KSB Guard Installation instructions

KSB Guard
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 09/11/2018

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 operating manual........................................7
2.5 Safety awareness ..............................................................................................................................................8
2.6 Software changes .............................................................................................................................................8
3 Transport/Temporary 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 plates ....................................................................................................................................................11
4.3 Technical data.................................................................................................................................................11
4.4 Function ..........................................................................................................................................................12
4.5 Gateway ..........................................................................................................................................................13
4.6 Sensor unit ......................................................................................................................................................14
4.7 Transmission and battery unit .......................................................................................................................14
5 Installation/Commissioning................................................................................................................. 15
5.1 Installation ......................................................................................................................................................15
5.1.1 Installing the gateway.......................................................................................................................15
5.1.2 Installing the sensor unit...................................................................................................................18
5.1.3 Establishing a connection between the sensor unit and the transmission and battery unit........20
5.1.4 Commissioning...................................................................................................................................20
5.1.5 Installing the transmission and battery unit ....................................................................................21
5.1.6 Routing the connecting cable ...........................................................................................................21
5.2 Commissioning the gateway..........................................................................................................................22
5.3 Assigning and setting up ...............................................................................................................................23
6 Operation.............................................................................................................................................. 25
6.1 Operating modes of transmission and battery unit.....................................................................................25
6.2 Taking manual measurement and displaying signal strength.....................................................................25
6.3 Reading out the transmission status .............................................................................................................25
7 Changing the Batteries........................................................................................................................ 27
8 Dismantling .......................................................................................................................................... 28
8.1 Dismantling the gateway...............................................................................................................................28
8.2 Dismantling the transmission and battery unit............................................................................................28
8.3 Dismantling the sensor unit...........................................................................................................................29
9 Trouble-shooting.................................................................................................................................. 30
9.1 Trouble-shooting the gateway......................................................................................................................30
9.2 Trouble-shooting the transmission and battery unit/ sensor unit...............................................................30
10 Related Documents.............................................................................................................................. 32
10.1 Recommended mounting position for sensor unit ......................................................................................32

Contents
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11 EU Declaration of Conformity............................................................................................................. 35
Index ..................................................................................................................................................... 36

1 General
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1 General
1.1 Principles
This instruction manual is valid for the type series and variants indicated on the front
cover.
The 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 instruction 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 for pump/
pump set
Description/operation of pump/pump set
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.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.

1 General
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Symbol Description
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 instruction 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.
The safety information in all sections of this manual must be complied with.
The instruction manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this instruction manual must be available to the specialist personnel
at the site at all times.
Information 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 in this instruction manual.
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 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.
It is impermissible to make any changes or additions to the software or parts of the
software.

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
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 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 by 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 (see Ambient conditions
for storage table).

3 Transport/Temporary 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 user 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.

4 Description
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4 Description
4.1 General description
Monitoring device for monitoring vibrations and temperatures of pump sets.
4.2 Name plates
KSB SE & Co.KGaA
www.ksb.com
Ambient Temperature:
Protection Class:
Id. No
0 - 90 °C
IP65
01852755
GS118W220001Serial No
KSB Guard Sensor Unit
Fig.1: Name plate of sensor unit
KSB SE & Co.KGaA
www.ksb.com
Battery Supply: 2 x 1.5V (baby-cell)
0 - 50 °C
IP65
2.4 GHz / < 10mW
Indoor use only
01852758 / 01852753
GT118W260001
Johann-Klein-Str. 9
D-67227 Frankenthal
Protection Class:
KSB Guard Transmission and Battery Unit
Ambient Temperature:
Id. No (Complete System/This Unit):
Serial No
Sensor Network Comm.:
Fig.2: Name plate of transmission and battery unit
Fig.3: Name plate of gateway
4.3 Technical data
Sensor unit Table5: Technical data of sensor unit
Characteristic Value
Material Aluminium
Dimensions [mm] 60x45x30
Enclosure IP65
Cable type 1.5m, PUR, 6-pin
Ambient temperature ≤90°C

4 Description
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Transmission and battery
unit
Table6: Technical data of transmission and battery unit
Characteristic Value
Material Plastic
Dimensions [mm] 120x80x50
Enclosure IP65
Temperature range 0-50°C
Power supply 2 C size batteries (baby), (R14)
Wireless module ISM band, 2.4GHz
Connection M8, 6-pin
Gateway Table7: Technical data of gateway
Characteristic Value
Mains voltage 110 - 240V, AC voltage
Mains frequency 50/60Hz
Power input <15W
In-service ambient temperature 0 to 40°C1)
Enclosure IP54
Weight <400g
Dimensions 158×95×45
SMA-RP socket (antenna sensor network) Antenna for 2.4 GHz (WLAN/
Bluetooth)
SMA socket (LTE antenna) Antenna for 2G/3G/4G mobile
data, included in standard
accessories with approx. 5 m
cable
Internal SIM card2) Pre-configured
4.4 Function
Transmission and battery
unit
The sensor unit and transmission and battery unit are connected by a connecting
cable. The sensor unit is installed on the pump’s bearing bracket or drive lantern,
where it measures the pump’s vibration and temperature using built-in sensors.
This data is sent to the transmission and battery unit.
The transmission and battery unit sends the recorded data to the gateway via a radio
signal. From there, the data collected is transferred directly and in encrypted format
to the KSB Cloud for processing.
Gateway One gateway can process the data of up to 20 transmission and battery units if they
send data every hour. This number is reduced with more frequent data transmission.
1) Higher temperatures than indicated are possible. Contact KSB Support before installation. Contact: [phone] and
[email protected].
2) The SIM card is pre-installed and cannot be replaced.

4 Description
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4.5 Gateway
1 2 3 4 5
6
Fig.4: Gateway
1 Antenna connection (data
transmission of transmission and
battery unit)
2 Status LED for supply voltage
3 Status LED S1 for connection status 4 Level LEDs for mobile network
signal strength (LTE)
5 Antenna connection for mobile
data (LTE)
6 Power supply connection
Table8: Description of LED indicators
No. LED Status Description
2 Supply voltage OFF Device is out of operation or in the initialisation phase.
Green Device is in operation. No faults present.
Red Device is in operation. Faults are present.
Flashing red Firmware update is being installed.
3 Connection status OFF No mobile network, no Internet
Yellow Mobile network accessible, no Internet
Green Mobile network and Internet accessible
4 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 Description
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4.6 Sensor unit
1
2
Fig.5: Sensor unit
1 QR code 2 Connecting cable to transmission
and battery unit
4.7 Transmission and battery unit
1
2
5
6
3
4
Fig.6: Transmission and battery unit
1 Pushbutton 2 Status LED A
3 Status LED B 4 Level LEDs for indicating the signal
strength of the gateway connection
5 Cover for housing screws 6 Connection for connecting cable to
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 the gateway connection

5 Installation/Commissioning
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5 Installation/Commissioning
5.1 Installation
5.1.1 Installing the gateway
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.
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 20 transmission and battery units to a gateway.
▷Maintain a minimum distance of approx. 100m between 2 gateways (or use
separate rooms/ halls).
One gateway can process the data of up to 20 transmission and battery units if they
send data every hour. This number is reduced with more frequent data transmission.
The manufacturer must be consulted if more than 20 transmission and battery units
are connected or if the data transmission rate is higher.
NOTE
Adding another gateway will not serve to increase the data transmission rate or the
number of connected transmission and battery units. If several gateways are within
transmission range of each other, this can lead to overlap and interference.
5.1.1.1 Checking the installation location of the gateway
The installation location of the gateway must meet the following requirements:
▪Temperature 0-40°C3) (ðSection4.3,Page11)
▪Only install and operate the gateway in closed rooms.
▪No direct sunlight
▪At least 2 m above the ground
▪Maximum distance between gateway and transmission and battery unit: 30m
▪Area between gateway and transmission and battery unit with as few obstacles
as possible (e.g. walls).
If possible: Install with a direct visual connection between the pump set to be
connected and the gateway.
3) Higher temperatures than indicated are possible. Contact KSB Support for more information.

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5.1.1.2 Installing the gateway antennas
1
2
Fig.7: Installing antennas
1 Rod antenna 2 Magnetic base antenna
The antenna cable should not exceed 20 m in length.
1. Screw the supplied rod antenna onto the left connection (Antenna sensor
network).
2. Screw the magnetic base antenna onto the right connection (Antenna LTE).
3. Place the magnetic base antenna in a location that has sufficiently high mobile
network signal strength. (ðSection5.1.1.4,Page17)
5.1.1.3 Electrically connecting the gateway
Connecting to a shockproof socket
1. Plug the mains power cable supplied into the socket.
2. Check the status LED.
Make sure that at least 2 LEDs are lit. This indicates that the connection to the
mobile network is sufficiently strong.
ðWhen the mains power cable is connected, the gateway starts automatically and
can then be used.
Alternative connection to customer’s own power supply
DANGER
Improper work on electrical connection
Electric shock!
▷The gateway may only be opened by a qualified electrical technician.
▷Electrical work may only be carried out by a qualified electrical technician.
Alternatively, the mains power cable supplied can also be replaced with the
customer’s own mains power cable:

5 Installation/Commissioning
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1
Fig.8: Gateway
1 Screw terminals for power supply
1. Insert customer’s own mains power cable into the device through the cable
gland.
2. Connect the mains power cable to the appropriate screw terminals on the circuit
board.
When the customer’s own mains power cable is connected, the gateway starts
automatically and can then be used.
3. Check status LED S1.
Make sure that at least 2 level LEDs are lit. This indicates that the connection to
the mobile network is sufficiently strong.
ðWhen the mains power cable is connected, the gateway starts automatically and
can then be used.
NOTE
When connecting the cable ensure that the enclosure requirements (IP54) are met
again after installation.
5.1.1.4 Checking the signal strength of the gateway
The signal strength of the mobile data connection can be changed by positioning the
magnetic base antenna. The current signal strength is indicated by the corresponding
level LEDs (see Table: Description of LED indicators). (ðSection4.5,Page13)
▪Minimum sufficient signal strength is indicated by 2 level LEDs lighting up.
▪Good signal strength is indicated by 3 level LEDs lighting up.
▪Maximum signal strength is indicated by 4 level LEDs lighting up.
It is recommended that you position the magnetic base antenna such that 3 or 4 level
LEDs are lit during installation. (ðSection4.5,Page13)
1. Place the magnetic base antenna in a location that has sufficiently high mobile
network signal strength.
2. Check the level LEDs for mobile network signal strength.
3. If necessary, change the position of the magnetic base antenna and check again.
If this condition cannot be met, check whether a more powerful LTE antenna can be
installed using a longer cable (if required). In this scenario, an LTE antenna suitable
for outdoor installation is recommended in particular.
The antenna cable should not exceed 20 m in length.

5 Installation/Commissioning
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NOTE
To improve data transmission between the gateway and the transmission and
battery unit, you can rotate and tilt the gateway antenna (data transmission of
transmission and battery unit). The gateway antenna acts in the plane
perpendicular to the antenna’s axis. The transmission and battery unit should be in
this plane. (ðSection4.5,Page13)
5.1.1.5 Fastening the gateway
1
2
Fig.9: Fastening the wall bracket
1 Wall bracket 2 Bolts/screws
üThe gateway antennas have been fitted.
üThe gateway is connected to the power supply.
üThe signal strength at the installation location has been checked and is sufficient.
1. Attach the wall mounting bracket supplied to a suitable wall using 2 screws.
2. Connect the rear adapter of the gateway to the wall bracket.
5.1.2 Installing the sensor unit
DANGER
Strong magnetic field
Danger of death for persons with pacemaker!
Interference with magnetic data carriers, electronic devices, components and
instruments!
Uncontrolled magnetic attraction forces between magnet-equipped components,
tools or similar!
▷Keep a safety distance of at least 0.3m.
WARNING
Hot surfaces of pump set
Risk of burns!
▷Observe the manufacturer’s safety instructions for fastening the sensor unit and
using the adhesive.

5 Installation/Commissioning
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WARNING
Sensor unit takes on temperature of bearing bracket or drive lantern
Risk of burns!
▷Observe the operating manual of the pump set.
▷When the pump set is being operated, only touch the sensor unit using suitable
protective gloves.
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.
Positioning the sensor unit Observe the following information when positioning and fastening the sensor unit:
▪Mount the sensor unit at a suitable location on the bearing bracket or drive
lantern up to a maximum height of 2 m.
Recommended mounting position (ðSection10.1,Page32)
▪Affix the sensor unit to magnetic material if possible (preferred).
▪The location on the bearing bracket or drive lantern where the sensor unit is
mounted should be level. Use the adhesive to compensate for minor uneven
spots or curvatures.
▪The sensor unit must also be glued in addition to the magnetic holders.
▪(For further information on the correct mounting position, see www.ksb.com/
product/ksbguard).
üThe operating manual for the pump set is accessible and has been observed.
üAll safety instructions for the adhesive have been read and observed.
1. Remove any coarse dirt from the mounting area.
2. Clean the back of the sensor unit using the supplied cleaning pad.
3. Clean the mounting area using the supplied cleaning pad.
4. Spread the supplied adhesive over the back of the sensor unit.
5. Position the sensor unit on the cleaned area of the bearing bracket or drive
lantern. The sensor unit is optimally aligned when one axis of the sensor unit is
parallel to the shaft and the other axis of the sensor unit is horizontal to the
shaft.
6. Firmly press down the sensor unit.
7. Allow the sensor unit to dry on the bearing bracket or drive lantern to ensure
that the position of the sensor unit is not unintentionally changed during
subsequent mounting. The adhesive bond must be able to withstand slight
vibrations at the sensor unit. The waiting time heavily depends on ambient
conditions.
NOTE
At an ambient temperature between +25 °C and +30 °C, the supplied adhesive will
have sufficiently cured after approximately 24 hours. After 3 days, the adhesive will
have fully cured. Increased temperatures (e.g. +60°C to +120°C) accelerate the
curing process.
8. Check that the sensor unit is firmly positioned on the bearing bracket or drive
lantern; re-glue the sensor unit if necessary.

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5.1.3 Establishing a connection between the sensor unit and the transmission and
battery unit
NOTE
The adhesive bond between the sensor unit and bearing bracket or drive lantern
must be sufficiently cured before continuing to install the connecting cable to avoid
changing the position of the sensor unit.
1. Connect the connecting cable of the sensor unit to the transmission and battery
unit.
5.1.4 Commissioning
Supplied condition The transmission and battery unit is delivered in Deep Sleep mode
(ðSection6.1,Page25) . This operating mode remains active until commissioning
has been completed successfully.
During commissioning, a sensor unit must be detected and a functioning gateway
found within wireless range.
If commissioning is not successful, the device remains in Deep Sleep mode until it is
woken up by pressing and holding down the relevant button.
Commissioning
1
2
5
6
3
4
Fig.10: Transmission and battery unit
1 Pushbutton 2 Status LED A
3 Status LED B 4 Level LEDs for indicating the signal
strength of the gateway connection
5 Cover for housing screws 6 Connection for connecting cable to
sensor unit
üThe gateway has been installed and the signal strength indicated is sufficient.
üThe sensor has been fitted at a suitable location on the pump set.
üThe sensor unit and the transmission and battery unit are interconnected and the
power cable has been connected.
1. Press and hold the pushbutton (1) on the transmission and battery unit for 3
seconds. Release the pushbutton as soon as status LEDs A and B of the
transmission and battery unit briefly light up simultaneously.
ðAll LEDs of the transmission and battery unit flash in a predefined sequence and
extinguish. The device is now in stand-by mode and commissioning/ start-up was
successful.
ðCommissioning/ start-up must be repeated if the LEDs of the transmission and
battery unit do not light up after a brief waiting period.