KIRLOSKAR i-CM32/13-0.75kW/2P User manual

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INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE i-CAN MOTOR PUMP
KIRLOSKAR BROTHERS LIMITED
REGD. AND HEAD OFFICE UDYOG BHAVAN, TILAK ROAD, PUNE-411002

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WARRANTY
We warrant that the um su lied from us is free from
defective material and faulty workmanshi . This warranty
holds good for a eriod of 12 months from the date of
commissioning the equi ment or 18 months from the date
of dis atch from our factory, whichever is earlier. Our
liability in res ect of any com laint is limited to re lacing
art/ arts free of charge ex-works or re airs of the
defective art/ arts only to the extent that such
re lacement/re airs are attributable or arise solely from
faulty workmanshi or defective material.
This warranty holds good only for the roducts
manufactured by us .
KIRLOSKAR BROTHERS LIMITED

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INDEX
Sr.No. DESCRIPTION PAGE
NO.
1 GENERAL 4
2 CONSTRUCTION 10
3 UNPACKING, STORAGE 10
4 INSTALLATION AND PIPING CHECK POINTS 11
5 ELECTRICAL CONNECTIONS 11
6 UTILITY CONNECTIONS 12
OPERATION 12
8 ASSEMBLY AND DISMANTLING OF THE PUMP 12
9 MAINTENANCE 14
10 TROUBLE SHOOTING 15
11 LIST OF RECOMMENDED SPARES 20
12 PARTS LIST 21
13 TECHNICAL DATA 22
14 CROSS-SECTIONAL ASSEMBLY DRAWING 23
15 EXPLODED VIEW 24

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1) GENERAL:
1.1 This booklet covers instructions for KIRLOSKAR make i-CAN
Motor Pump type i-CM.
The booklet covers instructions for installation, operation
and maintenance of following models of i-CM Pumps:
i-CM32/13- 0. 5kW/2P
i-CM32/13- 1.5kW/2P
i-CM32/13- 2.2kW/2P
i-CM32/16- 3. kW/2P
i-CM32/16- 5.5kW/2P
i-CM32/20- 3. kW/2P
i-CM32/20- 5.5kW/2P
i-CM32/20- .5kW/2P
i-CM40/13- 3. kW/2P
i-CM40/16- 3. kW/2P
i-CM40/16- 5.5kW/2P
i-CM50/13- 3. kW/2P
i-CM50/13- 5.5kW/2P
i-CM50/13- .5kW/2P
i-CM40/20A- 5.5kW/2P

1.2 Applications:
i-CM pumps are mainly used for chemical and process handling
applications which are free from suspended solids/particles.
1.3 Nameplate information:
Every pump has the following nameplate fitted on
pump provided with necessary identification of the
pump and its specific hydraulic characteristics.
The nameplate must not be removed. Loss of this plate
could make identification impossible. This in turn could
affect safety and cause difficulty in obtaining spare parts.
Such accidental loss or damage if occur, contact KBL
immediately.

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1.4 Pumps when properly installed and given due care in
operation and maintenance should operate satisfactorily
for a long period of time.
1.5 When the pump is received, sometime before the
actual use of pump, it should be inspected and located in
dry place. The shaft should be rotated once in a month
to prevent pitting of bearing surfaces.
1.6 General Information
Before performing any actions detailed within this
instruction, the site Health and Safety instructions and the
instructions in this document shall be read and fully
understood. Whenever the equipment is operated, maintained
or used in any way, the procedures detailed within these
instructions shall be followed. The pump supplied by
Kirloskar Brothers Limited (KBL) has been designed with
safety in mind; where hazards cannot be eliminated, the risk
has been minimized by the use of guards and other design
features. Some hazards cannot be guarded against and the
instructions below MUST BE COMPLIED WITH for safe
operation. These instructions cannot cover all circumstances.
It is the responsibility of the user of the equipment for
maintaining safe working practices at all times. The pumps
are supplied with stickers for hazard, caution and safety
wherever these are applicable.

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1.6.1 KBL products are designed for installation in
designated areas, which are to be kept clean and free
of obstructions that may restrict safe access to the
controls and maintenance access points.
1.6.2 Access to the equipment should be restricted to the
personnel responsible for installation, operation and
maintenance and they must be qualified, adequately
trained and supplied with the appropriate tools for
their respective tasks.
1.6.3 Access to the equipment should be restricted to the
personnel responsible for installation, operation and
maintenance and they must be qualified, adequately
trained and supplied with the appropriate tools for
their respective tasks.
1.6.4 This product must be serviced by qualified
personnel who are familiar with the design and
operation of this product and the system with the
essential safety aspects involved.
1.6.5 KBL firmly insists that all personnel responsible for
installation, operation and maintenance of the
equipment must read the manual before any work is
done.
1.6.6 Our guarantee will be valid only if the installation,
operation, maintenance and repairs of this pump are
carried out in accordance with these instructions.
The plant operator is to make sure that the contents
of these instructions are fully understood by the
operating personnel. During operation, periodic
inspections should be made to ensure safe operation
under the prevailing conditions.
1.6. Ear defenders should be worn where the specified
equipment noise level exceeds locally defined safe
levels. Safety glasses or goggles should be worn
where working with pressurized systems and
hazardous substances. Other personal protection
equipment must be worn where local rules apply.

1.6.8 Any modification may be made to the product
Only after consultation with the manufacturer.
Using spare parts and accessories authorized by
the manufacturer is a relevant safety aspect. Only
genuine spare parts which are in accordance with
the original delivery (in the parts list) are to be
used.
DO NOT wear loose or frayed clothing
or jewellery, which could catch on
the controls or becomes trapped in the
equipment.
1.7 Operation of the equipment for the application
other than for which it is supplied can increase the
risk from hazards. Please consult KBL before
making such change in the application of the
equipment.
1.8 Improper installation, operation and maintenance
of the product supplied by KBL could result in
injury or death.
Within the manual, safety instructions are marked
with safety symbol.
Im ortant:
Before operating canned motor pump, please read these "Instruction Guidelines"
and "Caution Notes for Your Safety" to avoid wrong operation or work. The same
is necessary for your safety and avoiding disaster.
LOCK THE ROTOR USING LOCKING PLUG WHILE PUMP IS IN TRANSIT.
Refer to This Material Often and Make Work lace Safety.
DANGER AND CAUTION
DANGER CAUTION
CAUTION

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Ignoring this warning can cause personal injury and or damage to the pump.
DO NOT RUN DRY!
If the pump is allowed to run dry, the bearings, sleeves and other components can
be damaged and serious overheating of the stator winding can occur.
AVOID RAPID TEMPERATURE CHANGES!
Sudden changes in temperature must be avoided. Rapid changes can cause leakage
through gaskets. Published procedures for proper heating and cooling must be
followed. If published procedures are not available consult to nearest KIRLOSKAR
office before starting the pump.
HOT - DO NOT TOUCH!
Motor and pump can be hot, even when pumping is stopped.
IF MOTOR TRIPS, DO NOT RESTART BEFORE DETERMINING THE CAUSE!

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Restarting the motor before finding and rectifying the cause may result in
excessive heat generation in the equipment thereby causing pump or motor failure.
DO NOT REMOVE INTERNAL BOLTS IN TERMINAL BOX!
If it is necessary to open the terminal box assembly for any reason, first ensure
that mains supply is switched off. Then loose the bolts of terminal box cover by 2
or 3 turns to release internal pressure or liquid if any present in the assembly. You
must take all safety measures before opening the terminal box assembly.
DO NOT REMOVE ANY BOLTS ON PUMP, MOTOR OR DRAIN PLUGS!
The internal pressure can be higher than the atmosphere. Always loose the drain
plug slowly to relieve any internal pressure before attempting to dismantle the
pump. You must take adequate precautions, as the liquid in the pump can be
hazardous to personnel or the environment.

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ALWAYS ASSUME THAT THERE IS LIQUID LEFT IN THE PUMP!
There is always possibility that the pump and motor may contain residual liquid in
spite of proper draining out. Pay particular attention to the clearances between the
shaft and the impeller, bearings, sleeves, bearing housings and gaskets. You must
take adequate precautions to protect personnel and the environment if the liquid
could be considered hazardous.
2) CONSTRUCTION:
The KIRLOSKAR make Canned Motor Pump ‘i-CM’ is of mono-block construction
consisting of volute case pump and water cooled electric motor with class ‘F’
insulation. The driving electric motor is canned and is inbuilt with the pump. The
stator and rotor are hermetically sealed with a thin metal “CAN”.
The pump has no sealing device such as mechanical seal or gland packing and
never allows any leakage of the liquid. The liquid being pumped lubricates the
bearings. A portion of liquid coming from delivery casing enters into the rear
cover. Openings are provided on the rear bearing housing through which it flows
into the bearings and motor assembly. Thus, the liquid lubricates the bearings and
also removes the heat generated in the motor compartment. Further it passes
through front bearing housing, thereby lubricating front bearing and taken out to
the backside of impeller inside delivery casing.
For details refer cross-sectional drawing enclosed .
3) UNPACKING, STORAGE:
1) After unpacking at site, ensure that the material received is free from any
damage and is as per specifications.
2) If any part is found to be damaged or short supply, please report it to
KIRLOSKAR BROTHERS LIMITED, PUNE.
3) Pump is handled from store to installation site with due care so as to avoid any
damage to the utility piping and pump internals.
3.1 Storage:
3.1.1 Temporary Storage for up to six weeks.
If the pump unit is not to be used immediately it should be stored
carefully in a horizontal position, in a sheltered, dry location.
Additional rust preventive should be applied to all unpainted carbon

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steel or cast-iron parts and should not be removed until final
installation.
3.1.2 Long Term Storage.
If the pump is not to be installed and operated soon after arrival,
store it in a clean, dry place, having slow, moderate changes in
ambient temperature. Step should be taken to protect the pump
from moisture, dust, dirt and foreign bodies. It is recommended
that the following precautions to be taken:
a) Ensure that suction and discharge branches of the pump and all
other openings are covered with cardboard, wood or masking tape
to prevent foreign objects entering the pump.
b) If the pump is to be stored where there is no protective
covering, it is advisable to cover the unit with a tarpaulin or other
suitable covering.
4) INSTALLATION AND PIPING CHECK POINTS:
During installation, please ensure the following –
 The pump mounting floor is leveled.
 The Stator Band bracket is firmly anchored to the floor with the help of
foundation bolts.
 Check for alignment of piping with pump nozzles is correct by loosening suction
and delivery flange nut/bolts, so that undue forces are not transferred to the
pump. Ensure gaskets and orifice plates are provided as applicable. Ensure firm
tightening after providing suitable supports to the piping and after completing
flushing of suction/delivery piping between strainer and NRV.
 Verify that suction strainer element provided is as per recommended mesh size
and suitable opening area.
 Check for correct installation of suction side compound gauge and delivery side
pressure gauge.
5) ELECTRICAL CONNECTIONS:
 Check the Earthing connection is provided to the pump motor.
 Open terminal box cover and check the winding insulation resistance and
continuity.
 Check for correct sizes, ratings and settings of relays/contactors to suit the
current drawn by the motor over the operating range. Complete wiring

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connections for power cables and control cables (for motor protection unit and
temperature control unit) as per wiring diagrams and with recommended cable
sizes.
6) UTILITY CONNECTIONS:
 Provide suitable drain piping with isolation valves to pump and motor drain
connections.
7) OPERATION:
STOPPING THE OPERATION / SHUT-DOWN:
1. Stop the power supply to pump.
2. Close delivery valve and vacuum equalizing valve.
3. Open drain valves on pump casing and motor.
4. Remove strainer element in suction i ing, check and clean for clogging, if
any and re lace the strainer element.
8) ASSEMBLY AND DISMANTLING OF THE PUMP :
Pre aration for Assembly:
Clean all the parts with cleaner / acetone to remove dust, dirt and foreign
particles, if any.
Assembly:
I) Bearing Housing Assembly:
Insert the bearing (3530001) in the front bearing housing (2400001) and
rear bearing housing (2400101) with the slotted end of the bearing facing
outwards.
Also confirm the orientation of bearing with respect to thrust washer
(3630001). Insert bearing firmly till it touches the end of the bearing
housing. Tighten the set screw of bearings such that bearings can move
slightly right and left.
II) Rotor Assembly:
Assemble thrust washer (3630001), shaft sleeves (3100001) along with
keys on the rotor. Lock the shaft sleeve (3100001) and spacers at rear side
with the help of lock washer and end nut on the assembly.

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Note : A figure in bracket indicates respective part nos.
III) Pum Motor Assembly:
Assemble the rear bearing housing at rear end of stator assembly with the
help of bolts and washers. Slowly insert the rotor assembly in the stator
assembly till the rotor assembly rests on rear bearing face. Avoid hitting of
rotor assembly on rear bearing face. Also take necessary care to avoid
rubbing of rotor assembly with stator liner while inserting rotor assembly.
Put the front bearing housing assembly on the stator assembly with the help
of hexagonal socketed head cap screw. Clamp the adapter plate/liner disc
(9480001) on the stator assembly taking guide of the studs. Fix adapter
plate (9480001) with the help of nut. Put the front side spacer (3100101)
on the rotor assembly. Assemble and tighten the impeller (1510001) on
rotor assembly along with washer for impeller, lock washer and impeller nut.
Lock the impeller nut. Put casing (10 0001) on the adapter plate (9480001)
by taking guide. Tight the casing. Tighten drain plug in the casing.
Fix the rear bearing housing (2400101) on the stator band assembly from
back side. Assemble the stand (9200001) and base (3800001).
Do the piping. Check the axial lift of the rotor, which should be within 0. 5
to 1.0 mm.Check free rotation of rotor after assembly.
IV) Dis-assembly:
Disassembly of Pum Portion:
Disconnect the motor wiring. Mark the disconnected leads so that errors
may be avoided during reconnection.
Disconnect the pump from suction and discharge piping.
Remove the studs and nuts of pump casing (1050001) and adapter plate
(9480001). Remove casing.
Remove the impeller (1510001), lock washer and nut. Then take out
impeller.
Dis-assembly of Rotor Assembly :
Remove shaft sleeve (3100001), spacers, thrust washer (3630001) along
with keys (3240001 and 3240501) from front side of rotor.
Remove rear bearing housing (2400001) from back side.

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Remove the end nut from back side of rotor assembly by removing
hexagonal nut and lock washer from rear side of rotor.
Remove shaft sleeve (3100001), thrust washer (3630001) along with key
(3240001) from rear side.
Store small components like keys and fasteners in a separate container in
order to avoid loss of components during re-assembly.
Check ‘O’ rings / gaskets visually for any damage. Replace them if found
damaged.
9) MAINTENANCE:
Ins ection during o eration:
Ensure the Ammeter reading periodically during operation to check the following
parameters and stop the pump during any abnormal condition.
Ensure that the current drawn by the pump is within specified limit.
If the current drawn by the pump is more as compared to the rated current, then
find out the cause, rectify it and then only put the pump in operation.
During operation Ammeter must show steady reading of current drawn by the
pump. In case ammeter is deflecting abnormally, then pump needs attention.
Also take vibration readings on regular basis, so as to ascertain requirement of
attending pumps for maintenance at early stages.
Periodical Ins ection:
Conduct the regular inspection on KIRLOSKAR PUMP at least once a year to get
optimum service from the equipment. The checkpoints and checking procedure for
periodical inspection are summarized below.
Wear of Bearing
If the bearings are excessively worn out beyond the wear limit, then the stator
liner and rotor sleeve can rub against each other, leading to damage of stator-
liner/rotor sleeve.

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Life of Bearing
Since bearings are used in the liquid, its life depends on the characteristics,
temperature, etc., of the liquid. Usually, the bearings are durable enough for half
year or longer (approx. 4200 hr) of continuous operation in liquid, equivalent to
water. Since some liquid and operation condition may decrease life of bearing,
the bearings should be checked more often than twice in a year.
Table-1 shows wear limit for replacement of bearings.
When inspecting bearings, check shaft sleeves and thrust washers also.
Generally, shaft sleeves and thrust washers have longer life than bearings.
However, it is undesirable to continuously use the sleeves and washers, which
have defect on the surface because it will promote wear of bearings. In such
case, it is recommended that they be replaced together with bearings at the time
of replacement of bearings.
Table-1 Limit of Bearings Wear
Bearing
inside Dia
φ D (mm)
Shaft
Sleeve
OD(mm)
Dia. Clearance
Bearings to Shaft
Sleeve (mm)
35 34.9
Min.
0.2 Max. 0.23
Ins ection of Stator Liner and Rotor Sleeve
Check stator liner and rotor sleeve for flaw caused by contact or biting of foreign
matter. In case flaw is in such a degree that, it can be removed by polishing it
with smooth polish paper, then the same can be reused.
10) TROUBLE SHOOTING:
If delivery pressure gauge reading is substantially less, motor may be rotating in
reverse direction. In case of reverse direction of rotation note the following and
take the corrective steps accordingly.

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How to solve phase reversal problem:
Q1: Control Panel is not showing phase reversal, but motor is rotating in
reverse direction.
A1: Incoming supply terminated is correct, but motor terminal phase
sequence is wrong. Please interchange R and Y or Y and B or B and R at motor
terminal only.
Q2: Control panel is tripping on phase reversal and motor is also rotating in reverse
direction.
A2: Incoming supply phase sequence is incorrect, please interchange Y and B at
incoming terminal only. Motor terminal sequence is correct.
Q3: Control panel is tripping on phase reversal, but motor is rotating in correct
direction.
A3: Incoming supply phase sequence is incorrect and also motor terminal phase
sequence is incorrect. Please interchange Y and B terminals at incoming and also
interchange Y and B at motor terminal.
Sym tom, cause and remedy of troubles are summarized: In many cases, trouble
is generally caused by lural causes, which are affecting each other, so that a
cause of trouble cannot be easily defined.
However, it is recommended to use contents of following table as a guideline.
(As the pumps are manufactured with special design, almost every part may not be
readily available from our stock. It is recommended therefore that when spare
parts are used, they should be replenished promptly).

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TROUBLE SHOOTING CHART
Phenomenon Cause Remedy
Pump does not start. 1,2,3,4 1,2,3,4
Pump does not deliver. 13,15 13,15
Pump does not deliver rated
flow.
5,12,13,14,15,16 5,12,13,14,15,16
Pump does not deliver rated
pressure.
5,12,13,14,15,16,18 5,12,13,14,15,16,18
Insufficient flow. 5,8,9,12,14,16 5,8,9,12,14,16
Over current of motor. 1,2,3,8,9,12,13,16,
1 ,18
1,2,3,8,9,12,13,16,
1 ,18
Over heating of motor. 1,2,3,8,9,13,16,1 ,18 1,2,3,8,9,13,16,1 ,
18
Vibration. 6, ,8,9,10,11,12,14,
19
6, ,8,9,10,11,12,14,
19
Noisy operation. ,8,9,10,11,12 ,8,9,10,11,12
Bearing seizure. 3,6, ,10,12,19 3,6, ,10,12,19
When liquid temperature
decreases, pump does not
deliver and electric current
increases.
15,16,1 15,16,1
Sr.No. Cause Remedy
01 Electric power supply. Check wiring, motor winding, fuse, etc.
02 Deterioration of insulation
resistance.
Check insulation resistance. Remove
moisture from motor.
03 Rotor lock. Dismantle and check biting due to seizure
of bearing or contact of rotor assembly.
04 Corrosion of can. Repair or change stator assembly and
rotor assembly. Change can material.
05 Corrosion of impeller. Repair or change. Change impeller
material.
06 Wear or corrosion of shaft
sleeves.
Change. If there are any problems,
change material.

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0 Wear of bearings. Change.
08 Contact of impeller and
casing or liner disk.
Readjust. Change bearing.
09 Defective thrust balance. Readjust.
10 Bending of shaft. Repair.
11 Vibration/surging in piping
system.
Check piping system. Eliminate cause.
Piping should be made not to have
surging.
12 Mixture of foreign particles. Check piping system. Check strainer.
13 Wrong rotation direction. Reconfirm direction of rotation and
correct the wiring.
14 Clogging of impeller. Clean and eliminate cause of clogging.
15 Excessive resistance (head)
on discharge side.
Re-select pump. Recheck piping system
on discharge side.
16 Where liquid viscosity larger
than specified.
Adhere to that of specified.
1 Where specific gravity of
liquid larger than specified.
Return to that of specified.
18 Excessive flow delivered. Check discharge side valve to get rated
flow.
19 Clogging of strainer. Check, clean the strainer.

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Trouble shooting Summary
Problem Possible Cause Solution
Pump does not
rotate.
Pump does not
deliver the
liquid.
Foreign matter in pump.
Input power circuit
breakers
tripped.
Bearings damaged.
Pump running dry; no
priming.
Discharge pressure too
high.
Remove foreign matter from
pump.
Reset circuit breakers.
Check motor electrical
circuits.
Repair pump.
Fill pump with liquid.
Open discharge valve.
Remove obstruction.
Pump is
delivering less
liquid.
Foreign matter in pump.
Pump running dry; no
priming.
Discharge pressure too
high.
Suction pipe leaks.
Remove foreign matter from
pump.
Fill pump with liquid.
Open discharge valve.
Tighten the pipe connections.
Fluctuation in
pump
discharge.
Air in suction line.
Leakage in suction pipe.
Tighten connections to stop
leaks.
Tighten pipe connections.
Pump drawing
more current
than
rated current.
(Overload).
Foreign matter in pump.
Discharge pressure too
high.
Remove foreign matter from
pump.
Open discharge valve.
Noise in the
pump.
Foreign matter in pump.
Pump running dry without
priming.
Worn out bearings.
Remove foreign matter from
pump.
Fill pump with liquid.
Replace bearings.
Leakage from
the pump
assembly.
Casing corroded or
damaged.
Leakage in cooling pipe.
Replace the pump.
Locate the leakage and
remove it.
Or replace the pipe.
Tighten pipe connections.

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11) List of Recommended S ares:
Sr.No. Part Descri tion Part No. Quantity
(Nos.)
1 Bearings 3530001 2
2 Thrust washer front 3630001 1
3 Thrust washer rear 3630001 1
4 Impeller nut 3300001 1
5 Gasket for pump casing and adapter
plate
8 50001 1
6 Gasket for stator assembly and
adapter plate
8 50101 1
Gasket for stator assembly and rear
cover
8 50201 1
8 Shaft sleeve 3100001 2