KSB Guard Installation instructions

KSB Guard
For Use in Potentially Explosive Atmospheres
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual KSB Guard
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 17/08/2021

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Target group.....................................................................................................................................................6
1.3 Other applicable documents............................................................................................................................6
1.4 Symbols .............................................................................................................................................................6
1.5 Key to safety symbols/markings.......................................................................................................................6
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.3 Personnel qualification and personnel training.............................................................................................8
2.4 Consequences and risks caused by non-compliance with this operating manual........................................8
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the user/operator.......................................................................................................9
2.7 Software changes .............................................................................................................................................9
2.8 Explosion protection ........................................................................................................................................9
2.8.1 Marking ................................................................................................................................................9
2.8.2 Installation, commissioning and maintenance...................................................................................9
3 Transport/Storage/Disposal ................................................................................................................ 10
3.1 Checking the condition upon delivery..........................................................................................................10
3.2 Transport.........................................................................................................................................................10
3.3 Storage............................................................................................................................................................10
3.4 Disposal ...........................................................................................................................................................10
4 Description............................................................................................................................................ 12
4.1 General description ........................................................................................................................................12
4.2 Product information.......................................................................................................................................12
4.2.1 Product information as per Regulation No. 1907/2006(REACH) ....................................................12
4.3 Name plates ....................................................................................................................................................12
4.4 Technical data.................................................................................................................................................13
4.5 Function ..........................................................................................................................................................14
4.6 Measured values.............................................................................................................................................14
4.7 KSB Guard Gateway .......................................................................................................................................14
4.8 Sensor unit ......................................................................................................................................................16
4.9 Transmission and battery unit .......................................................................................................................16
5 Installation/ Commissioning............................................................................................................... 18
5.1 Setting up access to the KSBGuard system ..................................................................................................18
5.2 Installation ......................................................................................................................................................18
5.2.1 Fitting KSBGuardGateway...............................................................................................................18
5.2.1.1 Checking the place of installation of KSBGuardGateway ....................................................19
5.2.1.2 Fastening KSBGuardGateway.................................................................................................19
5.2.1.3 Connecting KSBGuardGateway to the power supply...........................................................20
5.2.1.4 Fitting the KSBGuardGateway antennas...............................................................................21
5.2.1.5 Checking the signal strength of KSBGuardGateway ............................................................22
5.2.1.6 Commissioning KSBGuardGateway .......................................................................................22
5.2.2 Positioning the transmission and battery unit.................................................................................22
5.2.3 Establishing a connection between the sensor unit and the transmission and battery unit........23
5.2.4 Using an extension cable...................................................................................................................23
5.2.5 Installing the sensor unit...................................................................................................................24
5.2.6 Installing the transmission and battery unit ....................................................................................26
5.2.7 Routing the connecting cable ...........................................................................................................27
5.3 Assigning and setting up ...............................................................................................................................28
5.3.1 Data required for adding a pump set...............................................................................................28
5.3.2 Adding the pump...............................................................................................................................29

Contents
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5.4 Commissioning/ start-up ...............................................................................................................................29
6 Operation.............................................................................................................................................. 31
6.1 Operating modes of transmission and battery unit.....................................................................................31
6.2 Checking that the transmission and battery unit is in Deep Sleep mode...................................................31
6.3 Taking manual measurement and displaying signal strength.....................................................................31
6.4 Turning off the transmission and battery unit.............................................................................................32
7 Servicing/Maintenance........................................................................................................................ 33
7.1 Replacing the battery pack............................................................................................................................33
7.2 Replacing the sensor unit...............................................................................................................................35
7.3 Replacing the transmission and battery unit................................................................................................35
7.4 Replacing KSBGuardGateway......................................................................................................................35
8 Dismantling .......................................................................................................................................... 36
8.1 Removing KSBGuardGateway......................................................................................................................36
8.2 Dismantling the transmission and battery unit............................................................................................36
8.3 Dismantling the sensor unit...........................................................................................................................37
9 Trouble-shooting.................................................................................................................................. 38
9.1 Trouble-shooting KSBGuardGateway .........................................................................................................38
9.2 Trouble-shooting the transmission and battery unit/ sensor unit..............................................................38
10 Related Documents.............................................................................................................................. 40
10.1 Recommended mounting position for sensor unit ......................................................................................40
11 Purchase Order Specifications............................................................................................................. 44
11.1 Ordering spare parts ......................................................................................................................................44
11.2 Accessories ......................................................................................................................................................44
12 EC Declarations of Conformity............................................................................................................ 45
12.1 EU Declaration of Conformity .......................................................................................................................45
Index ..................................................................................................................................................... 47

Glossary
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Glossary
Mat. No.
This identification number is composed of an 8-
digit numerical code that uniquely identifies a
product entered in SAP.

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
Operating manual of the pump (set) Description/operation of the pump (set)
Supplementary operating manual of explosion
protection measures
Special information on installation in a potentially
explosive atmosphere
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
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.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
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 operating
manual
▪Non-compliance with this operating manual 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

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 Safety information for the user/operator
▪Make sure KSBGuardGateway cannot be accessed by unauthorised persons (e.g.
children).
2.7 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.
In irregular intervals updates will be made to KSBGuardGateway and to the
Transmission and battery units. These updates will run automatically in the
background and serve to enhance the product performance.
2.8 Explosion protection
!DANGER
Always observe the information on explosion protection given in this section when
operating the product in potentially explosive atmospheres.
Only devices marked as explosion-proof may be used in potentially explosive
atmospheres.
Special conditions apply to the operation of explosion-proof devices to EU Directive
2014/34/EU (ATEX).
Especially adhere to the sections in this manual marked with the Ex symbol and the
following sections, (ðSection2.8.1,Page9) to (ðSection2.8.2,Page9)
The explosion-proof status is only assured if the product is used in accordance with its
intended use.
Never operate the product outside the limits stated on the name plate.
Prevent impermissible modes of operation at all times.
2.8.1 Marking
The individual devices are marked as follows in accordance with Directive 2014/34/EU:
▪Sensor unit: II 2G Ex ib IIC T4 Gb
▪Transmission and battery unit: II 2G Ex ib IIC T4 Gb
▪KSB Guard Gateway: II 2(1) G Ex db eb mb [ia Ga] IIC T4 Gb
2.8.2 Installation, commissioning and maintenance
Special regulations apply to the installation, commissioning and maintenance of
explosion-proof devices. Modifications or alterations can affect explosion protection
and are only permitted after consultation with the manufacturer. Installation,
commissioning and maintenance must only be performed in accordance with the
manufacturer’s instructions.
The personnel employed to install, commission and maintain the device has to be
familiar with the corresponding ATEX standards (DINEN60079-14 and -17) as well as
with the details of the explosion protection regulations applicable to the system.

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
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 -40°C to +70°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.
3.4 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.

3 Transport/Storage/Disposal
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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.

4 Description
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4 Description
4.1 General description
Monitoring device for monitoring vibrations and temperatures of pump sets.
4.2 Product information
4.2.1 Product information as per Regulation No. 1907/2006(REACH)
For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see https://
www.ksb.com/ksb-en/About-KSB/Corporate-responsibility/reach/ .
4.3 Name plates
TYPE: KSB GUARD Ex SENSOR UNIT
DEKRA 20ATEX0140 X
IECEx DEK 20.0083 X
II 2 G Ex ib IIC T4 Gb
0035 -40°C < Ta < 70°C
-40°C < Tp < 90°C
IP65
Id. No
05088765
Serial No
GSA20W450040
Year
2020
Johann-Klein-Straβe 9
67227 Frankenthal
Germany
1
2
3
4
Fig.1: Name plate of sensor unit (example)
1 ATEX marking 2 Enclosure
3 Ambient temperature 4 Surface temperature of mounting
position
TYPE: KSB GUARD Ex TRANSMISSION UNIT
WARNINGS:
READ AND UNDERSTAND
USERMANUAL BEFORE USE.
USE ONLY REPLACEABLE BATTERY
PACKS DEFINED IN THE MANUAL.
DO NOT OPEN WHEN AN EXPLOSIVE
ATMOSPHERE IS PRESENT.
THIS EQUIPMENT MUST BE EARTHED.
Id. No 5088765
Serial No GTA20E520001
Year 2020
0035
Johann-Klein-Straβe 9, 67227 Frankenthal Germany
DEKRA 20ATEX0140 X
IECEx DEK 20.0083 X
II 2 G Ex ib IIC T4 Gb
-20°C < Ta < 70°C IP66
1
2
3
4
Fig.2: Name plate of transmission and battery unit (example)
1 Year of construction 2 ATEX marking
3 Enclosure 4 Ambient temperature

4 Description
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8265/55-2110
Steuerung / control panel
PTB 06 ATEX 1077
II 2(1) G Ex db eb mb [ia Ga] IIC T4 Gb
IP65
AC
238784_V01
143494_V09
110-240 V 1NPE 50/60 Hz max. 45 mA
IEC 61439-2
Date
Order no.: 751742/0010
HQ: R. STAHL, D-74638 Waldenburg x r-stahl.com x Made in Germany
serial number
-20°C x Ta x +40°C
0158
1
23 4 5 6 7 8
Fig.3: Name plate of KSB Guard Gateway (example)
1 ATEX marking 2 Type of power supply: AC voltage
3 Enclosure 4 Supply voltage range
5 Connection with 3-core cable (L1 /
N / PE)
6 Frequency of mains voltage
7 Ambient temperature 8 Supply current
4.4 Technical data
Sensor unit Table5: Technical data of sensor unit
Characteristic Value
Material Aluminium
Dimensions (L×W×H) [mm] 50x45x30
Enclosure IP65
Cable type 1.5m, PUR, 6-core
Permissible surface temperature of the pump
(process temperature)
-40 to90°C
Ambient temperature -20to+70°C
Transmission and battery
unit
Table6: Technical data of transmission and battery unit
Characteristic Value
Material Glass fibre reinforced polyester
Dimensions (L×W×H) [mm] 110x75x75
Enclosure IP66
Permissible surface temperature -20to+70°C
Power supply Battery pack with lithium thionyl
chloride battery (max. 17Ah, not
rechargeable)
Wireless module ISM band, 2.4GHz
Connection M8, 6-pin
KSBGuardGateway Table7: Technical data of KSBGuardGateway
Characteristic Value
Supply voltage 110 - 240V, AC voltage
Mains frequency 50/60Hz
Power input <5W
In-service ambient temperature -20to40°C
Weight Approx. 25kg
Dimensions Approx. 500×300×230
TypeN connector, connectionA Antenna for 2.4 GHz (WLAN/
Bluetooth)

4 Description
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Characteristic Value
TypeN connector, connectionB Antenna for 2G/3G/4G mobile
network, included in standard
accessories1)
Internal SIM card2) Pre-configured
4.5 Function
Sensor unit The sensor unit is preferably installed at the pump’s bearing bracket or drive lantern,
where it measures the pump’s vibrations and temperature trends using built-in
sensors. This data is sent to the transmission and battery unit.
Transmission and battery
unit
The sensor unit is connected to the transmission and battery unit with a connecting
cable.
The transmission and battery unit sends the measured data to KSBGuardGateway
via a radio signal.
KSB Guard Gateway KSBGuardGateway collects the data of the sensor unit and transfers it to the
KSBCloud in encrypted format. The data can be accessed via the KSBGuard app or
the ksbguard.net web portal.
One KSBGuardGateway can process the data of up to 40 transmission and battery
units, if they send data once an hour. If data transmission is more frequent, the
number of units per gateway is reduced.
4.6 Measured values
Temperature The temperature is measured inside the sensor unit. The values can therefore differ
from the actual surface temperature of the pump set.
Vibrations The vibration values are measured in three axes and usually output as RMS values.
4.7 KSB Guard Gateway
KSBGuardGateway cannot be accessed; it is located in a flameproof enclosure. All
connections (antennas, power supply) are located outside the flameproof enclosure.
1Extension cable available from KSB
2The SIM card is pre-installed and cannot be replaced.

4 Description
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1
2
3
4
5
Fig.4: KSBGuardGateway in flameproof enclosure
1 Antenna connection for mobile
data (LTE)
2 Sensor network antenna
connection
3 KSB Guard Gateway 4 Flameproof enclosure
5 Terminal box
12 3
Fig.5: KSBGuardGateway
1 Status LED for supply voltage 2 Status LED S1 for connection status
3 Level LEDs for mobile network
signal strength
Table8: Description of LED indicators
No. LED Status Description
1 Supply voltage OFF Device is out of operation or in the initialisation phase.
Green Device is in operation. No faults present.
Red or flashing red Device is in operation. Faults are present.

4 Description
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No. LED Status Description
2 Connection status
S1
OFF Device waiting for mobile data connection
Flashing in yellow, double
pulse signal (approx. 3min
after switch-on)
Problems with Internet connection
Green Mobile network and Internet accessible
Green, flashing slowly New firmware found. Internal firmware update started.
3 Mobile network
signal strength
4th LED green Signal strength > -75dBm
3rd LED green Signal strength > -85dBm
2nd LED green Signal strength > -95dBm
1st LED green Signal strength < -95dBm
4.8 Sensor unit
1
x
yz
23
4
Fig.6: Sensor unit with coordinate system
1 Coordinate system (for vibration
measurement)
2 QR code
3 Connecting cable to transmission
and battery unit
4 Earthing connections
4.9 Transmission and battery unit
1
234
5
6
7
Fig.7: Transmission and battery unit
1 Position of internal antenna 2 Status LED A (red)
3 Status LED B (green) 4 Pushbutton

4 Description
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5 Level LEDs for indicating the signal
strength of the KSBGuardGateway
connection
6 Earthing connection
7 Connection for the connecting
cable to the sensor unit
Table9: Description/ function of control elements and LED indicators
Control element/ LED indicator Description
Pushbutton Commissioning, status check, manual measurement
Status LED A Status LEDs for indicating the operating status and for coded output of fault
messages
Status LED B
Level LEDs Signal strength of KSBGuardGateway connection

5 Installation/ Commissioning
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5 Installation/ Commissioning
5.1 Setting up access to the KSBGuard system
Send the following information to this e-mail address:
▪E-mail: [email protected]
Table10: Required data
Required data Notes
Organisation’s name
(e.g. company name, such as XY Industrial
Estate, Exampleville Waterworks.)
Company's post/ zip code
Company’s city
Company’s country
Company’s customer number (at KSB if
applicable)
Administrator’s name
(the first company employee who is to have
access to/ use the KSBGuard. This person can
then add further users.)
Administrator’s e-mail address
A customer account will be created with this data.
A system-generated welcome e-mail will be sent to the e-mail address entered. This
e-mail will also contain a prompt to change the initial password.
5.2 Installation
NOTE
For all queries relating to the actual installation (e.g. positioning of components,
reception quality, etc.) KSBGuard Support will be available. (ðSection9,Page38)
5.2.1 Fitting KSBGuardGateway
DANGER
Sparks produced during installation work or servicing work
Explosion hazard!
▷Observe the safety regulations in force at the place of installation.
▷Always perform installation work or maintenance work on explosion-proof
devices outside of potentially explosive atmospheres.
DANGER
Risk of falling when working at a great height
Danger to life by falling from a great height!
▷Do not step onto the pump (set) during installation work or dismantling work.
▷Pay attention to safety equipment, such as railings, covers, barriers, etc.
▷Observe the applicable local health and occupational safety regulations and
accident prevention regulations.

5 Installation/ Commissioning
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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.
CAUTION
Incorrect installation
No data transmission!
▷Never connect more than 40 transmission and battery units to a
KSBGuardGateway.
One KSBGuardGateway can process the data of up to 40 transmission and battery
units, if they send data once an hour. If data transmission is more frequent, the
number of units per gateway is reduced.
Multi-gateway operation If more than 40 transmission and battery units are to be connected to a
KSBGuardGateway, multi-gateway operation is recommended. For this purpose, a
second KSBGuardGateway has to be fitted within 50m of the first
KSBGuardGateway. Multi-gateway operation is also recommended in the case of
poor wireless connection of individual transmission and battery units.
In general, several KSBGuardGateways can be installed in one area.
Data can be transmitted by Modbus transmission units and by transmission and
battery units in the same network (i.e. to the same KSBGuardGateway).
5.2.1.1 Checking the place of installation of KSBGuardGateway
The place of installation of KSBGuardGateway has to meet the following
requirements:
▪Sufficient clearance for dismantling
▪The power supply can be switched off via an external isolating switch.
▪Flood-proof
▪The IP enclosure and the temperature range at the place of installation match
the data on the name plate.
▪Maximum distance between KSBGuardGateway and transmission and battery
unit: 50m (direct line of sight between the transmission and battery unit and the
KSBGuardGateway antenna)
▪Area between KSBGuardGateway and the transmission and battery unit with as
few obstacles as possible (e.g. concrete walls and steel elements, pipelines).
If possible: Installation with direct line of sight between the transmission and
battery unit and KSBGuardGateway
5.2.1.2 Fastening KSBGuardGateway
NOTE
Fastening KSBGuardGateway at a height of approx. 2 to 3m above the floor is
recommended.

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Fig.8: Fastening the flameproof enclosure
1 Holes for wall mounting
1. Fasten the flameproof enclosure to a suitable wall with four screws (M10).
5.2.1.3 Connecting KSBGuardGateway to the power supply
DANGER
Opening the flameproof enclosure
Explosion hazard!
▷Never open the flameproof enclosure of KSBGuardGateway.
▷Electrical work in the terminal box may only be carried out by a qualified
electrical technician.