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

MULTIBOOST
1
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.

2
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
MULTIBOOST

3
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
4
MULTIBOOST

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.
5
MULTIBOOST

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
MULTIBOOST
6

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.
MULTIBOOST
Fig. 5
7

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.
MULTIBOOST
8

MULTIBOOST
Actual start-up
• Check the power supply condition as per the name plate
• Do proper earthling
• Fix the pressure gauge before control valve
• Set the relay as per current value given on name plate and start the pump.
• Set the duty parameters as per value given on name plate by control valve.
• Pump should run always on duty point specified on name plate
3.6 Operating limits of pump
Operational safety requirements stipulate that pump may only be operated
continuously within the flow rate and pump head limits which are specified on
operation range, provided that motor is not overloaded.(For ensuring this the motor
current should not exceed as specified on name plate)
3.7 Switching frequency
• In order to prevent the motor from heating up excessively due to many switching
cycles, a maximum of 15 starts per hour are permitted with a minimum of 3
minutes interval as a shut down period between two successive starts.
• It is advice able to run pump set for a few minutes to maintain freeness.
4 Maintenance
 Leakage through Mechanical Seal :
• Replace the mechanical seal if there is excessive leakage through it. The following
precautions to be taken while replacing a mechanical seal failure.
• Keep all the seal parts clean during handling. Any dirt or foreign particles on the
seal surface could cause a premature seal failure.
• Vibration of pump set may cause seal failure. Hence try to prevent vibrations in
pump set.
• Through cleaning of the housing is necessary before fixing counter face (stationary
ring – ceramic or metal ring in runner L ring) to eliminate all the dirt in that area.
• The outer diameter of the stationery L rubber ring and housing should be slightly
moistened with 10% of liquid soap and 90% of clean water. Using a brush moisten
the shaft and interior of seal with soap solution. Do not immerse seal in the
solvent.
• Always use fitting tube of fixing the counter face. Ensure that the counter face is
perpendicular to the shaft. Do not hammer the fitting sleeve.
9

• Before fitting the sealing ring (rotating part), clean the shaft with a solvent
(petrol or thinner), Fitting tube is necessary for placing the sealing ring in its
working position. Push the seal smoothly to contact ring face. Do not hammer the
fitting sleeve while fitting the sealing ring.
• During installation see that no dirt or foreign partials are housed inside the seal
chamber.
• Never run the pump-set dry
• While replacing an old mechanical seal, do not use old sealing ring with new
counter face or old counter face with new sealing ring. Always replace the seal
entirely.
 Airtight joint : Check for airtight ness of the joints in the suction pipe and casings.
 Strainer : Ensure that the clogging does not take place in strainer. Clean the
strainer periodically.
5 Services
• Do not attempt to open the Pump set for repair that will render our warranty null
& void.
• Please take up with Authorized Service Center or to the concerned dealer.
• Unauthorized repairs are not permitted since they cause poor performance and
shorter life of the pump set.
6. Recommended stock of spares parts for 2 years of
continuous operation
MULTIBOOST
Part No. Description No. of Pump (including Stand by Pumps)
1 3 4 5 6 8 10 (More)
160 Fan cover - - 1 2 3
230 Impeller - - 1 2 3
433 Mechanical seal - - 2 3 4 sets
545 Bearing - - 2 3 4
829 Cable grommet - - 2 3 4
831 Fan cover - - 2 3 4
10

MULTIBOOST
Problem Probable Cause Possible remedy
Motor does not start No power supply Check power supply, and panel
board connection diagram
Impeller is jammed Check if pump internals are clogged
and clean them.
Capacitor has failed Replace the capacitor as given.
Thermal overload protector Allow the motor to cool and switch
(T.O.P.) is open due to over ON. Install the pump set in a more
heat ventilated are, do not wrap the
pump with air tight materials,
avoid installing the pump near to
the heat generating equipment's.
Low voltage / Speed low Check supply voltage and operate
only if supply condition are healthy.
Pump does not deliver Speed is too slow Check supply voltage and frequency.
Water Air enters in the suction pipe Make air tight joints / if required
replace the pipe.
No water in the pumpset Fill water in pump casing.
Mechanical seal is leaking Refit the mechanical seal or
replace it.
Foot valve is not working Refit or change foot valve.
Foot valve is not submerged Lower the foot valve.
Pump discharge is less Suction lift (water level to Ensure that the suction lift is not
pump suction nozzle level) more than maximum recommended
too high. lift, if required lower the pump level.
Suction pipe inlet inadequately Increase submergence to
submerged in water recommended level.
Suction pipe / foot valve is Clean the pipe / foot valve.
clogged
Site head is higher than Select alternate suitable pumpset.
selection
Too many bends in suction Try to reduce the number of bends.
pipe
Pipe size diameter is smaller Use pipe of correct diameter.
than recommended
Fuse blow off frequently Improper pumpset selection Select suitable pumpset.
Pump set consumes
excessive power Lower voltage Wait for proper line voltage.
Bearings have short life Rotor excessively out Replace the rotor.
Lack of lubrication Ensure proper lubrication.
Excessive grease in bearings Remove excess grease from the
bearings.
7. Trouble shooting
11

MULTIBOOST
Part No. 106 108 145 160 230 300.01 300.02 361
Part No. 433 525.01 525.02 554 816 818 81-7 829
Part No. 833 903 905.01 905.02 912 920 922
Part Name Suction casing Stage casing Adapter Cover Impeller Ball bearing (NDE) Ball bearing (DE) End cover
Part Name Mechanical seal Stage sleeve Stage sleeve top Spacer sleeve Stator body Rotor Terminal board connector Cable gromet
Part Name Terminal box Threaded cap Tie rod pump Tie rod motor Drain plug Hex. nut Impeller lock nut
8. Sectional Drawing (MULTIBOOST)
12
920
903
912
106
922
525.02
525-01
905.01
108
230
554
433
145
300.02
816
829
81-7
833
905-02
818
300-01
361
831
160

MULTIBOOST
Annexure I – Environmental Protection – Product Disposal after
useful life
• Products manufactured by KSB are designed with an extreme care for
environmental protection. Innovative designs and wide product ranges take
care of customer’s requirements reducing material and electrical energy
consumption. Product materials are recyclable. Our customers are educated with
environment friendly methods of disposing product ingredients at the end of
product useful life. Please find herewith methods of disposing used ingredients.
• Environment Protection measures during product disposal – All the parts of
motors, pumps and accessories like tank, pressure switch etc. should be disposed
through authorized re-processor.
13

Zonal Offices :
Chennai : Guindy House, 2nd Floor, 95 Anna Salai, 600 032.
Tel.: [phone] Fax : [phone]
Kolkata : 30, Circus Avenue, 2nd Floor, 700 017.
Tel.: [phone] Fax : [phone]
Mumbai : 126, Maker Chambers III , Nariman Point, 400 021.
Tel.: [phone] Fax : [phone]
NOIDA : KSB House, A-96, Sector IV, Dist. Gautam Budh Nagar 201 301.
Tel.: [phone] Fax : [phone]
Service Stations :
Chennai : No.4, (Old No.18), Chakrapani Road, Guindy, 600 032. Tel.: [phone]
Raipur D-62, Sector - 2, Devendra Nagar, P.O. Pandri, Raipur - 492 001. :
Tel.: +91 771 - 2583658, 2583921 Fax : +91 771 - 2583921
NOIDA : KSB House, A-96, Sector IV, Dist. Gautam Budh Nagar 201 301. Tel.: [phone]
Odhav : Shed 22, Gujarat Vepari Mahamandal, Ahmedabad 382 410. Tel.: [phone]
Branch Offices :
Ahmedabad : Shed No. 22, Gujarat Vepari Mahamandal, Odhav, Ahmedabad - 382 410.
Tel.: +91 79 - 22900707, 22900717
Aurangabad : Plot No. P-204, Shivshankar Colony, Near Hotel Sayli, Aurangabad - 431 005.
Tel.: [phone] Fax : [phone]
Bangalore : 191, 1st Floor, West-off-Chord Road, 2nd Stage, 560 086.
Tel.: [phone] Fax : [phone]
Baroda : 4-B, Ramakrishna Chambers, Productivity Road, 390 005.
Tel.: [phone] Fax : [phone]
Bhubaneswar : N5/39, (1st Floor), IRC Village, Nayapalli, 751 013.
Tel.: [phone] Fax : [phone]
Chandigarh : S.C.O. 71, 2nd Floor, Sector 30-C, 160 030.
Tel.: [phone]Fax : [phone]
Indore : B-14, Ratlam Kothi, Kanchanbaug Road, 452 001
Tel.: [phone] Fax : [phone]
Jaipur : Anjali Chambers, 2nd Floor, C Block, 10, Raj Bhavan Road, Civil Lines, 302 001.
Tel.: [phone] Fax : [phone]
Jamshedpur : UG-4, Gangotri House, 'Q' Road, Bistupur, 831 001.
Tel.: [phone] Fax : [phone]
Lucknow : 309, Chintel's House, 16, Station Road, 226 001.
Tel.: [phone] Fax : [phone]
Nagpur : 203, Suryakiran Complex, Bajaj Nagar, 440 010.
Tel.: [phone] Fax : [phone] (P.P.)
Mumbai : 126, Maker Chambers III , Nariman Point, 400 021.
Tel.: [phone] Fax : [phone]
Pune : Aamod Apartments, ‘B’ Wing, Block No. 33, Behind Hotel Shravan,
Opp. Police Ground, Off Fergusson College Road, Pune - 411 016.
Tel.: +91 20 - 25650393 / 394 / 396 / 398
Raipur : House No. C/40, 1st Floor, Sector-2, Devendra Nagar, C.G.
Tel.: [phone] Fax : [phone]
Secunderabad : D.No. 12-13-197, 198, Flat No. 103 & 104, 1st Floor, Pavani Anusuya Towers,
Tarnaka, 500 017. Tel.: [phone] Fax : [phone]
Technical matter subject to change without notice.
Mktg. Services / 05-17 / 500
KSB Pumps Limited
Standard Pumps Division
Plot No. E3 & E4, MIDC Sinnar, Nashik - 422 113.
Tel.: [phone] / 253, 229700 Fax : [phone] www.ksbindia.co.in