KSB IE3 Installation & Operating Manual

Asynchronous Motor

KSB IE3-Motor

0.55 kW to 132 kW
2-pole, 4-pole

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual KSB IE3-Motor

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

© KSB SE & Co. KGaA, Frankenthal 15/12/2017

Contents

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Contents

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 .....................................................................................................................................................8

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

2.5 Consequences and risks caused by non-compliance with this manual .........................................................8

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

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

2.8 Safety information for maintenance, inspection and installation ................................................................8

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

2.10 Electromagnetic compatibility.........................................................................................................................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 Disposal/recycling ...........................................................................................................................................11

4 Description............................................................................................................................................ 12

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

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

4.3 Name plate......................................................................................................................................................13

4.4 Types of construction .....................................................................................................................................13

4.5 Mounting arrangements................................................................................................................................14

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

4.7 Balancing.........................................................................................................................................................14

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

5.1 Checks to be carried out prior to installation...............................................................................................15

5.2 Installing the motor........................................................................................................................................16

5.3 Electrical connection ......................................................................................................................................17

5.3.1 Motor connection inside the terminal box ......................................................................................17

5.3.2 Checking the direction of rotation ...................................................................................................19

5.4 Tightening torques.........................................................................................................................................20

5.5 Installing and removing output components...............................................................................................21

6 Commissioning/Start-up/Shutdown................................................................................................... 22

6.1 Checking earth conductor connection..........................................................................................................22

6.2 Checking insulation resistance.......................................................................................................................22

6.3 Prerequisites for commissioning/start-up......................................................................................................22

6.4 Start-up ...........................................................................................................................................................23

6.5 Operating limits..............................................................................................................................................23

6.5.1 Voltages and frequencies ..................................................................................................................23

6.5.2 Maximum permissible speed .............................................................................................................23

6.5.3 Ambient temperature........................................................................................................................23

6.5.4 Altitude...............................................................................................................................................23

6.6 Shutdown........................................................................................................................................................23

6.7 Idle periods .....................................................................................................................................................24

6.8 Returning to service .......................................................................................................................................24

7 Servicing/Maintenance........................................................................................................................ 25

7.1 Safety regulations...........................................................................................................................................25

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7.2 Maintenance/inspection.................................................................................................................................26

7.2.1 Supervision of operation ...................................................................................................................26

7.2.2 Inspection ...........................................................................................................................................27

7.3 Preparing disassembly....................................................................................................................................30

7.4 Dismantling the motor...................................................................................................................................30

7.4.1 General information/Safety regulations...........................................................................................30

7.4.2 Removing the protective roof (optional) .........................................................................................30

7.4.3 Dismantling the fan hood .................................................................................................................30

7.4.4 Dismantling the fan ...........................................................................................................................31

7.4.5 Dismantling the rotor ........................................................................................................................31

7.4.6 Dismantling the bearings ..................................................................................................................31

7.5 Assembling the motor....................................................................................................................................31

7.5.1 Fitting the bearings ...........................................................................................................................32

7.5.2 Installing the rotor............................................................................................................................. 32

7.5.3 Mounting the fan ..............................................................................................................................32

7.5.4 Mounting the fan hood.....................................................................................................................32

7.5.5 Mounting the protective roof (optional) .........................................................................................32

8 Trouble-shooting.................................................................................................................................. 33

9 EU Declaration of Conformity............................................................................................................. 34

Index ..................................................................................................................................................... 35

Glossary

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Glossary

Drive end

End of motor with bare shaft end for connecting
the machine to be driven via a coupling or traction
sheave and belt (driven output or machine
element).

Non-drive end

End of motor with fan and fan hood.

1 General

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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, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.

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

1.2 Target group

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

1.3 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Operating manual(s) for the
pump(s)

Proper and safe use of the pump in all phases of
operation

Wiring diagram Electrical connection

For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.

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-references

1.

2.

Step-by-step instructions

Note
Recommendations and important information on how to handle
the product

2 Safety

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2 Safety

!

DANGER

All 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

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

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 operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.

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

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

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

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

▪ Markings for connections

▪ Name plate

The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.

This electric motor has been designed and constructed in accordance with the
requirements of Directive 2014/35/EU (“Low-voltage Directive”). It is intended for use
in industrial plants.

If the motor is used in countries outside the European Community, adhere to the
regulations applicable to the relevant country. Also observe any local and industry­specific regulations governing installation and safety.

2 Safety

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2.3 Intended use

▪ This product must only be operated within the limit values stated in the technical

product literature for the mains voltage, mains frequency, ambient temperature,
motor rating, speed, density, pressure, temperature and in compliance with any
other instructions provided in the operating manual or other applicable
documents.

▪ The product must not be used in potentially explosive atmospheres.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the product this manual refers to. The responsibilities, competence and
supervision of all personnel involved in 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 product must always be supervised by specialist technical personnel.

2.5 Consequences and risks caused by non-compliance with this manual

▪ 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 regulations and safety regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the user/operator

▪ The operator shall fit contact guards for hot, cold and moving parts and check

that the guards function properly.

▪ Do not remove any contact guards during operation.

▪ Provide the personnel with protective equipment and make sure it is used.

▪ 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

▪ 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 maintenance, inspection and installation is performed

by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.

2 Safety

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▪ Any work on the product shall only be performed when it has been disconnected

from the power supply (de-energised).

▪ Carry out work on the product during standstill only.

▪ As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.

2.9 Unauthorised modes of operation

Never operate the product outside the limits stated in the data sheet and in this
manual.

The warranty relating to the operating reliability and safety of the product supplied
is only valid if the product is used in accordance with its intended use.

2.10 Electromagnetic compatibility

When operating the motor on a frequency inverter always observe the frequency
inverter manufacturer's information on compliance with the Electromagnetic
Compatibility Directive. Take additional measures to ensure compliance with the
Directive and obtain a connection approval from the local energy supply company, if
necessary.

3 Transport/Temporary Storage/Disposal

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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 and the insurer about the damage in writing
immediately.

3.2 Transport

DANGER

Improper transport

Danger to life from falling parts!

▷ Only transport the motor in the specified position.

▷ Always use all lifting lugs available at the motor during transport.

▷ Always screw in lifting lugs (lifting eyebolts) up to the contact face and tighten.

▷ Use suitable, permitted lifting accessories.

Only remove any transport locks provided prior to commissioning and store or
disable. Use transport locks for additional transport tasks or re-enable.

To transport motors weighing more than 25 kg, suspend them from the lifting tackle
as shown.

Fig.1: Transporting the motor by two lifting lugs attached to sides of motor housing

3.3 Storage/preservation

Exposed metal parts

Exposed locating surfaces (shaft ends, flange faces, centring spigots, connector
contacts) are treated with a layer of temporary corrosion protection (< 6 months) for
transport. Take suitable corrosion protection measures for extended storage periods.

Storage period

Rotate the shaft once annually to avoid permanent standstill markings. Extended
storage periods decrease the service life (increase ageing) of the grease applied to
the rolling element bearings.

Closed rolling element

bearings

Replace closed rolling element bearings after 48 months of storage.

3 Transport/Temporary Storage/Disposal

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Outdoor storage

CAUTION

Damage during storage due to humidity, dirt or vermin

Corrosion/contamination of the drive!

▷ Cover all components with water-proof material. Covers or tarpaulins must not

contact the surface of the stored goods.

▷ Ensure sufficient air circulation, e.g. by inserting wooden spacers.

▷ To ensure protection against ground moisture, arrange motors and packaged

motors on pallets, bars or foundations.

▷ Prevent the possibility of product sinking into the ground.

Implement appropriate measures to accommodate extreme climatic conditions, e.g.
salty, dusty or moist atmospheres.

Indoor storage

Storage rooms provide protection against extreme weather conditions and must be
dry, dust-free, frost-free, jolt-free, vibration-free and well-ventilated.

3.4 Disposal/recycling

Due to some components, the product is classified as special waste.

1. Dismantle the product.

2. Separate and sort the materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another

controlled manner. PCBs, power electronics, capacitors and electronic
components are all hazardous waste.

4 Description

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4 Description

4.1 General description

Low-voltage asynchronous motor of efficiency class IE3 to IEC 60034-30 for operation
on the public power grid or on a frequency inverter.

4.2 Designation

Table4: Designation example

Position

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

- 2 - 4 5 , 0 - 2 2 5 M - B W A 6 F 3 N T S D W F U W K S W

Table5: Designation key

Position Code Description

1-2 Number of poles

2 2 poles

4 4 poles

4-7 Rated power

4 5 , 0 45 kW (0.55 ... 45.0 kW)

9-12 IEC size

2 2 5 M Shaft centreline height [mm] = IEC size

14 Enclosure

B IP55

15 Type of protection

W Non-explosionproof

16 Rated voltage and rated frequency

A 3~, AC, 220 VΔ, 380 VY, 50Hz

17 Efficiency class

6 IE3

18 Thermal class

F Thermal class F

19 Motor and winding protection

3 3 PTCs

20 Direction of rotation

N Clockwise and counter-clockwise (bi-directional)

21 Position of terminal box

T Terminal box on top

22 Feet attached by bolts

S Feet attached by bolts

W Without feet

H Integrally cast feet

23 Position of fixed bearing

D Fixed bearing, drive end

24 Protective roof

W Without protective roof

25 Motor flange

F EN 50347 Type FF

W Without flange

26 Operation on inverter

U Operation on inverter permitted

27 Approval

4 Description

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Position Code Description

27 W Without approvals

28-29 Manufacturer

K S KSB

30 Manufacturer type

W KSB IE3 Motor

4.3 Name plate

The name plate provides, as a minimum, the following information:

▪ Manufacturer: KSB SE & Co. KGaA, Johann-Klein-Straße 9, 67227 Frankenthal

▪ KSB material number

▪ Type designation: KSB IE3 Motor

▪ Year of construction

▪ Number of phase windings

▪ Standards for design

▪ Enclosure

▪ Efficiency class to IEC60034-30

▪ Thermal class

▪ Rated power/ rated powers

▪ Rated voltage/ rated voltages

▪ Rated frequency/ rated frequencies

▪ Rated current/ rated currents

▪ Rated speed/ rated speeds

▪ Rated power factor/ rated power factors

▪ Total weight

4.4 Types of construction

The motors are available in different types of construction:

Table6: Types of construction and installation variants

Type of construction Shaft centreline

height

[mm]

IM codes

Flange type

1)

With

foot

None ✘ 71 to 315 B3

Flange with clearance
holes (FF)

- 71 to 112 V1, B5

✘ 132 to 315 V152), B35

1) Designations to EN50347

2) Detachable feet

4 Description

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4.5 Mounting arrangements

IM codes Illustration

IM B3

IM B5

IM B35

IM V1

IM V15

4.6 Noise characteristics

The noise characteristics stipulated by DINEN60034-9 are complied with.

4.7 Balancing

The rotor is balanced dynamically in accordance with the ISO1940-1 standard. The
rotor is balanced to balance quality grade G2.5.

The motor complies with vibration class A to IEC60034-14.

Marking

▪ For motors with key, the rotors are balanced dynamically with a half key ("H") as

standard in accordance with ISO21940-32 requirements. The output element
must also be balanced with a half key in accordance with the key convention.

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5 Installation at Site

5.1 Checks to be carried out prior to installation

Place of installation

WARNING

Installation on mounting surface which is unsecured and cannot support the load

Personal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets the

requirements of exposure class XC1 to EN206-1.

▷ The mounting surface must be set, flat, and level.

▷ Observe the weights indicated.

1. Check the structural requirements.

All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.

Installation altitude

(ðSection6.5.4,Page23)

Protective roof/additional roofing

Install a protective roof or additional roofing for vertical installation.

Vertical installation

▪ For vertical installation with the shaft end pointed downwards to prevent

foreign objects from falling into the fan hood.

▪ For vertical installation with the shaft end pointed upwards to prevent fluid

ingress along the length of the shaft.

Outdoor installation

Shield the motor by implementing suitable protection measures in order to prevent
condensation from forming and to avoid the long-term effects caused by direct
exposure to sunlight, rain, snow, ice and dust.

Flatness tolerance of contact surfaces

For foot-mounted motors, adhere to the following flatness tolerance of the contact
surfaces for the motor feet.

Table7: Flatness tolerance of contact surfaces for motor feet

Shaft centreline height Flatness tolerance (mm)

≤132mm 0,10

≥ 160mm 0,15

Ventilation

WARNING

Improper installation

Drive overheated!

▷ Maintain the specified minimum distances to neighbouring assemblies.

▷ Never restrict the ventilation ducting to/from the drive.

▷ Prevent exhaust air from neighbouring assemblies from being drawn in directly.

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X

Fig.2: Minimum distanceX

Table8: Minimum distanceX to neighbouring assemblies

Motors with shaft centreline height [mm] Minimum distanceX [mm]

71 - 100 30

112 - 132 40

160 - 180 50

200 - 225 60

5.2 Installing the motor

Checks prior to installation work

▪ Repair any damage to the paintwork. (ðSection7.2.2.1,Page28)

▪ Remove any anti-corrosives applied to exposed metal parts that are required to

ensure proper assembly or installation.

Alignment and fastening

NOTE

Maintain the vibration levels to ISO 10816-1 during operation.

Observe the following when aligning and fastening:

▪ Ensure that the motor feet are resting evenly on the support surface.

▪ Ensure that feet and flanges are mounted as specified in the manual.

▪ Avoid rigid couplings.

▪ Ensure precise alignment for direct coupling.

▪ Ensure that mounting surfaces are free from contamination.

▪ Avoid resonances caused by the structure at the rotational frequency and double

mains frequency.

▪ Unusual noise that may occur when rotating the rotor by hand.

Compensation of radial

misalignment at the

coupling and horizontal

adjustment

The following measures are required to compensate radial misalignment at the
coupling and horizontally adjust the motor in relation to the driven machine (e.g. the
pump):

▪ Vertical positioning

To avoid distortion (warping) of the driven machine and the motor, place thin
metal sheets under the motor feet.
The number of shims should be restricted to a minimum, in other words, they
should only be stacked if this is unavoidable.

▪ Horizontal positioning

For horizontal positioning, laterally shift the motor on the foundation while
maintaining axial alignment (to prevent angular misalignment).
Ensure a uniform circumferential axial clearance at the coupling when
positioning.

▪ Smooth running characteristics

A stable, vibration-free foundation to DIN4024, exact alignment of the coupling
and a well-balanced output element (coupling, pulley, fan, etc.) are prerequisites

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for smooth, vibration-free operation of the motor.
Complete balancing of the motor with the output element may be required.
Note the information and evaluation criteria to ISO 10816.

▪ Foot/flange mounting

Use the thread sizes specified by EN 50347 for fastening the foot and flange of
the motor to the foundation and to the motor flange respectively. Fasten the
motor at four foot holes or flange bolt holes positioned in rectangular
arrangement to each other. The customer is responsible for selecting the
strength of the fastening elements.
Property class recommendations: Class5.6 or higher for fastening elements for
motors with shaft centreline height up to and including 160 mm, and class 8.8 or
higher for motors with shaft centreline height 180 mm.

NOTE

Lifting lugs that have been screwed in must either be tightened or removed after
installation.

5.3 Electrical connection

DANGER

Hazardous voltage

Danger of death from electric shock!

▷ Have all work performed only by qualified specialist personnel and only when

the drive is at a standstill and secured against unintentional start-up. This also
applies to auxiliary circuits (e.g. standstill heater).

▷ The drive must not be electrically connected at any point in time when work is

performed on the open terminal box.

WARNING

Incorrect connection to the mains

Damage to the mains network, short circuit!

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

NOTE

Always protect three-phase motors with a current-dependent overload protection
device with additional phase failure protection.

Select the motor connection cables in accordance with IEC60364, taking into account
the current load of the cable at the given ambient temperature and the requisite
heat dissipation to IEC/EN60204-1 as a result of cable routing.

5.3.1 Motor connection inside the terminal box

Observe the following when performing any work on the terminal box:

▪ Always use the original sealing element to close the terminal box so that it is dust

tight and watertight.

▪ Do not damage any components inside the terminal box, such as terminal board

and cable connections.

▪ Ensure that no foreign matter, contamination or moisture are present in the

terminal box. Terminal box cable entries to DIN42925.

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▪ Close additional open cable entries, using O-rings or suitable gaskets.

▪ Observe prescribed tightening torques for cable glands and other screws/bolts.

▪ When retrofitting cable glands to safeguard the required level of enclosure

protection, ensure that the gasket is seated properly on the outside of the
terminal box.

Connecting the motor

1. Check the electrical voltage of the available power supply network against the

data on the motor name plate.

2. Connect the earth conductor (PE).

3. Knock out any knock-out openings in the terminal box. While doing this, avoid

causing damage to the terminal board, cable connections, etc. inside the
terminal box.

4. Connect the motor in star configuration or delta configuration in accordance

with the rated voltage (see name plate) and the available power supply
network. Alternatively, the 6-core connection of the three windings can be
connected to an external switchgear for automatic switchover.

Fig.3: Star configuration

Fig.4: Delta configuration

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ð The terminal boards of motors with shaft centreline heights of 80mm and

90mm may differ from the schematic shown. In this case, star configuration
or delta configuration is selected by setting jumpers.

5. Optionally, the 2-core connection of the series-connected PTC thermistors for

temperature monitoring of the motor can be connected to terminals 1T1 and
1T2 with a suitable thermistor relay (PTC thermistor tripping unit). Observe the
maximum measuring voltage!

Changing the jumpers

Fig.5: Jumper position

1. Disengage the red locking lever (1) and pull the jumper (2) out of the slot.

2. Undo the snap hook at the storage pocket and take out the jumper (3).

3. Push the jumper (3) into the slot until it rests on the bottom. Engage the locking

lever again.

4. Place the jumper (2) into the storage pocket and engage the snap hook.

5.3.2 Checking the direction of rotation

WARNING

Parts flying off

Personal injury and damage to property!

▷ When checking the direction of rotation with the coupling removed, secure the

respective keys to protect them from being thrown off.

The motors are configured for clockwise and anti-clockwise rotation as standard.
Select the drive's direction of rotation to match the direction of rotation required by
the driven centrifugal pump.

Clockwise rotation

Connecting the power cables in the phase sequence U1, V1, W1 to L1, L2, L3 of the
power supply network results in clockwise rotation (looking at the drive shaft end).

Anti-clockwise rotation

Interchanging two connections, e.g. V1, U1, W1 to L1, L2, L3 results in anti-clockwise
rotation.

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5.4 Tightening torques

Unless other tightening torques are indicated on the motor the following torques
shall be used:

Table9: Tightening torques for terminal board connections

Thread Tightening torque

[Nm]

M4 2,0

M5 3,0

M6 5,0

M8 10

Table10: Tightening torques for terminal board fastening elements

Thread Tightening torque

[Nm]

M4 2,0

M5 4,0

M6 9,0

M8 23

Table11: Tightening torques for terminal box cover

Thread Tightening torque

[Nm]

M5 4,0

M6 7,0

M8 19

M10 37

M12 63

Table12: Tightening torques for strain relief fasteners

Thread Tightening torque

[Nm]

M12 1,5

M16 2,0

M20 4,0

M25 4,0

M32 6,0

M40 6,0

M50 6,0

M63 8,0

Table13: Tightening torques for earth conductor, bearing cover, fan hood, foot in
aluminium material variant

Thread Tightening torque

[Nm]

M4 2,0

M5 4,5

M6 7,5

M8 19

M10 37

M12 64

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Table14: Tightening torques for earth conductor, bearing cover, fan hood, foot in
grey cast iron material variant

Thread Tightening torque

[Nm]

M4 3,0

M5 6,0

M6 10

M8 25

M10 50

M12 86

5.5 Installing and removing output components

▪ Please also note the information about installing output components in the

operating manual of the driven machine (e.g. pump).

▪ To install output components (coupling, pulley, etc.), use the thread on the shaft

end and heat up the components if necessary.

▪ Use an appropriate device for removal.

▪ Do not apply hard impacts (e.g. with a hammer or similar) when installing and

removing.

▪ Observe the maximum permissible radial and axial forces transmitted via the

shaft end to the rolling element bearing and do not exceed them.

6 Commissioning/Start-up/Shutdown

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6 Commissioning/Start-up/Shutdown

DANGER

Hazardous voltage

Danger of death from electric shock!

▷ Have all work performed only by qualified specialist personnel and only when

the drive is at a standstill and secured against unintentional start-up. This also
applies to auxiliary circuits (e.g. standstill heater).

▷ The drive must not be electrically connected at any point in time when work is

performed on the open terminal box.

Before commissioning and whenever returning the product to service, perform the
electrical safety checks stipulated by EN 60204-1.

6.1 Checking earth conductor connection

Check that the earth conductor has been correctly connected in accordance with
EN60204.

6.2 Checking insulation resistance

Prior to commissioning and following prolonged storage or standstill periods, the
insulation resistance will need to be checked and verified.

NOTE

If windings have been dried after having been repaired or cleaned, bear in mind
that the insulation resistance of warm windings is lower. The insulation resistance
can only be correctly evaluated after converting to the reference temperature of
25°C.

The insulation resistance of the stator winding must equal at least 1.5megohms in
motors for 220-1000V.

6.3 Prerequisites for commissioning/start-up

Before commissioning/starting up the drive, make sure that the following conditions
are met:

▪ The drive has been properly installed and aligned.

▪ The drive has been connected correctly for the specified direction of rotation.

▪ The operating conditions correspond to the data provided on the name plate.

▪ The output elements have been correctly configured depending on type (e.g.

alignment and balancing of couplings, belt forces for belt drive, tooth forces and
tooth flank clearance for gearwheel drive, radial and axial clearance for coupled
shafts).

▪ The earthing and equipotential bonding connections have been properly made.

▪ All fastening bolts, connecting elements, and electrical connections have been

properly tightened to the specified tightening torques.

▪ Screwed-in lifting lugs have been removed following installation or secured

against working loose.

▪ The shaft rotates freely.

▪ Measures have been taken to prevent accidental contact with moving and live

parts.

▪ The unused shaft end has been covered and the key secured to prevent it from

being thrown off.

▪ Components (cables, etc.) that are sensitive to temperature do not come into

contact with the motor housing.

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6.4 Start-up

WARNING

High sound pressure level >70dB(A) can occur during operation

Injury to the ear and hearing impairment. Hardness of hearing, tinnitus and hearing
loss can be caused!

▷ Wear ear protection!

▷ Observe the applicable local occupational health and safety regulations.

The motor must only be started from a standstill.

1. Re-check the direction of rotation immediately after starting.
(ðSection5.3.2,Page19)

6.5 Operating limits

6.5.1 Voltages and frequencies

Motor operation off the rated point will cause a rise in motor temperature. A voltage
tolerance of ±5% and a frequency tolerance of ±2% are permissible.

Any situation where both the voltage and the frequency tolerance apply
simultaneously shall be governed by the provisions of range A as described in
EN60034-1. The motors can be operated continuously in range A. In accordance with
EN60034-1, prolonged operation in range B is not recommended.

6.5.2 Maximum permissible speed

Comply with the rotational speed indicated on the name plate.

6.5.3 Ambient temperature

CAUTION

Operation outside the permissible ambient temperature

Damage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table15: Permissible ambient temperatures

Permissible ambient temperature Value

Maximum 40 °C

Minimum - 20 °C

6.5.4 Altitude

▪ ≤ 1000 m above MSL: without power derating

▪ > 1000 m above MSL: installation at altitudes of up to 4000 m above MSL is

possible with power derated by 3.8 % per 500m.

6.6 Shutdown

The motor is only regarded as being shut down if it has been de-energised and the
shaft has stopped rotating.

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6.7 Idle periods

Extended idle periods (> 1month)

For extended idle periods (> 1month), start up the drive regularly (e.g. once per
month), or at least turn the rotor. For motors with a transport lock, remove the lock
prior to turning the rotor. Before you start the drive, read the information in section
"Returning to service".

If you plan to take the drive out of service for more than 12months, implement
appropriate corrosion protection, preservation, packaging and drying measures.

6.8 Returning to service

WARNING

High sound pressure level >70dB(A) can occur during operation

Injury to the ear and hearing impairment. Hardness of hearing, tinnitus and hearing
loss can be caused!

▷ Wear ear protection!

▷ Observe the applicable local occupational health and safety regulations.

Also follow the instructions for maintenance/inspection before you return a drive to
service after storage.

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7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Improperly serviced/maintained motor

Damage to the motor!

▷ Service the motor regularly.

▷ Prepare and adhere to a maintenance schedule.

The operator ensures that maintenance, inspection and installation is performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.

WARNING

Unintentional starting of the motor

Risk of injury by moving components and shock currents!

▷ Always make sure the electrical connections are de-energised before carrying

out work on the motor. In addition to the main circuits, ensure that
supplementary and auxiliary circuits are also de-energised.

▷ Ensure that the motor cannot be started up on unintentionally.

WARNING

Insufficient stability

Risk of crushing hands and feet!

▷ Secure the motor against tilting or tipping over during assembly/dismantling.

A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the motor with a minimum of maintenance
expenditure and work.

NOTE

All maintenance work, service work and installation work can be carried out by KSB
Service or authorised workshops. For contact details please refer to the enclosed
"Addresses" booklet or visit "www.ksb.com/contact" on the Internet.

Never use force when dismantling and reassembling the motor.

Five safety rules in accordance with EN 50110-1 ensuring work is only performed
after the equipment has been disconnected from the power supply (de-energised)

Observe the following safety rules:

1. Disconnect the equipment from the power supply.

2. Secure the equipment against unintentional start-up.

3. Verify that the equipment is de-energised.

4. Earth and short-circuit.

5. Cover or cordon off adjacent live parts.

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7.2 Maintenance/inspection

KSB recommends the following regular maintenance schedule:

Table16: Overview of maintenance work

Maintenance interval Maintenance work For details see ...

Every 500operating hours

3)

Initial inspection (ðSection7.2.2,Page27)

Every 14,000 operating hours

4)

General inspection (ðSection7.2.2,Page27)

Depending on local degree of pollution Cleaning

Careful and regular maintenance, inspections and overhauls make it possible to
identify and eliminate faults in good time before they can cause any damage.

Operating conditions and characteristics can vary widely. For this reason, only general
maintenance intervals for trouble-free operation can be specified here. Maintenance
intervals must be matched to the local conditions (dirt, frequency of starts, load, etc.).

If problems or unusual conditions arise which might cause electrical or mechanical
overstressing of the motor (e.g. overload, short circuit), carry out the necessary
inspection work immediately.

7.2.1 Supervision of operation

DANGER

Rotating or live parts

Death, serious injury or damage to property!

▷ If covers have to be removed, de-energise the motor beforehand.

▷ Avoid touching live or rotating parts.

DANGER

Hot surface

Risk of burns!

▷ Never touch a motor when it is in operation.

▷ Let the motor cool down.

▷ Only remove covers if indicated.

WARNING

Condensing air humidity inside the motor if the motor and/or ambient
temperatures frequently change

Risk of corrosion by condensation!

▷ Always observe the information provided on ambient conditions.

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

▪ Deviations from normal operation such as increased power consumption,

temperatures or vibrations, unusual noises or odours, tripping of monitoring
devices, etc.

▪ If rough running or abnormal noises are detected, switch off the motor and find

the cause of the problem as the motor coasts down.

– If mechanical operation improves immediately after the motor is switched

off, the causes are magnetic or electrical phenomena.

3) At least every 6months

4) At least every 2 years

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– If mechanical operation does not improve after the motor is switched off, it

can be assumed that the cause is mechanical, e.g. unbalance of the electric
motor or the driven machine, poor alignment between the motor and the
driven machine or operation of the motor at system resonance (system =
motor + base frame + foundation, etc.)

– If mechanical operation of the motor is OK, switch on the cooling

equipment, if any, and continue to observe the motor for a while as it runs
under no-load conditions.

– If the motor continues to operate satisfactorily, restore the motor load.

Check running characteristics and read and log values for voltage, current
and output. Also read and log relevant values of the driven machine if
possible.

▪ Monitor and log temperatures of the bearings, windings, etc. until the steady

state has been reached by using whatever measuring devices are available.

▪ Check the effectiveness of the cooling system for frequent starting or braking, or

if the operating speed continually changes below the nominal speed.

7.2.2 Inspection

Initial inspection

Inspection interval

After about 500 operating hours, or 6 months at the latest

Procedure

Check the following during operation:

▪ The specified electrical characteristics are complied with.

▪ Permissible temperatures at the rolling element bearings are not exceeded.

▪ The smooth running characteristics and running noise of the drive have not

deteriorated.

When the drive is at a standstill, check:

▪ If the foundation is free from depressions or cracks.

Immediately correct impermissible deviations that are detected during inspection
work.

NOTE

Further inspections/tests may be required in accordance with the additional
operating manuals or in accordance with the particular system-specific conditions.

General inspection

Inspection interval

Once annually

Procedure

Check the following during operation:

▪ The specified electrical characteristics are complied with.

▪ Permissible temperatures at the rolling element bearings are not exceeded.

Check the following when the drive is at a standstill:

▪ The foundation is free from depressions or cracks.

▪ The drive alignment is within the specified tolerance.

▪ All the fastening bolts/screws for the mechanical and electrical connections have

been securely tightened.

▪ The insulation resistances of the windings are sufficient.

▪ Cables and insulating parts are in good condition and there is no evidence of

discolouring.

Immediately correct impermissible deviations that are detected during inspection
work.

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7.2.2.1 Correct damage to paintwork

CAUTION

Damage to paintwork

Risk of corrosion!

▷ Immediately correct damage to paintwork to ensure sufficient corrosion

protection.

We recommend contacting your nearest KSB service centre for important information
about proper layering as well as paint repair instructions.

7.2.2.2 Lubrication and lubricant change

7.2.2.2.1 Maintenance of rolling element bearings

Maintenance of rolling element bearings after an extended storage period

Extended storage periods decrease the service life of the lubricating grease. This in
turn reduces the service life of the bearings.

▪ The rolling element bearings should be completely replaced after a storage

period of more than 4 years.

▪ After a storage period of more than 12 months, it is advisable to change the

bearing grease in rolling element bearings that are not greased for life.

Maintenance of rolling element bearings under normal operating conditions

Recommended bearing replacement interval under normal operating conditions:

Table17: Bearing replacement

Ambient temperature Bearing replacement interval

40°C 20,000 h

NOTE

The bearing service life is reduced e.g. for vertical installations, high vibration and
shock loads, frequent reversing duty, higher ambient temperature and higher
rotating speeds.

7.2.2.2.1.1 Grease lubrication

The bearings are supplied packed with high-quality lithium-soap grease.

7.2.2.2.1.2 Intervals

The rolling element bearings of the motor are grease-packed and maintenance-free.
Motors with axially reinforced bearings are excluded. These drive-end rolling element
bearings must be re-lubricated as part of the maintenance routine.

NOTE

On some pump designs the rolling element bearings are lubricated for life. These
pumps are not provided with a lubricating nipple on the bearing bracket.

NOTE

If re-lubrication intervals are short, we recommend that the grease be completely
replaced once a year.
Otherwise, the grease fill must be replaced completely every two years. To do so,
remove the rolling element bearings, clean and pack with new grease.

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Motors with lubricating nipple must be re-lubricated every 2000 hours.

If the motor is operated under extreme conditions, such as vibrations or high
temperatures, the bearings must be re-lubricated more frequently.

7.2.2.2.1.3 Re-lubrication

DANGER

Excessive temperatures as a result of bearings running hot or defective bearing
seals

Fire hazard!
Damage to the motor!

▷ Regularly check the condition of the lubricant.

▷ Regularly check the rolling element bearings for running noises.

WARNING

Work in the immediate vicinity of rotating parts

Risk of hand injury!

▷ Always have this work performed by trained personnel.

▷ Take particular caution when performing this work.

Grease quality

Optimum grease properties for rolling element bearings

▪ High melting point lithium soap base grease

▪ Free of resin and acid

▪ Rust-preventive characteristics

Grease quantity

▪ 15 g per rolling element bearing

CAUTION

Contaminated lubricating nipples

Contamination of the lubricating grease!

▷ Clean the grease lubricating nipples before re-lubricating them.

1. Clean the lubricating nipples, if contaminated.

2. Position the grease gun on the lubricating nipple.

3. Press in the grease.

CAUTION

Incomplete re-lubrication

Bearing damage!

▷ Always re-lubricate the bearings while the motor is running.

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7.3 Preparing disassembly

DANGER

Work on the motor/drive by unqualified personnel

Danger of death from electric shock!

▷ Have motors/drives modified and dismantled by authorised personnel only.

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

ü General safety rules are adhered to. (ðSection7.1,Page25)

1. Disconnect all electrical connections and remove all cables.

2. Drain, collect and properly dispose of all liquids.

3. Remove all motor fastening elements.

4. Transport the motor to a clean dismantling area. (ðSection3.2,Page10)

7.4 Dismantling the motor

7.4.1 General information/Safety regulations

DANGER

Hot surface

Risk of burns!

▷ Never touch a motor when it is in operation.

▷ Let the motor cool down.

▷ Only remove covers if indicated.

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to move

heavy assemblies or components.

Always observe the safety instructions and information.

For dismantling and reassembly, refer to the general assembly drawing.

In the event of damage, you can always contact our service department.

Prior to dismantling, label the respective assignment of fastening elements as well as
the arrangement of internal connections required for reassembling.

Switching connections

▪ Replace any corroded bolts.

▪ Never damage the insulation of live parts.

▪ Document position of any rating and additional plates to be removed.

▪ Avoid damaging the centring spigots.

Protect rolling element bearings against the ingress of contamination and moisture.

7.4.2 Removing the protective roof (optional)

1. Unscrew fastening bolts of the protective roof.

2. Remove protective roof.

7.4.3 Dismantling the fan hood

1. Remove bolts of the fan hood.

2. Push the fan hood back to remove it.

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7.4.4 Dismantling the fan

1. Remove the clamping screws or circlip (depending on the size).

2. Pull off the fan using a suitable tool.

7.4.5 Dismantling the rotor

ü Suitably sized lifting equipment is available.

1. Remove non-drive-end and drive-end keys and store them in a safe place.

2. Remove the bolts from the drive-end bearing cover.

3. Stand the motor housing upright (drive end up); pull the bearing cover and

rotor out of the motor housing using suitable lifting equipment and set them
down.

7.4.6 Dismantling the bearings

Fixed bearing at drive end

ü The rotor has been removed.

ü The keys have been removed and are stored in a safe place.

1. Remove the circlip or bearing cover plate from the bearing cover, then remove
the bearing cover.

2. Pull off the bearing using a suitable tool.

Radial bearing at non-drive end

ü The rotor has been removed.

ü The keys have been removed and are stored in a safe place.

1. Pull off the spring washer from the shaft end.

2. Pull off the bearing using a suitable tool.

7.5 Assembling the motor

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to move

heavy assemblies or components.

CAUTION

Incorrect assembly

Damage to windings!

▷ When installing the bearing cover, take care not to damage the windings

protruding out of the motor housing.

General

▪ The motor should be assembled on a marking-out plate if possible. This will

ensure that the foot areas of the motor are properly aligned.

▪ Always reassemble the motor in accordance with the corresponding exploded

view.

▪ Clean all dismantled components and check them for signs of wear.

▪ Damaged or worn components must be replaced by new ones.

▪ Always use new tolerance rings.

▪ Make sure that sealing surfaces are clean and that O-rings or gaskets are properly

fitted.

Tightening torques

For reassembly, tighten all screws and bolts as specified in this manual.

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7.5.1 Fitting the bearings

CAUTION

Incorrect assembly

Damage to the shaft seal ring!

▷ Ensure correct centring when installing the rotor in the motor housing.

Drive-end fixed bearing

1. Fit the specified bearing on the shaft.

2. Install the bearing cover.

3. Affix bearing onto the end shield with circlip or bearing cover plate.

4. Attach drive-end key to shaft.

Non-drive-end radial bearing

1. Fit the specified bearing on the shaft.

2. Install the spring washer on the shaft.

7.5.2 Installing the rotor

CAUTION

Incorrect assembly

Damage to the shaft seal ring!

▷ Ensure correct centring when installing the rotor in the motor housing.

1. Apply liquid sealant to the centring spigot of the bearing cover and the motor
housing.

2. Stand the motor housing upright (drive end up) and guide the bearing cover
and rotor into the motor housing using suitable lifting equipment.

3. Tighten the bolts on the drive-end bearing cover .

4. Insert non-drive-end key.

7.5.3 Mounting the fan

1. Fit the fan.

2. Fit clamping screws or circlip (depending on size).

7.5.4 Mounting the fan hood

1. Position fan hood and affix with bolts .

7.5.5 Mounting the protective roof (optional)

1. Place the protective roof on the motor.

2. Tighten fastening bolts of the protective roof.

8 Trouble-shooting

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8 Trouble-shooting

WARNING

Improper work to remedy faults

Risk of injury!

▷ For any work performed to remedy faults, observe the relevant information

given in this operating manual and/or in the product literature provided by the
accessories manufacturer.

If problems occur that are not described in the following table, consultation with the
KSB customer service is required.

A

Drive does not start.

B

Rumbling noise during start-up

C

Rubbing noises

D

Radial vibrations

E

Axial vibrations

F

Wrong direction of rotation

Table18: Trouble-shooting

A B C D E F Possible cause Remedy

✘ - - - - - No voltage Check mains fuses, mains voltage and

operating status of the frequency inverter.

✘ - - - - - Mains cables connected incorrectly/

Fault in supply line

Check wiring.

✘ ✘ - - - - Driven machine is blocked Manually clear the blockage from the driven

machine, observing the operating manual of
the driven machine!

- - ✘ - - - Bearings defective Check bearings and replace if necessary.

- - ✘ - - - Rubbing contact between rotor and stator Check bearings and replace if necessary.
Check rotor and replace if necessary.

- - - ✘ - - Rotor unbalance Check key convention applicable to the shaft
and output element; remove rotor and re­balance if required.

- - - ✘ - - Improper installation Check the foundation, the place of installation
and the mounting surface.

- - - - ✘ - Incorrect connection of pump/load Check correct alignment between motor and
driven machine, check coupling.

- - - - - ✘ Wrong direction of rotation setting Change the direction of rotation by altering
the parameters of the frequency inverter or
interchanging two phase conductors.

9 EU Declaration of Conformity

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9 EU Declaration of Conformity

Manufacturer: KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

KSB IE3 Motor

01619633 - 01619636 01619641 - 01619646 01619657 - 01619676
01619688 - 01619712 01619717 - 01619724 01619727 - 01619739
01619797 - 01619798 01619807 - 01619808

01550184 - 01550202 01550225 01550248 - 01550250
01607772 - 01607773 01607791 - 01607792 01607809 - 01607811
01607914 - 01607915 01607933 - 01607934 01607951 - 01607953
01629106 - 01629148

01607812 - 01607826 01655597 - 01655611 01655493 - 01655496
01655597 - 01655611

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Motor: Low-voltage Directive 2014/35/EU

– Motor: Ecodesign Directive 2005/32/EG (2009/125/EC), Regulation 640/2009

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– EN60034

The product must not be put into service for its intended use until the final product has been declared in
conformity with the Machinery Directive.

The EU Declaration of Conformity was issued in/on:

Frankenthal, 01.02.2018

Joachim Schullerer

Head of Product Development Pump Systems and Drives

KSB SE & Co. KGaA

Johann-Klein-Straße 9

67227 Frankenthal

Index

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Index

C

Commissioning/start-up22

D

Dismantling30
Disposal11

F

Fan31, 32
Faults

Causes and remedies33

I

Installation at site15
Intended use8

K

Key to safety symbols/markings7

M

Maintenance work26

O

Other applicable documents6

P

Personnel8
Personnel qualification8
Product code12
PTC19
PTC thermistor19

S

Safety7
Safety awareness8
Servicing/Maintenance25
Specialist personnel8

T

Thermistor19
Tightening torques20, 21
Training8
Transport10

W

Warnings7

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)

Tel. [phone]

www.ksb.com

4076.8/05-EN (01659417)