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
3 of 50
KSB Guard
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
4 of 50 KSB Guard
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
5 of 50
KSB Guard
4079.83/01-EN
Glossary
Mat. No.
This identification number is composed of an 8-
digit numerical code that uniquely identifies a
product entered in SAP.

1 General
6 of 50 KSB Guard
4079.83/01-EN
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
7 of 50
KSB Guard
4079.83/01-EN
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
8 of 50 KSB Guard
4079.83/01-EN
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
9 of 50
KSB Guard
4079.83/01-EN
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
10 of 50 KSB Guard
4079.83/01-EN
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.