KSB SuPreme Series Installation instructions

Synchronous Reluctance Motor
KSB SuPremE
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual KSB SuPremE
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 06/03/2019

Contents
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KSB SuPremE
Contents
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 training...............................................................................................................8
2.4 Consequences and risks caused by non-compliance with this manual .........................................................8
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the user/operator.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ................................................................9
2.8 Unauthorised modes of operation..................................................................................................................9
2.9 Electromagnetic compatibility.........................................................................................................................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 Disposal ...........................................................................................................................................................11
4 Description............................................................................................................................................ 12
4.1 General description ........................................................................................................................................12
4.2 Designation.....................................................................................................................................................12
4.3 Name plate......................................................................................................................................................13
4.4 Technical data.................................................................................................................................................15
4.5 Types of construction .....................................................................................................................................15
4.6 Mounting arrangements................................................................................................................................16
4.7 Noise characteristics .......................................................................................................................................18
4.8 Balancing.........................................................................................................................................................19
5 Installation at Site................................................................................................................................ 20
5.1 Safety regulations...........................................................................................................................................20
5.2 Checks to be carried out prior to installation...............................................................................................20
5.3 Installing the motor or electric drive.............................................................................................................21
5.4 Electrical connection ......................................................................................................................................23
5.4.1 Version with terminal box.................................................................................................................23
5.4.2 Version with connector contact and/or conductors.........................................................................24
5.4.3 Direction of rotation..........................................................................................................................26
5.5 Tightening torques.........................................................................................................................................26
5.6 Installing and removing output components ...............................................................................................27
6 Commissioning/Start-up/Shutdown................................................................................................... 28
6.1 Checking insulation resistance.......................................................................................................................28
6.2 Prerequisites for commissioning/start-up......................................................................................................29
6.3 Start-up ...........................................................................................................................................................29
6.4 Shutdown........................................................................................................................................................30
6.5 Idle periods .....................................................................................................................................................30
6.6 Returning to service .......................................................................................................................................30
7 Servicing/Maintenance........................................................................................................................ 31
7.1 Safety regulations...........................................................................................................................................31
7.2 Maintenance/inspection.................................................................................................................................31
7.2.1 Supervision of operation ...................................................................................................................32

Contents
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7.2.2 Inspection ...........................................................................................................................................33
7.3 Dismantling the motor...................................................................................................................................36
7.3.1 General information/Safety regulations...........................................................................................36
7.3.2 Removing the protective roof (optional) .........................................................................................37
7.3.3 Dismantling the fan hood .................................................................................................................37
7.3.4 Dismantling the fan ...........................................................................................................................37
7.3.5 Dismantling the rotor ........................................................................................................................37
7.3.6 Dismantling the bearings ..................................................................................................................37
7.4 Assembling the motor....................................................................................................................................38
7.4.1 Fitting the bearings ...........................................................................................................................38
7.4.2 Installing the rotor.............................................................................................................................39
7.4.3 Mounting the fan ..............................................................................................................................39
7.4.4 Mounting the fan hood.....................................................................................................................39
7.4.5 Mounting the protective roof (optional) .........................................................................................39
8 Troubleshooting................................................................................................................................... 40
9 Related Documents.............................................................................................................................. 42
9.1 General assembly drawing with list of components ....................................................................................42
10 EU Declaration of Conformity............................................................................................................. 47
Index ..................................................................................................................................................... 48

Glossary
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KSB SuPremE
Glossary
Drive end
End of motor with bare shaft end for connecting
the machine to be driven via a coupling or traction
sheave and belt (driven output or machine
element).
IE4
Efficiency class to IECTS60034-30-2:2016=Super
Premium Efficiency (IE= International Efficiency)
IE5
Efficiency class to IECTS60034-30-2:2016=Ultra
Premium Efficiency (IE= International Efficiency)
Motor
Device that performs mechanical work by
converting different forms of energy (e.g.
electrical energy) into kinetic energy.
Non-drive end
End of motor with fan and fan hood.

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 centre 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
Pump operating manual Proper and safe use of the pump in all phases of
operation
Operating manual for
PumpDrive2 and PumpDriveR
Proper and safe use of PumpDrive in all phases of
operation
Wiring diagram Electrical connection
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.
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
▪This product must only be operated within the limit values stated in the technical
product literature for the mains voltage, mains frequency, ambient temperature,
motor rating, speed, density, pressure, temperature and in compliance with any
other instructions provided in the operating manual or other applicable
documents.
▪The product must not be used in potentially explosive atmospheres.
2.3 Personnel qualification and training
▪ All personnel involved must be fully qualified to install, operate, maintain and
inspect the product 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 product 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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KSB SuPremE
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
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety information for the user/operator
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Any work on the product shall only be performed when it has been disconnected
from the power supply (de-energised).
▪Carry out work on the product during standstill only.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.
2.8 Unauthorised modes of operation
Never operate the product outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the product supplied
is only valid if the product is used in accordance with its intended use.
2.9 Electromagnetic compatibility
This product may only be operated on a frequency inverter, which is why the
electromagnetic compatibility must be evaluated together with the inverter used.
Observe the information provided by the manufacturer of the inverter!

3 Transport/Temporary Storage/Disposal
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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 and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
DANGER
Improper transport
Danger to life from falling parts!
▷Only transport the motor in the specified position.
▷Always use all lifting lugs available at the motor during transport.
▷Always screw in lifting lugs (lifting eyebolts) up to the contact face and tighten.
▷Use suitable, permitted lifting accessories.
Only remove any transport locks provided prior to commissioning and store or
disable. Use transport locks for additional transport tasks or re-enable.
To transport the motor, suspend it from the lifting tackle as shown.
Transporting the motor by two lifting
lugs attached to sides of motor
housing
Transporting the motor by one lifting
lug attached to top of motor housing
3.3 Storage/preservation
Exposed machined metal
surfaces
Exposed locating surfaces (shaft ends, flange faces, centring spigots, connector
contacts) are treated with a layer of temporary corrosion protection (<6months) for
transport. Take suitable corrosion protection measures for extended storage periods.
Storage period Rotate the shaft once annually to avoid permanent standstill markings. Extended
storage periods decrease the service life (increase ageing) of the grease applied to
the rolling element bearings.
Closed rolling element
bearings
Replace closed rolling element bearings after 48months of storage.
Condensation during
storage To prevent condensation inside the motor, switch on the motor standstill heater1).
1) If any

3 Transport/Temporary Storage/Disposal
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If condensation water has formed and a drain hole is provided, position the motor in
such a way that the water drain plug is at the lowest point of the housing. Drain off
the condensation water. (ðSection7.2.2.1,Page33)
Drain off the condensation water as required by the ambient conditions but at least
every 6months.
Outdoor storage
CAUTION
Damage during storage due to humidity, dirt or vermin
Corrosion/contamination of the drive!
▷Cover all components with water-proof material. Covers or tarpaulins must not
contact the surface of the stored goods.
▷Ensure sufficient air circulation, e.g. by inserting wooden spacers.
▷To ensure protection against ground moisture, arrange motors and packaged
motors on pallets, bars or foundations.
▷Prevent the possibility of the product sinking into the ground.
Implement appropriate measures to accommodate extreme climatic conditions, e.g.
salty and/or dusty, moist atmospheres.
Indoor storage
Storage rooms should provide protection against extreme weather conditions and be
dry, dust-free, frost-free, jolt-free, vibration-free and well ventilated.
Storage of motors of type of construction X2 with mounting plate for PumpDrive2
For storing a motor of this type of construction please note that when the frequency
inverter is not mounted, the motor's enclosure is IP40. Protect the connection
provided at the motor from the ingress of moisture and dust.
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 user is
responsible for deleting it before the equipment is returned.
Due to some components, the product is classified as special waste.
1. Dismantle the product.
2. Separate and sort the materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner. PCBs, power electronics, capacitors and electronic
components are all hazardous waste.

4 Description
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4 Description
4.1 General description
Magnetless synchronous reluctance motor of efficiency class IE4/IE5 in compliance
with IECTS60034-30-2:2016, for operation with frequency inverter without rotor
position sensors
4.2 Designation
Table4: Designation example
Position
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
- 2 - 4 5 , 0 - 2 2 5 M - B W A 7 F 3 N R S D W F Z W K S F
Table5: Designation key
Position Code Description
1-2 Rated speed n [rpm]
2 3000
4 1500
4-7 Motor rating PN [kW]
0,55 0,55
... ...
45,0 45,00
9-12 Motor size
71M Shaft centreline height [mm]
... ...
225M Shaft centreline height [mm]
14 Enclosure
B IP55 or IP40/55
15 Type of protection
W Non-explosionproof
16 Electrical voltage
A / P 3~, AC, 220VΔ, 380VY, 50Hz
17 Efficiency class
7 IE4/ IE5 (NEMA Super Premium/Ultra Premium)
18 Thermal class
F Thermal class 155 (F)
19 Motor protection/ winding protection
3 3 PTC thermistors
20 Direction of rotation
N Clockwise / counter-clockwise (bi-directional)
21 Position of terminal box
T Terminal box on top
N Not defined
P Adapter for PumpDrive 2 on top
22 Feet attached by bolts
S Feet attached by bolts
W Without feet
H Integrally cast feet
23 Position of fixed bearing
D Fixed bearing, drive end
C Fixed bearing, drive end, reinforced

4 Description
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KSB SuPremE
Position Code Description
23 F Fixed bearing, drive end, axially reinforced
24 Protective roof
W Without protective roof
25 Motor flange
F EN 50347 Type FF
T EN 50347 Type FT
A EN 50347 Type FF, shaft without keyway
B EN 50347 Type FT, shaft without keyway
W Without flange
C Without flange, shaft without keyway
26 Operation on a frequency inverter
Z Compulsory operation on a frequency inverter
27 Approval
W Without approvals
28-30 Manufacturer
KSB KSB SuPremE B, primed
KSF KSB SuPremE B, pearl gold, RAL 1036
KSH KSB SuPremE B, vermilion, RAL 2002
KSH KSB SuPremE B, ultramarine blue, RAL 5002
SCD KSB SuPremE C, pearl gold, RAL 1036
SCD KSB SuPremE C, ultramarine blue, RAL 5002
4.3 Name plate
IE 5
159 kg Th.Cl 155(F) IP55 -20°C ≦ TAMB ≦ 40°C
Converter Duty Only VPWM
V Hz A kW cos φ Nm 1/min
380 Y 100 50 22.0 0.71 70 3000
01634340
Nmax 4200 1/min
1 2 3 4 5 6
7
8910111213141516
17
18
19
20
KSB SE & Co. KGaA
67227 Frankenthal
Deutschland
Johann-Klein-Straße 9
3~IEC60034 180M IMB3 1FP3038 1612/1234-001-002 KSB SuPremE
Fig.1: Name plate (example)
1 Efficiency class 2 Technical standard
3 Size 4 Type of construction
5 Production code/ type designation 6 Serial number
7 Type series 8 Maximum speed
9 Ambient temperature limits 10 Enclosure
11 Rated speed 12 Rated torque

4 Description
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13 Power factor (no effect on power supply
network)
14 Rated power
15 Rated current 16 KSB material number
17 Rated frequency 18 Rated voltage for the supplying frequency
inverter
19 Thermal class 20 Weight

4 Description
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4.4 Technical data
Table6: Technical data
Characteristic Value
Ambient temperature -20°C to +40°C
Atmospheric humidity Maximum of 55% relative atmospheric
humidity at 40°C ambient temperature
Altitude ≤ 1000m (without power derating)
Thermal class F
Starting torque in [%] of rated torque
IC 411 continuous 50%
IC 416 continuous 100%
IC 411/416, 10seconds max. 110 %
Maximum torque in [%] of rated torque 110%
Enclosure
KSB SuPremE with terminal box IP55
KSB SuPremE with adapter plate for
PumpDrive2
IP552)
Paint coat RAL5002, RAL1036 or, if combined with
a pump, in the same colour as the pump.
4.5 Types of construction
The motors are available in different types of construction:
KSB SuPremE X1:
▪With terminal box for connecting to PumpDrive2 or PumpDriveR for mounting
on walls and in control cabinets
KSB SuPremE X2:
▪Equipped for being fitted with a motor-mounted PumpDrive2
Table7: Designs
Flange type3)
Version with foot Shaft centreline height [mm] Mounting arrangement IM ...
None ✘71 - 225 ▪B3 4)
▪B6
▪B7
▪B8
▪V5
▪V6
Flange with clearance holes (FF) ✘71 - 225 ▪V15 4)
▪V355)
▪B35
- 71 - 225 ▪V1 4)
▪V35)
▪B5
2) With motor-mounted PumpDrive2
3) Designations to EN50347:2001
4) Standard mounting arrangement
5) Not possible for special design for Movitec

4 Description
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Flange type3)
Version with foot Shaft centreline height [mm] Mounting arrangement IM ...
Flange with tapped holes (FT)6) ✘- -
- ≤ 132 ▪V18 4)
▪B14
▪V19
4.6 Mounting arrangements
Table8: Mounting arrangement for B3
Standard mounting
arrangement
Further mounting arrangements Shaft centreline height [mm]
H≤160 H≥180
IM B3 IM B6
✔ ✔
IM B7
✔ ✔
IM B8
✔ ✔
IM V5
✔ ✔
6) Special design for Movitec

4 Description
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KSB SuPremE
Standard mounting
arrangement
Further mounting arrangements Shaft centreline height [mm]
H≤160 H≥180
IM B3
IM V6
✔ ✔
Table9: Mounting arrangements for V15
Standard mounting
arrangement
Further mounting arrangements Shaft centreline height [mm]
H≤160 H≥180
IM V15
IM V35
✔ ✔
IM B35
✔ ✔
Table10: Mounting arrangements for V1
Standard mounting
arrangement
Further mounting arrangements Shaft centreline height [mm]
H≤160 H≥180
IM V1 IM V3
✔7) -
7) Feet can be removed from IM V15 basic type of construction

4 Description
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Standard mounting
arrangement
Further mounting arrangements Shaft centreline height [mm]
H≤160 H≥180
IM V1 IM B5
✔7) -
Table11: Mounting arrangements for V18
Standard mounting
arrangement
Further mounting arrangements Shaft centreline height [mm]
H≤132
IM V18
IM B14
✔
IM V19
✔
4.7 Noise characteristics
Table12: Sound pressure level LpA
Rated speed Rated power Motor size Sound pressure
level LpA
8)
[rpm] [kW] [dB (A)]
1500 0,55 80M 60
1500 0,75 80M 60
1500 1,1 90S 60
1500 1,5 90L 60
1500 2,2 100L 60
1500 3 100L 60
1500 4 112M 61
1500 5,5 132S 61
1500 7,5 132M 61
1500 11 160M 61
1500 15 160L 61
1500 18,5 180M 63
1500 22 180L 63
1500 30 200L 64
1500 37 225S 64

4 Description
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KSB SuPremE
Rated speed Rated power Motor size Sound pressure
level LpA
8)
[rpm] [kW] [dB (A)]
1500 45 225M 64
3000 0,55 71M 70
3000 0,75 80M 70
3000 1,1 80M 70
3000 1,5 90S 70
3000 2,2 90L 70
3000 3 100L 71
3000 4 112M 71
3000 5,5 132S 71
3000 7,5 132S 71
3000 11 160M 71
3000 15 160M 71
3000 18,5 160L 72
3000 22 180M 72
3000 30 200L 72
3000 37 200L 72
3000 45 225M 72
4.8 Balancing
The rotor is balanced dynamically in accordance with DINISO21940-11. The rotor is
balanced to balance quality grade G2.5.
Marking
▪For motors with key, the rotors are balanced dynamically with a half key ("H") as
standard in accordance with ISO21940-32 requirements. The output element
must also be balanced with a half key in accordance with the key convention.
8) Measured at idle with rated speed to IEC60034-9

5 Installation at Site
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5 Installation at Site
5.1 Safety regulations
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
Damage to the motor!
▷Comply with the applicable local explosion protection regulations.
▷Never install the motor in potentially explosive atmospheres.
DANGER
Hot surface
Risk of burns!
▷Never touch a motor when it is in operation.
▷Let the motor cool down.
▷Only remove covers if indicated.
Observe the following:
▪Let the motor first cool down before you start to work on the drive.
▪Only remove covers if indicated.
▪Components (lines, etc.) must not come into contact with the motor housing.
▪Check and take into account the technical data printed on the name plate
attached to the motor housing.
5.2 Checks to be carried out prior to installation
Place of installation
WARNING
Installation on mounting surface which is unsecured and cannot support the load
Personal injury and damage to property!
▷Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN206-1.
▷The mounting surface must be set, flat, and level.
▷Observe the weights indicated.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
Altitude
≤ 1000metres above MSL
Protective roof/additional
roofing
Install a protective roof or additional roofing for vertical installation.
Vertical installation ▪For vertical installation with the shaft end pointed downwards to prevent
foreign objects from falling into the fan hood.
▪For vertical installation with the shaft end pointed upwards to prevent fluid
ingress along the length of the shaft.