KSB Multiboost Instruction Manual

Operating Instruction Manual
Multiboost - Multistage Booster Motor Pumps
Our technology. Your success.

MULTIBOOST
Index
Sr.No. Contents Page No.
1 General 1
1.1 Safety of pumping unit 1
1.1.1 Check & Safety of pumping unit 1
1.1.2 Instructions on unit (Printed Matter) 1
1.1.3 For unauthorized spare part and modifications 1
1.1.4 For unauthorized modes of operation 1
1.1.5 Water characteristics 2
1.2 Description of product 2
2 Installation 2
2.1 General 2
2.2 Assembly parts 3
2.3 Piping 4
2.4 Priming the Pump 4
2.5 Important 5
2.6 Verification of power line with respect to motor design 5
2.7 Starting Mode 6
3 Commissioning and start up 8
3.1 Verification of rated current 8
3.2 Switching ON of mains 8
3.3 Checking the direction of rotation 8
3.4 Operation against a closed discharge valve 8
3.5 Operation against a throttled discharge valve 8
3.6 Operating limits of pump 9
3.7 Switching frequency 9
4 Maintenance 9
5 Services 10
6 Recommended stock of spares 10
7 Trouble shooting 11
8 Sectional Drawing (Multiboost) 12
Annexure I – Environmental Protection – 13
Product Disposal after useful life

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1. General
Multi-boost multistage surface motor pumps by KSB have been developed in
accordance with state of the art of design and manufacturing technology with
extreme care and rigid quality control. The manual contains important information
for reliable operation of pump.
The special feature of these mutiboost multistage surface pumps is automatic
operation through a pressure switch depending on the discharge pressure. These
systems are useful to pump clean water for pressure boosting applications in small
bungalows / flats or even individual bathrooms, domestic supply systems, irrigation
systems, fountains etc.
For any additional information or instructions please contact KSB's nearest office.
1.1 Safety of pumping unit
This operating manual contains fundamental installation, operation and maintenance
instructions. Hence this must be clearly understood by concerned people, prior to
installation. The booklet must always be located for easy access at site.
1.1.1 Checks & Safety of pumping unit
Check for any transit damage. After unpacking inspect the pump motor, tank, switch
and accessories for any signs for the damage of the lead cable.
This operating manual does not take into account any safety regulations those may
apply. It’s a pump operator’s responsibility that any such regulations are adhered to.
1.1.2 Instructions on unit (Printed matter)
Follow the instructions attached on the motor / pump e.g.
• Arrow indicating the direction of rotation.
• Various plugs for water connections viz. priming, venting, etc. on motor.
1.1.3 For unauthorized spare part and modifications
Modifications or alterations of the equipment supplied are strictly not permitted.
Original spare parts and accessories authorized by the manufacturer ensure safety.
The use of spurious parts invalidates any liability of the manufacturer for
consequential damage.
1.1.4 For unauthorized modes of operation
The warranty related to the operation reliability and safety of the unit supplied is
valid only if the equipment is operated according to designated parameters. The
operating limits should not differ from the limits specified on the nameplate.

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1.1.5 Water characteristics
Multistage open well surface pumps are designed for handling the clean or slightly
contaminated water with the following main characteristics: (As per IS 9079 : 2002)
a) Turbidity : 50 ppm*, Max (Silica scale)
b) Chlorides : 500 ppm*, Max
c) Total Solids : 3000 ppm*, Max
d) pH value : 6.5 to 8.5
e) Temperature : 33º C, Max
f) Specific gravity : 1.004 Max
g) Hardness : 300, Max (Drinking water)
* ppm - parts per million
1.2 Description of product
2. Installation
2.1 General
• Install the pump on a rigid foundation having enough strength to absorb any
vibration and shock. Never fix the pump at an inclined position. (See Figure 2)
• Install pump in a dry place and make it safe from any possible flooding. Proper
shielding should be provided to protect the pump set from direct solar radiation
and rain.
• The pump set operates on electrical power supply and poses electric power.
Adequate care must be taken to avoid accident.
Type Series
3
Nominal flow in m /hr
No. of Stages
KHM 04 02
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Fig. 1
Foundation
Bolt & Nut
Rubber Pad
2.2 Assembly Parts
• The Multi-boost system is available with 24 lit. Vertical tank. Along with the pump
and accumulator tank - a non-return valve, 5 way connector, pressure gauge,
pressure switch, and necessary connectors / fasteners shall be part of the supply.
Refer exploded view figure 2.
8
5
6
7
2
1
4
3
Fig 2
1. Pump
2. Hex. Nipple
3. O-ring
4. 5 Way Connector
5. Danfoss Pressure switch
6. Pressure Gauge
7. NRV
8. Tank
Sr. No. Part Name
MULTIBOOST

2.3 Piping
a. Use ISI marked PVC / HDPE pipes for suction and delivery.
b. Use only recommended pipe size for suction and delivery, as using smaller pipe
size will affect the discharge and total head. The pipes must be well supported to
avoid transmitting stress to pump body, which leads damage to the pump parts.
c. Reduce number of bends, T-joints and valves in the pipe line. Use elbows with
smoother bends as far as possible.
d. Do not use fibers / threads for pipe joints. Always use Teflon tape for joining pipe
threads.
e. Foot valve is required at end of suction pipe. Use good quality 'low friction' foot
valve for getting better performance .
f. Ensure that the foot valve is placed minimum 0.5 mtrs above the base level / floor
level of the well to avoid an entry of muddy water. The foot valve needs to be
submerged minimum 1 meter below water level, to prevent entry of air into pump
which can damage the pump due to cavitations.
The suction height from water level to the pump suction nozzle level should not be
more than 6 mtrs minus suction line losses to avoid cavitations and damage to the
pump.
2.4 Priming the Pump
Priming the pump set as shown in figure 3 is necessary at first startup and then as and
when required.
Ensure that the casing is filled adequately with water before starting. If the pump set
is idle for a very long duration
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Suction Pipe Securing Clamp
to avoid load on the
Suction Flange
GL GL
Delivery
Maximum
(6 mtr. minus
Suction line
losses)
2.0 mtr
min.
0.5 mtr
min.
0.5 mtr
min.
Foot Valve
More thread length will damage the
foot valve
Well
Fig. 3
2.5 IMPORTANT
• Never run the pump set with delivery valve closed or in dry condition to prevent
damage to the mechanical seal. The pump set must be protected from rain.
• Ensure the motor is ON at-least once in day for a few minutes to maintain freeness.
2.6 Verification of power line with respect to motor design
Verify the voltage and frequency of main supply with the data given on the pump set
nameplate.
If it is not matching then consult with concerned electrical authority.
Ensure that the main power supply is stable.
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2.7 Starting Mode
• The supply to the motor must be given through the pressure switch.
• The connection must be done as given in figure 4.
• The switch must be connected in series with the motor in live / phase terminal.
• Do not change the settings of pressure switch. In case any doubt contact nearest
authorized service center
Fig. 4
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Typical examples of name plate:-
Pump name plate:-
• Refer nameplate for the values
• As KSB products are subject to continuous design improvements, KSB reserve the
right to modify / change the parts, performance without any notice
• The sample name plate is as shown in figure 5.
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Fig. 5
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3 Commissioning and start up
3.1 Verification of rated current
Please refer to the motor nameplate for the values of rated current required for relay
setting.
3.2 Switching ON mains
The pump set should be switched ON only if water level in well/sump is above limit
given in figure 2.
3 .3 Checking the direction of rotation
For Three-phase motors
1) Let the pumping set run for a short time against a closed discharge valve, in both
the directions of rotation and check the flow. Reversing of poles of connection,
reverses the direction of rotation. The higher flow rate gives the direction of
rotation. OR
2) Using pressure gauge, check the discharge pressure in both the direction of
rotations. The higher value corresponds to the correct direction of rotation. OR
3) By visual inspection see the flow rate in both cases. If water comes out up to the
short length through the raiser pipe, flow rate is lower while if it comes farther,
results in higher flow rate. The higher flow indicates the correct direction of
rotation.
For Single-phase motors
In case of single-phase AC motors the direction of rotation of the motor itself
corresponds to the correct direction of rotation of the pump, irrespective of mode of
connection to the power supply.
3.4 Operation against a closed discharge valve
Pumps should not be allowed to run against a closed discharge valve for longer than 5
minutes. This would cause the water in the pump to warm up quickly and the heat
would be transferred to the motor, which causes a risk to the motor.
3.5 Operation against a throttled discharge valve
If the pump set is to be operated against a throttled discharge valve for a prolonged
period of time, the minimum rate of flow should be at least 10% of flow at the best
efficiency point * (BEP) of the characteristic curve, this must be observed in order to
reduce noisy operation and the overheating of the pump set.
* For best efficiency point (BEP) of the characteristic curve consult with KSB dealer.
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