KSB PumpMeter Installation instructions

PumpMeter
Type Series Booklet

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Type Series Booklet PumpMeter
Original operating manual
KSB Aktiengesellschaft Pegnitz
All rights reserved. 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 KSB´s express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 10.11.2010

Monitoring
Intelligent Pressure Sensor
PumpMeter
PumpMeter
Product description
The PumpMeter device is an intelligent pressure sensor for
pumps, with local output of measured values and operating
data.
The device consists of two pressure sensors and a display unit.
It records the load profile of the pump in order to indicate any
potential for optimising energy efficiency and availability.
PumpMeter is supplied completely assembled and
parameterised for the corresponding pump. It is ready for
operation as soon as the M12 plug connector is plugged in.
Main applications
Industry:
▪Refrigeration/distribution
▪Heat generation/distribution
▪Water conditioning
▪Cooling lubricant distribution
▪Water extraction
▪Service water supply
Water:
▪Water extraction/withdrawal
▪Water treatment/conditioning
▪Water distribution/transport
Building Services:
▪Air-conditioning systems
▪Heat generation/distribution
▪Water supply systems
Technical data
Technical data of the display unit
Characteristics Value
Power supply 24V DC ± 15%
Power input 150 mA
Analog signal output 4-20 mA, 3-core
Digital connection RS485, Modbus RTU
(Slave)
Enclosure IP 651)
Service interface RS232
Bearing temperature -30 °C to 80 °C
Operating temperature -10 °C to 60 °C
Technical data of the sensors
Characteristics Value
Signal 4-20 mA
Gauge pressure 40 bar max.
Enclosure IP 671)
Burst pressure 80 bar max.
Fluid temperature -30 °C to 140 °C
Installation torque 10 Nm
Ambient temperature -10 °C to 60 °C
Materials
Overview of materials
Wetted components Material
Pressure sensor measuring unit 1.4542
Pressure sensor process connection 1.4301
Adapter for fitting a sensor2) 1.0037 or 1.4571
Joint ring Centellen®
Product benefits
▪Transparent pump operation
Local output of the relevant operating data, especially the
operating point of the pump.
▪Identifies energy saving potentials
by recording and analysing the load profile and displaying
the energy efficiency icon (EFF), if applicable.
▪Saves time and money
The sensors are fitted to the pump at the factory, unlike
conventional instruments used in systems.
▪Helps increase pump availability
by recognising and avoiding operation outside of the
intended operating range.
Functions
Pressure transmitter function
The discharge pressure or differential pressure of the pump are
transmitted as a 4-20 mA signal. Connection via the RS485
serial interface with Modbus protocol is also possible.
1) Provided that the plugs are connected correctly
2) Depending on the basic material design of the pump
Monitoring
Intelligent Pressure Sensor
PumpMeter 3

Operating data display
The device alternately displays the suction pressure and
discharge pressure as well as the differential pressure or head.
Recording and analysing of the load profile
The operating hours of the pump in the
different modes of operation are recorded in
a load profile and saved in a non-volatile
memory (protected against power failure).
The energy efficiency symbol is displayed
when a potential for optimisation is
recognised.
Qualitative indication of the pump's current operating point
The flashing segment indicates the position of the current
operating point on the generalised characteristic curve.
Qualitative indication of the pump's current operating point
Operating range Segment display Description
Operation at
extremely low
flow3)
First quarter
flashing (1)
▪Pump possibly not
operated in
accordance with its
intended use
▪Increased load on
the components
Operation at
moderately low
flow3)
Second quarter
flashing (2)
▪Operation with
potential for
optimising energy
efficiency
Operation near
the optimum
Third quarter
flashing (3)
▪Operation within
intended operating
range. Optimum
energy efficiency
Operation in
overload
conditions
Fourth quarter
flashing (4)
▪Limit of the
intended operating
range
▪Possibly overload
of pump and/or
motor
Design variants
▪Adapter:
Depending on thread type and size of the pump's pressure
gauge connections
▪Cable length:
600 mm or 1200 mm, depending on the pump size
▪Measuring ranges of the pressure sensors:
Depending on the inlet pressure and maximum head
Available measuring ranges
Colour code Measuring range
Minimum Maximum
red -1 bar 3 bar
blue -1 bar 10 bar
light grey -1 bar 16 bar
green -1 bar 25 bar
black -1 bar 40 bar
Electrical connections
1
1 2 3 4
2
3
4
1 2
3
4
Connections at the device
1 IN1 / port for the suction-side pressure sensor
2 IN2 / port for the discharge-side pressure sensor
3 Service interface
4 EXT / external port for energy supply and signal output
Dimensions and weights
Dimensions of the sensor
3) For some pump characteristics, no differentiation is made between the low-flow operating conditions in the curve's first
two quarters (both flashing simultaneously).
Monitoring
Intelligent Pressure Sensor
4PumpMeter

Dimensions of the display unit
Scope of supply
▪Display unit fitted
▪Sensors fitted with adapter
Fluids handled
Overview of fluids handled
Fluid handled Concentration
[%]
Max. temperature
[°C]
Fluid handled Concentration
[%]
Max. temperature
[°C]
Alum, acid-free 3 80 Diesel oil – 80
Alkaline solution, bottle rinsing, max. 2% sodium
hydroxide
– 40 Diesel oil, fuel oil EL – 60
Alcohol – – Lubricating oil, turbine oil, does not apply to
SF-D oils (hardly flammable)
– 80
Aluminium sulphate, acid-free 5 60 Heating oil – 80
Ammonium bicarbonate 10 40 Water-oil emulsion (95%, 5%), free of solids – 80
Ammonium sulphate 20 60 Phosphate sludge …10 60
Anolyte (dialyte) with acetic acid or formic acid,
free of solids
– 30 Phosphoric acid 5 20
Accelerator (as preparation) – – Propanol – 80
Drilling/grinding emulsion – 60 Cleaning agents – –
Spirits (40% ethanol) – 60 Juice (fruit and sugar juice) – 60
Service water – 60 Nitric acid 15-20 80
Brewery applications – – Silicate-free, alkaline degreasing or cleaning
solution containing solid particles
0.3-5 80
Beer mash – 100 Fuel – –
Beer wort – 100 Trisodium phosphate 4 80
Brewing water – 60 Water – –
Ice water (brewery) – 60 Deionised water (fully desalinated) – 140
Vapour condensate (brewery) – 140 Dealkalised water – 120
Butanol – 60 Decarbonised water – 120
Calcium acetate, acid-free 10 60 Fire-fighting water4) – 60
Calcium nitrate, acid-free 10 60 River water – 60
Diethylene glycol – 100 Heating water5) – 140
4) General criteria for results of water analysis: pH value ≥ 7; chloride content (Cl) ≤ 250 mg/kg. Chlorine (Cl 2) ≤ 0.6 mg/kg
5) Treatment to VdTÜV 1466; additional requirement: O2≤ 0.02 mg/l
Monitoring
Intelligent Pressure Sensor
PumpMeter 5

Fluid handled Concentration
[%]
Max. temperature
[°C]
Fluid handled Concentration
[%]
Max. temperature
[°C]
Ferric sulphate (II) 5 80 Boiler feed water to VdTÜV1466 – 140
Iron phosphating solution (alkaline phosphating) approx
. 5
70 Cooling water4) (without anti-freeze) – 60
Acetic acid 10 60 Closed circuit cooling water – 100
Acetic acid 5 60 Open circuit cooling water – 100
E-coating (water), anaphoresis – 35 Cooling water pH value > 7.5 (with anti-
freeze)6)
– 110
E-coating (water), cataphoresis – 35 Paint-laden water containing residues of wood
paints
– 30
Ethanol – 60 Paint-laden water containing residues of
plastics paints
– 30
Ethylene glycol – 100 Paint-laden water containing residues of metal
paints
– 30
Ethylene glycol base anti-freeze, inhibited, closed
system
50 110 Slightly contaminated water4) – 60
Tannic acid 20 80 Tap water – 60
Glycerine 40 80 Clean water7) – 60
Potassium hydroxide 5 40 Raw water4) – 60
Potassium nitrate, acid-free 5 30 Swimming pool water (fresh water)4) – 60
Potassium sulphate, acid-free 3 20 Lake water (fresh water) – 60
Kerosene (jet fuel) – 80 Barrier water – 70
Condensate5) – 120 Fresh water – 60
Condensate, not conditioned – 120 Dam water – 60
Conventional paint on solvent basis 10-40 – Partly desalinated water – 120
Copper sulphate 5 80 Drinking water4) – 60
Magnesium sulphate 10 80 Permeate (osmosis) – 140
Maleic acid 10 60 Ultrafiltrate = permeate, pure filtrate, solids
content <1 %
– 30
Milk – 60 Deionised water, free of solids – 60
Lactic acid 5 60 Fully desalinated water – 120
Lactic acid 40 60 Hot water (brewery) – 60
Sodium carbonate 6 60 Water treated to VdTÜV1466 – 140
Sodium hydroxide 5 40 Water with anti-freeze, pH value > 7.5 4) 6) – 110
Sodium nitrate, acid-free 10 60 Water, waste water, slightly contaminated
water, surface water
– 60
Sodium sulphate, acid-free 5 60 Water, fire-fighting water – 60
Sodium hydroxide 15-20 20 Water, surface water – 60
Oils/emulsions – – Water, rainwater, with strainer – 60
Peanut oil – 90 Water, raw water – 60
Corn oil – 100 Water, drinking water – 60
Linseed oil – 60 Tartaric acid 8 40
Rapeseed oil – 100 Citric acid 25 30
Soybean oil – 100 Lye for bottle rinsing – 90
Spare parts
List of spare parts
Description Ident. No.
Pressure sensor
-1..3 bar 0.6 m cable (red)
01146960
Pressure sensor
-1.0.10 bar 0.6 m cable (blue)
01146961
Description Ident. No.
Pressure sensor
-1.0.16 bar 0.6 m cable (light grey)
01146962
Pressure sensor
-1..25 bar 0.6 m cable (green)
01146963
Pressure sensor
-1..40 bar 0.6 m cable (black)
01146965
6) Anti-freeze on ethylene glycol basis with inhibitors. Content: >20 % to 50 % (e.g. Antifrogen N)
7) No ultra-pure water! Conductivity at 25 °C: < 800 µS/cm, neutral with regard to chemical corrosion
Monitoring
Intelligent Pressure Sensor
6PumpMeter

Description Ident. No.
Pressure sensor
-1..3 bar 1.2 m cable (red)
01146895
Pressure sensor
-1..10 bar 1.2 m cable (blue)
01146896
Pressure sensor
-1..16 bar 1.2 m cable (light grey)
01146957
Pressure sensor
-1..25 bar 1.2 m cable (green)
01146958
Pressure sensor
-1..40 bar 1.2 m cable (black)
01146959
Joint ring A 8 X 11.5 01015232
Display unit 01146894
Adapter R 1/4 - M8 01146970
Adapter G 1/4 - M8 01146971
Adapter NPT 1/4 - M8 01146972
Adapter R 3/8 - M8 01146973
Adapter G 3/8 - M8 01146974
Adapter NPT 3/8 - M8 01146975
Adapter R 1/2 - M8 01146976
Adapter G 1/2 - M8 01146977
Adapter NPT 1/2 - M8 01146978
Adapter R 1/4 - M8 01186472
Adapter G 1/4 - M8 01186474
Adapter R 3/8 - M8 01191765
Adapter R 1/2 - M8 01191766
Adapter G 3/8 - M8 01191857
Adapter G 1/2 - M8 01191858
Accessories
Overview of accessories
Description Ident. No.
Extension cord
▪Length 5 m
▪For extending the sensor cables
01146980
Extension cord
▪Length 10 m
▪For extending the sensor cables
01146981
Connection cable
▪Length 1 m
▪5-pole cable with M12 plug for power supply
and signal output
01146982
Connection cable
▪Length 5 m
▪5-pole cable with M12 plug for power supply
and signal output
01146983
Connection cable
▪Length 10 m
▪5-pole cable with M12 plug for power supply
and signal output
01146984
Power supply unit for the PumpMeter
▪24 V / 750 mA (for maximum 5 PumpMeter
devices)
01147695
Monitoring
Intelligent Pressure Sensor
PumpMeter 7

KSB Aktiengesellschaft
67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany)
Tel. [phone] • Fax [phone]
www.ksb.com
4072.5/2-10 10.11.2010