Riotherm® Installation/Operating Manual - KSB€¦ · 2 Safety ... Electrical hazard ... safety regulations and/or regulations issued by the local energy supply companies.) 2.8 Safety

Hot Water Service Pump

Riotherm®

Installation/OperatingManual

Copyright/Legal information Installation/Operating Manual Riotherm®Original operating manual KSB Aktiengesellschaft Pegnitz All rights reserved. Contents provided herein must neither be distributed, copied, reproduced,processed for any other purpose, nor otherwise transmitted to a third party without KSB´s expresswritten consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 13.04.2010

Contents

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

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

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

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

1.3 Other applicable documents .......................................................................... 6

1.4 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 Transport ....................................................................................................... 10

3.2 Storage and preservation ............................................................................. 10

3.3 Return to supplier ......................................................................................... 10

3.4 Disposal .......................................................................................................... 11

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

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

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

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

4.4 Design details ................................................................................................ 12

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

4.6 Noise characteristics ...................................................................................... 13

4.7 Scope of supply ............................................................................................. 13

4.8 Dimensions and weights ............................................................................... 14

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

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

5.2 Checking the site before installation ........................................................... 15

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

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

5.5 Protective equipment ................................................................................... 16

5.6 Connection to power supply ........................................................................ 17

Contents

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5.7 Checking the direction of rotation .............................................................. 17

6 Commissioning/Start-up/Shutdown ................................................. 18

6.1 Commissioning/start-up ................................................................................ 18

6.2 Shutdown/storage/preservation ................................................................... 20

6.3 Returning to service after storage ............................................................... 21

7 Servicing/Maintenance ...................................................................... 22

7.1 Safety regulations ......................................................................................... 22

7.2 Servicing/inspection ...................................................................................... 22

7.3 Drainage/disposal .......................................................................................... 24

7.4 Dismantling the pump set ............................................................................ 24

7.5 Reassembling the pump set .......................................................................... 26

8 Trouble-shooting ............................................................................... 28

9 Related Documents ........................................................................... 29

9.1 Installation examples .................................................................................... 29

9.2 Wiring diagram ............................................................................................. 29

9.3 Exploded view and list of components ........................................................ 30

10 EC Declaration of Conformity .......................................................... 31

11 Certificate of Decontamination ....................................................... 32

Index .................................................................................................. 33

Contents

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Glossary

Back pull-out designThe complete back pull-out unit can be pulledout without having to remove the pump casingfrom the piping.

Back pull-out unitPump without pump casing; partly completedmachinery

Certificate of decontaminationA certificate of decontamination certifies thatthe pump (set) has been properly drained toeliminate any environmental and healthhazards arising from components in contactwith the fluid handled.

Close-coupled designMotor directly fitted to the pump via a flangeor a drive lantern

Discharge lineThe line which is connected to the dischargenozzle

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

PumpMachine without drive, additional componentsor accessories

Pump setComplete pump set consisting of pump, drive,additional components and accessories

Suction lift line/suction head lineThe line which is connected to the suctionnozzle

Glossary

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1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicatedon the front cover. It describes the proper and safe use of this equipment in allphases of operation.

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

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

Noise characteristics. (⇨ Section 4.6 Page 13)

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 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsData sheet Description of the technical data of the pump

(set)General arrangement drawing/Outline drawing

Description of mating and installation dimensionsfor the pump (set)

Drawing of auxiliary connections Description of auxiliary connectionsHydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power inputGeneral assembly drawing1) Sectional drawing of the pump

Sub-supplier product literature1) Operating manuals and other product literatureof accessories and integrated machinerycomponents

Spare parts lists1) Description of spare parts

Piping layout1) Description of auxiliary piping

List of components1) Description of all pump components

1.4 Symbols

Table 2: 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) If agreed to be included in the scope of supply

1 General

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

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk situation which, if notavoided, will result in death or serious injury.

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

CAUTION CAUTIONThis signal word indicates a hazardous situation which, if notavoided, could damage 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 voltages and provides informationabout protection against electrical voltages.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazardous situation 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 responsible specialistpersonnel/operators 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 meeting all local regulations which are not taken intoaccount in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits which aredescribed in the other applicable documents.

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

▪ Do not operate partially assembled pumps/pump sets.

▪ Only use the pump to handle the fluids specified in the data sheet or productliterature of the respective design variant.

▪ Never operate the pump without the fluid to be handled.

! DANGER

2 Safety

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

▪ 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 install, operate, maintain andinspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved ininstallation, operation, maintenance and inspection must be clearly defined by theoperator.

Deficits in knowledge must be rectified by sufficiently trained specialist personneltraining and instructing the personnel who will carry out the respective tasks. Ifrequired, the operator can commission the manufacturer/supplier to train thepersonnel.

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.

2 Safety

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▪ 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.

▪ 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 consequentialdamage.

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

▪ Carry out work on the pump (set) during standstill only.

▪ 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.

▪ 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 18)

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

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3 Transport/Temporary Storage/Disposal

3.1 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.

3.2 Storage and 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 pump (set) or the packaged pump (set) andaccessories with 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.

Rotate the shaft by hand once a month, e.g. via the motor fan.

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 instructionsgiven in this manual. (⇨ Section 6.2.1 Page 20)

3.3 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3 Page 24)

2. Always flush and clean the pump, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.

3. If the fluids handled by the pump leave residues which might lead to corrosiondamage when coming into contact with atmospheric humidity, or which mightignite when coming into contact with oxygen, the pump set must also beneutralised, and anhydrous inert gas must be blown through the pump fordrying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set). (⇨ Section 11 Page 32)It is imperative to indicate any safety and decontamination measures taken.

NOTEIf required, a blank certificate of decontamination can be downloaded from the KSB website at: www.ksb.com/certificate_of_decontamination


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http://www.ksb.com/GRAS-Cert

3.4 Disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.

▷ 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 another controlledmanner.


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4 Description of the Pump (Set)

4.1 General description

▪ Non-self-priming in-line pump

▪ Hot water service pump

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

4.2 Designation

Example: Riotherm R 2 25 E

Table 4: Key to the designation

Code DescriptionRiotherm Type seriesR Material of pump casing (gunmetal)2 Pipe connection Rp 1

3 = Pipe connection Rp 1 1/4

2 2-pole motors5 Max. motor power P2 in Watts: 10

E Single-phase a.c.

4.3 Name plate

Riotherm R 22-5 D S - W

230/400 V 3~ 50 Hz

0,64/0,37 A

P1 130 W 2850 1/min

Cl. B max. 2,5 m PN 16

AktiengesellschaftD-67225 Frankenthal

00 132 545 Made by KSB ZNI 1448C

max. 3,6 m3/h max. 110°C

1

2

5

4

3

9

10

11

8

7

6Fig. 1: Name plate

1 Type series, size 2 Power cable3 Motor current at 230/400 V 4 Motor power P15 Maximum flow rate 6 Maximum head7 Series number 8 Mains frequency9 Motor speed 10 Maximum fluid temperature

11 Maximum operating pressure

Table 5: Key to the series number

Calendar year 2009 2010 2011 2012 20131st half of the year S-U S-W S-Y S-A S-C2nd half of the year S-V S-X S-Z S-B S-D

4.4 Design details

▪ Close-coupled design/in-line design

▪ Single-stage

Key to the series number


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▪ Horizontal installation

▪ Back pull-out design

▪ Rigid connection between pump and motor

▪ Pump and motor on a common shaft

▪ Standardised mechanical seal to EN 12756

▪ Radial ball bearings in the motor housing

▪ Grease-lubricated for life

4.5 Configuration and function

1 2 3

4

5 6Fig. 2: Sectional drawing Riotherm

1 Discharge nozzle 2 Mechanical seal3 Motor 4 Impeller5 Suction nozzle 6 Radial ball bearing

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 fluid enters the pump via the suction nozzle (5) and is accelerated outward in acylindrical flow by the rotating impeller (4). The flow profile of the pump casingconverts the kinetic energy of the fluid into pressure energy. The fluid is pumped tothe discharge nozzle (1), where it leaves the pump. The shaft passage through thedischarge cover is sealed towards the atmosphere with a dynamic mechanical seal (2).The shaft runs in radial ball bearings (6), which are supported by a motor (3).

The pump is sealed by a mechanical seal.

4.6 Noise characteristics

Sound pressure level < 70 dB(A)

4.7 Scope of supply

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

▪ Pump set

▪ Pipe unions

Shaft seal

Bearings

Design

Function

Sealing

Special accessories


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4.8 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outlinedrawing of the pump (set).


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5 Installation at Site

5.1 Safety regulations

DANGERInstallation in potentially explosive atmospheresExplosion hazard!

▷ Do not 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 Checking the site before installation

Place of instal lat ion

The place of installation should meet the following requirements:

▪ Well ventilated

▪ Level

▪ Clean

▪ Of sufficient strength

▪ No direct sunlight

▪ Protected from weather

▪ Sufficient clearance for ventilation and dismantling

▪ All welding and soldering work has been completed.

▪ The piping has been flushed as required.

5.3 Installing the pump set

Install the pump set in an easily accessible place.

If the pump is installed in a drinking/service water circulation system, a swing checkvalve must be fitted on the discharge side.

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. (⇨ Section 9.1 Page 29)

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

▷ Undo socket head cap screws 914. Then turn the motor housing.

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 arrow on drive lantern 822 indicates the direction of rotation; the arrow onpump casing 102 indicates the direction of flow.


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5.4 Connecting the piping

DANGERExcessive 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.

CAUTIONIncorrect earthing during welding work at the pipingDestruction of rolling element bearings (pitting effect)!

▷ Never earth the electric welding equipment on the pump or baseplate.

▷ Prevent current flowing through the rolling element bearings.

NOTEIt is recommended to install check and shut-off elements in the system, depending on thetype of plant and pump. However, such elements must not obstruct proper drainage orhinder disassembly of the pump.

✓ The suction lift line/suction head line has been laid with a rising/downward slopetowards the pump.

✓ The nominal diameters of the pipelines are at least equal to the nominaldiameters of the pump nozzles.

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

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

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

▷ Free the piping from any impurities.

5.5 Protective equipment

WARNINGThe volute casing and casing/discharge cover take on the same temperature as the fluidhandledRisk of burns!

▷ Insulate the volute casing.

▷ Fit protective equipment.

CAUTIONHeat build-up inside the drive lanternDamage to the bearing!

▷ Never insulate the casing cover and the drive lantern.


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5.6 Connection to power supply

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

▷ Always have the electrical connections installed by a trained electrician.

▷ Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pumpsets, IEC 60079 (DIN VDE 0165).

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.

NOTEIt is recommended to fit a motor protection device.

5.6.1 Connecting the motor

NOTEIn compliance with DIN VDE 0530 - Part 8, three-phase motors are always wired forclockwise rotation (looking at the motor shaft stub).The pump's direction of rotation is indicated by an arrow on the pump.

1. Change the motor's direction of rotation to match that of the pump.

2. Observe the manufacturer's product literature supplied with the motor.

5.7 Checking the direction of rotation

CAUTIONMotor and pump running in the wrong direction of rotationSpecified performance data are not achieved!

▷ Refer to the arrow indicating the direction of rotation on the pump.

▷ Check the direction of rotation. If required, interchange any two phases tocorrect the direction of rotation.

The correct direction of rotation of motor and pump is clockwise (seen from themotor end).

1. Start the motor and stop it again immediately to determine the motor's directionof rotation.

2. Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the directionof rotation on the pump.

3. If the motor is running in the wrong direction of rotation, check the electricalconnection of the motor and the control system, if applicable.


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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

Before starting up the pump set make sure that the following requirements 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 handled. (⇨ Section 6.1.3 Page18)

▪ The direction of rotation has been checked. (⇨ Section 5.7 Page 17)

▪ All auxiliary connections required are connected and operational.

▪ After prolonged shutdown of the pump (set), the activities described in (⇨Section 6.3 Page 21) have been carried out.

6.1.2 Checking the shaft seal

The mechanical seal only leaks slightly or invisibly (as vapour) during operation.Mechanical seals are maintenance-free.

6.1.3 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 them with the fluid to be handled.

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

NOTEFor design-inherent reasons a remaining gas volume in the hydraulic system cannot beexcluded after the pump has been primed for commissioning/start-up. However, once themotor is started up the pumping effect will immediately fill this volume with the fluidhandled.

6.1.4 Start-up

DANGERNon-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 with the discharge-side gate valve slightly or fullyopen.

Mechanical seal


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DANGERExcessive temperatures due to dry runningDamage to the pump set!


▷ Prime the pump as specified.

▷ 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 handled.

✓ The filling and venting lines 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.

DANGERSeal leakage at operating temperatureHot fluid may escape!

▷ Once the operating temperature has been reached, re-tighten the hexagon nutsbetween casing and casing cover.

4. When the operating temperature has been reached and/or in the event ofleakage, switch off the pump set and re-tighten the bolts between lantern andcasing.

6.1.5 Shutdown

CAUTIONHeat build-up inside the pumpDamage to the shaft seal!

▷ Depending on the type of installation, the pump set requires sufficient after-runtime – with the heat source switched off – until the fluid handled has cooleddown.

✓ 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-off elementmay remain open as long as there is back pressure.

For prolonged shutdown periods:

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


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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.

6.1.6 Operating limits

DANGERNon-compliance with operating limits for pressure, temperature and speedHot 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.

6.1.6.1 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 6: Permissible ambient temperatures

Permissible ambient temperature ValueMaximum 40 °CMinimum See data sheet.

6.1.7 Density of the fluid handled

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

CAUTIONImpermissibly high density of the fluid handledMotor overload!

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

▷ Make sure the power reserve of the motor is sufficient.

6.2 Shutdown/storage/preservation

6.2.1 Measures to be taken for shutdown

The pump (set) remains instal led

✓ 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.


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The pump (set) i s removed from the pipe and stored

✓ The pump has been properly drained (⇨ Section 7.3 Page 24) and the safetyinstructions for dismantling the pump have been observed. (⇨ Section 7.4.1 Page24)

1. Spray-coat the inside wall of the pump casing, and in particular the impellerclearance areas, with a preservative.

2. Spray the preservative through the suction and discharge nozzles.It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).

3. Oil or grease all blank parts and surfaces of the pump (with silicone-free oil andgrease, food-approved if required) to protect them against corrosion. Observe the additional instructions. (⇨ Section 3.2 Page 10)

If the pump set is to be stored temporarily, only preserve the wetted componentsmade of low alloy materials. Commercially available preservatives can be used for thispurpose. Observe the manufacturer's instructions for application/removal.

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

6.3 Returning to service after storage

For returning the pump to service observe the sections on commissioning/start-up (⇨Section 6.1 Page 18) and the operating limits. (⇨ Section 6.1.6 Page 20)

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. (⇨ Section 7 Page 22)

WARNINGFailure to re-install or re-activate protective devicesRisk of personal injury from moving parts or escaping fluid!

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

NOTEIf the pump has been out of service for more than one year, replace all elastomer seals.


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7 Servicing/Maintenance

7.1 Safety regulations

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

WARNINGPump set started up inadvertentlyRisk of injury by moving parts!

▷ Make sure that the pump set cannot be started up accidentally.

▷ Always make sure the electrical connections are disconnected before carryingout work on the pump set.

WARNINGFluids posing a health hazard or hot fluidsRisk of personal injury!

▷ Observe all relevant laws.

▷ When draining the fluid take appropriate measures to protect persons and theenvironment.

▷ Decontaminate pumps handling fluids posing a health hazard.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the pump (set) with a minimum of maintenanceexpenditure and work.

NOTEAll maintenance, service and installation work can be carried out by KSB Service. Findyour contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/contact".

Never use force when dismantling and re-assembling a pump set.

7.2 Servicing/inspection

7.2.1 Supervision of operation

DANGERIncorrectly serviced shaft sealFire hazard!Leakage of hot fluids!Damage to the pump set!

▷ Regularly service the shaft seal.

DANGERExcessive temperatures as a result of bearings running hot or defective bearing sealsFire hazard!Damage to the pump set!

▷ Regularly check the rolling element bearings for running noises.


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CAUTIONIncreased wear due to dry runningDamage to the pump set!


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

CAUTIONImpermissibly high temperature of fluid handledDamage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted (heatingup of the fluid).

▷ Observe the temperature limits in the data sheet and in the section onOperating limits. (⇨ Section 6.1.6 Page 20)

While the pump is in operation, observe and check the following:

▪ The pump must run quietly and free from vibrations at all times.

▪ Check the shaft seal. (⇨ Section 6.1.2 Page 18)

▪ Check the static seals for leakages.

▪ Check the rolling element bearings for running noises.Vibrations, noise and an increase in current input occurring during unchangedoperating conditions indicate wear.

▪ Monitor the bearing temperature.The bearing temperature must not exceed 90 °C (measured at the motorhousing).

CAUTIONOperation outside the permissible bearing temperatureDamage to the pump!

▷ The bearing temperature of the pump (set) must never exceed 90 °C (measuredon the outside of the motor housing).

NOTEAfter commissioning, increased temperatures may occur at grease-lubricated rollingelement bearings due to the running-in process. The final bearing temperature is onlyreached after a certain period of operation (up to 48 h depending on the conditions).

7.2.2 Inspection work

CAUTIONExcessive temperatures caused by friction, impact or frictional sparksDamage to the pump set!

▷ Regularly check the coupling guard, plastic components and other guards ofrotating parts for deformation and sufficient distance from rotating parts.


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7.3 Drainage/disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any fluid residues.

▷ 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. Providea cleaning record for the pump.

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

WARNINGUnqualified personnel performing work on the pump (set)Risk of personal injury!

▷ Always have repair and maintenance work performed by specially trained,qualified personnel.

WARNINGHot surfaceRisk of personal injury!

▷ Allow the pump set to cool down to ambient temperature.

Observe the general safety instructions and information. (⇨ Section 7.1 Page 22)

For any work on the motor, observe the instructions of the relevant motormanufacturer.

For dismantling and reassembly observe the exploded view and the general assemblydrawing. (⇨ Section 9.3 Page 30)

NOTEAll maintenance, service and installation work can be carried out by KSB Service. Findyour contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/contact".

DANGERInsufficient preparation of work on the pump (set)Risk of personal injury!

▷ Properly shut down the pump set. (⇨ Section 6.1.5 Page 19)

▷ Close the shut-off elements in the suction and discharge line.

▷ Drain the pump and release the pump pressure. (⇨ Section 7.3 Page 24)

▷ Allow the pump set to cool down to ambient temperature.

NOTEAfter a prolonged period of operation the individual parts may be hard to pull off theshaft. If this is the case, use a brand name penetrating agent and/or - if possible - anappropriate pull-off device.


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7.4.2 Preparing the pump set

1. Disconnect the power supply (e.g. at the motor).

7.4.3 Dismantling the complete pump set

NOTEThe pump casing can remain installed in the piping for further dismantling.

✓ The notes and steps stated in (⇨ Section 7.4.1 Page 24) to (⇨ Section 7.4.2 Page25) have been observed/carried out.

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

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

3. Remove the complete pump set from the piping.

7.4.4 Removing the back pull-out unit

WARNINGBack pull-out unit tipping overRisk of squashing hands and feet!

▷ Suspend or support the back pull-out unit at the pump end.


1. If required, suspend or support the back pull-out unit to prevent it from tippingover.

2. Undo nut 920.2 (with bolted discharge cover) or 920.1 (with clamped dischargecover) at the volute casing.

3. Pull the back pull-out unit out of the volute casing.

4. Remove and dispose of gasket 400.1.

5. Place the back pull-out unit on a clean and level surface.

7.4.5 Removing the impeller


✓ The back pull-out unit is kept in a clean and level assembly area.

1. Undo impeller nut 920.5 (right-hand thread).Take washer 930 and disc 550.1 off the impeller hub.

2. Remove impeller 230 with an impeller removal device.

3. Place impeller 230 on a clean and level surface.

4. Remove key 940 from shaft 210.

7.4.6 Removing the mechanical seal


✓ The back pull-out unit is kept in a clean and level assembly area.

✓ Impeller 230 has been removed.

1. Remove shaft sleeve 523 with the rotating part of the mechanical seal (spring-loaded ring) from shaft 210.

2. Unscrew hexagon nuts 920.3 and 920.1 on drive lantern 341.

3. Remove discharge cover 163 from drive lantern 341.

Mechanical seal withoutshaft sleeve


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4. Remove the stationary part of the mechanical seal (seat ring) from dischargecover 163.

7.5 Reassembling the pump set

7.5.1 General notes/Safety regulations

CAUTIONImproper reassemblyDamage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of soundengineering practice.

▷ Use original spare parts only.

Always reassemble the pump in accordance with the corresponding general assemblydrawing or exploded view.

Check the O-rings for any damage and replace them by new O-rings, if required.

Always use new gaskets, making sure that they have the same thickness as the oldones.

Always fit gaskets of asbestos-free materials or graphite without using lubricants(e.g. copper grease, graphite paste).

Avoid the use of assembly adhesives, if possible.

Should an assembly adhesive be required after all, use a commercially availablecontact adhesive (e.g. "Pattex") or sealant (e.g. HYLOMAR or Epple 33).

Only apply adhesive at selected points and in thin layers.

Never use quick-setting adhesives (cyanoacrylate adhesives).

Coat the locating surfaces of the individual components with graphite or similarbefore reassembly.

When reassembling the pump set, tighten all screws/bolts as indicated.

7.5.2 Installing the mechanical seal

Always observe the following rules when installing the mechanical seal:

▪ Work cleanly and accurately.

▪ Only remove the protective wrapping of the contact faces immediately beforeassembly takes place.

▪ Prevent any damage to the sealing surfaces or O-rings.

✓ The notes and steps stated in (⇨ Section 7.5.1 Page 26) have been observed/carried out.

✓ The assembled bearing as well as the individual parts are kept in a clean andlevel assembly area.

✓ All dismantled components have been cleaned and checked for wear.

✓ Any damaged or worn parts have been replaced by original spare parts.

✓ The sealing surfaces have been cleaned.

1. Clean the seat ring location in discharge cover 163 and seat ring holder 476.

CAUTIONElastomers in contact with oil/greaseShaft seal failure!

▷ Use water as assembly lubricant.

▷ Never use oil or grease as assembly lubricant.

Sequence

Seal elements

Assembly adhesives

Tightening torques

Installing the mechanicalseal


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2. Carefully insert seat ring and seat ring holder 476.Press them in evenly.

3. Fit discharge cover 163 into the locating surface of drive lantern 341.

NOTETo reduce friction forces when assembling the seal, wet the seat ring location with water.

4. Fit the rotating part of the mechanical seal (spring-loaded ring) on shaft 210.

7.5.3 Fitting the impeller


✓ The pre-assembled unit (motor, shaft, drive lantern, discharge cover) as well asthe individual parts are kept in a clean and level assembly area.

✓ All dismantled components have been cleaned and checked for wear.



1. Tighten impeller nut 920.5 with washer 930 and disc 550.1, if any.

7.5.4 Installing the back pull-out unit

WARNINGBack pull-out unit tipping overRisk of squashing hands and feet!

▷ Suspend or support the back pull-out unit at the pump end.




1. If required, suspend or support the back pull-out unit to prevent it from tippingover.

2. Fit new gasket 400.1 into the recess of volute casing 102.

3. Push the back pull-out unit into volute casing 102.

4. Fasten hexagon nut 920.2 (for bolted discharge cover) at volute casing 102.


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8 Trouble-shootingPump is running but does not deliver

Noises during pump operation

Leakage at the pump

Insufficient flow rate

Table 7: Trouble-shooting

A B C D Possible cause Remedy2)

X Motor protection switch has tripped thepump set.

Check setting.

Fit new motor protection switch.X Pump blocked Remove deposits/foreign matter.X Motor is running on two phases only. Replace defective fuse.

Check cable connections. X Cavitation due to insufficient inlet pressure Increase system pressure.

X No operating voltage Check mains voltage.

Check cable connections. X Pump casing defective Fit new sealing elements. X Mechanical seal defective due to

aggressive, abrasive fluidContact KSB Service.

X 3-phase motor running in the wrongdirection of rotation

Interchange two of the phases of thepower cable.

A

B

C

D

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

8 Trouble-shooting

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9 Related Documents

9.1 Installation examples

Fig. 3: Installation examples

9.2 Wiring diagram

Fig. 4: Wiring diagram

9 Related Documents

Riotherm® 29 of 34

9.3 Exploded view and list of components

832 831 81-22550. 5

837 575 321. 1 822

914

507 163 433 550. 2

230

550. 1

920. 1

412. 3 102

800

500321. 2

Part No. Description Part No. Description102 Volute casing 5753) Strip163 Suction cover 800 Motor230 Impeller 81-22 Terminal box cover321.1/.2 Radial ball bearing 822 Motor bearing housing411 Joint ring 831 Fan impeller412.3 O-ring 832 Fan hood433 Mechanical seal 8373) Capacitor500 Ring 914 Socket head cap screw507 Thrower 920.1 Nut550.1/.2/.5 Disc

3) For single-phase a.c. motor only

9 Related Documents

30 of 34 Riotherm®

10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Riotherm▪ is in conformity with the provisions of the following directives as applicable in their current version:

– EC Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– ISO 12100-1/A1, ISO 12100-2/A1,

– ISO 14121-1,

– EN 809/A1

Pegnitz, 29.12.2009

Jürgen Gröschel

Head of Product Development Seal-less Pumps/Building Services

Responsible for compiling the technical documentationKSB Aktiengesellschaft

Bahnhofplatz 1

91257 Pegnitz (Germany)

10 EC Declaration of Conformity

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11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number4) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled4) : ................................................................................................................................

Please tick where applicable4) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return4) : ................................................................................................................................ Comments: ................................................................................................................................ ................................................................................................................................ The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placingat your disposal.

On seal-less pumps, the rotor has been removed from the pump for cleaning.

⃞ No special safety precautions are required for further handling.⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

............................................................................................................................................................... ............................................................................................................................................................... We confirm that the above data and information are correct and complete and that dispatch is effected in accordance withthe relevant legal provisions.

.................................................................... ....................................................... .......................................................Place, date and signature Address Company stamp

4) Required fields

11 Certificate of Decontamination

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Index

BBearing temperature 23

CCertificate of decontamination 32Commissioning/start-up 18

DDirection of rotation 17Dismantling 24Disposal 11

FFaults/malfunctions 28

IInstallation 15Intended use 7

MMechanical seal 18Misuse 8

NName plate 12

OOperating limits 7, 20Other applicable documents 6

PPiping 16Positioning the pump set 15Preservation 10, 21

RReassembly 24, 26Return to supplier 10Returning to service 21

SSafety 7Safety awareness 8Scope of supply 13Servicing/maintenance 22Shutdown 21Start-up 19Storage 10, 21

Index

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KSB AktiengesellschaftP.O. Box 1361 • 91253 Pegnitz • Bahnhofplatz 1, 91257 Pegnitz (Germany) Tel. +49 9241 71-0 • Fax +49 9241 71-1793www.ksb.com

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