplied with product under vacuum, there
must be sealant supply to the shaft seal even at stand-
still.
3.2.2 Oil (optional)
The first oil change must be carried out after 300 hours
of operation; all subsequent oil changes after 3000
hours.

If there is a danger of freezing and/or if the pump is to Procedure

be out of service for a long period, then drain the pump
or otherwise protect it against freezing.
Remove the plug below the constant level oiler and
drain off the oil. When the bearing bracket is empty,
replace the drain plug and fill with oil as described in
2.1.1.

3 Maintenance and Lubrication

3.1 Supervision of Operation
The pump must run quietly and evenly at all times.
The pump must never run dry.

The bearing temperature may be 50°C above room

temperature, but must not exceed 90°C (measured at
the outside of the bearing housing).
Do not run the pump for more than three minutes
against a closed discharge valve.

If the pump has gland packing, this must drip during

operation. The gland nuts should only be lightly tight-
ened up.
If a packing ring of pure graphite is used there must
always be leakage.

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4 Dismantling and Reassembly Under no circumstances use force.

4.1 General
Before dismantling, make sure the pump is dis-
connected from the power supply and cannot be
switched on accidentally.
The suction and discharge shutoff valves must be
closed.
The pump casing must have cooled down to ambient
temperature.
The pump casing must be empty and not under pres-
sure.
Dismantle the pump in the sequence shown in the ex-
ploded view diagram.
4.2.1 Mechanical seal
To replace the mechanical seal it is necessary to dis-
mantle the pump.
After removing the impeller 230 draw the mechanical
seal 433 from the shaft by hand.
Before reassembly, touch up any grooves or scratches:
if it is not possible to remove any grooves or indenta-
tions completely, fit a new shaft. Clean the stationary
seal ring seat on the seal holder. Refer 4.4.2.5.

4.3 Deep Groove Ball Bearing/Lubricant Fill

4.2 Dismantling
1 On oil lubricated pumps drain off the oil as de 4.3.1 Grease Change
scribed in 3.2.2. Use a lithium soap based grease, resin and acid free,
2 Detach all auxiliary supply lines. not liable to crumble, with good rust preventative prop-
3 Remove coupling guard. erties. It should have a penetration number between 2
and 3, corresponding to a worked penetration between
4 For coupling without spacer: 220 and 295mm/10. Its drop point must be above 175°
4.1 Dismantling of complete pump. C. The hollow spaces around the bearings must not be
4.1.2 Remove discharge and suction branch from more than half packed with grease. For example: Shell
pipeline. Alvania R2, Mobil Mobilux 2, B.P. Energrease LS2,
4.2 Loosen pump from baseplate. Caltex Multifak 2.
4.2.1 During dismantling the volute casing can remain
on the baseplate and in the pipline. Lubrication Quantity
4.2.2 Uncouple pump from motor. Bearing
4.2.3 Disconnect motor power supply cables. Shaft unit Grease Oil
Size
4.2.4 Loosen motor from baseplate. Approx.gms Approx.litre
4.2.5 Remove supporting foot 183 from the baseplate
A30 6306 5 0.2
and loosen nuts on discharge cover.
A40/A40R 6308 10 0.35
4.2.6 Pull out bearing bracket with discharge cover
A50 6310 15 0.65
and complete rotor (assembled unit).
A60 6312 15 0.65
With larger pumps, suspend or support bearing
Shaft
bracket to prevent the rotating bracket from fal- Model
Unit
ling over.
A30 M32-160, M32-200, M32-250, M40-160, M40-200,
M50-160, M50-200
5 For coupling with spacer: A40 M40-250, M50-250, M65-160, M65-200, M80-160
During dismantling the volute casing can remain A40R M40-315, M50-315, M65-250, M80-200, M80-250,
on the baseplate and in the pipeline. M100-160, M100-200
A50 M65-315, M80-315, M80-400, M100-250,
5.1 Remove spacer of the coupling.
M100-315, M100-400, M125-200, M125-250,
5.2 Remove supporting foot 183 from the baseplate M125-315, M125-400, M150-200, M150-250
and loosen nuts on the discharge cover. A60 M150-315,M150-400
5.3 Pull out bearing bracket with discharge cover A50HD MH100-315, MH100-400, MH125-250, MH125-
and complete rotor (assembled unit). 315, MH125-400

With larger pumps, suspend or support bearing

bracket to prevent the rotating bracket from fal-
ling over.
If the pump has been in operation for a long time some
parts may be difficult to move. In this case use a brand
name penetrating oil or suitable pull off device.
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4.4 Reassembly
4.4.1 Pump
Reassemble in accordance with standard engineering
practice.
Coat the fits and screw connections with graphite or
similar before reassembly.
Check o-rings for wear and replace if necessary. All
gaskets must be renewed; make sure the new ones
are the same thickness as the old ones.
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Dimensions of packing compartment/packing rings,

number of rings.

Packing com-
Shaft partment Packing
Number rings 1)
unit ring
di da l
5 Packing rings
A30 35 55 73 10
1 Lantern ring
A40 5 Packing rings
45 65 73 10
A40R 1 Lantern ring
A50 60 85 90.5 12.5 5 Packing rings
A60 70 95 90.5 12.5 1 Lantern ring
Fig. 4 Mounting the deep groove
ball bearings Dimensions (in mm)
1)
With positive suction operation and suction pressure
above 0.5 bar, the lantern ring is replaced by 2 packing
If the sealing area between impeller neck and casing rings.
wear ring is worn, replace the casing wear rings 502.1
and 502.2 where fitted.
4.4.2.2 Packing Ring Cut to size

Gap clearances:
New 0.3mm on diameter, maximum wear to 0.9mm on
diameter.
Fig. 6 Packing ring cut to size.

Reassemble the pump in reverse order to dismantling.

Make sure you reassemble in the right sequence. Insert the first packing ring and push home.

Fit each subsequent ring separately with its joint stag-

gered through 90˚ in relation to the previous one using
4.4.2 Shaft Seal the stuffing box ring.

Thoroughly clean the packing compartment and shaft Tighten the gland nuts lightly and evenly.
sleeve before packing the gland. It must be possible to rotate the rotor without difficulty.

4.4.2.3 Gland Leakage

4.4.2.1 Stuffing Box Compartment Gland leakage must occur in any operating condition.
A normal leakage rate would be between 10 to 20 cm3/
minute. This is approximately 100 to 150 drops per
minute.

Slacken off the gland nuts is there is insufficient leak-

age.
If leakage ceases entirely:
- Switch pump off immediately
- Slacken gland nuts and repeat the startup procedure.

After adjustment, observe the leakage for around 2

hours with the temperature of the product at its maxi-
mum.
Fig. 5 Stuffing Box Compartment.

Then with the pressure of the product at its minimum

check whether there is sufficient leakage.

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4.4.2.4 Flushing Arrangement

Code Packing Application

Clean, non aggressive liquids, temperature up to 105˚C

0
Internal sealing

Liquids which are toxic, aggressive and/or with bad

smell.
1 Also pumps with suction from a vacuum tank. Sealing
with a clean liquid from an external source.
(max. temp. = 105˚C)

Liquids having particles in suspension, or when a major

2 contamination from the external source is to be avoided.
(Sealing t max. = 105˚C)

Liquids with abrasive particles or with tendency to crys-

3 tallization. Flushing with clean liquid from an external
source. (max. temp. = 105˚C)

g Mechanical Seal

10E - Flushing liquid inlet Fit the o-ring to the stationary seal ring, then push the
10S - Flushing liquid outlet stationary seal ring into the seal plate, applying pres-
sure evenly to all sides.
4.4.2.5 Mechanical Seal
Reassemble in reverse order to dismantling. 4.5 Spare Parts

When fitting a mechanical seal bear the following 4.5.1 Ordering Spare Parts
points in mind: When ordering spare parts please always indicate the
Maximum care and maximum cleanliness are manda- following information which may be taken from the
tory. nameplate of the pump e.g.
Do not remove the guard on the seal faces until just
before fitting. Pump Type MEGA 2000
The seal faces and o-rings must not be damaged. Pump Size 80 - 200
ID No. 140428
Clean or carefully remove any deposits from the shaft
and stationary ring seat in the bearing housing. The Ser. No. 9401234
shaft 210 may be oiled to reduce friction when mount- Impeller Dia. 196
ing the seal.

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4.5.2 Exploded View

Packed Gland

Mechanical Seal

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4.5.3 List of Components

PART NO DESCRIPTION PART NO DESCRIPTION
102 CASING 502.1 CASING WEAR RING
163 BACK COVER 502.2 IMPELLER WEAR RING
183 SUPPORT FOOT 507 SLINGER
210 SHAFT 524 SHAFT PROTECTIVE SLEEVE
230 IMPELLER 525 SPRING SLEEVE
321 BEARING 554.1/2/3 WASHER
330 BEARING BRACKET 565 DRIVE SCREW
360 BEARING COVER 636 GREASE NIPPLE (OPTIONAL)
400.1/2/3/4 GASKET 901.2/4 SETSCREW
411.1/2/3/4 GASKET 901.3 SETSCREW *
412.1/2 O-RING 901.5/6/7 SETSCREW
421 OIL SEAL 902 STUD
433 MECHANICAL SEAL 903.1/2/3/4/5 PLUG
452 GLAND 920 NUT
458 LANTERN RING 922 IMPELLER NUT
461 PACKING 940.1/2 KEY
471 SEAL PLATE 970 NAME PLATE
* Jacking screw- Use 901.2 or 901.4 as applicable
On some models part numbers 922 Imp. Nut, may be substituted with
901.7 Setscrew, 554.2 Impeller washer and 412.20 o-ring-Imp. bolt

4.5.4 Recommended List of Spare Parts for 2 Years’ Continuous Operation

Part Number of pumps (including stand-by pumps)

Part designation
no. 2 3 4 5 6 and 7 8 and 9 10 and more
Pumps with gland packing Quantity of spare parts
210 Shaft 1 1 2 2 2 3 30%
230 Impeller (including impeller wear ring 502.2) 1 1 1 2 2 3 30%
321 Deep groove ball bearing 2 2 4 4 6 8 100%
330 Bearing bracket - - - - - 1 2 off
461 Gland packing (set) 4 6 8 8 9 12 150%
502.1 Casing wear ring 2 2 2 3 3 4 50%
524 Shaft protecting sleeve 2 2 2 3 3 4 50%
- Gaskets (set) 4 6 8 8 9 12 150%
Pumps with mechanical seal
525 Spring Sleeve (Replaces part 524) 2 2 2 3 3 4 50%
433 Mechanical seal, complete (Replaces part 461) 2 3 4 5 6 7 90%

4.5.5 Recommended Impeller Nut Torques

Shaft Unit A30 A40/A40R A50/A50HD A60

Impeller Nut
24 30/36 41 41
Across FIat (mm)
Torque (Nm) 70 80/90 110 110
Impeller Bolt
16 19 24 24
Across Flat (mm)
Torque (Nm) 15 25 65 65

Casing Bolts/Nuts

Across FIat (mm) 17 19 24

Torque (Nm) 16 27 43
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5 Faults

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KSB Ajax Pumps Pty Ltd ABN: 29 006 414 642

Victorian Head Office New South Wales Queensland Western Australia South Australia New Zealand
27 Indwe St, Unit 1, 28 Skinner Ave, Carberry St, Unit 2, 86 Catalano Circuit, Unit 4, 348 Richmond Rd, Unit 2, 5 Civil Place,
Tottenham, 3012 Riverwood, 2210 Ebbw Vale, 4304 Canning Vale, 6155 Netley, 5037 Albany, Auckland
Tel: +61 (03) 9314 0611 Tel: +61 (02) 9584 2099 Tel: +61 (07) 3282 1766 Tel: +61 (08) 9455 7900 Tel: +61 (08) 8234 0066 Tel: +64 (09) 476 4047
Fax: +61 (03) 9314 7435 Fax: +61 (02) 9584 2111 Fax: +61 (07) 3816 0225 Fax: +61 (08) 9455 7800 Fax: +61 (08) 8443 5411 Fax: +64 (09) 476 4048
ksbvicsales@ksbajax.com.au ksbnswsales@ksbajax.com.au ksbqldsales@ksbajax.com.au ksbwasales@ksbajax.com.au ksbsasales@ksbajax.com.au pumps@ksbajax.co.nz

WEBSITE: www.ksbajax.com.au 24 HOUR EMERGENCY SERVICE LINE: 1300 301 356

Due to our policy of constant research and development, product specification may change without notice Publication 1045 08/05 1K AGP
Part No. 99100