KSB KSB Leakage Sensor Installation instructions

Monitoring System
KSB Leakage Sensor
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual KSB Leakage Sensor
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 27/11/2020

Contents
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Contents
1 General.................................................................................................................................................... 5
1.1 Principles ...........................................................................................................................................................5
1.2 Target group.....................................................................................................................................................5
1.3 Other applicable documents............................................................................................................................5
1.4 Symbols .............................................................................................................................................................5
1.5 Key to safety symbols/markings.......................................................................................................................5
2 Safety...................................................................................................................................................... 7
2.1 General..............................................................................................................................................................7
2.2 Intended use .....................................................................................................................................................7
2.3 Personnel qualification and personnel training.............................................................................................7
2.4 Consequences and risks caused by non-compliance with this manual .........................................................7
2.5 Safety awareness ..............................................................................................................................................8
2.6 Software changes .............................................................................................................................................8
2.7 Explosion protection ........................................................................................................................................8
3 Transport/Storage/Disposal .................................................................................................................. 9
3.1 Checking the condition upon delivery............................................................................................................9
3.2 Transport...........................................................................................................................................................9
3.3 Storage..............................................................................................................................................................9
3.4 Disposal ...........................................................................................................................................................10
4 Description............................................................................................................................................ 11
4.1 General description ........................................................................................................................................11
4.2 Name plate......................................................................................................................................................11
4.3 Operating limits..............................................................................................................................................11
4.4 Fluids handled.................................................................................................................................................12
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 sensor .......................................................................................................................................15
5.3.1 Installing a KSB Leakage Sensor that has been supplied but not fitted ........................................16
5.3.2 Installing a pre-mounted KSB Leakage Sensor ................................................................................16
5.4 Electrical connection ......................................................................................................................................17
5.4.1 Standard design .................................................................................................................................17
5.4.2 Variant for use in potentially explosive atmospheres .....................................................................18
5.4.3 Connecting the power supply and message signals ........................................................................18
5.4.4 DIP switch configuration ...................................................................................................................19
5.5 Display functions during operation...............................................................................................................20
5.5.1 Display ................................................................................................................................................20
5.5.2 Analog output....................................................................................................................................20
6 Commissioning/ Start-up.................................................................................................................... 22
6.1 Carrying out a functional test........................................................................................................................22
6.2 Measures to be taken for shutdown.............................................................................................................23
7 Servicing/Maintenance........................................................................................................................ 24
7.1 Safety regulations...........................................................................................................................................24
7.2 Maintenance/inspection.................................................................................................................................24
7.2.1 Cleaning the drop capillary ...............................................................................................................24
7.3 Dismantling and reassembly..........................................................................................................................25
7.3.1 Dismantling and reassembling the KSB Leakage Sensor.................................................................25
7.3.2 Rotating the upper half of the sensor housing ...............................................................................25
7.3.3 Removing and re-mounting the inductive sensor ...........................................................................25
7.3.4 Resetting the analysing unit .............................................................................................................26

Contents
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8 Trouble-shooting.................................................................................................................................. 27
9 Related Documents.............................................................................................................................. 28
9.1 General assembly drawing with list of components ....................................................................................28
9.2 Layout / connection diagram.........................................................................................................................29
9.2.1 Standard design .................................................................................................................................29
9.2.2 Variant for use in potentially explosive atmospheres .....................................................................30
10 EU Declaration of Conformity............................................................................................................. 31

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating 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 facility 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
Sub-supplier product literature Operating manuals and other product literature
describing accessories and integrated machinery
components
For accessories and/or integrated machinery components observe the product
literature of the relevant manufacturer.
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
1.5 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.

1 General
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Symbol Description
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 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 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.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪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 and markings 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.
2.2 Intended use
▪The values specified in the technical product literature for the mains voltage and
ambient temperature must not be exceeded. The device must only be operated
in accordance with the instructions provided in the operating manual and other
applicable documents.
2.3 Personnel qualification and personnel training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the equipment 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 device must always be supervised by specialist technical personnel.
2.4 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 Safety
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2.5 Safety awareness
In addition to the safety information contained in this operating 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
2.6 Software changes
The software has been specially created for this product and thoroughly tested.
Making changes or additions to the software or parts of the software is prohibited.
2.7 Explosion protection
!DANGER
Always observe the information on explosion protection given in this section when
operating the product in potentially explosive atmospheres.
The standard design of the KSB Leakage Sensor is not approved for use in potentially
explosive atmospheres.
The KSB Leakage Sensor may be used in potentially explosive atmospheres (II2GT5-
T1) provided that an inductive sensor1) approved for use in potentially explosive
atmospheres and a switching amplifier1) are used.
In this case, it must be ensured that the switching amplifier and the display unit are
located outside of the potentially explosive atmosphere. (ðSection9.2.2,Page30)
This operating manual’s additional sections containing information on use in
potentially explosive atmospheres must be observed. In addition, observe the
operating manuals provided by the manufacturers of components supplied with this
product that are marked as explosion-proof.
The KSB Leakage Sensor does not have its own marking (mechanical part: housing
parts and balance scale without inductive sensor) as it is considered an integral part
of the pump.
KSB Leakage Sensors fitted on pumps of a make other than KSB must not be used in
potentially explosive atmospheres.
1Only to be purchased from KSB

3 Transport/Storage/Disposal
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3 Transport/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 of the pump with fitted KSB Leakage Sensor
Risk of injury from falling parts!
▷Never use the piping, leakage sensor or its fastening elements as attachment
points.
CAUTION
Improper transport
Damage to the device!
▷Always transport the device properly and in its original packaging.
▷For transport, observe the transport instructions on the original packaging.
▷Do not throw the device.
1. Upon receipt, unpack the device and check for in-transit damage.
2. Report any in-transit damage to the manufacturer immediately.
3. Dispose of packaging material in accordance with local regulations.
3.3 Storage
If the ambient conditions for storage are met, the function of the device will be
ensured even after a prolonged period of storage.
CAUTION
Damage during storage due to humidity, dirt or vermin
Corrosion/contamination of the device!
▷For outdoor storage cover the (packed or unpacked) device and accessories with
water-proof material.
Table4: Ambient conditions for storage
Ambient condition Value
Relative humidity 85% max. (non-condensing)
Ambient temperature -30°C to +60°C
1. Store the device in dry conditions and in its original packaging.
2. Store the device in a dry room in which the atmospheric humidity is maintained
at a constant level (as far as this is possible).
3. Prevent excessive fluctuations in atmospheric humidity.

3 Transport/Storage/Disposal
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3.4 Disposal
Electrical or electronic equipment marked with the adjacent symbol must not be
disposed of in household waste at the end of its service life.
Contact your local waste disposal partner for returns.
If the used electrical or electronic equipment contains personal data, the operator is
responsible for deleting it before the equipment is returned.
NOTE
Due to certain components it contains, the device is classified as special waste and
meets RoHs 2011/65/EC requirements.
Once decommissioned, the device must be properly disposed of in accordance with
local regulations.