KSB Rio-Therm N Series Operating Manual
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
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
KSB's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 01.08.2012
Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ...........................................................................................................6
1.2 Target group ..................................................................................................... 6
1.3 Symbols .............................................................................................................6
2 Safety .....................................................................................................7
2.1 Key to safety symbols/markings ....................................................................... 7
2.2 General .............................................................................................................. 7
2.3 Intended use .....................................................................................................7
2.4 Personnel qualification and training ............................................................... 8
2.5 Consequences and risks caused by non-compliance with these 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
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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
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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
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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/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
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
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/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
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
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▪ 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.
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▪ 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
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