Agri KAM INSTALLATION, OPERATION AND MAINTENANCE MANUAL. A View of KBL Dewas Manufacturing Plant. A Kirloskar Group Company KIRLOSKAR BROTHERS LIMITED

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A View of KBL Dewas Manufacturing Plant KIRLOSKAR Agri KAM MONOBLOC KIRLOSKAR BROTHERS LIMITED A Kirloskar

98 (-7), Baner, Pune 411 045 (India) Phone : +91 0 714444 E-mail : kblin@kbl.co.in Visit us at : www.

: +91 0 4444444 Fax : +91 0 4444198 E-mail : kbl@kbl.co.in WORKS : Ujjain Road, Dewas - 455 001 (M.P.

1 A View of KBL Dewas Manufacturing Plant KIRLOSKAR Agri KAM MONOBLOC KIRLOSKAR BROTHERS LIMITED A Kirloskar Group Company CORPORATE OFFICE : YAMUNA, Survey No. 98 (-7), Baner, Pune (India) Phone : kblin@kbl.co.in Visit us at : REGISTERED OFFICE : Udyog Bhavan, Tilak Road, Pune (India) Tel. : Fax : kbl@kbl.co.in WORKS : Ujjain Road, Dewas (M.P.) Phone : //5/9 Fax : Toll Free No INSTALLATION, OPERATION AND MAINTENANCE MANUAL KIRLOSKAR BROTHERS LIMITED A Kirloskar Group company CM

2 Content Our products are meant for pumping water and they do not have any significant effect on environment during their use, if properly selected and used as per instructions given in this manual. Installation Piping Electrical Connections 4 Connection Diagram 5 Customers are advised to dispose unusable components through appropriate disposal agencies to avoid the impact on work environment. Electrical Details 6 Operational Instruction 6 Priming 7 Maintenance 7 Operational Problems & Causes 9 Exploded View (M. Seal) 1 Exploded View (G.P.) 1 Part List 14 FOR PROMPT SERVICE & SPARES Register on our website : Product Range 15 Warranty Certificate 16

pump. The suction pipe should be as short as possible for getting better

of bends and other fittings should be as minimum as possible to reduce

WRONG RIGHT Adequate supports should be provided to pipes so that its dead

WRONG RIGHT The horizontal length of the suction pipe should be straight to

For deliverypressure more than 0 meters, it is recommended to install a check

The check valve placed near the pump is to protect the pump from excessive

3 The piping should be airtight. Any leakage in suction pipe may drastically affect the performance of the pump. The suction pipe should be as short as possible for getting better discharge. No. of bends and other fittings should be as minimum as possible to reduce frictional lossses. WRONG RIGHT Adequate supports should be provided to pipes so that its dead weight should not fall on delivery casing completely. WRONG RIGHT The horizontal length of the suction pipe should be straight to avoid air trapping in pipe. It should not be inclined towards the pumps. For deliverypressure more than 0 meters, it is recommended to install a check (non-return) valve in the discharge line. The check valve placed near the pump is to protect the pump from excessive back-pressure to prevent the water running back through the pump in case of sudden failure of prime mover. It is recommended to use KIRLOSKAR low friction foot valve having K factor less than 0.8 for better discharge. ELECTRICAL CONNECTIONS : Proper earthing connection should be made at the bolts provided for earthing. 4

4 Proper size of cable should be used between supply and motor KAM ELECTRICAL DETAILS terminals to minimise voltage drop and to carry full load current (FLC) as well as the maximum current in the operating voltage range speci fied. MOTOR RATING IN kw/hp POLES NO. OF PHASES RATED VOLTAGE (VOLTS) FULL LOAD CURRENT (AMPS) MAX OPERATING CURRENT (AMPS) CURRENT FOR REPLAY SELECTION (AMPS) TYPE OF STARTING VOLTAGE RANGE Nuts at terminal should be tightened properly. 0.7/ No. of joints in cabls should be as minmum as possible preferably, joints should be avoided. 0.56/ / / Wires and connections should be properly insulated. lf not it may lead to fatal shock../.0.7/ Proper backup protection (reputed make starter, main switch and 5.5/ fuse) should be used. 7.5/ / / CONNECTION DIAGRAM 1.0 or Auto transformer with Ieads or 6 Ieads 5 6

Insert the spacer. RECOMMENDED SPARES FOR TWO YEARS OF NORMAL WORKING : 1. Impeller.. Ball bearings.. Mechanical seal (In case of mechanical seal pumps). 4.

5 PROCEDURE FOR FITTING THE MECHANICAL SEAL IN CASE OF MECHANICAL SEAL ARRANGEMENT : l l l l Apply soap solution of rubber cap of stationary part. Insert the stationary part of mechanical seal and press it upto the bore face of the mounting casing. Insert upper part of mechanical seal (i.e. Rotating part) on the shaft. Insert the spacer. RECOMMENDED SPARES FOR TWO YEARS OF NORMAL WORKING : 1. Impeller.. Ball bearings.. Mechanical seal (In case of mechanical seal pumps). 4. Gland packing (In case of gland packed pumps). 5. Shaft sleeve (In case of gland packed pumps). 6. Bush bearing (If provided). 7. Wearing ring (if provided). 8. Capacitors (in case of single phase monobloc pumps). 9. Water deflector. 10. Paper packing. 7 8

6 OPERATIONAL PROBLEMS AND CAUSES : OPERATIONAL PROBLEMS AND CAUSES : TYPE OF THE FAILURE Failure to deliver water Pump does not delvier rated discharge Pump does not deliver rated head Pump looses water after start Pump overloads Primemover Vibration Stuffing Box overheats Bearing overheat Bearing wear rapidly Motor heating up Seized pump Irregular delivery Pump does not prime Noisy Pump TYPE OF THE FAILURE Failure to deliver water Pump does not delvier rated discharge Pump does not deliver rated head Pump looses water after start Pump overloads Primemover Vibration Stuffing Box overheats Bearing overheat Bearing wear rapidly Motor heating up Seized pump Irregular delivery Pump does not prime Noisy Pump REASON FOR FAILURE REASON FOR FAILURE Worong direction of rotation Speed too high Pump not primed or filled with liquid Total head lower than recommended Suction line not filled with liquid Viscosity and/or specific gravity higher than rated Air or vapour pocket in suciton line Starved suction Inlet or suciton pipe insufficiently submerged Wom or loose bearings NPSH available too low Rotor out of balance Pump not upto rated speed Impeller blocked or damaged Air leaks in suction line or stuffing box Bent shaft Foot valve too small Foundation not rigid or poor mixture Foot valve clogged Gland packing too tight Viscosity greater than rated Gland packing not lubricated Wear rings worn Wrong grade of gland packing Impeller damaged Insufficient cooling water Internal leakage (gasket) Stuffing box badly packed Priming air/vent valves open Wrong grade of Grease Gas or vapour in liquid Dirt in bearings 9 10

7 OPERATIONAL PROBLEMS AND CAUSES : EXPLODED VIEW OF KAM TYPE OF THE FAILURE Failure to deliver water Pump does not delvier rated discharge Pump does not deliver rated head Pump looses water after start Pump overloads Primemover Vibration Stuffing Box overheats Bearing overheat Bearing wear rapidly Motor heating up Seized pump Irregular delivery Pump does not prime Noisy Pump REASON FOR FAILURE Moisture in lubricant Failure of lubricating system Bearings to tight Excessive thrust Lack of lubrication Bearing badly installed Too much grease in bearings Pump does not deliver rated capacity Pipes exert forces on pump Vibration Foreign matter in pump Viscosity lower than rated Speed too low Foundation bolts loose, motor/pump bolts loose leak in delivery pipe-work Mechanical seal fault FIG 1 EXPLODED VIEW OF KAM (M. SEAL) PUMPS 11 1

8 EXPLODED VIEW OF KAM PART LIST (GENERAL) FOR MONOBLOC PUMPS FIG EXPLODED VIEW OF KAM (G.P.) PUMPS 1 14

9 Product range manufactured by Kirloskar Brothers Limited, Dewas Pump Series Construction Feature Drive Unit Power Rating This product is warranted against manufacturing defects and workmanship under normal use and service for the period of 4 months from the date of manufacturing OR 1 months from date purchase of the end user whichever is earlier. KDS+/++ KDT+ KS+ 1.5 HP HP 1.0 HP HP.0 HP HP We undertake to repair or replace the product at our discretion or any part thereof, for which we are satisfied that it was originally defective in material or workmanship, provided that product or its parts are returned to our nearest regional office / dealer on freight paid basis, within the warranty period. This warranty does not cover any consequential damage of any nature. KOS SP /Coupled Electric Sub. Motor 0.5 HP HP 0.5 HP HP This warranty excludes every condition, whether statutory or otherwise, whatsoever is not expressly set out here. KJV/H,KJ+ () 0.5 HP -.0 HP Product Model: MINI,DC,DHX 0.5 HP HP Sr. No. : Submersible Electric Sub. Motor 0.5 HP HP Date of Purchase : Ku4 Winner Bill/Cash Memo No. : NW,KE,KH KHDT+,SR Coupled Engine / Motor SPECIAL INSTRUCTIONS: Customers are advised to go through the product KV, DV /Coupled manual carefully for proper installation, use and servicing product & genuine spare parts. It is also advisable to go through the company s published literature, Alternator KVA - 50 KVA catalogue or other official publication. Any deviation, if made by the customers will void the warranty obligations. Repair by trained mechanics will get you better Motor HP - 10 HP results. For details contact the dealer This card must be produced at the time of claiming the warranty along with purchase documents. Dealer s stamp and signature : 15 16

T E C H N I C A L M A

A View of KBL Dewas Manufacturing Plant Enriching Lives T E C H N I C A L M A N U A L KIRLOSKAR BROTHERS LIMITED A Kirloskar Group Company CORPORATE OFFICE : YAMUNA, Survey No. 98 (3-7), Baner, Pune 411