Bomba Vertical MK

Operating instructions
2324.81/11-10 G3
MK
MK 20, MKA 20
as per Directive 94/9/EC
MKY 20
not as per Directive 94/9/EC

Waste water, condensate and
heat transfer liquid pumps
Works No.:
Type series:
MK
These operating instructions contain fundamental

information and precautionary notes. Please read
the manual thoroughly prior to installation of unit,
connection to the power supply and commissioning. It is
imperative to comply with all other operating instructions
referring to components of this unit.
This manual shall always be kept close to the units
location of operation or directly on the pump set.
MK
Contents
Page
1
General
2
2.1
2.2
2.3
2.4
2.5
2.6
4
4
4
4
4
4
2.9.4
2.9.5
2.9.6
Safety
Marking of instructions in the manual
Personnel qualification and training
Non-compliance with safety instructions
Safety awareness
Safety instructions for the operator / user
Safety instructions for maintenance,
inspection and installation work
Unauthorized modification and
manufacture of spare parts
Unauthorized modes of operation
Explosion protection
Unit fill
Marking
Checking the direction of rotation (see
also 6.1.4)
Pump operating mode
Temperature limits
Maintenance
3
3.1
3.2
Transport and interim storage

Transport
Interim storage / Preservation
6
6
6
Description of the product and

accessories
Technical specification
Designation
Design details
Noise characteristics
Materials
Accessories
7
7
7
7
7
7
7
2.7
2.8
2.9
2.9.1
2.9.2
2.9.3
4.1
4.2
4.3
4.4
4.5
4.6
5
5.1
5.2
5.3
5.4
5.5
5.5.1
5.5.2
Installation at site
Safety regulations
Checks to be carried out prior to
installation
Installing the pump / unit
Connecting the piping
Connection to power supply
Connecting the motor
Setting the time relay
5
5
5
5
5
5
5
5
5
6
7
7
7
7
7
8
8
8
Page
6
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.3
6.3.1
6.3.2
6.4
7
7.1
7.2
7.2.1
7.2.2
7.3
7.4
7.4.1
8
8
8
8
8
8
8
9
9
9
9
9
9
9
9
9
9
9
9
10
10
10
10
10
10/11
12
12
7.4.2
7.4.3
7.5
7.5.1
7.5.2
7.5.3
7.5.4
7.6
7.6.1
7.6.2
Servicing / maintenance
General instructions
Servicing / inspection
Supervision of operation
Lubrication
Drainage / Disposal
Dismantling
Fundamental instructions and
recommendations
Preparations for dismantling
Pump
Reassembly
Pump
Shaft seal
Shaft seal MKY
Tightening torques
Spare parts
Ordering spare parts
Recommended spare parts stock
Trouble-shooting
14
9
9.1
9.2
Related documents
Circuit diagrams
General assembly drawings and list of
components MK, MKA
Exploded view and list of components
MK 20, MKA 20
MKY 20
15
15
9.3
9.4
Commissioning, start-up / shutdown

Commissioning
Lubricants
Shaft seal
Priming the pump and checks to be
carried out
Checking the direction of rotation
Control elements
Final check
Start-up
Shutdown
Operating limits
Temperature of fluid pumped
Switching frequency
Density of fluid pumped
Abrasive fluids
Minimum/Maximum Flow
Shutdown / storage / preservation
Storage of new pumps
Measures to be taken for prolonged
shutdown
Returning to service after storage
12
12
12
12
12
12
12
13
13
13
13
16/17
18/19
20/21
MK
Index
Section
Page
Abrasive fluids
Accessories
6.2.4
4.6
9
7
2.9.3/
6.1.4
5
8
5.2
9.1
6.1
6
5.5.1
5.4
5.5
6.1.5
7
15
8
8
8
7
8
8
6.2.3
Checks to be carried out prior to

installation
Circuit diagrams
Commissioning
Commissioning, start-up / shutdown
Control elements
Density of fluid pumped
accessories
Design details
Designation
Dismantling
Drainage / Disposal
MK 20, MKA 20
MKY 20
4
4.3
4.2
7.4
7.3
7
7
7
12
12
9.3
18/19
9.4
2.9
20/21
5
Final check
Fundamental instructions and
recommendations
6.1.6
7.4.1
12
General
General assembly drawings and list of
components MK, MKA
1
9.2
7.1
16/17
10
Interim storage / Preservation
5
5.3
3.2
7
7
6
Lubricants
Lubrication
6.1.1
7.2.2
8
10/11
Maintenance
Marking
Materials
Measures to be taken for prolonged
shutdown
Minimum/Maximum Flow
2.9.6
2.9.2
2.1
4.5
6
5
4
7
6.3.2
6.2.5
9
9
4.4
2.3
7
4
Section
Page
Operating limits
6.2
7.6.1
9
13

Preparations for dismantling
Priming the pump and checks to be
carried out
Pump
2.2
7.4.2
4
12
Pump operating mode
6.1.3
7.4.3/
7.5.1
2.9.4
8
12/
12
5
Reassembly
Recommended spare parts stock
Related documents
7.5
7.6.2
9
6.4
12
13
15
10
Safety
Safety awareness
Safety instructions for maintenance,
inspection and installation work
Safety regulations
Shaft seal
2
2.4
4
4
Shaft seal MKY

Shutdown
Spare parts
Start-up
Switching frequency
2.6
2.5
5.1
7.2
7
5.5.2
6.1.2/
7.5.2
7.5.3
6.1.8
6.3
7.6
6.1.7
6.3.1
7.2.1
6.2.2
5
4
7
10
10
8
8/
12
12
9
9
13
9
9
10
9
Temperature limits
Temperature of fluid pumped
Tightening torques
Transport
Trouble-shooting
4.1
2.9.5
6.2.1
7.5.4
3.1
3
8
7
5
9
13
6
6
14

Unauthorized modification and
manufacture of spare parts
Unit fill
2.8
2.7
2.9.1
5
5
MK
1
General
Caution This KSB product has been developed in
accordance with state-of-the-art technology; it is

manufactured with utmost care and subject to continuous
quality control.
These operating instructions are intended to facilitate
familiarization with the unit and its designated use.
The manual contains important information for reliable, proper
and efficient operation. Compliance with the operating
instructions is of vital importance to ensure reliability and a long
service life of the unit and to avoid any risks.
These operating instructions do not take into account local
regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for
installation.
This pump / unit must not be operated beyond the limit
values for the fluid handled, capacity, speed, density,
pressure, temperature and motor rating specified in the
technical documentation. Make sure that operation is in
accordance with the instructions laid down in this manual or in
the contract documentation. Contact the manufacturer, if
required.
The name plate indicates the type series / size, main operating
data and identification number; please quote this information in
all queries, repeat orders and particularly when ordering spare
parts.
If you need any additional information or instructions exceeding
the scope of this manual or in case of damage please contact
KSBs nearest customer service centre.
Noise characteristics see section 4.4.
Safety
These operating instructions contain fundamental information

which must be complied with during installation, operation,
monitoring and maintenance. Therefore this operating manual
must be read and understood both by the installing personnel
and the responsible trained personnel / operators prior to
installation and commissioning, and it must always be kept
close to the location of operation of the machine / unit for easy
access.
Not only must the general safety instructions laid down in this
chapter on Safety be complied with, but also the safety
instructions outlined under specific headings, particularly if the
pump/unit is operated in potentially explosive atmospheres
(see section 2.9).
2.1
The safety instructions contained in this manual whose

non-observance might cause hazards to persons are specially
marked with the symbol
general hazard sign to ISO 7000-0434,

the electrical danger warning sign is
safety sign to IEC 417 - 5036,

and special instructions concerning explosion protection are
marked
The word
Caution
is used to introduce safety instructions whose non-observance

may lead to damage to the machine and its functions.
Instructions attached directly to the machine, e.g.
- arrow indicating the direction of rotation
- markings for fluid connections
must always be complied with and be kept in a perfectly legible
condition at all times.
2.2
All personnel involved in the operation, maintenance,
inspection and installation of the unit must be fully qualified to
carry out the work involved.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question is
not already in possession of the requisite know-how,
appropriate training and instruction must be provided. If
required, the operator may commission the manufacturer /
supplier to take care of such training. In addition, the operator is
responsible for ensuring that the contents of the operating
instructions are fully understood by the responsible personnel.
2.3
Non-compliance with safety instructions can jeopardize the
safety of personnel, the environment and the machine / unit
itself. Non-compliance with these safety instructions will also
lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
- failure of important machine/system functions,
- failure of prescribed maintenance and servicing practices,
- hazard to persons by electrical, mechanical and chemical
effects as well as explosion,
- hazard to the environment due to leakage of hazardous
substances.
2.4
Safety awareness
It is imperative to comply with the safety instructions contained
in this manual, the relevant national and international explosion
protection regulations, health and safety regulations and the
operators own internal work, operation and safety regulations.
Ex symbol relates to additional requirements which must
be adhered to when the pump is operated in potentially
explosive atmospheres.
2.5
- Any hot or cold components that could pose a hazard must be
equipped with a guard by the operator.
- Guards which are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed whilst the
unit is operating.
- Leakages (e.g. at the shaft seal) of hazardous fluids handled
(e.g. explosive, toxic, hot) must be contained so as to avoid
any danger to persons or the environment. All relevant laws
must be heeded.
- Electrical hazards must be eliminated. (In this respect refer to
the relevant safety regulations applicable to different
countries and/or the local energy supply companies.)
If the pumps/units are located in potentially explosive
atmospheres, it is imperative to make sure that
unauthorized modes of operation are prevented.
Non-compliance may result in the specified temperature limits
being exceeded.
MK
2.6
Safety instructions for maintenance, inspection

and installation work
The operator is responsible for ensuring that all maintenance,

inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the manual.
The pump must have cooled down to ambient temperature,
pump pressure must have been released and the pump must
have been drained.
Work on the machine / unit must be carried out only during
standstill. The shutdown procedure described in the manual for
taking the unit out of service must be adhered to without fail.
Pumps or pump units handling fluids injurious to health must be
decontaminated.
Immediately following completion of the work, all
safety-relevant and protective devices must be re-installed and
/ or re-activated.
Please observe all instructions set out in the chapter on
Commissioning before returning the unit to service.
2.7
Unauthorized modification and manufacture of

spare parts
Modifications or alterations of the equipment supplied are only

permitted after consultation with the manufacturer and to the
extent permitted by the manufacturer . Original spare parts and
accessories authorized by the manufacturer ensure safety. The
use of other parts can invalidate any liability of the manufacturer
for consequential damage.
2.8
The warranty relating to the operating reliability and safety of the

unit supplied is only valid if the equipment is used in accordance
with its designated use as described in the following sections.
The limits stated in the data sheet must not be exceeded under
any circumstances.
2.9
If the pumps/units are installed in potentially explosive

atmospheres, the measures and instructions given in the
following sections 2.9.1 to 2.9.6 must be adhered to without fail,
to ensure explosion protection.
2.9.1
Unit fill
It is assumed that the system of suction and discharge

lines and thus the wetted pump internals are completely
filled with the product to be handled at all times during pump
operation, so that an explosive atmosphere is prevented.
If the operator cannot warrant this condition, appropriate
monitoring devices must be used.
Note: In addition, it is imperative to make sure that the
seal chambers, auxiliary systems of the shaft
seal and the heating and cooling systems are properly filled.
2.9.2
Marking
The marking on the pump only refers to the pump part,

i.e. the motor must be regarded separately. The driver
must be regarded separately.
Example of marking on the pump part:
Ex II 2 G T1 - T5
The marking indicates the theoretically available temperature
range as stipulated by the respective temperature classes. The
temperatures permitted for the individual pump variants are
outlined in section 2.9.5.
2.9.3
Checking the direction of rotation (see also 6.1.4)
If the explosion hazard also exists during the installation

phase, the direction of rotation must never be checked
by starting up the unfilled pump unit, even for a short period, to
prevent temperature increases resulting from contact between
rotating and stationary components.
2.9.4
Pump operating mode
Make sure that the pump is always started up with the

suction-side shut-off valve fully open and the discharge-side
shut-off valve slightly open. However, the pump can also be
started up against a closed swing check valve. The
discharge-side shut-off valve shall be adjusted to comply with
the duty point immediately following the run-up process (see
6.1.7 ).
Pump operation with the shut-off valves in the suction
and/or discharge pipes closed is not permitted.
Note: In this condition, there is a risk of the pump casing
taking on high surface temperatures after a very
short time, due to a rapid temperature rise in the pumped
product inside the pump.
Additionally, the resulting rapid pressure build-up inside the
pump may cause excessive stresses on the pump materials or
even bursting.
The minimum flows indicated in section 6.2.5 refer to water and
water-like liquids. Longer operating periods with these liquids
and at the flow rates indicated will not cause an additional
increase in the temperatures on the pump surface. However, if
the physical properties of the fluid handled are different from
water, it is essential to check if an additional heat build-up may
occur and if the minimum flow rate must therefore be increased.
To check, proceed as described in section 6.2.5.
In addition, the instructions given in section 6 of this operating
manual must be observed.
Both gland packings and mechanical seals may
exceed the specified temperature limits if run dry.
Dry running may not only result from an inadequately filled
seal chamber, but also from excessive gas content in the
fluid handled.
Pump operation outside its specified operating range may
also result in dry running.
In potentially explosive atmospheres, gland packings shall
only be used if combined with a suitable temperature
monitoring device.
If pump speed is reduced (speed control), appropriate
measures must be taken to ensure sufficient lubrication
of the mechanical seal.
2.9.5
Temperature limits
In normal pump operation, the highest temperatures are

to be expected on the surface of the pump casing, the
pipe assembly, the plain bearings and in the bearing areas. The
surface temperature at the pump casing corresponds to the
temperature of the fluid handled.
In the thrust bearing and radial bearing areas, the unit surfaces
must be freely exposed to the atmosphere.
In any case, responsibility for compliance with the
specified fluid temperature (operating temperature) lies
with the plant operator. The maximum permissible fluid
temperature depends on the temperature class to be
complied with.
MK
The table below lists the temperature classes to EN 13463-1
and the resulting theoretical temperature limits of the fluid
handled. In stipulating these temperatures, any temperature
rise in the shaft seal area has already been taken into account.
Temperature class as
per EN 13463-1:
T5
T4
T3
T2
T1
Temperature limit of fluid handled

90 C 1)2)
90 C 1)
--- C 1)
--- C 1)
--- C 1)
3.1
Transport
Transport of the unit requires proper preparation and handling.

Always make sure that the pump or unit remains in vertical
position during transport and cannot slip out of the transport
suspension arrangement. Do not use a lifting sling on the motor
eyebolt.
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and damage
to property!
1) due to max. permissible fluid temperature.

2) T5 only permissible if bearing temperature is monitored,
t max. bearings = 80 C
Safety note:
Caution The permissible operating temperature of the
pump in question is indicated on the data sheet. 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, the
maximum permissible operating temperature must be enquired
from the pump manufacturer.
Based on an ambient temperature of 40C and proper
maintenance and operation, compliance with temperature
class T4 is warranted in the area of the rolling element bearings.
2.9.6
Maintenance
Only a pump unit which is properly serviced and

maintained in perfect technical condition will give safe
and reliable operation.
This also applies to the reliable function of the rolling element
bearings whose actual lifetime largely depends on the
operating mode and operating conditions.
Regular checks of the lubricant and the running noises will
prevent the risk of excessive temperatures as a result of
bearings running hot or defective bearing seals (also see
section 7.2.1.2).
The correct function of the shaft seal must be checked regularly.
Any auxiliary systems installed must be monitored, if
necessary, to make sure they function correctly.
Gland packings must be tightened correctly, to prevent
excessive temperatures due to packings running hot.
2324:29
Fig. 3.1-1 Transport of the complete unit

3.2
Interim storage (indoors) / Preservation
When the unit is temporarily put into storage, only the wetted
low alloy components (e.g. grey cast iron JL1040) must be
preserved. Commercially available preservatives can be used
for this purpose. Please observe the manufacturers
instructions for application/removal.
The relevant procedure is described in section 6.3.
The unit / pump should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.
Caution Protect all stored goods against humidity, dirt,
vermin and unauthorized access! All openings of
the assembled unit components are closed and must only be
opened when required during installation.
All blank parts and surfaces of the pump are oiled or greased
(silicone-free oil and grease) to protect them against corrosion.
MK
4

accessories
4.1
Submerged pumps for handling waste water, oils, emulsions,

aggressive fluids, condensate and heat transfer liquids.
4.2
1)
2)
Accessories
Drive
Type:
electric motor / to be supplied by operator
Coupling:
coupling sleeve
Monitoring:
On request, the following equipment can be supplied by KSB:
- Temperature sensor at the drive-end fixed bearing with G 1/8
thread.
Designation
Example
Type series
Variant 1) e.g.
Casing material 2) e.g.
Pipe connection Rp 2
Design status
Power code
Installation depth in cm, e.g.
4.6
MK A - B 2 0 - 1 / 100
5.1
Safety regulations
Equipment operated in potentially explosive
atmospheres must comply with the relevant
explosion protection regulations. This is indicated on the
pump name plate and motor name plate (see 2.9).
A = with square installation / cover plate and screw-ended

discharge pipe
Y = with round installation flange, lantern, gland packing
and flanged discharge pipe
X = special design
no letter = cast iron JL1040
B = tin bronze CC480K-GS
C = Chrome nickel molybdenum cast steel
5.2
Checks to be carried out prior to installation
All structural work required must have been prepared in

accordance with the dimensions stated in the dimension
table / general arrangement drawing.
5.3
Remove the transport plugs from the volute casing and the
discharge pipe.
Caution The rods for MKA pumps with rod-actuated float
switch are placed inside the discharge pipe to

facilitate transport, those of MK pumps are fastened inside the
transport crate.
4.3
Design details
Pump
Type:
Vertical volute casing pump, single-stage, with

three-channel impeller. The pump and motor shafts
are rigidly connected by a coupling sleeve.
Bearings: drive-end:
deep-groove ball bearings,

grease-packed for life
impeller-end: bearing bush, product-lubricated
4.4
Pump with motor
Surface sound pressure level
L pA (dB) 1)
kW
1/min
0.55
1450
52
0.75
2800
64
1.1
2800
64
1.5
2800
65
2.2
2800
66
1) measured at a distance of 1 m from the pump outline as per DIN 45635,

Part 1 and 24. Room and foundation influences have not been
included. The tolerance for these factors is 1 to 2 dB.
The above values apply to the unit without cover plate. If a cover
plate is fitted, the sound pressure level may increase by up to
2 pA (dB).
The above noise characteristics apply to non-cavitating pump
operation in the Qopt range!
4.5
Materials
For handling combustible fluids, the pump casing and

the pipe assembly must be made of ductile material with
a maximum magnesium content of 7.5 % (see EN 13463-1).
This is a standard feature in all KSB supplies.
On pumps with an installation depth of 1900 (optional;

mandatory for ATEX requirement) and 2800 mm and
without cover plate (MK) the Ermeto pipe fitting (X), which
is supplied separately strapped to the pump, must be fitted
(see 9.2).
The pump shall be installed in such a way that the motor is
protected against flooding.
Place the pump on the floor of a 500 x 500 mm pit at the
installation depth it is designed for, i.e. 1000, 1900 or 2800 mm.
If it is installed in a tank, mount it on the cover plate supplied
along with the pump.
The motor and float switch must be located outside the pit or
tank; they must be well-ventilated and protected against
humidity.
When the unit is installed in a pit, secure it to the pit wall using
mounting clamps, if the pump is not installed with a cover plate
and angular frame. The pump must not be subject to stresses
and strains when installed (risk of bearing damage).
5.4
Caution Never use the pump itself as an anchorage point

for the piping.
The pipelines shall be anchored and connected without

transmitting any stresses or strains.
The pump must not be subjected to any pipeline forces and
moments!
With short pipelines, the nominal diameters should be at least
equal to the nominal diameters of the pump nozzles. For long
pipelines, the most economical nominal diameter has to be
determined from case to case.
Adapters to larger diameters should have a diffuser angle of
approx. 8 in order to avoid any increase in pressure losses.
A flow velocity of 2-3 m/s is recommended.
7
MK
It is recommended to install shut-off elements in the system,
depending on the type of plant and pump.
If the pump is used for automatic drainage, a non-return or
check valve shall be fitted.
Before commissioning new installations thoroughly clean, flush
and blow through all vessels, pipelines and connections.
Thermal expansions of the pipelines must be compensated by
appropriate measures so as not to impose any extra loads on
the pump.
excessive, impermissible increase in the pipeline
! An
forces may cause leaks on the pump where the fluid
handled can escape into the atmosphere.
Danger to life when hot fluids are handled!
The flange covers on the volute casing and discharge pipe must
be removed prior to installation.
5.5
Connection to the power supply must be effected by a

trained electrician only. Check available mains voltage
against the data on the motor rating plate and select appropriate
start-up method.
We strongly recommend to use a motor protection device.
In potentially explosive atmospheres, compliance with
IEC60079-14 is an additional requirement for electrical
connection.
5.5.1
For circuit diagrams and connection layout please refer to 9.1.
5.5.2
Make sure that in the case of three-phase motors with star-delta
starting method switching over from star to delta will be effected
at very short intervals. Prolonged switch-over intervals will result in pump damage.
Time relay setting for star-delta starting:
3 seconds 30 %.
Commissioning, start-up /
Shutdown
Caution Compliance with the following requirements is of
paramount importance. Damage resulting from

non-compliance shall not be covered by the scope of warranty.
6.1
Commissioning
Caution
6.1.2
Shaft seal
Shaft seal see 7.5.2/7.5.3.
6.1.3
Priming the pump and checks to be carried out
Before start-up, the pump must always be immersed in the
liquid; the liquid level must never be lower than the minimum
liquid levels given below.
Lowest liquid level (switch-off level) 120 mm from lower
edge of casing, 400 mm for condensate transport.
Caution Dry running will result in increased wear and

must be avoided!
6.1.4
The motors direction of rotation must correspond to the direction indicated by the arrow on the name plate.
The rotors direction of rotation can be verified by switching the
unit on and then off again immediately and watching the fan impeller through the fan hood.
If the pump runs in the wrong direction of rotation, interchange
any two phases L1, L2 or L3 of the power cable in the motor terminal box.
Before checking the direction of rotation make sure that
there is no foreign matter in the pump casing!
Never hold your hands or any other objects into the pump!
Do not allow the pump to run dry for longer
Caution
periods of time!
The safety instructions set forth in section 2.9.3 must be
complied with.
6.1.5
Control elements
6.1.5.1 Control element for MK/MKA

If the pump is supplied with a control element, operation is fully
automatic, depending on the fluid level.
The single-pole float switch or another type of contactor
controls an air-break contactor with integrated motor protection.
Fluid levels shall be set to 120 mm (min.) from the lower casing
edge and 150 mm (max.) below the cover plate.
6.1.5.2 Rod-actuated float switch control
The unit is controlled by a float switch fitted on the motor flange.
The float switch is actuated by a float via a switch rod with stop
clamps. At the bottom, the rod 574 is led through the strip 575; at
the top, it is connected to the float switch 81-45 via the split pin
933. The start-up and switch-off point can be altered by moving
the adjusting rings 500.2 along the rod 574.
Before starting up the pump make sure that

- the pump unit has been properly connected to the electric
power supply and is equipped with all protection devices;
- the operating data and the direction of rotation has been
checked.
- If the pump has been out of service for a longer period of time,
proceed in accordance with section 6.4.
6.1.5.3 Cable pull float switch control

Pumps for an installation depth of 2800 mm and pumps in
explosion-proof design with cover plate for all installation
depths are supplied with a separate cable pull float switch
control. The switching points can be altered by repositioning the
stops on the cable. If required, the float must be partially filled
with sand or water to provide an adequate control weight.
6.1.1
6.1.5.4 Magnetic float switch control

For details refer to 6.1.5.6.
On MKA pumps it is fitted in the cover plates clearance hole for
the rod control element (G 3/4 thread is available); the switching
points measured from the cover plate - are located at 300 mm
(ON) and 800 mm or 1700 mm (OFF), respectively, and
cannot be altered. Its contact rating is 1 A; on MK pumps it is
fitted separately on the tank.
Lubricants
6.1.1.1 Thrust bearings

The sealed-for-life deep-groove ball bearings are already
packed with grease.
6.1.1.2 Radial bearings
The bearing bushes are exclusively lubricated by the fluid
pumped.
Therefore, the start-up point must be situated above the top
bearing.
8
MK
6.1.5.5 EURO float switch control
The float switch with 5, 10 or 20 m connection cable must only
be used for fluids with a max. temperature of 70 C.
6.1.5.6 Control element for MKY
Heat transfer media and recirculating systems usually do not
need any control elements. Units used for condensate
transport at temperatures of up to 110 C and installed at
installation depths of 1000 mm and 1900 mm can be equipped
with a magnetic float switch control element. After the blind plug
has been removed, the control element is firmly screwed into
the G3/4 opening provided in the drive stool.
For switching points refer to 6.1.5.4.
6.1.6
Final check
Check the integrity and proper functioning of all connections.
6.1.7
Start-up
Before starting the pump, ensure that the shut-off valve (if any)
in the suction line is fully open! The pump may be started up
against a closed discharge-side swing check valve or slightly
open shut-off valve. Only after the pump has reached full
rotational speed shall the shut-off valve in the discharge line be
opened slowly and adjusted to comply with the duty point.
When starting up against an open discharge-side shut-off
valve, take the resulting increase in input power into account!
Pump operation with the shut-off valves in
Caution
the discharge and suction pipes closed is
not permitted.
The permissible pressure and temperature limits might be
exceeded. In extreme cases, the pump may burst.
6.1.8
Shutdown
Close the shut-off valve in the discharge line.
Switch off the motor, making sure that the unit runs down
smoothly to a standstill.
In the event of frost and/or prolonged shutdowns, the pump
must be protected against freezing.
6.2
Operating limits
The pumps/units application limits regarding pressure,
temperature and speed are stated on the data sheet and
must be strictly adhered to!
If a data sheet is not available, contact KSB!
6.2.1
Temperature of the fluid pumped

Caution Do not operate the pump at temperatures
exceeding those specified on the data sheet or
the name plate unless the written consent of the manufacturer
has been obtained. Damage resulting from disregarding this
warning will not be covered by the KSB warranty.
The safety instructions set forth in section 2.9 must be
complied with.
6.2.2
Switching frequency
To prevent high temperature increases in the motor and

excessive loads on the pump, coupling, motor, seal elements
and bearings, the switching frequency shall not exceed
20 start-ups per hour.
6.2.3 Density of fluid pumped

The power input of the pump will increase in proportion to the
density of the fluid pumped. To avoid overloading of the motor,
pump and coupling, the density of the fluid must comply with the
data specified on the purchase order.
6.2.4
Abrasive fluids
When the pump handles liquids containing abrasive
substances, increased wear of the hydraulic system and the
shaft seal are to be expected. The intervals recommended for
servicing and maintenance shall be shortened.
6.2.5
Minimum/maximum flow
Unless specified otherwise in the characteristic curves or on the
data sheets, the following applies:
Qmin = 0.1 x Qopt for short operation
Qmin = 0.3 x Qopt for continuous operation
Qmax = 1.1 x Qopt for 2-pole operation
Qmax = 1.25 x Qopt for 4-pole operation
Qopt = optimum efficiency
The data refer to water and water-like liquids. However, if the
physical properties of the fluids handled are different from
water, the calculation formula below must be used to check if an
additional heat build-up may lead to a dangerous temperature
increase at the pump surface. If necessary, the minimum flow
must be increased.
To=Tf+DJ
DJ=
c
g
H
Tf
To
h
DJ
g*H
c* h
* (1-h)
Specific heat
Acceleration due to gravity
Pump head
Temperature of fluid handled
Temperature of casing surface
Pump efficiency at duty point
Temperature difference
[J / kg K]
[m/s2]
[m]
[C]
[C]
[-]
[C]
6.3
Each KSB pump leaves the factory carefully assembled. If
commissioning is to take place some time after delivery, we
recommend that the following measures be taken for pump
storage.
6.3.1
- New pumps are supplied by our factory duly prepared for
storage.
Maximum protection for up to 12 months, if the pump is
properly stored indoors.
- Store the pump in a dry location.
- Rotate the shaft by hand once a month.
6.3.2
Measures to be taken for prolonged shutdown
1. The pump remains installed; periodic check of
operation
In order to make sure that the pump is always ready for
instant start-up and to prevent the formation of deposits
within the pump and the pump intake area, start up the pump
set regularly once a month or once every 3 months for a short
time (approx. 5 minutes) during prolonged shutdown
periods. Prior to an operation check run ensure that there is
sufficient liquid available for operating the pump.
9
MK
2. The pump is removed from the pipe and stored
Before putting the pump into storage, carry out all checks
specified in paragraphs 7.1 to 7.4. Then apply appropriate
preservatives:
- Spray-coat the inside wall of the pump casing, and in
particular the impeller clearance areas, with a
preservative. Spray the preservative through the suction
and discharge nozzles. It is advisable to close the pump
nozzles (e.g. with plastic caps or similar).
6.4
Before returning the pump to service, carry out all checks and
maintenance work specified in sections 7.1 and 7.2.
In addition, the instructions laid down in the sections on
Commissioning (6.1) and Operating Limits (6.2) must
be observed.
Immediately following completion of the work, all
safety-relevant and protective devices must be
re-installed and/or re-activated.
7.1
The operator is responsible for ensuring that all maintenance,

inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the manual.
For monitoring the bearing temperature, a G 1/8 connection

hole ( 7 mm) is provided in the thrust bearing (303.1) (max.
width across corners of fastener used: 18 mm).
For required minimum flows please refer to section 6.2.5.
During pump operation the shut-off valve in the suction
line must not be closed.
Make sure that the float can always slide along the guide rod
without obstruction (MK/MKA only).
Any stand-by pumps installed shall be switched on and then
immediately off again once a week to keep them operational.
Attention shall be paid to the correct functioning of the auxiliary
connections.
7.2.2
Lubrication
7.2.2.1 Deep-groove ball bearing

The shaft runs in a deep-groove ball bearing in the thrust
bearing, which is equipped with washers on both sides and
sealed for life.
It is lubricated with high-performance lithium soap grease to
DIN 51825, free of resin and acid, not liable to crumble and with
good rust-preventive characteristics. With this grease, a
theoretical bearing life L h10 of 25,000 h at an operating
temperature of 75 C can be achieved. If temperatures are
higher, grease life will be reduced; a temperature increase of
15 K will reduce grease life by half.
However, bearing life may be reduced by vibrations, aggressive
gases, moisture, etc.
Deep-groove ball bearing (thrust bearing)
Deep-groove ball bearing
A regular maintenance schedule will help avoid expensive

repairs and contribute to trouble-free, reliable operation of the
pump with a minimum of maintenance expenditure and work.
Washer
Work on the unit must only be carried out with the

electrical connections disconnected. Make sure that
the pump set cannot be switched on accidentally (danger
to life!).
Pumps handling liquids posing health hazards must
be decontaminated. When draining the fluid see to it
that there is no risk to persons or the environment. All
relevant laws must be adhered to (danger to life)!
2324:9/2
Grease fill
Nilos ring
Fig. 7.2-1 Deep-groove ball bearing (thrust bearing)

7.2
7.2.1
Caution The pump must run quietly and free from
vibrations at all times. Rough running may

damage the bearings and the shaft seal.
The pump must never be allowed to run dry.

The fluid level must be at least 120 mm above the lower edge of
the casing. The max. fluid level must be 150 mm below the
cover plate.
Do not run the pump against a closed shut-off valve for
prolonged periods of time so as to avoid heating up of the
fluid pumped. When operating the pump set with the shut-off
valve in the discharge line slightly open for a short period of
time, the permissible pressure and temperature limits must not
be exceeded.
Max. permissible room temperature 40 C.
The bearing temperature may exceed room temperature by up
to 50 C, but must never rise above + 90 C.
10
Deep-groove
ball bearing
Nilos ring
MK, MKA
20-1 to 5
80
6006 2 RS
ZJV 6006
MK, MKA
20-6
90 S, L
6008 2 RS
ZJV 6008
MKY
20-1 to 4
80
6006 2 RS
ZJV 6006
MKY
20-5 and 6
90 S, L
6008 2 RS
ZJV 6008
Pump sizes
MK
7.2.2.2 Bearing bushes
The bearing bushes (radial bearings) in the support column and
volute casing are lubricated by the fluid handled.
Bearings shall be checked for wear in the following cases:
1. When the pump has been operated under dry-running or
cavitation conditions, the bearings should be checked
immediately, if possible.
2. Vibrations, noise and an increase in current input occurring
during unchanged operating conditions indicate wear at the
bearings (insufficient lubrication). Check the bearings!
7.2.2.3 Internal lubrication by the fluid handled

Internal lubrication by the fluid handled is used for bearing
bushes with a risk of dry running. Connection x leads from the
discharge pipe to the support column (see fig. 7.2-2).
7.2.2.4 Grease lubrication
Each bearing bush in the support column must be provided with
its own lubricating device including a lubricator (see fig. 7.2-2).
Make sure that the lubrictors are properly filled at all times and
are screwed down at regular intervals.
Use a high-quality lithium-soap grease, free of resin and acid,
not liable to crumble and with good rust-preventive
characteristics. The grease should have a penetration number
between 2 and 3, corresponding to a worked penetration
between 220 and 295 mm/10. Its drop point must not be below
175 C.
7.2.2.5 External liquid lubrication

For external liquid lubrication a flushing liquid connection z (see
fig. 7.2-3) must be provided.
The minimum pressure required is 2.5 bar. The relevant
regulations stipulate that the connection line must be equipped
with a shut-off element and a non-return valve. An expedient
method of control is a solenoid valve connected in parallel with
the motor.
2324:28
x = internal lubrication by fluid handled

y = grease lubrication
Fig. 7.2-2 Internal lubrication / grease lubrication
min. 2.5 bar
z
(not included in KSBs
scope of supply)
2324:13/4
z = external liquid lubrication

Fig. 7.2-3 External liquid lubrication
11
MK
7.3
Drainage / disposal
Caution If the pump was used for handling liquids posing
health hazards, see to it that there is no risk to
persons or the environment when removing the pump and
draining the fluid. All relevant laws must be heeded. If required,
wear safety clothing and a protective mask!
If the fluids handled by the pumps leave residues which might
lead to corrosion when coming into contact with atmospheric
humidity, or which might ignite when coming into contact with
oxygen, then the unit must be flushed through, neutralized, and
then for drying purposes anhydrous gas must be blown through
the pump.
The flushing fluid used and any liquid residues in the pump must
be properly collected and disposed of without posing any risk
to persons or the environment.
7.4
Dismantling
Before dismantling the pump, secure it so as to make

sure it cannot be switched on accidentally. The shut-off
valves in the discharge line must be closed.
The pump must have cooled down to ambient temperature,
pump pressure must have been released and the pump must
have been drained.
It is recommended to place a drip pan under the pump along its

entire length, to collect the pumped fluid escaping during
dismantling.
7.5
Reassembly
7.5.1
Pump
The pump shall be reassembled in accordance with the rules of

sound engineering practice.
The locating surfaces of the individual components must be
coated with graphite or similar before reassembly. The same
applies to bolted connections.
Gaskets shall always be replaced by new ones. Make sure that
new gaskets have the same thickness as the old ones.
Reassembly is effected in reverse order to dismantling. Make
sure to assemble the components in their correct sequence.
7.5.2
Shaft seal
The shaft is sealed by washers in the ball bearing of the thrust

bearing assembly and a grease-backed Nilos ring.
The MK/MKA models are additionally equipped with a vapour
trap (PTFE ring) in the support column.
Dismantling and reassembly must always be carried out in

accordance with the relevant exploded view / general assembly
drawing.
7.4.1
Fundamental instructions and recommendations
Repair and maintenance work to the pump must only be carried

out by specially trained personnel, using original spare parts
(see 2.7).
Observe the safety regulations laid down in section 7.1.
Any work on the motor shall be governed by the specifications and regulations of the respective motor supplier.
Dismantling and reassembly must always be carried out in
the sequence shown in the exploded view / general assembly drawing.
In the case of damage or pump failure please contact our
nearest customer service centre.
For customer service centres please refer to the attached list of
addresses.
7.4.2 Preparations for dismantling
1.
2.
3.
4.
Interrupt power supply.

Disconnect the motor from the power supply.
Unbolt the discharge nozzle from the pipeline.
Remove the pump unit with support column 712 / discharge
pipe 710 and cover plate from the tank.
2324:16/3
A
B
C
D
E
F

Washers
Grease fill
Nilos ring
Vapour trap (PTFE ring)
Vent groove
Fig. 7.5-1 MK/MKA shaft seal

7.5.3
MKY shaft seal
After a prolonged period of operation the individual components

may be hard to pull off the shaft. If this is the case, use a brand
name penetrating agent and/or - if possible - an appropriate
pull-off device.
Under no circumstances use force.
Thoroughly clean the gland packing chamber before packing.

Insert the first packing ring and press it home with the gland
cover.
Each subsequent packing ring is inserted separately with its
joint displaced by approx. 90 in relation to the previous one and
pushed into the packing chamber using the stuffing box ring.
7.4.3
Tighten the gland cover gently and evenly.

It must be easy to rotate the rotor.
Pump
Dismantle the pump in the sequence shown in the exploded

view (see 9.3 or 9.4) or general assembly drawing (see 9.2).
If the shaft 210 is worn at the bearing positions, it may be turned
upside down and installed again for continued use. At first
re-installation in reversed position, the running faces on the
shaft are as new. The bearing bushes 545 must always be
replaced simultaneously.
12
MKY not approved to Directive 94/9/EC
MK
7.5.4
Tightening torques
2324:30
Fig. 7.5-2 Tightening points

Thread size
[mm]
M 10
Position
A, B, C, D
7.6
Spare parts
7.6.1
Tightening torque MA
[Nm]
25
When ordering spare parts please always quote the following

data stated on the name plate, e.g.
Type
Works No.
MKA 20-6/190
4-N 34-286 325
7.6.2 Recommended spare parts stock for two years continuous operation
Part No.
210
230
321
400
422
457
461.1/.2
461.3
502
545
Description
Shaft
Impeller
Gasket
PTFE ring
Gland ring
Gland packing, support column 1)
Gland packing, discharge pipe 1)
Casing wear ring
Bearing bushfor installation depth of 1000 mm
for installation depth of 1900 mm
for installation depth of 2,800 mm
Number of pumps (including stand-by pumps)

2
3
4
5
6 and 7 8 and 9
Quantity of spare parts
1
1
2
2
2
3
1
1
1
2
2
3
1
1
2
2
3
4
1
1
2
2
3
4
1
1
2
2
3
4
1
1
2
2
3
4
4
6
8
8
9
12
2
3
4
4
6
6
2
2
2
3
3
4
1
1
1
2
2
3
2
2
2
4
4
6
3
3
3
6
6
9
10 and more
30 %
30 %
50 %
50 %
50 %
50 %
150 %
100 %
50 %
30 %
60 %
90 %
1) For MKY only
13
MK
Excessive wear on bearings.
Trouble-shooting
Pump does not start up.

Motor is overloaded,
Motor protection switch trips the pump.
Pump delivers insufficient flow rate.
Excessive pump flow rate.
Vibrations during pump operation.
*
*
*
*
*
Cause
Wrong direction of rotation.
Wear of internal pump parts.
System head is lower than specified in the

purchase order.
Density or viscosity of the fluid pumped is higher
than stated in the purchase order.
Gland cover too tight or askew.
Motor is running on two phases only.
Motor is not running because of lack of voltage.
*
*
Switchgear, control unit or overcurrent relay

defective.
Pump delivers against an excessively high
discharge pressure.
Supply line or impeller clogged/jammed.
Insufficient inflow.
* *
Pump is warped or sympathetic vibrations in the

piping.
Defective bearing(s).
*
* *
Pump clogged by sand, dirt in the pump sump.

Rotating assembly is out of balance, shaft is
warped.
Current exceeds the value set in the motor
protection switch.
Excessive temperature of the fluid pumped.
*
*
Cavitation (rattling noise).
*
*
Aggressive fluid.
Abrasive fluid.
Remedy 1)
Interchange two of the phases of the power supply
cable.
Replace worn components by new ones.
Adjust duty point accurately by means of the shut-off
valve in the discharge line.
Check whether the impeller could be turned down. 2)
2)
Correct.
Replace the defective fuse.
Check the electric cable connections.
Check the electric equipment.
Notify the energy supply company.
Check and replace, if necessary.
Re-adjust to duty point.
Remove deposits/solids in the pump and/or piping.
Replace worn components by new ones.
Check suction opening / screen of the volute casing
for dirt accumulation.
Check pipeline connections and secure fixing of
pump; if required, reduce the distances between the
pipe clamps.
Fix the pipelines using anti-vibration material.
Fit new bearings.
If required, re-install the shaft upside down.
Clean the intake, pump components and swing
check or non-return valve.
Drain and clean the pump sump.
Clean the impeller.
Re-balance the rotating assembly.
Fit a new shaft.
Set motor protection switch to rated value stated on
the motor rating plate.
Reduce temperature.
Check vapour trap.
Increase suction head.
Reduce condensate temperature.
Increase back pressure by throttling.
Use other bearing material.
Use other bearing material, if required
Flushing liquid connection (external liquid
lubrication).
1) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
2) Request particulars.
14
MK
Related documents
9.1
Circuit diagrams / Connection layouts
Three-phase current in star configuration
Single-phase alternating current
Mains
Mains
2324:23/4
2324:21/4
Three-phase current with magnetic float switch

Contact rating max. 1 A
Three-phase current in delta configuration
Mains
Alarm / alarm /
alarme
Ein / On
enclenchement
2324:24/3
Aus / Off /
dclenchement
2324:22/4
B
C
K1M
F1
OF
F2
M
X
X1
S
Immersion probe
Run capacitor
Mains protection
Mains fuse
Control current fuse
Overcurrent relay
Pump motor
Terminal board
Terminal strip
Float switch
15
MK
9.2
General assembly drawings and list of components MK, MKA
801
81-45
81-45
710.3
68-3
400
894
933
481
520
561.2
422
303.1
321
500.1
574
210
712.2
545.1
74-4
303.2
561.1
230
102
500.2
575
502
2324:26
2324:12/7
Installation depth 1000 mm
16
MK
Part No.
Description
Part No.
Description
102
210
230
303.1
303.2
Volute casing
Shaft
Impeller
Thrust and radial bearing
without vertical holes
with vertical holes
Gasket
PTFE ring
Bellows
Ring
Adjusting ring
Casing wear ring
Retaining ring
Sleeve
Bearing bush
Grooved pin
Rod
Strip
Rope
Grease cup
Cover plate
Lubrication line
710.1
710.2
710.3
712.1 1)
712.2
731.1
731.2
731.3
731.4
731.5
731.6
731.7
732
733
74-4
801
81-39
81-45
894
933
99-3
x
y
z
Pipe 10 x 1 x 300
Pipe
Pipe
Support column without hole
Support column with hole
Pipe union BLL 10
Pipe union XL 10
Pipe union NL 10
Pipe union DL 10
Pipe union GL 10
Socket
Pipe union EL 10
Holder
Pipe clamp
Float
Flanged motor
Clamp
Float switch
Bracket
Split pin
Set of accessories, pipe union
Internal fluid lubrication
Grease lubrication
External fluid lubrication
303.3
321
400
422
481
500.1
500.2
502
506
520
545.1-.3
561.1/.2
574
575
59-24
635
68-3
707
1)
Number of support columns without hole 712.1 for installation depth ET:
1000 mm = 0
1900 mm = 1
2800 mm = 2 off
17
MK
9.3
Exploded view and list of components MK 20, MKA 20
2324:25/4
18
MK
Part No.
Description
Part No.
Description
102
210
230
303.1
303.2
Volute casing
Shaft
Impeller
without vertical hole
with vertical hole
Gasket
PTFE ring
Bellows
Ring
Adjusting ring
Casing wear ring
520
545.1-.3
561.1/.2
574
575
68-3
710.3
712.1 1)
712.2
74-4
801
81-45
894
933
99-3
Sleeve
Bearing bush
Grooved pin
Rod
Strip
Cover plate
Pipe
Float
Flanged motor
Float switch
Bracket
Split pin
set of accessories, pipe union
303.3
321
400
422
481
500.1
500.2
502
1)
1000 mm = 0
1900 mm = 1
2800 mm = 2 off
19
MK
9.4
Exploded view and list of components MKY 20
2324:31
20
MK
Part No.
Description
Part No.
Description
102
210
230
303.1
303.2
Volute casing
Shaft
Impeller
without vertical holes
with vertical holes
Motor stool
Gasket
Gland cover
Gland ring
Gland packing
500
502
520
545.1
550
561.1/.2
710
712.1 1)
712.2
801
81-45
81-92
903.1/.2
Ring
Casing wear ring
Sleeve
Bearing bush
Disc
Grooved pin
Pipe
Flanged motor
Float switch
Cover plate
Screwed plug
303.3
321
341
400
452.1/.2
457
461.1-.3
1)
1000 mm = 0
1900 mm = 1
2800 mm = 2 off
21
MK
22
MK
23
2324.81/11-10
15.10.2003
Subject to technical modification without prior notice.
MK
KSB Aktiengesellschaft
P.O. Box 1361, 91253 Pegnitz Bahnhofplatz 1, 91257 Pegnitz (Germany)
Tel. +49 (92 41) 71 0 Fax +49 (92 41) 71 17 91 www.ksb.com

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Operating instructions

not as per Directive 94/9/EC

These operating instructions contain fundamental

Transport and interim storage

Description of the product and

Commissioning, start-up / shutdown

Checking the direction of rotation

Checks to be carried out prior to

Personnel qualification and training

Pump operating mode

Shaft seal MKY

Unauthorized modes of operation

accordance with state-of-the-art technology; it is

These operating instructions contain fundamental information

Marking of instructions in the manual

The safety instructions contained in this manual whose

general hazard sign to ISO 7000-0434,

safety sign to IEC 417 - 5036,

is used to introduce safety instructions whose non-observance

Safety instructions for maintenance, inspection

The operator is responsible for ensuring that all maintenance,

Unauthorized modification and manufacture of

Modifications or alterations of the equipment supplied are only

Unauthorized modes of operation

The warranty relating to the operating reliability and safety of the

If the pumps/units are installed in potentially explosive

It is assumed that the system of suction and discharge

The marking on the pump only refers to the pump part,

Checking the direction of rotation (see also 6.1.4)

If the explosion hazard also exists during the installation

Pump operating mode

Make sure that the pump is always started up with the

In normal pump operation, the highest temperatures are

Temperature limit of fluid handled

Transport and interim storage

Transport of the unit requires proper preparation and handling.

1) due to max. permissible fluid temperature.

Caution The permissible operating temperature of the

pump in question is indicated on the data sheet. If

Only a pump unit which is properly serviced and

Fig. 3.1-1 Transport of the complete unit

Interim storage (indoors) / Preservation

Description of the product and

Submerged pumps for handling waste water, oils, emulsions,

electric motor / to be supplied by operator

A = with square installation / cover plate and screw-ended

Checks to be carried out prior to installation

All structural work required must have been prepared in

Installing the pump / unit

Caution The rods for MKA pumps with rod-actuated float

switch are placed inside the discharge pipe to

Vertical volute casing pump, single-stage, with

deep-groove ball bearings,

Pump with motor

Surface sound pressure level

1) measured at a distance of 1 m from the pump outline as per DIN 45635,

For handling combustible fluids, the pump casing and

On pumps with an installation depth of 1900 (optional;

Connecting the piping

Caution Never use the pump itself as an anchorage point

The pipelines shall be anchored and connected without

Connection to power supply

Connection to the power supply must be effected by a

paramount importance. Damage resulting from