Rio-Eco N / Z / Therm N - Smedegaard...In the event of damage, immediately contact your nearest KSB...

High-efficiency Circulator / Drinking WaterPump

Rio-Eco N / Rio-Eco Z N / Rio-Eco Therm N

Rio-Eco N 25-100, 30-100 to 80-120Rio-Eco Z NRio-Eco Therm N 30-100 to 65-120

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual Rio-Eco N / Rio-Eco Z N / Rio-Eco Therm N

Original operating manual

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

Subject to technical modification without prior notice.

© KSB Aktiengesellschaft, Frankenthal 22.08.2016

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 this manual .......................................................8

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

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

2.8 Safety information for maintenance, inspection and installation ..............................................................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 .........................................................................................................................14

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

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

4.8 Dimensions and weight ................................................................................................................................15

5 Installation at Site ....................................................................................................................... 16

5.1 Safety regulations .........................................................................................................................................16

5.2 Checks to be carried out prior to installation .............................................................................................16

5.3 Installing the pump set ................................................................................................................................16

5.4 Connecting the piping .................................................................................................................................18

5.5 Casing/insulation ..........................................................................................................................................18

5.6 Electrical connection ....................................................................................................................................19

6 Commissioning/Start-up/Shutdown ........................................................................................... 20

Contents

Rio-Eco N / Rio-Eco Z N / Rio-Eco Therm N 3 of 36

6.1 Commissioning/start-up ...............................................................................................................................20

6.2 Shutdown ......................................................................................................................................................27

6.3 Operating limits ............................................................................................................................................28

6.4 Shutdown/storage/preservation ..................................................................................................................28

6.5 Returning to service .....................................................................................................................................29

7 Servicing/Maintenance ............................................................................................................... 30

7.1 Servicing/inspection ......................................................................................................................................30

7.2 Drainage/cleaning ........................................................................................................................................30

7.3 Removing the pump set from the piping ...................................................................................................30

8 Trouble-shooting ........................................................................................................................ 32

9 Related Documents .................................................................................................................... 33

9.1 Sectional drawing with list of components ................................................................................................33

9.2 Electrical connection, overview of settings, LED displays ..........................................................................33

10 EU Declaration of Conformity ................................................................................................... 34

Index ............................................................................................................................................ 35

Contents

4 of 36 Rio-Eco N / Rio-Eco Z N / Rio-Eco Therm N

Glossary

Discharge line

The pipeline which is connected to thedischarge nozzle

Noise characteristics

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

Pump

Machine without drive, additional componentsor accessories

Pump set

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

Suction lift line/suction head line

The pipeline which is connected to the suctionnozzle

Glossary


1 General

1.1 Principles

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

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

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

Noise characteristics see (⇨ Section 4.6 Page 14)

1.2 Target group

This operating manual is aimed at the target group of trained and qualified specialisttechnical 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-references1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General


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

2.1 Key to safety symbols/markings

Table 2: Definition of safety symbols/markings

Symbol Description

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

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

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

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

2.2 General

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

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

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

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

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

▪ Arrow indicating the direction of rotation

▪ Markings for connections

▪ Name plate

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

2.3 Intended use

▪ The pump (set) must only be operated within the operating limits described inthe 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 productliterature of the pump model or variant.

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

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

! DANGER

2 Safety


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

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

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

Prevention of foreseeable misuse

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

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

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

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

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

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

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

▪ Non-compliance with this operating manual will lead to forfeiture of warrantycover and of any and all rights to claims for damages.

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

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

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

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

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the operator/user

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

▪ Do not remove any contact guards during operation.

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

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

2 Safety


▪ If shutting down the pump does not increase potential risk, fit an emergency-stop control device in the immediate vicinity of the pump (set) during pump setinstallation.

2.8 Safety information for maintenance, inspection and installation

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

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

▪ The operator ensures that maintenance, inspection and installation is performedby authorised, qualified specialist personnel who are thoroughly familiar withthe manual.

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

▪ Any work on the pump set shall only be performed when it has beendisconnected from the power supply (de-energised).

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

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

▪ When taking the pump set out of service always adhere to the proceduredescribed in the manual. (⇨ Section 6.4 Page 28)

▪ Decontaminate pumps which handle fluids posing a health hazard.

▪ As soon as the work has been completed, re-install and/or re-activate any safety-relevant and protective devices. Before returning the product to service, observeall instructions on commissioning. (⇨ Section 6.1 Page 20)

2.9 Unauthorised modes of operation

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

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

2 Safety


3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

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

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

3.2 Transport

CAUTIONImproper pump transportDamage to the pump!

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

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

3.3 Storage/preservation

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

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

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

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

▷ Clean and cover pump openings and connections as required prior to puttingthe pump into storage.

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

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

For storing a pump (set) which has already been operated, observe the instructions in(⇨ Section 6.4.1 Page 28)

3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.2 Page 30)

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

3. If the pump set has handled fluids whose residues could lead to corrosiondamage in the presence of atmospheric humidity or could ignite upon contactwith oxygen, the pump set must also be neutralised, and anhydrous inert gasmust be blown through the pump to ensure drying.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set).Always indicate any safety and decontamination measures taken.



3.5 Disposal

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

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

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

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

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

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

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



4 Description of the Pump (Set)

4.1 General

▪ Non-self-priming in-line pump

Pump for handling clean or aggressive fluids which are neither chemically normechanically aggressive to the pump materials.

4.2 DesignationExample: Rio-Eco Z N 40-120

Table 3: Designation key

Code DescriptionRio Type seriesEco High-efficiency pumpTherm Drinking water pumpZ Twin pumpN New generation40 Nominal diameter of pipe connection

15 = Rp 1/225 = Rp 130 = Rp 1 1/440 to 80 = DN 40 to DN 80

120 Head in m x 10 (example: 120 = 12 m)-130 Height 130 mm

4.3 Name plate

1

8Made in EU 29134165

Rio-Eco N 40-120

230V50HzMax 2,70AEEI ≤ 0,27Class FPN6/10 / IP 42 / TF110

234567

KSB AktiengesellschaftJohann-Klein-Straße 967227 Frankenthal

Fig. 1: Name plate (example)

1 Type series, size 2 Power supply3 Mains frequency 4 Maximum power input5 Energy efficiency index 6 Thermal class7 Maximum operating pressure,

enclosure, temperature class8 Material number

Example: 1235-0867

Table 4: Key

Code Description12 Year 201235 Week0867 Consecutive number

Key to the series code



4.4 Design detailsDesign

▪ Highly efficient, maintenance-free wet rotor pump (glandless)

Drive

▪ Electronically commutated synchronous motor with permanent magnet rotor

▪ 230 V - 50 Hz

▪ IP42 enclosure

▪ Thermal class F

▪ Temperature class TF 110

▪ Variable speed electric drives to EN 61800-3 EMC requirements

▪ Interference emissions EN 61 000-6-3

▪ Interference immunity EN 61 000-6-2

Bearings

▪ Product-lubricated special plain bearing

Connections

▪ Screw-ended or flanged

Operating modes

▪ Automatic mode with variable differential pressure

▪ Open-loop control mode with external 0 - 10 V setpoint signal for speed

▪ Open-loop control mode with manual setpoint input

Automatic functions

▪ Continuous output adjustment depending on the operating mode

▪ Deblocking function

▪ Soft start (slow start)

▪ Full motor protection with integrated trip electronics

Manual functions

▪ Setting the operating mode

▪ Setting the differential pressure setpoint

▪ Setting the speed level

External control functions

▪ Control input "start/stop"

▪ Control input for remote speed adjustment 0-10 V

Signalling and display functions

▪ General fault indication (volt-free changeover contact)

▪ Fault indication, display of error codes

Interfaces

▪ Serial digital Modbus RTU interface for connecting higher-level automationsystems via the RS485 system bus

Twin pump management

▪ Duty/stand-by mode with timer-controlled pump changeover every 24 hours andautomatic changeover in the event of a fault



4.5 Configuration and function

1 2

4

5 6

3

Fig. 2: Sectional drawing of the pump

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

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

The motor housing is equipped with a terminal box. Mechanical sealing is notrequired as the rotor is completely separate from the stator winding. The rotor islubricated and cooled by the fluid handled. The motor housing is made ofaluminium. Most of the internal parts are made of stainless steel. The advancedlubricating system with high-quality carbon bearings combined with the precision-balanced impeller ensure very smooth running and a long service life.

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

4.6 Noise characteristics

Table 5: Noise characteristics [dB A]

Sound pressure levelRio-Eco (Therm) N 25-100 to 40-140 35 max.Rio-Eco (Therm) N 50-70 to 80-120 50 max.

4.7 Scope of supply

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

▪ Pump set

▪ Installation/operating manual

▪ Sealing elements

Design

Function



4.8 Dimensions and weight

For dimensions and weights please refer to the type series booklet of the pump.



5 Installation at Site

5.1 Safety regulations

DANGER

Installation in potentially explosive atmospheresExplosion hazard!

▷ Never install the pump in potentially explosive atmospheres.

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

DANGER

Rio-Eco N and Rio-Eco Z N pumps used for drinking water or foodstuff applicationsDanger of poisoning!

▷ The pump materials are not suitable for drinking water and foodstuffapplications. Never use the pump for drinking water or foodstuff applications.

5.2 Checks to be carried out prior to installation

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

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

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

▪ The above safety instructions have been complied with.

5.3 Installing the pump set

Install the pump set in an easily accessible place.

CAUTIONIngress of fluid into the motorDamage to the pump set!

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

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

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

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



Table 6: Permissible installation positions

Sizes Rio-Eco (Therm) N 30-100, 30-120 32-120,40-100, 40-120, 50-70, 50-90

Rio-Eco (Therm) N 40-140, 50-140, 65-90,65-120, 80-120

Rio-Eco Z N

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

DANGER

Leakage at the pumpLeakage of hot fluids!

▷ Insert the O-ring in the correct position.

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

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

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

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

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

1. Place the pump in the specified installation position.

2. Accurately insert the sealing element.

3. Connect the pump and piping with a pipe union.

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

5. Accurately insert the sealing element in the opposite pipe union.

6. Tighten the pipe union hand tight with an assembly tool (e.g. pipe wrench).

1. Place the pump in the specified installation position.

Screw-ended pumps

Flanged pump



2. Accurately insert the sealing element.

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

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

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

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

5.4 Connecting the piping

DANGER

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

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

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

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

CAUTIONContamination/dirt in the pipingDamage to the pump!

▷ Flush the piping prior to commissioning or replacing the pump. Remove anyforeign matter.

NOTEInstalling check and shut-off elements in the system is recommended, depending onthe type of plant and pump. However, such elements must not obstruct properdrainage or hinder disassembly of the pump.

✓ Suction lift lines have been laid with a rising slope, suction head lines with adownward slope towards the pump.

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

✓ The pipelines have been anchored in close proximity to the pump andconnected without transmitting any stresses or strains.

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

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

▷ Free the piping from any impurities.

5.5 Casing/insulation

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

▷ Insulate the volute casing.

▷ Fit protective equipment.



CAUTIONHeat building up at motor housing and pump casingPump overheating!

▷ Never insulate the motor and electronic system housings.

5.6 Electrical connection

DANGER

Electrical connection work by unqualified personnelDanger of death from electric shock!

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

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

DANGER

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

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

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

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

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

2. Select an appropriate start-up method.

NOTEThe cable must be of type H05VV-F 3G1 or similar, with an outside diameter≥ 7.2 mm. Circuit breaker: 10/16 A (minimal rated current x 1.4) slow blowing fuseor automatic circuit breaker type C.

NOTEIf the pump set is to be switched off by means of an owner-supplied mains relay,this relay must meet the following requirements as a minimum: ratedcurrent ≥ 10 A, rated voltage 250 VAC.

NOTEConnection to the power supply must be effected by means of a fixed power cablewith a minimum cross-section of 3 x 1.5 mm2, which is fitted with a plug-typeconnection or an all-pole isolating switch with a minimum contact opening of3 mm.



6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

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

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

▪ The pump has been primed with the fluid to be handled. The pump has beenvented. (⇨ Section 6.1.2 )

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

6.1.2 Priming and venting the pump

CAUTIONIncreased wear due to dry runningDamage to the pump set!

▷ Never operate the pump set without liquid fill.

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

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

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

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

DANGER

Hot fluid handled spurting out in the vent plug areaRisk of burns!

▷ Wear protective clothing.

4. Close the screw plug again.

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

6.1.3 Start-up

DANGER

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

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

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

DANGER

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

▷ Never operate the pump set without liquid fill.

▷ Prime the pump as per operating instructions.

▷ Always operate the pump within the permissible operating range.



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

▷ Switch off the pump (set) immediately.

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

✓ The system piping has been cleaned.

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

✓ The lines for priming and venting have been closed.

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

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

3. Start up the motor.



6.1.4 Mode of operation

6.1.4.1 Automatic control

The closed-loop control mode integrated in the pump is active when the operatingmode is set to Internal. The operating mode can be set at DIP switch 1.

DIP switch 1 = ON Operating mode ExternalDIP switch 1 = OFF Operating mode Internal

21

ON

OFF

Fig. 3: DIP switch (example: single pump in Internal mode)

The pump starts up when the terminal pair RUN is bridged (factory setting) and stopswhen the terminal pair is not bridged.

RU

N0V

IN

Fig. 4: Terminal pair RUN

The pump is operated within the control curve for maximum pump power outputPmax = Q x H (point A, dashed line) and automatically adjusts itself to different outputrequirements. The control knob is set to its middle position (see illustration).

H

Q

A

By turning the control knob at the control module the pump power output can beadjusted manually. By turning the control knob anti-clockwise the pump poweroutput can be reduced, e.g. in case of flow noises. This means the control curve willshift towards lower heads. By turning the control knob clockwise the pump power output can be increased, e.g.if some radiators remain cold despite hydraulic input. This means the control curvewill shift towards higher heads.

H

Q

H

Q

Control mode function

Closing of thermostatic valves (or similar control devices) reduces the volume flowrate to be pumped, which also decreases the friction loss in the piping. The pumpcontrol system recognises this event and reduces the pump input power. As thevolume flow rate decreases, the head decreases correspondingly. This ensures smoothand trouble-free running of the pump at minimised power input.



6.1.4.2 Open-loop control:

The closed-loop control mode integrated in the pump is active when the operatingmode is set to Internal. The operating mode can be set at DIP switch 1.


21

ON

OFF

Fig. 5: DIP switch (example: single pump in Internal mode)

The pump starts up when the terminal pair RUN is bridged (factory setting) and stopswhen the terminal pair is not bridged.

RU

N0V

IN


The pump is operated at the set speed level (characteristic curve). The speed can beset to up to four different levels. In the example (see illustration) the pump is operated at speed level 1. The requiredspeed level is selected by turning the control knob at the control module.

H

Q1 2 3 4

6.1.4.3 Open-loop control mode with external setpoint 0 - 10 V

The external open-loop control mode via analog signal 0-10 VDC is active when theoperating mode is set to External. The operating mode can be set at DIP switch 1.


21

ON

OFF

Fig. 7: DIP switch (example: single pump in "External" mode)

The external analog signal is wired to the terminal pair (OV / IN) integrated in thepump. The pump starts up when the terminal pair RUN is bridged (factory setting)and stops when the terminal pair is not bridged.

RU

N0V

IN

Fig. 8: Terminal pair OV / IN and RUN



The pump is operated in open-loop control mode depending on the external analogspeed signal (0-10 VDC) (setpoint) (0 VDC = minimum speed / 10 VDC = maximumspeed).

n [min-1]

U [V]

10 V0 V

nmax

0

Fig. 9: Interdependence between the speed setpoint and the external input signal

6.1.4.4 Operation via Modbus

The pumps Rio-Eco N 25-100, 30-100 to 80-120 come with a Modbus interfaceintegrated in the control module. The Modbus interface (plug-type connection) islocated on the bottom of the control module. It is closed with a protective cap(IP 42).

The Modbus operating mode is assigned top priority and is always active regardlessof the position of DIP switch 1. Active Modbus settings can be deactivated bychanging the position DIP switch 1 once. The internal pump control will then takeover controlling the pump. To return to the Modbus operating mode, the Modbusinput must be re-activated in the control station.

All Modbus data points (variables) can be read at all times (monitoring). If theModbus setting is activated the control module will not react to any external analogsignal which may be connected. Internal pump control with automatic or manualoutput adjustment is deactivated.

For connecting the pump to a Modbus network connect the Modbus data cable,which is available as an accessory (19075536), to the plug integrated in the controlmodule and to the Modbus.

Table 7: Technical data of the Modbus interface

Parameters Description/valueTerminal cross-section 1.5 mm2

Interface RS485 (TIA-485A) optically isolatedBus connection Shielded bus cable, twisted in pairs, 1x 2x 0.5 mm2

Cable length 1000 m maximum, stub lines impermissibleWave impedance 120 ohm (cable type B to TIA 485-A)Data rate [baud] 2,400

9,600 (factory setting) 19,200

Protocol Modbus RTU (see Modbus installation/operatingmanual)

Data format 8 data bits, no parity, 1 stop bit

6.1.4.5 Operating mode single pump

The single pump operating mode can be set at DIP switch 2.

DIP switch 2 = ON Twin pumpDIP switch 2 = OFF Single pump

21

ON

OFF

Fig. 10: DIP switch (example: single pump operating mode and control integrated inthe pump)



6.1.4.6 Operating mode twin pump

DIP switch 2 = ON Twin pumpDIP switch 2 = OFF Single pump

21

ON

OFF

Fig. 11: DIP switch (example: twin pump operating mode and control integrated inthe pump)

The control modules of both pumps are connected with the data cable which iscontained in the scope of supply of the Rio-Eco Z N pump (also see accessories). Theterminals of the terminal pair RUN must be bridged at both pumps.

The data cable is connected to the two COM ports of the control modules, which arealso used for connecting the Modbus. This means that pumps in twin pumpoperating mode cannot be connected to a higher-level automation system viaModbus.

Function

The twin pump operating mode is activated when both pumps are started up. Theduty/stand-by operating mode becomes active after a few seconds and will stop oneof the pumps. The pump which remains active (on duty) is operated at 0 - 100 %; theother pump will be on stand-by. The red LED of the stand-by pump will light up andthe function "external start/stop" will be deactivated for the stand-by pump,irrespective of the wiring of the terminal pair RUN. The duty pump can be controlledby means of the integrated functions "open loop control with external setpoint0-10 VDC" and/or "external start/stop".

NOTEThe two pumps can be parameterised differently.

Each pump is operated in accordance with its settings. For example, one pump couldbe operated in closed-loop control and the other in open-loop control. To ensurethat the changeover from duty pump to stand-by pump will not have any impact onthe operation regarding duty point and operating mode, the parameter settings ofboth pumps must be identical.

The two functions (1) and (2) will be carried out automatically.

Automatic pump changeover (1)

The pumps come with an integrated timer, which switches off the duty pump after24 hours of operation and starts up the stand-by pump. To this effect, two minutesbefore the duty pump is switched off it signals a start command to the stand-bypump. The stand-by pump will be started up and the first pump will be switched off.

Redundant operation (2)

In the event of a failure of the duty pump the stand-by pump will be started upautomatically to take over the function of the failed pump.

6.1.4.7 Operating mode dual pump

DIP switch 2 = ON Dual pumpDIP switch 2 = OFF Single pump

21

ON

OFF

Fig. 12: DIP switch (example: Dual-pump Operation operating mode and controlsystem integrated in the pump)



Two individual pumps of the same performance data can be controlled and operatedindividually by an automation system via Modbus. In this case, the automation systemwill control the operating mode and the operating status of each pump separately.

The two pumps must be connected to the automation system with the Modbusconnection cable, which is available as an option (see accessories).

6.1.4.8 External start/stop

The pump is started up/stopped as a function of a volt-free external signal.

The external signal is wired to the terminal pair RUN integrated in the pump. Thepump is switched off when the connected cable is separated from the terminals andthe red LED flashes. (⇨ Section 9.2 Page 33) .

RU

N0V

IN


6.1.4.9 Alerts

The relay with volt-free NC and NO contact, which is integrated in the pump, willreact if the control module is defective. (⇨ Section 9.2 Page 33) .

The signal is wired to the terminal pair NO/NC/COM.

NO

NC

COM

REL

AY

Fig. 14: Terminal pair NO/NC/COM

Acknowledging an alert

1. Disconnect the pump from the power supply.

2. Re-connect the pump to the power supply.

6.1.4.10 Displays

The operating status of the pump is signalled by two LEDs at the control module ofthe pump.

Table 8: Description of the LED signal

LED signal Operating status of pumpNo display Pump switched off, not energisedGreen Pump started up, failure-free operationRed (permanent) Failure of the electronicsRed (flashing) Start/stop function interrupted

The red LED signals the type of failure by different flashing frequencies. The errorcode is repeated every minute, approximately.



Table 9: Display of error codes

Flashing frequency Cause of failure1)

1 - pause - 1 Excessive electronics temperature2 - pause - 2 Excessive motor temperature3 - pause - 3 Motor is overloaded4 - pause - 4 Pump is overloaded5 - pause - 5 Internal control error6 - pause - 6 Supplied voltage too high / too low

Number of flashes

2

3

4

5

6

1

1 2 3 4 5 6

1 2 3 4 5

1 2 3 4

1 2 3

1 2

1

150 150 150 150 150 150 150 150 150 150 150 150 Time in ms

Total time 2100 ms

Fig. 15: Duration and frequency of flashing light

Trouble-shooting (⇨ Section 8 Page 32)

6.2 Shutdown

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

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

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

NOTEIf the discharge line is equipped with a check valve, the shut-off element in thedischarge line may remain open, provided the site's requirements and regulationsare taken into account and observed.

For prolonged shutdown periods:

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

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

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

1) The pump tries to continue its operation regardless of any failure messages.



6.3 Operating limits

DANGER

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

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

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

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

6.3.1 Ambient temperature

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

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table 10: Temperature of the fluid handled as a function of the ambient temperature[°C]

Temperature of the fluidhandled

Ambient temperature

Rio-Eco (Therm) N 25-100,30-100, 30-120, 32-120,40-100, 40-120, 40-140,50-70, 50-90, 50-140

110 3090 40

Rio-Eco N 65-90, 65-120 to80-120

90 3070 40

6.3.2 Density of the fluid handled

The pump input power changes in proportion to the density of the fluid handled.

CAUTIONImpermissibly high density of the fluid handledMotor overload!

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

6.4 Shutdown/storage/preservation

6.4.1 Measures to be taken for shutdown

The pump (set) remains installed

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

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

The pump is removed from the pipe and stored

The pump has been properly drained (⇨ Section 7.2 Page 30) and the safetyinstructions for dismantling the pump have been observed.

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



6.5 Returning to service

For returning the pump to service observe the sections on commissioning/start-upand the operating limits.

In addition, carry out all servicing/maintenance operations before returning thepump (set) to service.

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

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

Also see

● Electrical connection, overview of settings, LED displays [⇨ 33]



7 Servicing/Maintenance

7.1 Servicing/inspection

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

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

7.2 Drainage/cleaning

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

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

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

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

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

7.3 Removing the pump set from the piping

7.3.1 Dismantling the complete pump set

DANGER

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

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

DANGER

Strong magnetic field in the rotor areaDanger of death for persons with pacemaker!

▷ Keep a safety distance of at least 0.3 m.

DANGER

Pump acting as a generator when running in reverseDanger to life from hazardous induction voltage at the motor terminals!

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



WARNINGDanger by strong magnetic fieldDanger of crushing injuries when pulling out the rotor!Due to the strong magnetic field the rotor can be suddenly pulled back into itsoriginal position!Danger of magnetic parts near the rotor being attracted!

▷ The rotor must generally only be removed from the motor housing byauthorised specialist personnel.

▷ Remove any magnetic parts from the vicinity of the rotor.

▷ Keep the assembly area clean.

▷ Keep a safety distance of at least 0.3 m from electronic components.

CAUTIONStrong magnetic field in the rotor areaInterference with magnetic data carriers, electronic devices, components andinstruments!Uncontrolled magnetic attraction forces between magnetic components, tools orsimilar!

▷ Remove any magnetic parts from the vicinity of the rotor.

▷ Keep the assembly area clean.

CAUTIONDanger by strong magnetic fieldNegative impact on or damage to electrical devices!

▷ The rotor must generally only be removed from the motor housing byauthorised specialist personnel.

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

✓ The pump has cooled down to ambient temperature.

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

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

2. Close the shut-off elements.

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

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

5. Remove the complete pump set from the piping.



8 Trouble-shooting

WARNINGImproper work to remedy faultsRisk of injury!

▷ For any work to remedy faults observe the relevant information in this manualor in the relevant accessory manufacturer's product literature.

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

Pump not running — no LED display

Pump starts up but stops again immediately

Pump not running — LED display flashes 1x - pauses - flashes 1x



Pump running irregularly — LED display flashes 4x - pauses - flashes 4x



Table 11: Trouble-shooting

A B C D E F G H Possible cause Remedy2)

✘ - - - - - - - Master switch OFF, defective fuse, earthconductor not or incorrectly connected

Check master switch and fuse. Check thepump connection.

- ✘ - - - - - - Remote start/stop contact has beenremoved

Fit connecting bridge for start/stopfunction.

- - ✘ - - - - - Temperature of electronics increased for ashort time

Verify that the water and ambienttemperature are within the indicatedtemperature ranges.

- - - ✘ - - - - Temperature of the motor increased for ashort time

Verify that the water and ambienttemperature are within the indicatedtemperature ranges.

- - - - ✘ - - - Pump overloaded for a short time Check whether the impeller is polluted.- - - - - ✘ - - Pump overloaded Check whether the impeller is polluted.- - - - - - ✘ - Internal control error Contact KSB Service.- - - - - - - ✘ Overvoltage of supply network (exceeding

the tolerance)Check that the pump is connected properlyand verify the operating voltage againstthe data on the name plate.

A

B

C

D

E

F

G

H

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

8 Trouble-shooting


9 Related Documents

9.1 Sectional drawing with list of components

102

230

81-59 818 814817

310 81-22

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

9.2 Electrical connection, overview of settings, LED displays

L N

Power

NO

1 2

34

1

2

Fig. 16: Overview

1 Electrical connection 2 Setting for operation3 LED red = alert 4 LED green = ready for operation

9 Related Documents


10 EU Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

Rio-Eco N, Rio-Eco Z N, Rio-Eco Therm NSeries code range: 1616 to 1752

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

– Pump set: EC Machinery Directive 2006/42/EC

– Pump set: Electromagnetic Compatibility Directive 2014/30/EU

– Pump set: Ecodesign Directive 2009/125/EC, Regulations No. 641/2009 and 622/2012

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

– EN 809

– EN 60335-1, EN 60335-2-51

– EN 61800-3

– EN 16297-1, EN 16297-2

Person authorised to compile the technical file: Christopher Hamkins

Head of ProductionalisationKSB AktiengesellschaftJohann-Klein-Straße 967227 Frankenthal (Germany)

The EU Declaration of Conformity was issued in/on:

Frankenthal, 20 April 2016

Joachim Schullerer

Head of Product Development Pump Systems and DrivesKSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal

10 EU Declaration of Conformity


Index

AApplications 7Automatic functions 13

BBearings 13

CCommissioning 20Connections 13

DDesign 13Designation 12Disposal 11Drive 13

EExternal control functions 13

FFaults

Causes and remedies 32Fluid handled

Density 28

IIntended use 7Interfaces 13

MManual functions 13Misuse 8

NName plate 12

OOperating limits 28Operating modes 13

PPiping 18Preservation 10, 28Product description 12

RReturn to supplier 10Returning to service 29

SSafety 7Safety awareness 8Scope of supply 14Shutdown 28Signalling and display functions 13Start-up 21Storage 10, 28

Index


1140

.82/

04-EN

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

Rio-Eco N / Z / Therm N - Smedegaard...In the event of damage, immediately contact your nearest KSB...

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Transcript of Rio-Eco N / Z / Therm N - Smedegaard...In the event of damage, immediately contact your nearest KSB...