TSU - EW Process
INSTALLATION &
MAINTENANCE MANUAL
MODELS: KM1515 & KM2156
Issued November 4, 2004
KM
ANSI, ISO, JIS
FLANGED NON-METALLIC MAGNETIC
DRIVE PUMP
T. S. U.
♦♦♦♦Do not run dry ♦♦♦♦
This pump is NOT self-priming. The pump must
be filled with liquid before starting otherwise
severe damage may occur.
“Simple by Design”
Sundyne Corporation is ISO 9001-2000 compliant is certified by Lloyd’s Register Quality Assurance Limited.
1
TABLE OF CONTENTS
1-
LIMITED WARRANTY
5
2-
PUMP IDENTIFICATION
2-a Pump Code
6
3-
SAFETY CHECK LIST
7
4-
PRINCIPLE OF MAGNETIC DRIVE PUMPS
8
5-
PIPING & INSTALLATION
5-a Suction Piping
5-b Discharge Piping
5-c Foundation
5-d Electrical Connection
9
6-
PUMP START UP AND SHUTDOWN
6-a Pre-Start Check List
6-b Start-Up and Operation
6-c Shut-Down
12
7-
DISASSEMBLY FOR PREVENTIVE MAINTENANCE
7-a Separating the pump for Inspection
16
8-
ASSEMBLY
19
9-
SPECIAL PROCEDURES
23
10-
DRAWINGS
10-a Dimensional
10-b Exploded View
10-c Sectional
26
11-
PARTS LIST
28
12-
PUMP SPECIFICATIONS
30
13-
COMMON CONVERSIONS
30
2
EC Declaration of ConformityEC Declaration of Conformity
Manufacturer:
Sundyne Corporation
Details of
Equipment:
Model
Prefix
KF
KF
K
K
KM
KM
KV
KV
KP
KP
Alternative Model
Description
Description
ALA (PR, PS, QS, QT Couplings)
ALI (PR, PS, QS, QT Couplings)
ALA (A, B,C Couplings)
ALI (A, B, C Couplings)
ALA (AA, AB Couplings)
ALI (AA, AB Couplings)
VALA
VALI
SPALA
SPALI
Magnetic Drive
Sealless
Centrifugal Pumps
Harmonised Standards applied in order
to verify compliance to the Directive
MACHINERY DIRECTIVE 98/37/EEC:
EN 292-1 Safety of Machinery - Basic Concepts, general
EN 292-2/A1 Technical principles and specifications
(and amendment 1).
EN 809 Pumps and pump units for liquids - Common
Safety Requirements.
ATEX DIRECTIVE 94/9/EC:
N 13463-1 Non-Electrical equipment for potentially
explosive atmospheres.
Part 1: Basic method and requirements.
EN 13463-5 Non-electrical equipment
Part 5: Protection by constructional safety ‘c’.
Directives to which the above equipment
complies to:
Machinery Directive
Directive relating to Machinery (98/37/EC)
ATEX Directive
Directive on equipment and
protective systems intended for use in
potentially explosive atmospheres
(94/9/EC)
Group II Categories 2 and 3 (gas)
Notified body:
Intertek Testing and Certification
Ltd
Intertek House
Cleeve Road, Leatherhead,
Surrey, KT22 7SB
UK
Certification Numbers:
ITS03ATEX11180
ATEX Technical Construction File
Number:
ATEX-ANSIMAG-001
Year in Which CE Mark was affixed:
1996
We certify that Plastic Lined magnetically driven bareshaft, close-coupled, and separately mounted
pumps manufactured by the Sundyne Corporation meet the requirements of the above Directives,
when installed, operated and maintained in accordance with our published Installation and Operating
Manual. Plastic Lined magnetic drive pumps must not be put into service until all the conditions
relating to safety noted in these documents have been met.
Authorised Signatories on behalf of Sundyne Corporation:
Name:
Jeff Wiemelt
Position:
3
Vice President and General
Manager of Sundyne
Corporation, The Americas
Name:
Kerry Kramlich
Date of issue:
Position:
th
16 June 2003
Pump Engineering Manager
Place of Issue:
United Kingdom
SAFETY WARNING
Genuine parts and accessories have been specifically designed and tested for use with these products to
ensure continued product quality and performance. Testing cannot be performed on all parts nor on
accessories sourced from other vendors, incorrect design and/or fabrication of such parts and accessories
may adversely affect the performance and safety features of these products. Failure to properly select,
install or use authorised Sundyne parts and accessories is considered misuse, and damage or failure
caused by misuse is not covered by Sundyne’s warranty. Additionally, modification of Sundyne products or
removal of original components may impair the safety of these products and their effective operation.
EUROPEAN UNION MACHINERY DIRECTIVE
(CE mark system)
This document incorporates information relevant to the Machinery Directive 98/37/EC. It should be read prior
to the use of any of our equipment. Individual maintenance manuals which also conform to the EU Directive
should be read when dealing with specific models.
EUROPEAN UNION ATEX DIRECTIVE
This document incorporates information relevant to the ATEX Directive 94/9/EC (Directive on equipment and
protective systems intended for use in potentially explosive atmospheres). It should be read prior to the use
of any of our equipment.
Compliance to the Directive is based on Atmospheres having pressures up to but not exceeding 350psi and
temperatures ranging from –120 °F to + 250 °F depending on the model.
As indicated in the ATEX Directive 94/9/EC, it is the responsibility of the user of the pump to indicate to
Sundyne Corporation the Zone and Corresponding group (Dust or Gas) that the pump is to be installed
within. Should the pump be put into service in a potentially explosive atmosphere, the user of the pump
must put the grounding connector into use.
4
1.
Limited Warranty
One year limited warranty
Ansimag pumps are warranted by Ansimag to the original user against defects in workmanship
and materials under normal use for one year after the date of purchase. Any part returned to an
Ansimag- designated, authorized service location, shipping cost prepaid, will be evaluated for
defects. Parts determined by Ansimag to be defective in material or workmanship will be
repaired or replaced at Ansimag's option as the exclusive remedy.
Limitation of liability
To the extent allowable under applicable law, Ansimag's liability for consequential damages is
expressly disclaimed. Ansimag's liability in all events is limited to and shall not exceed the
purchase price paid.
Warranty disclaimer
Ansimag has made a diligent effort to illustrate and describe the products in this literature
accurately; however, such illustrations and descriptions are for the sole purpose of identification
and do not express or imply a warranty that the products are merchantable, or fit for a particular
purpose, or that the products will necessarily conform to the illustration or descriptions.
Except as provided below, no warranty or affirmation of fact, expressed or implied, other than as
stated in "LIMITED WARRANTY" is made or authorized by Ansimag.
Product suitability
Many states and localities have codes and regulations governing the sale, construction,
installation and/or use of products for certain purposes, which may vary from those in
neighboring areas. While Ansimag attempts to assure that its products comply with such codes,
it cannot guarantee compliance, and cannot be responsible for how the product is installed or
used. Before purchasing and using a product, please review the product application as well as
the national and local codes and regulations, and be sure that product, installation, and use
complies with them.
Warranty exclusions
Wear items that must be replaced on a regular basis are not covered under this warranty. Such
items include, but are not limited to mouth rings/pads, thrust rings, O-rings, bushings and shafts.
Items that have been subject to extreme heat or have been used with abrasive or incompatible
chemicals are not covered under this warranty.
5
2. PUMP IDENTIFICATION
Pump identification is provided on every KM pump or
wet end hipped. This 316 stainless steel nameplate is
located on the pump casing and secured by two rivets.
The serial number provided links to recorded data on
manufacturing specifications. Any further information
regarding the pump is available through local
distributors or factory direct.
Figure 2-1: KM Name Plate
2-a Pump Code
KM
1515
C
01
SERIES
KM-Series
KM
HYDRAULICS
1515
2156
1515
2156
CONFIGURATION
Close Couple
Wet End
Cartridge
C
W
NC
MOTOR FRAME SIZE
NEMA
IEC, JIS
Wet End
56
142/145TC
182/184TC
00
01
02
03
213/215TC
04
80 IEC & JIS
90 IEC & JIS
100/112 IEC & JIS
132 IEC & JIS
30
31
32
33
DRIVE SIZE
5HP
7.5HP
AA
AB
O-RING
Viton
EPDM
Gortex
1
2
4
WEAR PARTS
SIC / CFR-PTFE
SIC / SIC
Carbon / CFR PTFE
Carbon / SIC
1
2
3
4
WETTED MATERIAL
ETFE
GFR-PFA
1
2
PUMP CASE MATERIAL
CI / ETFE
CI / GFR-PFA
316 SS
Hastelloy C
1
3
4
6
PUMP CASE FLANGE
Universal (ANSI, ISO, JIS)
5
THIRD PARTY CERTIFICATION
None
ATEX / CE
0
A
6
AA
1
1
1
1
5
A
3. SAFETY CHECKLIST
The following checklist presents some
when working with magnetic drive pumps.
common precautions to remember
;
Warning! Magnetic Field Hazard. Magnetic drive pumps contain some of the
;
Warning! Hot Surfaces Hazard. These pumps are designed to handle liquids at
temperatures up to 250oF and will become hot on the outside. This creates a hazard of
burns to personnel coming in contact with the equipment.
;
Warning! Magnetic Forces Hazard. Use only the recommended disassembly and
;
Warning! Rotating Parts Hazard. The pump contains parts, which rotate during
operation. Before operation the pump must have the coupling guard secured in place and
be completely assembled. To prevent injury during maintenance the pump and/or driver
must be disconnected from the power source. Local safety standards apply.
;
Warning! Chemical Hazard. The pumps are designed to handle all types of
world's strongest magnets. These magnets are located in the impeller and outer drive
magnet assemblies. The powerful magnetic fields could adversely affect persons who are
assisted by electronic devices. Pacemakers and defibrillators are examples of these devices.
assembly procedures when separating the wet end from the drive end.
chemical solutions. Many are hazardous to personnel. This hazard could take the form of
leaks and spills during maintenance. Plant procedures for decontamination should be
followed during pump disassembly and part inspection. There is always the possibility of
small quantities of liquid being trapped between pump components
;
Caution! Magnetic Field Sensitive Items. Do not put magnetic field sensitive
items such as credit cards, floppy diskettes or magnetic tapes near the impeller or drive
magnet assemblies.
;
Caution! Metal Tools. Do not use steel or iron tools near magnets. Steel tools such
as wrenches and screwdrivers are easily attracted to magnets and can break them on
contact.
7
4 . PRINCIPLE OF MAGNETIC DRIVE PUMPS
Attraction
OUTER DRIVE
MAGNET
ASSEMBLY
repulsion
NO LOAD
LOAD APPLIED
INNER DRIVE MAGNET
ASSEMBLY
Figure 4-1: No load
Figure 4-2: Load applied
Figure 4-3: Drive assembly
A magnetic coupling consists of two magnet assemblies. One is the outer drive magnet assembly
(the driver magnet) and the other is the inner drive magnet assembly (the driven magnet) as
shown in Figure 4-3. The outer drive magnet assembly is connected to a motor and the inner
drive magnet assembly is directly or indirectly attached to a pump impeller. As Figure 4-1
shows, at rest, magnet components of the outer drive magnet assembly are aligned with their
counterparts in the inner assembly. When load (torque) is applied (Figure 4-2), the coupling
deflects angularly and the magnets create a force of simultaneous attraction and repulsion. This
force is used to transfer torque from the motor to the impeller. This permanent-permanent
magnet coupling creates neither slippage nor induction current during rotation. If excessive
torque is applied, the magnets will de-couple. The magnets will not re-couple unless the pump is
stopped. There is no energy loss in this permanent-permanent coupling unless an electrically
conductive containment is placed between the outer and inner drive magnet assemblies. If an
electrically conductive material is used for the containment shell, eddy currents will be generated
which will cause some energy loss. ANSIMAG's KM Series pumps use only non-conductive
containment shells.
8
5.
PUMP INSTALLATION
5-a. PIPING
1.
Install the pump as close as possible to the suction tank. Pumps are designed to push, not
pull, liquid.
2.
Ansimag recommends supporting and restraining both the suction and discharge pipes near
the pump to avoid the application of forces and moments to the pump casing. All piping
should line up with the pump flanges naturally to minimize any bending moments at the
pump nozzles.
3.
To minimize friction the suction line should have a short straight run to the pump, and be
free of fittings, for a length equivalent to or larger than ten (10) times its diameter.
4.
The suction line size should be at least as large as the pump's suction port or one size larger
if the suction line is so long that it significantly affects NPSH available. Never reduce the
suction piping size.
5.
The suction line should have no high points since these can create air pockets.
6.
The NPSH available to the pump must be greater than the NPSH required. Screens and
filters in the suction line will reduce the NPSH available, and must be considered in the
calculations.
7.
Caution: Do not install a check valve in the suction line even if a check valve is
installed in the discharge line. The suction line check valve could shut off before the
discharge line check valve closes. This would cause water hammer, which may burst
the containment shell.
8.
The discharge piping should be equal in size to the pump outlet port.
9.
A stop valve and a check valve should be installed in the discharge line. The stop valve is
used when starting and stopping the pump, and to isolate the pump for maintenance. It is
advisable to close the stop valve before stopping the pump. The check valve will protect the
pump from water hammer damage. These recommendations are especially important when
the static discharge head is high.
AIR POCKET
NOT RECOMMENDED
NOT RECOMMENDED
Fig. 5-1: Pump Installations
9
5-b. FOUNDATION
Fig. 5-2
1.
The foundation should be sufficiently substantial to absorb vibration and form a permanent,
rigid support for the base plate. This is essential for maintaining alignment of a long
coupled unit. A concrete foundation should be satisfactory. Embed foundation bolts of the
proper size (1/2" -13 x 7" recommended for ordinary installation) in the concrete, located by
a drawing or template. Use a pipe sleeve larger than the bolt to allow enough base
movement for final positioning of the bolts.
2.
Support the base plate on rectangular metal blocks and shims, or on metal wedges with a
small taper. Place the support pieces close to the foundation bolts. A spacing of 24" is
suggested. Allow a gap of 3/4" to 1-1/2" between the base plate and the foundation for
grouting.
3.
Adjust the metal supports or wedges until the shafts of the pump and driver are level. Check
the horizontal or vertical positions of the coupling faces as well as the suction and discharge
flanges of the pump by means of a level. Correct the positions, if necessary, by adjusting
the supports or wedges under the base plate as required.
4.
When alignment is correct, tighten foundation bolts evenly but not too firmly. The units can
then be grouted to the foundation. The legs of the base plate should be completely filled
with grout and the leveling pieces, shims, or wedges should be grouted in place. The
foundation bolts should not be tightened until the grout is hardened, usually about 48 hours
after pouring.
NEVER OPERATE THE PUMP WITHOUT FIRST SECURING IT INTO POSITION!
10
5-c.
INSTALLATION AND ELECTRICAL CONNECTIONS
Ansimag KM Series pumps are easily inspected without removing the casing from any piping,
by separating the drive end from the wet-end. This requires moving the motor, drive magnet and
bracket backwards and away from the casing. To be able to do this the motor must have
sufficient clearance behind the motor fan cover to move the motor backward approximately 6"
[150 mm]. Installations should feature the following:
1.
Allow at least 6" [150 mm] of clearance behind the motor.
2.
The base plate under the motor must be flat and long enough to allow for safe movement of
the motor.
3.
The motor electrical wiring should include a flexible section near the motor to allow
movement of 6" [150 mm] for servicing of the pump without disconnecting piping. The
recommended installation is illustrated in Figure 5-3.
Flexible
conduit
Figure 5-3: Flexible electrical connection on motor.
11
6.
PUMP START UP AND SHUTDOWN
6-a. PRE-START CHECKLIST
Before initial start up and after inspections of the wet end of pump, perform the following
inspections:
1.
With the pump starter locked out, manually turn the motor fan or flexible coupling to insure
that it rotates freely. For a motor mounted directly to the pump (close coupled), insert a
screwdriver or other tool through the fan cover and rotate the fan. It should rotate freely.
2.
Check all electrical connections with a wiring diagram. Make sure that the voltage,
frequency and horsepower on the motor nameplate match the line circuit.
3.
Check that flange bolts are tightened and that the drain cover is in place.
6-b. START UP AND OPERATION
Caution!: KM Series horizontal end suction models are not self-priming pumps! The pump
must be filled with liquid by gravity from a flooded suction tank or primed by other methods
such as injecting liquid from an outside source into the pump and suction line with an
attached foot valve.
1.
Make sure that the pump is full of liquid and the suction valve is open.
2.
Fully open the discharge valve once and then close it, so that any air trapped in the pump
and suction line can be purged.
3.
With the pump full of liquid, check motor rotation by jogging the pump and motor for about
1/2 second. The proper rotation is clockwise as viewed from the motor fan end. Once
proper motor rotation is confirmed jog the motor 5 or 6 more times. This process is very
important to fully wet sleeve bushing and pump shaft, and to purge some of the air
trapped in the pump and discharge line.
4.
Open the discharge valve once and close it again so that more air can be released
downstream.
5.
Turn the pump on. Open the discharge valve slowly. It is important to open the valve
very slowly. Sudden opening of the valve while air is trapped between the pump and the
valve may cause water hammer.
6.
Keep the suction valve fully opened. Do not use the suction valve to adjust flow rate.
Adjust the flow rate with the discharge valve only.
NOTE: Subsequent pump starts do not require motor jogging or valve position changes
provided that the piping and pump have remained full of liquid.
12
Caution! Do not run the pump dry. The pump may be severely damaged. The pumps
use slide bearings that are lubricated by the pumped product. No lubrication, no bearings.
Even short periods of dry running could damage the pump.
Caution! Do not Dead Head. Although the radial loads on the bearings are not a concern,
the liquid in the pump will rapidly increase in temperature. This will continue until the
boiling point is reached. Some liquids boil at temperatures sufficient to melt pump
components and destroy the magnets. Other liquids will flash into vapor. This vapor
collects at the main bushing causing dry running.
Caution! Cavitation. Prolonged cavitation may cause pitting on the pump components.
Short term severe cavitation, such as that caused by a closed suction may damage the pump
bearings.
Caution! Water Hammer. Sudden changes in fluid velocity can cause large, rapid
pressure surges. These pressure surges can damage the pump, piping and instrumentation.
Typical causes are rapidly closing valves. Check valves on the suction can also cause water
hammer if the liquid has time to reverse direction before the valve closes.
Recommended! Power Monitors. We recommend installing a Sundyne power monitor
on all pumps. These devices are very effective at protecting the pumps from dry running,
cavitation or when frequent overload is expected. They are also very effective for stoppage
during tank unloading applications.
•
•
•
Dry Running
Closed Valve
Clogged Suction Filter
•
•
•
Pump Seizure
Severe Cavitation
Excess (High) Flow
13
Safety
TEMPERATURE CLASSIFICATION - (ATEX DIRECTIVE 94/9/EC)
The maximum surface temperature of a metallic magnetic drive pump is the highest temperature
ascertained from any one of the following conditions:
1. The temperature of the pumped liquid, plus 20°C.
or
2. The ambient temperature plus 20°C.
or
3. The ambient temperature plus 39°C (only in the case of separately mounted pumps with oil lubricated
bearing assemblies)
or
4. The temperature of the heating medium being used in the heating jacket (if fitted)
The actual classification is calculated by obtaining the maximum surface temperature and than using the
following table to obtain the relevant Temperature Class:
Temperature Class
Maximum Surface
Temperature (°C)
450 (842°F)
300 (572°F)
200 (392°F)
135 (275°F)
100 (212°F)
85 (185°F)
T1
T2
T3
T4
T5
T6
Example:
The pump is pumping a liquid with a temperature of 120°C. The pump is close coupled and therefore
does not have an external oil lubricated bearings. The maximum ambient temperature in which the pump
may operate is 30°C
Condition 1 equates to 120°C + 20°C = 140°C
Condition 2 equates to 30°C + 20°C = 50°C
Condition 3 does not apply.
Condition 4 does not apply.
Thus the maximum surface temperature of the pump is 140°C which equates to a temperature
classification of T3.
14
6-c.
SHUTDOWN
If the pump is to be shut down for any reason, use the following procedure:
1.
Close the discharge valve slowly to prevent water hammer.
2.
Shut off the motor.
3.
Close the suction valve.
15
7. DISASSEMBLY FOR PREVENTIVE MAINTENANCE
WARNING! Before disassembly, the pump must have the drive “locked out” and be flushed of
all dangerous liquids. Follow all federal, state, local and company regulations with regard to
pump decontamination prior to disassembly and inspection. ANSIMAG KM Series pumps
are provided with a low point casing drain to maximize pump decontamination. Refer to section
9 “Special Procedures”
Simple features of the KM Series pump make possible a 20-minute maintenance check by
following the provided instructions. Please prepare the necessary tools for pump maintenance.
7-a Tool Checklist
;
;
;
;
;
8mm hex key or 5/16" hex
19mm combination wrench
PT0377 - bushing installation/removal & trimming tool
PT0285 - shaft support installation tool
Arbor press
Since most wearing parts on a mag-drive pump cannot be monitored, it is important to inspect
the pump for wear after the initial 500 hours or three months of operation, whichever comes first.
The next inspection will be six to twelve months depending on the result of the first inspection.
Before inspecting, be sure you have a spare casing O-ring on hand to re-install after the
inspection is completed. To inspect inside of the pump, be sure that the pump has been flushed
of all dangerous liquids before isolating the pump by closing the inlet and outlet valves.
Operating conditions vary so widely that recommending one schedule of preventive maintenance
for all centrifugal pumps is not possible. In the case of magnetic drive pumps, particularly of
non-metallic pumps, traditional maintenance techniques, such as vibration monitoring are
not useful or reliable techniques for wet end preventive maintenance. These are effective
only for non-liquid contact components such as motor bearings. One of the best rules to follow
in proper maintenance is to keep a record of actual operating data such as flow, pressure, motor
load and hours of operation. The length of the safe operation period will vary with different
applications and can only be determined from experience.
16
7-b Separating The Pump For Inspection
1
2
Loosen and remove three socket bolts connecting
the bracket to the rear casing support/wet end.
(Figure 7-1) Jackscrews (M10 Hex) are provided
to break the magnetic attraction on impeller and
outer drive coupling. This force is close to 40 lbs.
Extend the jackscrews approximately two inches to
separate the pump wet end from the motor drive.
Grasp the motor and carefully pull away from the
wet end. For maximum safety protection against
the strong magnetic forces, it is important to
separate here first to safely break the magnetic
field.
Figure 7-1: Loosen
3 M10 socket bolts
to separate pump
Figure 7-2: Separate
wet end from drive
using jackscrews
Figure 7-3:
Separate wet end
Figure 7-4: Remove
impeller
Caution: When opening the wet end be sure that
product is completely drained and flushed clean.
Loosen and remove six M10 socket bolts from the
rear support/pump casing. (Figure 7-3) Separate
the rear support from the pump casing (Figure 7-3).
Hold the impeller by the shroud and carefully pull
away from the containment shell (Figure 7-4).
Inspect the following parts: (Use table 7-1 0n page 14 for detailed measurements of wear parts)
3 Viewing from the front of
impeller, check for wear
on the mouth ring. SiC
must be free of chips or
cracks. Polished marks
on the surface are normal.
As a guide use the 3
lubrication flutes for
reference; if they are not
visible, replace- ment is
necessary.
The
main
bushing
material (carbon or SiC)
must be free of chips or
cracks. See Table 7-1
for
detailed
measurements on mouth
ring and main bushing.
Figure 7-5: Inspect
impeller mouth ring
17
Inspect the shaft for
wear.
A polished
contact mark is normal.
SiC must be free of
chips or cracks. Check
the containment shell
for abrasion or signs of
melting. If either is
noticed, replacement is
advised to ensure safe
operation. Replace the
O-ring if cracked.
Figure 7-6:
Containment Shell
assembly
4 Check the outside of
the containment shell
for abrasive marks or
cracks.
Replace if
necessary.
A 304 Stainless Steel
cover protects the
outer drive magnets.
Check
for
any
particles and clean if
necessary.
Figure 7-7: Inspect
Containment Shell
Figure 7-8: Inspect
outer drive magnet
assembly
5 Casing lining must be
free of cracks. Check
the integrity of lining
by using 15-20 KV
electrostatic discharge
tester commonly used
for lined pipe.
Inspect SiC thrust ring
for cracks or chips.
Figure 7-9: Inspect
casing lining
Figure 7-10: Inspect
thrust ring
7-c Part Wear Measurements
T
OD
OD
ID
MOUTH RING
(25% CFR/PTFE or SiC)
As new condition
KM1515 T = 0.250" +/- 0.010"
KM2156 T = 0.375" +/- 0.010"
Recommended replacement
if wear is greater than 0.063"
if cracks/chips are visible (SiC)
PUMP SHAFT
(SiC)
MAIN BUSHING
(Carbon or SiC)
As new condition
OD = 0.750" +0.000/- 0.002"
As new condition
ID = 0.751" +0.001/- 0.000"
Recommended replacement
OD=0.740" or
if cracks/chips are visible
Recommended replacement
ID=0.770" or
if cracks/chips are visible
Table 7-1: Wear parts
18
8. ASSEMBLY
1 Prepare a clean surface for assembly on the shop
workbench. An upright or vertical assembly of
the KM is preferred; however, horizontal
assembly methods work well too. Place the
motor on the clean surface vertically with the
motor shaft pointing up. Place the KM motor
mounting plate on the C-face of the motor with
bolt holes aligned (Figure 8-1). Motor mounting
plates vary in size and will only work with the
correct motor frame size. Insert and tighten the
four bolts securing the mounting plate to the
motor face. (Refer to Table 8-1 for bolt torque
requirements.)
Figure 8-1: Assemble
motor mounting plate
Bolt Size
mm
M10
M12
Figure 8-2: Tighten
bolts
Recommended Torque
Ft-lb
N-m
20
27
40
45
Table 8-1: Bolt torque
2 Slide the KM close coupled bracket over the
motor shaft onto the motor mounting plate with
the four bolt holes aligned. (Figure 8-3) Insert
four M10 socket bolts and torque to 20 ft-lbs.
(Figure 8-4)
Figure 8-3: Assemble
close coupled bracket
3 Put the motor shaft key into the KM outer drive
keyway. Align outer drive and key with motor
keyway and slide onto the motor shaft. (Figure
8-5) The correct position of the outer drive is
indicated in Figure 8-6. Measurement from the
raised bracket surface to the flat end of outer
drive should be 7/8". (+/- 1/32") Use a ruler or
caliper.
Figure 8-4: Tighten
bolts
7/8"
Note: Use a lubricant such as “anti-seize” or
grease on the motor shaft.
Figure 8-5:Assemble
outer drive
19
Figure 8-6: Outer
drive position
4 To secure the outer drive position remove the
bracket plug and insert a 3/16" hex key to
tighten the two set screws on the hub. Keep the
proper distance set from step 3 while tightening.
A torque of 10 ft-lbs is recommended.
Figure 8-7:Tighten the outer drive
5
6
7
Assemble the pump foot to the close coupled
bracket fastening with three M12 hex bolts.
Torque requirements are listed in Table 8-1 on
page 15.
Figure 8-8: Assemble
foot
Figure 8-9: Tighten
bolts
Figure 8-10:
Containment Shell
and Rear Support
Figure 8-11:
Assembled
Containment Shell
and Rear Support
Figure 8-12: Insert
shaft
Figure 8-13: Insert
O-ring
Insert the containment shell into the rear
support (Figure 8-10). There is a projection on
the outer diameter of the containment shell that
must line up with the rear support groove.
Inserting properly will align the shaft groove to
the correct orientation. The assembly is a light
press fit. Use a small rubber hammer to tap the
containment shell into position if necessary.
Insert the SiC pump shaft into back of
containment shell socket (Figure 8-12). Align
the flat on the shaft with the mating flat in the
socket. A rear thrust ring made of CFR/ETFE
is located on the front of the socket. Place the
O-ring in the groove (Figure 8-13). Be sure
that the O-ring groove is clean before
installation.
20
8
9
10
11
Align the notch in the back of the mouth ring
with the driving dog in the nose of the
impeller. Place a flat piece of stock aluminum
or ANSIMAG tool number PT0285 over the
mouth ring and use an arbor press to apply the
assembly force snapping into position.
Figure 8-14: Insert
mouth ring
Figure 8-15: Mouth
ring positioned
Figure 8-16: Insert
main bushing into
impeller
Figure 8-17: Main
bushing in position
Figure 8-18:Insert
shaft support/thrust
ring
Figure 8-19: Use
arbor press to
install
Figure 8-20:
Assembly of impeller
into containment shell
Figure 8-21:
Impeller positioned
on shaft
Align the two flats of the main bushing with
the two matching flats in the impeller bore.
The main bushing is pressed into the impeller
bore using ANSIMAG tool number PT0377
and an arbor press (Figure 8-16). Assembly
forces are low, so avoid using a hydraulic
press.
The shaft support/SiC thrust ring is assembled
into the suction of the pump casing (Figure 818) and held into position by a light
interference fit. Use ANSIMAG tool number
PT0285 and an arbor press (Figure 8-19).
Assembly forces are low, so avoid using a
hydraulic press.
Continuing from step 7, carefully slide the
impeller assembly onto the shaft positioned in
the containment shell assembly (Figure 8-20).
Use caution when handling the impeller due
to the strong internal magnets used. Attraction
to metal objects will occur. Keep the drive
end clean and free of metal chips and
particles.
21
12
The correct position of the rear support is with
the smaller lobe positioned up and the two
other larger lobes 120 degrees apart down
(Figure 8-22). Place the impeller drive and
containment shell assembly onto the pump
casing. (Figure 8-23)
Figure 8-22: Correct
rear support position
13
Figure 8-23: Wet
end assembly
Tighten the six M10 socket bolts to a torque
of 20 (ft-lbs).
Figure 8-24: Tighten wet end
14
Carefully put the assembled pump wet end
into the outer drive magnet end. Caution:
The magnet force is 40 lbs. When the two
drives start to attract be prepared. Extend
the jackscrews and place your hands around
the suction flange holding the wet end (Figure
8-25). Keep all fingers away from the back of
the casing. Retract the jackscrews a couple of
turns at a time in an alternative pattern until
the two parts mate.
Figure 8-25: Assembly of wet end to motor
drive
Assembly DON’T DO!
AVOID
PINCHING
FINGERS!!
Assembling the rear support to the bracket
is not recommended because the next
step involves assembling the impeller into
the containment shell where magnetic
attraction is strongest. Always assemble
the wet end first as shown in previous
steps.
Caution: The coupling requires 40 lbs of
axial force to separate the impeller from
outer drive magnet assembly.
Figure 8-25: Don’t Do!
22
15
The magnetic pull will keep the two ends of
the pump held together while the three M10
socket bolts are tightened to 20 ft-lbs (Figure
8-26). Once the wet end is secured to the
motor drive make sure that the internal parts
move freely by inserting a screwdriver into
the motor fan to rotate drive (Figure 8-27). If
resistance is felt inspect the internal parts for
debris.
Figure 8-26: Tighten
wet end bolts
16
Figure 8-27: Check
for resistance
Completed KM pump.
Figure 8-28: KM pump assembly
9. SPECIAL PROCEDURES
Pumps that have been supplied in accordance to the ATEX Directive (94/9/EC) will be identified
by a label with the following symbol on it:
Such units are supplied with an earthing ground lug that is attached by a M6 screw (60-70 in-lb)
and a lock washer (kit, P4107) to the bracket. Once the unit is installed and leveled, it should be
wired to earth with a suitable earthing cable (Figure 9-1).
23
Standard accessories for the KM pump include a drain port located on the bottom on the front
casing. A ¼" NPT drain port and ¼" drain plug (P2035) is supplied with every casing. To
utilize the drain option complete the following:
1
Loosen and remove the supplied drain
plug with a ¾" wrench. To protect the
molded threads while drilling tighten a
¼" pipe nipple to the drain hole
(Figure 9-2).
2
Drill the drain hole using a ¼"
diameter drill size. The pipe nipple
will easily and safely guide the ¼"
drill through the casing lining (Figure
9-3).
Figure 9-2: Insert pipe
nipple
3
Figure 9-3: Drilling
hole
Remove the pipe nipple used for guiding
the drill. Generously wrap the molded
¼" drain plug (P2035) with Teflon tape
and tighten.
Figure 9-4: Assemble drain plug.
24
Use the following drawings to make your own KM installation tools. Material should be
Aluminum or brass. (Never use carbon steel or iron.)
Figure 9-5: Bushing installation/removal tool
25
10. DRAWINGS
10-a Dimensional Drawings
Figure 10-1: KM dimensional drawing
Dimension Table
Model
Suct.
Dis.
W
X
Y
Z
F
F1
F2
F3
LJ
WB
CP
L
KM1515
(mm)
KM2156
(mm)
1½
(40)
2
(50)
1
(25)
1½
(40)
10
(254)
10
(254)
5.50
(140)
5.50
(140)
3.15
(80)
3.42
(87)
2.34
(59)
2.56
(65)
3.58
(91)
3.79
(96)
5.31
(135)
5.58
(144)
5.31
(171)
7.22
(183)
13.86
(344)
13.96
(354)
5.50
(140)
5.50
(140)
8.00
(203)
8.00
(203)
9.92
(252)
11.50
(292)
20
(508)
23
(584)
Table 10-1
Note: For Reference only! Some dimensions may vary slightly with different motor sizes.
26
10-b. Exploded View
Figure 10-2: KM isometric view
10-c Sectional Drawing
Figure 10-3: KM sectional drawing
27
11. PARTS LIST
Recommended Spare Parts for all levels of service.
Item#
1
Part Name
Qty
Ductile Iron lined ETFE
Ductile Iron lined GFR-PFA
316L Stainless Steel
Hastelloy C
2
3
5
6
8
9
11
12
13
14
15
17
18
KM1515 Part #
KM2156 Part #
P2055A
P2055B
P2308A
P2308B
P2735A
P2735B
N/A
N/A
P2258A
P2258B
P2861A
P2861B
P2056A
P2056B
P2862A
P2862B
P2063
P2285
P2060
K0501
K0506
P2738
P2339A
P2339B
P2339C
P2339D
P2339E
P2339F
P1997
P1996
P1997
P1996
P2066A
P2066B
K1102
K1102P
P2058
P2371A
P2749
N/A
P2104
P2104
P2172D
P2172A
P2172B
P2172D
P2172A
P2172B
P2172C
P2172E
P2172F
P2172G
P2172H
1
Casing
1
Impeller
AA and AB-drive, CFR-ETFE
AA and AB-drive, GFR-PFA
Containment Shell
CFR-ETFE
GFR-PFA
Mouth Ring
CFR-PTFE
SiC
Shaft - SiC
Casing O-ring
Viton®
EPDM
Teflon®-Viton® wrapped Gore-Tex®
Main Bushing
Carbon
SiC
Shaft Support/Thrust Ring
CFR-ETFE/SiC
GFR-PFA/SiC
Rear Support
Ductile
Iron
316 Stainless
Steel
Bracket
Outer Drive
AA Drive
56C frame (NEMA)
143/145TC frame (NEMA)
182/184TC frame (NEMA)
213/215TC frame (NEMA)
80 frame (IEC)
90 frame (IEC)
100/112 frame (IEC)
132 frame (IEC)
AB Drive
182/184TC frame (NEMA)
213/215TC frame (NEMA)
100/112 frame (IEC)
132 frame (IEC)
Bracket Foot
Lock Washer
Hex Bolt, Rear Support/Pump Case
28
1
1
1
1
1
1
1
1
1
P2172E
P2172F
P2172G
1
6
6
P2172I
P2172C
P2172J
P2172H
P1942
HLM10
HSM10X20
P2172I
P2172C
P2172J
P2172H
P1942
HLM12
HHM12X30
Item#
19
16
21
25
34
35
37
51
55
65
73
74
75
76
Part Name
Socket Bolt, Bracket/Rear Support
Lock Washer
Motor Mounting Plate
56C & 143/145TC frame (NEMA)
182/184TC & 213/215TC frame
(NEMA)
80/90 frame (IEC)
100/112 frame (IEC)
132 frame (IEC)
Jack Screws
Riser, Bracket Foot
All
All except 100 frame IEC
100 frame IEC (only)
Hex Bolt, Bracket Foot
All
All except 100 frame IEC
100 frame IEC only
Lock Washer
Name Plate, ATEX / CE
Earthing Kit, Grounding Lug
Drain Plug 1/4" NPT, Pump Case
Carbon Filled
Tefzel®
Glass Filled
PFA
Drain Plug, Bracket
Set Screw Plug, Bracket
Set Screw, Outer Drive
Motor Shaft Key
56C frame (NEMA)
14_frame (NEMA)
18_frame (NEMA)
21_frame (NEMA)
80 frame (IEC)
90 frame (IEC)
100/112 frame (IEC)
132 frame (IEC)
29
Qty
KM1515 Part #
KM2156 Part #
7
7
1
HSM10X20
HLM10
HSM10X20
HLM10
P2095
P2093
P2096
P2097
P2095
P2093
P2096
P2097
P2508
2
HSM 10 x 40
HSM 10 x 40
1
1
1
NA
NA
P2726
P2792
3
3
3
3
1
1
1
HHM12X25
HHM12X60
HLM12
P4070
P4107
HLM12
P4070
P4107
P2035A
P2035B
P2035A
P2035B
K3903-Z
K3903-Z
K1601
K3903-Z
K3903-Z
K1601
P2200A
P2200B
P2200C
P2200A
P2200B
P2200C
P2200G
P2200D
P2200E
P2200F
P2200H
1
1
2
1
HHM12X60
P2200D
P2200E
P2200F
12. PUMP SPECIFICATIONS
hp:
Temperature:
Pressure:
Viscosity:
Minimum Flow:
Port size:
Solids:
Impeller:
Mounting:
Ship Weight
KM1515
• 5 hp max.
• 250°F max. -20°F min.
• 150 psi (Hydrostatic 225 psi)
• 700 SSU (150 centistokes) max.
• 1 gpm at 3600 rpm
• Sub-ANSI 1-1/2" x 1" x 5.00"
ISO 40 x 25 x 127mm
JIS 40 x 25 x 127mm
• 500 microns max., 0.5% by
weight max.
• 5.00" (127mm) 3.00" trimmed
• Close coupled NEMA and IEC
• 53 lbs (24 kg) standard pump
end without motor
KM2156
• 7.5 hp max.
• 250°F max. -20°F min.
• 150 psi (Hydrostatic 225 psi)
• 700 SSU (150 centistokes) max.
• 1 gpm at 3600 rpm
• Sub-ANSI 2 x 1-1/2" x 6.00"
ISO 50 x 40 x 152mm
JIS 50 x 40 x 152mm
• 500 microns max., 0.5% by
weight max.
• 6.00" (152mm) 3.00" trimmed
• Close coupled NEMA and IEC
• 70 lbs (24 kg) standard pump
end without motor
13. COMMON CONVERSIONS
Flow (Capacity)
gpm (US)
1
4.403
0.2642
1.201
Volume
ft3
1
35.31
0.03531
0.1337
0.1606
0.01620
L/min
3.785
16.6667
1
4.5458
m3/h
0.2271
1
0.06
0.2727
m3
0.02832
1
0.001
0.003785
0.004545
0.0004536
Head ( Pressure / Vacuum )
ft (H²O)
m (H²O)
1
0.3048
3.281
1
2.307
0.7031
32.83
10.01
0.3346
0.1020
1.133
0.3453
0.0446
0.0136
33.458
10.195
liter
28.32
1000
1
3.785
4.548
0.4536
psi
0.4335
1.423
1
14.23
0.145
0.491
0.01933
14.504
gpm (UK)
0.8327
3.666
0.22
1
gallon (US)
7.481
264.2
0.2642
1
1.201
.1198
gallon (UK)
6.229
220.00
0.22
0.8327
1
0.09975
KPa
2.989
9.807
6.895
98.07
1
3.386
0.1330
100
kg/cm2
0.03047
0.1
0.07029
1
0.0102
0.0345
0.001356
1.01956
30
lbs of water
62.44
2205
2.205
8.347
10.025
1
inch Hg
0.8826
2.896
2.036
28.96
0.2953
1
0.03937
29.5
mmHg
22.42
73.55
51.71
735.5
7.501
25.4
1
750.1
bar
0.02988
0.0981
0.0690
.981
0.01
0.0339
0.00133
1
ANSIMAG 14845 W. 64th Avenue Arvada, CO 80007 USA
Phone: (303)425-0800
Fax: (303)425-0896 www.sundyne.com
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