Rio N / Rio Z N Smedegaard - KSB...Rio N / Rio Z N 7 of 28 Observe the maximum flow rates indicated...

Circulator Pump

Rio N / Rio Z N

Rio N 25-70 to 80-150Rio Z N 30-40 to 80-80

Installation/OperatingManual

Legal information/Copyright

Installation/Operating Manual Rio N / Rio Z N

Original operating manual

KSB Aktiengesellschaft

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited orprocessed for any other purpose, nor otherwise transmitted, published or made available to a third party withoutKSB's express written consent.

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft Frankenthal 01.11.2012

Contents

Glossary .................................................................................................5

1 General ..................................................................................................6

1.1 Principles ...........................................................................................................6

1.2 Target group ..................................................................................................... 6

1.3 Symbols .............................................................................................................6

2 Safety .....................................................................................................7

2.1 Key to safety symbols/markings ....................................................................... 7

2.2 General .............................................................................................................. 7

2.3 Intended use .....................................................................................................7

2.4 Personnel qualification and training ............................................................... 8

2.5 Consequences and risks caused by non-compliance with these operatinginstructions ........................................................................................................ 8

2.6 Safety awareness ..............................................................................................8

2.7 Safety information for the operator/user ....................................................... 8

2.8 Safety information for maintenance, inspection and installation work ....... 9

2.9 Unauthorised modes of operation .................................................................. 9

3 Transport/Temporary Storage/Disposal .............................................10

3.1 Checking the condition upon delivery .......................................................... 10

3.2 Transport ......................................................................................................... 10

3.3 Storage/preservation ...................................................................................... 10

3.4 Return to supplier ........................................................................................... 10

3.5 Disposal ...........................................................................................................11

4 Description of the Pump (Set) ............................................................12

4.1 General ............................................................................................................ 12

4.2 Designation ..................................................................................................... 12

4.3 Name plate ...................................................................................................... 12

4.4 Design details .................................................................................................. 13

4.5 Configuration and function ........................................................................... 13

4.6 Noise characteristics .......................................................................................14

4.7 Scope of supply ............................................................................................... 14

4.8 Dimensions and weight .................................................................................. 14

5 Installation at Site ...............................................................................15

5.1 Safety regulations ........................................................................................... 15

5.2 Checks to be carried out prior to installation ............................................... 15

5.3 Installing the pump set .................................................................................. 15

5.4 Connecting the piping ...................................................................................16

5.5 Enclosure/insulation .......................................................................................17

5.6 Electrical connection ...................................................................................... 17

Contents

Rio N / Rio Z N 3 of 28

6 Commissioning/Start-up/Shutdown ...................................................19

6.1 Commissioning/start-up ................................................................................. 19

6.2 Shutdown ........................................................................................................ 21

6.3 Operating limits .............................................................................................. 21

6.4 Shutdown/storage/preservation .................................................................... 22

6.5 Returning to service .......................................................................................22

7 Servicing/Maintenance .......................................................................23

7.1 Servicing/inspection ........................................................................................ 23

7.2 Drainage/cleaning ..........................................................................................23

7.3 Removing the pump set ................................................................................. 23

8 Trouble-shooting ................................................................................25

9 Related Documents ............................................................................26

9.1 Sectional drawing with list of components ..................................................26

9.2 Wiring diagrams ............................................................................................. 26

Index ....................................................................................................27

Contents

4 of 28 Rio N / Rio Z N

Glossary

Discharge line

The line which is connected to the dischargenozzle

Noise characteristics

The noise emission to be expected, indicated assound pressure level LpA in dB(A)

Pump set

Complete pump set consisting of pump, drive,additional components and accessories

Suction lift line/suction head line

The line which is connected to the suctionnozzle

Glossary


1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variantsindicated on the front cover. The manual describes the proper and safe use of thisequipment in all phases of operation.

The name plate indicates the type series/size and main operating data. They uniquelyidentify the pump (set) and serve as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB service centre tomaintain the right to claim under warranty.

Noise characteristics. (⇨ Section 4.6 Page 14)

1.2 Target group

This manual is aimed at the target group of trained and qualified specialist technicalpersonnel.(⇨ Section 2.4 Page 8)

1.3 Symbols

Table 1: Symbols used in this manual

Symbol Description✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions⊳ Safety instructions⇨ Result of an action⇨ Cross-references1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General


2 SafetyAll the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 2: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies information aboutprotection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent personal injuryand damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the specialist personnel/operators responsible prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pump must always be complied with and bekept in a perfectly legible condition at all times. This applies to, for example:

▪ Arrow indicating the direction of rotation

▪ Markings for connections

▪ Name plate

The operator is responsible for ensuring compliance with all local regulations nottaken into account in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits described in theother applicable documents.

▪ Only operate pumps/pump sets which are in perfect technical condition.

▪ Do not operate the pump (set) in partially assembled condition.

▪ Only use the pump to handle the fluids described in the data sheet or productliterature of the pump model.

▪ Never operate the pump without the fluid handled.

▪ Observe the minimum flow rates indicated in the data sheet or product literature(to prevent overheating, bearing damage, etc).

! DANGER

2 Safety


▪ Observe the maximum flow rates indicated in the data sheet or productliterature (to prevent overheating, mechanical seal damage, cavitation damage,bearing damage, etc).

▪ Do not throttle the flow rate on the suction side of the pump (to preventcavitation damage).

▪ Consult the manufacturer about any use or mode of operation not described inthe data sheet or product literature.

Prevention of foreseeable misuse

▪ Never exceed the permissible operating limits specified in the data sheet orproduct literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintainand inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved intransport, installation, operation, maintenance and inspection must be clearlydefined by the operator.

Deficits in knowledge must be rectified by means of training and instructionprovided by sufficiently trained specialist personnel. If required, the operator cancommission the manufacturer/supplier to train the personnel.

Training on the pump (set) must always be supervised by technical specialistpersonnel.

2.5 Consequences and risks caused by non-compliance with these operatinginstructions

▪ Non-compliance with these operating instructions will lead to forfeiture ofwarranty cover and of any and all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,the following safety regulations shall be complied with:

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and checkthat the guards function properly.

▪ Never remove a contact guard while the pump is running.

▪ Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g.explosive, toxic, hot) so as to avoid any danger to persons and the environment.Adhere to all relevant laws.

2 Safety


▪ Eliminate all electrical hazards. (In this respect refer to the applicable nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

2.8 Safety information for maintenance, inspection and installation work

▪ Modifications or alterations of the pump are only permitted with themanufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughlyfamiliar with the manual.

▪ Only carry out work on the pump (set) during standstill of the pump.

▪ The pump casing must have cooled down to ambient temperature.

▪ Pump pressure must have been released and the pump must have been drained.

▪ When taking the pump set out of service always adhere to the proceduredescribed in the manual.(⇨ Section 6.4 Page 22)

▪ Decontaminate pumps which handle fluids posing a health hazard.

▪ As soon as the work is completed, re-install and/or re-activate any safety-relevantand protective devices. Before returning the product to service, observe allinstructions on commissioning.(⇨ Section 6.1 Page 19)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in thismanual.

The warranty relating to the operating reliability and safety of the supplied pump(set) is only valid if the equipment is used in accordance with its intended use.

2 Safety


3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it andnotify KSB or the supplying dealer (as applicable) and the insurer about thedamage in writing immediately.

3.2 Transport

CAUTIONImproper pump transportDamage to the pump!

▷ Never suspend the pump/pump set from the power cable.

▷ Prevent the pump (set) from getting knocked or dropped.

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for pump (set) storage.

CAUTIONDamage during storage by humidity, dirt, or verminCorrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessorieswith waterproof material.

CAUTIONWet, contaminated or damaged openings and connectionsLeakage or damage to the pump set!

▷ Only remove caps/covers from the openings of the pump set at the time ofinstallation.

Store the pump (set) in a dry, protected room where the atmospheric humidity is asconstant as possible.

If properly stored indoors, the pump set is protected for a maximum of 12 months.

For storing a pump (set) which has already been operated, observe the instructions in(⇨ Section 6.4.1 Page 22) .

3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.2 Page 23)2. Always flush and clean the pump, particularly if it has been used for handling

noxious, explosive, hot or other hazardous fluids.

3. If the fluids handled by the pump set leave residues which might lead tocorrosion damage when coming into contact with atmospheric humidity, orwhich might ignite when coming into contact with oxygen, the pump set mustalso be neutralised, and anhydrous inert gas must be blown through the pumpfor drying purposes.



3.5 Disposal

WARNINGFluids, consumables and supplies which are hot or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pump (set).Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:- Metals- Plastics- Electronic waste- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in anothercontrolled manner.



4 Description of the Pump (Set)

4.1 General

▪ Non-self-priming in-line pump

Pump for handling clean or aggressive fluids not chemically and mechanicallyaggressive to the pump materials.

4.2 DesignationExample: Rio N 40-30 T

Table 3: Key to the designation

Code DescriptionRio Type seriesN New generation40 Nominal diameter of pipe connection

25 = Rp 130 = Rp 1 1/4

40 ... 80 = DN 40 ... DN 8030 Head in m x 10 (example 30 = 3m)T Three-phase current

S = single-phase a.c. current

4.3 Name plate

Fig. 1: Name plate (example)

1 Size 2 Voltage, frequency3 Thermal class 4 Maximum operating pressure,

enclosure, temperature class5 Speed levels 6 Material number

Example: 1246-00113

Table 4: Key to the designation

Code Description12 Year 201246 Week00113 Consecutive number

Key to the series code



4.4 Design detailsDesign

▪ Maintenance-free, screw-ended or flanged wet rotor pump (glandless) with up tofour speed levels.

Modes of operation

▪ Open-loop control mode (n = constant) with manual setpoint

Automatic functions

▪ Full motor protection with integrated trip electronics

Manual functions

▪ Setting of speed

Drive

▪ AC asynchronous motor

▪ 230 V - 50 Hz

▪ Enclosure IP 42 for all pumps with 3 speed levelsEnclosure IP 44 for all pumps with 4 speed levels

▪ Thermal class F

▪ Temperature class TF 110

▪ Generic emission standard EN 61 000-6-3

▪ Generic immunity standard EN 61 000-6-1

Bearings

▪ Product-lubricated special plain bearing

4.5 Configuration and function

1 2

4

5 6

3

Fig. 2: Sectional drawing of the pump



1 Discharge nozzle 2 Plain bearing3 Motor 4 Impeller5 Suction nozzle 6 Motor shaft

The pump is designed with a radial fluid inlet and a radial outlet arranged on thesame axis. The impeller is rigidly connected to the motor shaft.

The motor housing is equipped with a terminal box. Mechanical sealing is notrequired as the rotating assembly is completely isolated from the stator winding. Therotating assembly is lubricated and cooled by the fluid pumped. The motor housing ismade of aluminium. Most of the internal parts are made of stainless steel. Theadvanced lubricating system, high-quality carbon bearings and precision-balancedimpeller ensure smooth running and a long service life.

The fluid enters the pump via the suction nozzle (5) and is accelerated outward in acylindrical flow by the rotating impeller (4), which is driven by the motor shaft (6). Inthe flow passage of the pump casing the kinetic energy of the fluid is converted intopressure energy. The fluid is pumped to the discharge nozzle (1), where it leaves thepump. The shaft runs in plain bearings (2), which are supported by the motor (3).

4.6 Noise characteristics

Table 5: Noise characteristics [dB A]

Sound pressure levelAll 45 max.

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Pump set

▪ Installation/operating manual

▪ Sealing elements

4.8 Dimensions and weight

For dimensions and weights please refer to the data sheet of the pump.

Design

Function



5 Installation at Site

5.1 Safety regulations

DANGER

Installation in potentially explosive atmospheresExplosion hazard!

▷ Never install the pump in potentially explosive atmospheres.

▷ Observe the information given in the data sheet and on the name plates of thepump system.

5.2 Checks to be carried out prior to installation

Before installing the pump make sure that the following requirements are met:

▪ Check the data on the name plate of the pump to make sure it can be operatedon the available mains.

▪ The fluid to be handled matches the description of suitable fluids.

▪ The above safety instructions have been complied with.

5.3 Installing the pump set

Install the pump set in an easily accessible place.

CAUTIONIngress of fluid into the motorDamage to the pump set!

▷ Install the pump set with the pump shaft in horizontal position. Connect thepiping without transmitting any stresses and strains.

▷ Never install the pump set with the motor terminal box pointing downwards.

NOTEIt is recommended to install shut-off valves upstream and downstream of the pump.Make sure that no leaking water can drip into the pump motor or terminal box.

The terminal box can be positioned correctly by turning the motor head.

Table 6: Permissible installation positions

Pump sizes All

To do so, undo the bolts/screws and turn the motor head until it has reached itscorrect position. Tighten the bolts/screws again.

DANGER

Leakage at the pumpLeakage of hot fluids!

▷ Insert the O-ring in the correct position.

An arrow on the pump casing indicates the direction of flow.



NOTEThe direction of flow of a vertically installed pump should be upwards.

CAUTIONAir entering the pumpDamage to vertically installed pump sets whose direction of flow is downwards!

▷ Fit a vent valve at the highest point of the suction line.

NOTETo prevent any impurities from collecting in the pump do not install the pump atthe lowest point of the system.

1. Place the pump in the specified installation position.

2. Accurately insert the sealing element.

3. Establish a screwed connection between pump and piping.

4. Tighten the screwed connection hand tight with an assembly tool (e.g. pipewrench).

5. Accurately insert the sealing element in the opposite part on the screwedconnection.

6. Tighten the screwed connection hand tight with an assembly tool (e.g. pipewrench).

1. Place the pump in the specified installation position.

2. Accurately insert the sealing element.

3. Connect the pump flange to the pipe flange by means of screws.

4. Tighten the screws hand tight with an assembly tool (e.g. wrench).

5. Accurately insert the sealing element on the opposite side.

6. Connect the pump flange to the pipe flange by means of screws. Tighten thescrews hand tight.

5.4 Connecting the piping

DANGER

Excessive loads acting on the pump nozzlesDanger to life from leakage of hot fluids!

▷ Do not use the pump as an anchorage point for the piping.

▷ Anchor the pipelines in close proximity to the pump and connect them withouttransmitting any stresses or strains.

▷ Take appropriate measures to compensate thermal expansion of the piping.

NOTEIt is recommended to install check and shut-off elements in the system, dependingon the type of plant and pump. However, such elements must not obstruct properdrainage or hinder disassembly of the pump.

✓ The suction lift line has been laid with a rising slope, the suction head line with adownward slope towards the pump.

✓ The nominal diameters of the pipelines are equal to or greater than the nominaldiameters of the pump nozzles.

✓ The pipelines have been anchored in close proximity to the pump and connectedwithout transmitting any stresses or strains.

Screw-ended pumps

Flanged pumps



1. Thoroughly clean, flush and blow through all vessels, pipelines and connections(especially of new installations).

CAUTIONWelding beads, scale and other impurities in the pipingDamage to the pump!

▷ Free the piping from any impurities.

5.5 Enclosure/insulation

WARNINGThe pump takes on same temperature as the fluid pumpedRisk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

5.6 Electrical connection

DANGER

Work on the pump set by unqualified personnelDanger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualifiedelectrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

DANGER

Work performed on an energised terminal boxDanger of death from electric shock!

▷ Switch off the supply voltage at least 5 minutes prior to commencing work andensure that it cannot be switched on again unintentionally.

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

1. Check the available mains voltage against the data on the name plate.

2. Select an appropriate start-up method.

The pumps must be connected in accordance with the applicable regulations. Theelectrical data is printed on the name plate of the pump. A wiring diagram isprovided under the cover of the terminal box. PG cable glands are fitted at theterminal box for connecting the cables.

Pumps of sizes 25-30 S to 25-60 T do not require any external motor protection.Pumps of sizes 25-60 T and larger require external overload protection.

NOTEIf a conventional motor protection switch is used, the overload setting must beadjusted to the current indicated on the name plate of the pump. When changingthe speed level, this setting must be adjusted accordingly.

For three-phase pumps ("Rio N xx-xx T" models) the direction of rotation of thepump should be checked after the electrical connection. To do so, use a suitablescrewdriver to remove the vent plug in the centre of the name plate. This will open



up a view of the motor shaft. If the direction of rotation is incorrect, interchange anytwo phases. Prior to commissioning, the vent plug must be re-inserted and tightenedwith a suitable screwdriver.

If the piping is not filled with water, the pump should only be operated for a shortperiod of time to prevent any damage to the pump bearings (lubricated by theproduct pumped).



6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the followingconditions are met:

▪ The pump set has been properly connected to the power supply and is equippedwith all protection devices.

▪ The pump has been primed with the fluid to be pumped.

▪ After prolonged standstill of the pump (set) the pump rotor has been rotated bymeans of a screwdriver to make sure the motor is not locked.

6.1.2 Priming and venting the pump

CAUTIONIncreased wear due to dry runningDamage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Never close the shut-off element in the suction line and/or supply line duringpump operation.

1. Vent the pump and suction line and prime both with the fluid to be pumped.

2. Fully open the shut-off element in the suction line.

3. During operation (at top speed) loosen the screw plug until some air escapes.

4. Close the screw plug again.

5. Repeat this procedure several times until all air has escaped.

DANGER

Hot fluid spraying out of the pumpRisk of burns!

▷ Wear protective clothing.

6.1.3 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits if the pump isoperated with the suction and discharge lines closed.Leakage of hot fluids!

▷ Never operate the pump with the shut-off elements in the suction line and/ordischarge line closed.

▷ Only start up the pump set against a slightly or completely open discharge-sideshut-off element.

DANGER

Excessive temperatures due to insufficient lubrication of shaft sealDamage to the pump set!

▷ Never operate the pump set without liquid fill.

▷ Prime the pump as per operating instructions.

▷ Always operate the pump within the permissible operating range.



CAUTIONAbnormal noises, vibrations, temperatures or leakageDamage to the pump!

▷ Switch off the pump (set) immediately.

▷ Eliminate the causes before returning the pump set to service.

✓ The system piping has been cleaned.

✓ Pump, suction line and inlet tank, if any, have been vented and primed with thefluid to be pumped.

✓ The lines for priming and venting have been closed.

1. Fully open the shut-off element in the suction head/suction lift line.

2. Close or slightly open the shut-off element in the discharge line.

3. Start up the motor.



6.1.4 Mode of operation

6.1.4.1 Open-loop control mode with manual setpoint input

The pump is operated at the set speed level (characteristic curve). The required speedlevel is selected by turning the control knob on the pump. In this example (seeillustration) the pump is operated at medium speed. For all pumps of sizes 40-60 S and larger the motor must be de-energised prior tochanging the speed level.The speed level should be set for trouble-free operation of the system, minimisingrunning noises and energy consumption.

H

Q

123

1 2 3

Fig. 3: Setting of open-loop control mode

6.2 Shutdown

✓ The shut-off element in the suction line is and remains open.

1. Close the shut-off element in the discharge line.

2. Switch off the motor and make sure the pump set runs down smoothly to astandstill.

NOTEIf the discharge line is equipped with a non-return or check valve, the shut-offelement in the discharge line may remain open, provided the site's requirementsand regulations are taken into account and observed.

For prolonged shutdown periods:

1. Close the shut-off element in the suction line.

CAUTIONRisk of freezing during prolonged pump shutdown periodsDamage to the pump!

▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protectthem against freezing.

6.3 Operating limits

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled andspeedHot fluid may escape!

▷ Comply with the operating data indicated in the data sheet.

▷ Avoid prolonged operation against a closed shut-off element.

▷ Never operate the pump at product temperatures exceeding those specified inthe data sheet or on the name plate.



6.3.1 Ambient temperature

CAUTIONOperation outside the permissible ambient temperatureDamage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table 7: Fluid temperature specified for the ambient temperature [°C]

Fluid temperature Ambient temperature

Rio N 90 3070 40

6.3.2 Density of the fluid pumped

The pump input power increases in proportion to the density of the fluid pumped.

CAUTIONImpermissibly high density of the fluid pumpedMotor overload!

▷ Observe the information on fluid density in the data sheet.

6.4 Shutdown/storage/preservation

6.4.1 Measures to be taken for shutdown

The pump (set) remains installed

✓ Sufficient fluid is supplied for the operation check run of the pump.

1. Start up the pump (set) regularly between once a month and once every threemonths for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pumpintake area.

The pump is removed from the pipe and stored

The pump has been properly drained (⇨ Section 7.2 Page 23) and the safetyinstructions for dismantling the pump have been observed.

Observe any additional instructions and information provided. (⇨ Section 3 Page 10)

6.5 Returning to service

For returning the pump to service observe the sections on commissioning/start-up (⇨Section 6.1 Page 19) and the operating limits.

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. (⇨ Section 7 Page 23)

WARNINGFailure to re-install or re-activate protective devicesRisk of injuries by escaping fluid!

▷ As soon as the work is completed, re-install and/or re-activate any safety-relevant and protective devices.



7 Servicing/Maintenance

7.1 Servicing/inspection

The circulator pumps are almost maintenance-free. If the pump has not been in operation for a prolonged period of time or if thesystem is severely contaminated, the rotor can become locked. The rotor can be unlocked by undoing the screw plug, inserting a screwdriver intothe shaft end, and rotating the rotor.

NOTE Any repairs on the pump must only be performed by one of our authorised servicepartners.In the event of a failure, please contact your heating system engineer.

7.2 Drainage/cleaning

WARNINGFluids, consumables and supplies which are hot or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Always flush the pump if it has been used for handling noxious, hot or otherhazardous fluids.Always flush and clean the pump before transporting it to the workshop.Provide a cleaning record for the pump.

7.3 Removing the pump set

7.3.1 Removing the complete pump set

DANGER

Work performed on an energised terminal boxDanger of death from electric shock!

▷ Switch off the supply voltage at least 5 minutes prior to commencing work andensure that it cannot be switched on again unintentionally.

DANGER

Residual voltage at the motor contactsDanger to life by rotors acting as generators!

▷ Prevent the fluid from flowing back by closing the shut-off elements.

✓ The relevant notes and steps have been observed/carried out.

✓ The pump has cooled down to ambient temperature.

✓ A container for collecting the fluid has been positioned underneath the pumpset.

1. De-energise the pump set (disconnect the motor) and ensure that it cannot bere-energised unintentionally.

2. Close the shut-off elements.

3. Disconnect the discharge and suction nozzles from the piping.



4. Depending on the pump/motor size, remove the supports from the pump set.

5. Remove the complete pump set from the piping.



8 Trouble-shootingPump is running but does not deliver

Pump does not start up or pump running unevenly

Pump running but not delivering water.

Noises during pump operation

Table 8: Trouble-shooting

A B C D Possible cause Remedy1)

✘ See section on modes of operation. (⇨ Section6.1.4 Page 21)

Reset the voltage. Check the power supply and fuses.

✘ Impurities in the pump See section on maintenance. (⇨ Section 7.1 Page23)

✘ Air in the system Vent the system and the pump. ✘ Gate valve closed Open the gate valve. ✘ Wrong direction of rotation Check the direction of rotation. Correct it, if

required. ✘ Excessive pump power output Select a lower speed level. ✘ System pressure too low Increase the system pressure by filling more water

into the boiler. ✘ Air in the system Vent the pump (vent plug) and piping.

A

B

C

D

1) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

8 Trouble-shooting


9 Related Documents

9.1 Sectional drawing with list of components

102

230

81-59 818 814817

310 81-22

Part No. Description Part No. Description102 Volute casing 230 Impeller310 Plain bearing 81-22 Terminal box cover81-59 Stator 814 Copper windings817 Can 818 Rotor

9.2 Wiring diagramsSingle-phase (S models)

PE L N

Fig. 4: Wiring diagram for single-phase a.c. current

Three-phase (T models)

PE L1 L2 L3

Fig. 5: Wiring diagram for three-phase current

9 Related Documents


Index

CCommissioning/start-up 19

DDisposal 11

FFault 25

IIntended use 7

MMisuse 8

NName plate 12

OOperating limits 7, 21

PPiping 16Preservation 10, 22Product description 12

RReturn to supplier 10Returning to service 22

SSafety 7Safety awareness 8Scope of supply 14Shutdown 22Start-up 20Storage 10, 22

Index


1153

.82/

01-EN

KSB Aktiengesellschaft67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)Tel. +49 6233 86-0 • Fax +49 6233 86-3401www.ksb.com

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