KSB Rio-Therm N Series Montageanleitung

Hot Water Service Pump

Rio-Therm N

Rio-Therm N 25-30 to 80-80

Installation/Operating

Manual

Legal information/Copyright

Installation/Operating Manual Rio-Therm N

Original operating manual

KSB Aktiengesellschaft

processed for any other purpose, nor otherwise transmitted, published or made available to a third party without

KSB's express written consent.

Subject to technical modification without prior notice.

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 operating

instructions ........................................................................................................ 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 Casing/insulation ............................................................................................17

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

Contents

Rio-Therm N 3 of 30

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 Dismantling 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

10 EC Declaration of Conformity ............................................................27

Index ....................................................................................................28

Contents

4 of 30 Rio-Therm N

Glossary

Discharge line

The line which is connected to the discharge

nozzle

Noise characteristics

The noise emission to be expected, indicated as

sound pressure level LpA in dB(A)

Pump

Machine without drive, additional components

or accessories

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 suction

nozzle

Glossary

Rio-Therm N 5 of 30

1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variants

indicated on the front cover. The manual describes the proper and safe use of this

equipment in all phases of operation.

The name plate indicates the type series/size and main operating data. They uniquely

identify the pump (set) and serve as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB service centre to

maintain the right to claim under warranty.

Noise characteristics.

1.2 Target group

This manual is aimed at the target group of trained and qualified specialist technical

personnel.(⇨ 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-references

Step-by-step instructions

Note

Recommendations and important information on how to handle

the product

1 General

6 of 30 Rio-Therm N

1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variants

indicated on the front cover. The manual describes the proper and safe use of this

equipment in all phases of operation.

The name plate indicates the type series/size and main operating data. They uniquely

identify the pump (set) and serve as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB service centre to

maintain 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 technical

personnel.(⇨ Section 2.4 Page 8)

1.3 Symbols

Table 1: Symbols used in this manual

2 Safety

All 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

DANGER

This signal word indicates a high-risk hazard which, if not avoided,

will result in death or serious injury.

!WARNING

WARNING

This signal word indicates a medium-risk hazard which, if not

avoided, could result in death or serious injury.

CAUTION

This signal word indicates a hazard which, if not avoided, could

result in damage to the machine and its functions.

General hazard

In conjunction with one of the signal words this symbol indicates a

hazard which will or could result in death or serious injury.

Electrical hazard

In conjunction with one of the signal words this symbol indicates a

hazard involving electrical voltage and identifies information about

protection against electrical voltage.

Machine damage

In conjunction with the signal word CAUTION this symbol indicates

a hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructions

that must be observed to ensure safe pump operation and prevent personal injury

and 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 site

at all times.

Information attached directly to the pump must always be complied with and be

kept 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 not

taken into account in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits described in the

other 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 product

literature 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

Rio-Therm N 7 of 30

▪Observe the maximum flow rates indicated in the data sheet or product

literature (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 prevent

cavitation damage).

▪Consult the manufacturer about any use or mode of operation not described in

the data sheet or product literature.

Prevention of foreseeable misuse

▪Never exceed the permissible operating limits specified in the data sheet or

product 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, maintain

and inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved in

transport, installation, operation, maintenance and inspection must be clearly

defined by the operator.

Deficits in knowledge must be rectified by means of training and instruction

provided by sufficiently trained specialist personnel. If required, the operator can

commission the manufacturer/supplier to train the personnel.

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

personnel.

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

instructions

▪Non-compliance with these operating instructions will lead to forfeiture of

warranty 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 chemical

effects 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 check

that 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

8 of 30 Rio-Therm N

▪Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply

companies.)

2.8 Safety information for maintenance, inspection and installation work

▪Modifications or alterations of the pump are only permitted with the

manufacturer's prior consent.

▪Use only original spare parts or parts authorised by the manufacturer. The use of

other parts can invalidate any liability of the manufacturer for resulting damage.

▪The operator ensures that all maintenance, inspection and installation work is

performed by authorised, qualified specialist personnel who are thoroughly

familiar 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 procedure

described 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-relevant

and protective devices. Before returning the product to service, observe all

instructions 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 this

manual.

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

Rio-Therm N 9 of 30

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 and

notify KSB or the supplying dealer (as applicable) and the insurer about the

damage in writing immediately.

3.2 Transport

CAUTION

Improper pump transport

Damage 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 the

following measures be taken for pump (set) storage.

CAUTION

Damage during storage by humidity, dirt, or vermin

Corrosion/contamination of the pump (set)!

▷For outdoor storage cover the packed or unpacked pump (set) and accessories

with waterproof material.

CAUTION

Wet, contaminated or damaged openings and connections

Leakage or damage to the pump set!

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

installation.

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

constant 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 to

corrosion damage when coming into contact with atmospheric humidity, or

which might ignite when coming into contact with oxygen, the pump set must

also be neutralised, and anhydrous inert gas must be blown through the pump

for drying purposes.

3 Transport/Temporary Storage/Disposal

10 of 30 Rio-Therm N

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